CN101968404A - Method for detecting fault hidden trouble of intermittent low-speed heavy equipment - Google Patents

Abstract

The invention relates to a method for detecting fault hidden trouble of intermittent low-speed heavy equipment. The method comprises the following steps of: 1, detecting and judging, wherein the judgment result is whether the fault hidden trouble exists; and 2, making the following choice according to the judgment result of the step 1: when the judgment result of the step 1 contains the fault hidden trouble, emitting early warning; or when the judgment result of the step 1 has no fault hidden trouble, ending. The step 1 at least comprises: periodically detecting an oil sample and making a judgment, and detecting the temperature in real time and making a judgment. The method overcomes the defect that the available fault characteristic information in the conventional vibration analyzing method is easily disturbed by noise signals, and can effectively monitor the fault hidden trouble of the intermittent low-speed heavy equipment and effectively improve the fault diagnosis success rate of the intermittent low-speed heavy equipment. The method can realize comprehensive fault monitoring and diagnosis of the equipment and reduce the missing measurement risk.

Description

A kind of method that is used to detect intermittent low-speed heave-load device potential faults

Technical field

The present invention relates to be used to detect the method for production equipment potential faults, especially for the method that detects intermittent low-speed heave-load device potential faults.

Background technology

Be that rotating speed is low, bearing load big, geneva motion is main low-speed heave-load device greatly in modern steel manufacturing enterprise production equipment.This kind equipment complex structure, automatization level is higher, in case catastrophic failure, maintenance difficult, and maintenance cost is very high, even can cause the whole production interruption, cause enormous economic loss.At present, enterprise the intermittent low-speed heave-load device is carried out fault detect is to carry out vibration signal monitoring mostly.But vibration monitoring itself is for the insensitivity of low frequency signal, make that vibration monitoring is not very desirable in the low-speed heave-load device fault detect, the fault signature signal that needs to gather is flooded by the low frequency environments noise signal that relative amplitude is bigger on every side easily, thereby can't effectively detect potential faults.

Summary of the invention

Technical matters to be solved by this invention is: a kind of method that is used to detect intermittent low-speed heave-load device potential faults is provided, and this method can effectively detect the potential faults of intermittent low-speed heave-load device.

The present invention solves the problems of the technologies described above the technical scheme that is adopted:

A kind of method that is used to detect intermittent low-speed heave-load device potential faults, it comprises:

Step 1, the step that detects and judge;

The result who judges is for having potential faults or non-fault hidden danger;

Step 2, make the following choice according to the judged result of step 1:

Containing in the judged result of step 1 has potential faults, sends early warning;

Or,

Be non-fault hidden danger in the judged result of step 1, finish;

Described step 1 comprises at least: regularly detect oil sample and the step that judges and detected temperatures and the step that judges in real time;

The step that regularly detects oil sample and judge is specially:

Step 1.1.1, regularly extract the step of oil sample in the intermittent low-speed heave-load device parts;

The step of galling thing composition, content in step 1.1.2, the detection oil sample;

The step of step 1.1.3, judgement; Be specially:

The content of the arbitrary composition in the oil sample in the galling thing surpasses setting value, and the result of judgement is for there being potential faults;

The content of none composition in the oil sample in the galling thing surpasses setting value, and the result of judgement is a non-fault hidden danger;

Real-time detected temperatures and the step that judges are specially:

Step 1.2.1, detect the step of intermittent low-speed heave-load device part temperatures in real time;

Step 1.2.2, the step of drawing temperature-time curve according to the testing result of step 1.2.1;

The step of step 1.2.3, judgement; Be specially: temperature-time curve and setting curve that step 1.2.2 is drawn mate;

Do not match, the result of judgement is for there being potential faults;

Coupling, the result of judgement is a non-fault hidden danger.

In the such scheme, described step 1 also comprises real-time detection strain and the step that judges, and is specially:

Step 1.3.1, detect the step of intermittent low-speed heave-load device parts shell strain in real time; Strain detecting point is two or more;

The step of step 1.3.2, judgement; Be specially:

Arbitrary strain value in each strain detecting value surpasses setting value, and the result of judgement is for there being potential faults;

None surpasses setting value each strain detecting value, and the result of judgement is a non-fault hidden danger.

In the such scheme, described step 1 also comprises real-time detection FEATURE PARAMETERS OF ACOUSTIC EMISSION and the step that judges, and is specially:

Step 1.4.1, detect the step of intermittent low-speed heave-load device parts FEATURE PARAMETERS OF ACOUSTIC EMISSION in real time;

The step of step 1.4.2, judgement; Be specially:

Arbitrary parameter in each FEATURE PARAMETERS OF ACOUSTIC EMISSION surpasses setting value, and the result of judgement is for there being potential faults;

None surpasses setting value each FEATURE PARAMETERS OF ACOUSTIC EMISSION, and the result of judgement is a non-fault hidden danger.

In the such scheme, FEATURE PARAMETERS OF ACOUSTIC EMISSION comprises: Ring-down count, root-mean-square value, signal amplitude and kurtosis coefficient value.

Compared with prior art, the inventive method has the following advantages:

1, overcomes the shortcoming that useful fault characteristic information is easily disturbed by noise signal in the existing vibration analysis method, can effectively monitor out the potential faults of intermittent low-speed heave-load device, effectively improved the fault diagnosis success ratio of intermittent low-speed heave-load device.

2, can realize comprehensive malfunction monitoring of equipment and diagnosis, reduce the test leakage risk.

3, be convenient to early detection equipment failure hidden danger, avoid causing major accident.

4, be convenient to the overall operation situation of the equipment of grasping, improve maintenance efficiency, save man-hour.

Description of drawings

Fig. 1 is an embodiment of the invention process flow diagram

Fig. 2 is the normal temperature rise curve of bearing

Fig. 3 is a bearing overheating curve

Fig. 4 regularly detects oil sample and the step that judges, detects FEATURE PARAMETERS OF ACOUSTIC EMISSION and the step that judges, the fault detect boundary figure of detected temperatures and the step that judges in real time in real time

Fig. 5 is a pressure box measuring point distribution plan

Fig. 6,7 is grease spectral analysis figure as a result

Embodiment

As shown in Figure 1, the inventive method embodiment is the method that is used for detecting the blast furnace furnace roof pressure box potential faults of intermittent low-speed heave-load device, arranges point position as shown in Figure 5 on the pressure box, the monitoring location illustrated in table 1 among Fig. 5.

Table 1: monitoring location explanation

The monitoring point

Sensor type

Sensor model number

The installation site explanation

A1?	Acoustic emission	SRI50?	The planetary reducer outer wall
				A2?	Acoustic emission	SRI50?	Gear wheel box outer wall upper edge
A3?	Resistance strain gage	ZFLA-1·350-11?	The gear wheel box outer wall is vertically pasted
				A4?	Resistance strain gage	ZFLA-1·350-11?	The gear wheel box outer wall is laterally pasted
A5?	Resistance strain gage	ZFLA-1·350-11?	The gear wheel box outer wall is vertically pasted
				A6?	Resistance strain gage	ZFLA-1·350-11?	The gear wheel box outer wall is laterally pasted
A7?	The wireless temperature collector	ZB-200SP?	The bearing shell fascinates
				A8?	The wireless temperature collector	ZB-200SP?	The bearing shell fascinates

The inventive method embodiment comprises:

Step 1, the step that detects and judge;

The result who judges is for having potential faults or non-fault hidden danger;

Step 1 comprises:

Regular detection oil sample and the step that judges,

Real-time detected temperatures and the step that judges,

Real-time detection strain and the step that judges,

The real-time step that detects FEATURE PARAMETERS OF ACOUSTIC EMISSION and judge.

The step that regularly detects oil sample and judge is specially:

Step 1.1.1, regularly extract the step of oil sample in the intermittent low-speed heave-load device parts;

The step of galling thing composition, content in step 1.1.2, the detection oil sample;

The step of step 1.1.3, judgement; Be specially:

The content of the arbitrary composition in the oil sample in the galling thing surpasses setting value, and the result of judgement is for there being potential faults;

The content of none composition in the oil sample in the galling thing surpasses setting value, and the result of judgement is a non-fault hidden danger.

The blast furnace pressure box grease sampling period is generally three months once, from the blast furnace pressure box, take out a small amount of oil sample, utilize spectrometer that sample is carried out spectral analysis, determine wherein galling thing composition, content, judge by observing in the grease galling thing content whether machine run, oil quality be normal, and warn in view of the above, to prevent the generation of grease deterioration, the heavy wear of machine movement part and fault.The analysis result that constituent content shown in the spectral analysis report (seeing Table 2) of sampling in blast furnace pressure box on October 14th, 2008 grease and Fig. 6,7 is changed by certain steel mill is as can be seen in September in 2008 on October 14th, 26 days 1 this time period, the content of the iron in the grease, zinc, P elements is propradation rapidly, can judge that in view of the above pressure box breaks down.OOBA (out of box audit) finds that the pivoting support workplace quench-hardened case that used 3 years damages, changes immediately.

Table 2:

Real-time detected temperatures and the step that judges are specially:

Step 1.2.1, detect the step of intermittent low-speed heave-load device part temperatures in real time;

Step 1.2.2, the step of drawing temperature-time curve according to the testing result of step 1.2.1;

The step of step 1.2.3, judgement; Be specially: temperature-time curve and setting curve (as shown in Figure 2) that step 1.2.2 is drawn mate;

Do not match, the result of judgement is for there being potential faults (as shown in Figure 3);

Coupling, the result of judgement is a non-fault hidden danger.

Utilization is installed in fascinate wireless temperature collector collecting temperature variable signal on the bearing seat of pressure box, can make deduction according to Fig. 2, Fig. 3 bearing temperature rise curve: if temperature rises gradually during the equipment entry into service, temperature variation tends towards stability after operation a period of time, can judge that then bearing runs well; If temperature sharply rises at the beginning, occur fluctuation then and then can be judged as bearing and break down.

The step that detects strain in real time and judge is specially:

Step 1.3.1, detect the step of intermittent low-speed heave-load device parts shell strain in real time; Strain detecting point is two or more;

The step of step 1.3.2, judgement; Be specially:

Arbitrary strain value in each strain detecting value surpasses setting value (during normal condition 1.25 of numerical value times), and the result of judgement is for there being potential faults;

None surpasses setting value each strain detecting value, and the result of judgement is a non-fault hidden danger.

When the pressure box tilting equipment broke down, the pressure box body produced miniature deformation because of unbalance stress, at uniform four foil gauges of pressure box shell, the stressed situation of change of pressure box was monitored as shown in Figure 5.A3-A6 in the square frame is the stickup direction of foil gauge.When gathering strain signal numerical value and be normal condition numerical value more than 1.25 times the time, the decidable pressure box breaks down.

The step that detects FEATURE PARAMETERS OF ACOUSTIC EMISSION in real time and judge is specially:

Step 1.4.1, detect the step of intermittent low-speed heave-load device parts FEATURE PARAMETERS OF ACOUSTIC EMISSION in real time;

The step of step 1.4.2, judgement; Be specially:

Arbitrary parameter in each FEATURE PARAMETERS OF ACOUSTIC EMISSION surpasses setting value, and the result of judgement is for there being potential faults;

None surpasses setting value each FEATURE PARAMETERS OF ACOUSTIC EMISSION, and the result of judgement is a non-fault hidden danger.

FEATURE PARAMETERS OF ACOUSTIC EMISSION comprises: Ring-down count, root-mean-square value, signal amplitude and kurtosis coefficient value.

Utilize the acoustic emission signal acquisition instrument to gather the acoustic emission signal of equipment under test, analyze the characteristic feature parameter (Ring-down count, root mean square, signal amplitude, kurtosis coefficient) of acoustic emission signal, whether situation of change and each the principal character parameter value of analyzing main characteristics of Acoustic Emission parameter are in the operation conditions of normal range shown in the table 3 with judgment device.

Table 3: characteristics of Acoustic Emission parameter criterion

Parameter type	Normal range
		Ring-down count	≤18?
Root-mean-square value X rms	≤70?
		Signal amplitude X p	≤90?
The kurtosis COEFFICIENT K v	2.7≤K v≤3.3

The parameter analysis of acoustic emission signal

Acoustic emission is the transient state elastic wave of being sent by accident defect itself, can detect dynamic defect, and the acoustic emission wave wide frequency range can effectively suppress the interference of ambient noise, utilizes the acoustic emission testing technology can timely and effective discovering device internal bearings fault.

The acoustic emission basic parameter is introduced:

(1) Ring-down count

Ring-down count is exactly the number of oscillation of crossing the threshold signal.Ring-down count is the most general acoustic emission assessment counting, and it has reflected the intensity and the frequency of acoustic emission signal to a certain extent.Be subjected to the influence of threshold bigger.

(2) signal amplitude Xp

The peak swing value of event signal waveform.With the size of incident direct relation is arranged, be not subjected to the influence of threshold, directly determine the measurability of incident.

Computing formula: X _p=max{X _iX _i-amplitude

(3) root-mean-square value Xrms

Root-mean-square value is applicable to the fault diagnosis that the amplitude of picture wearing and tearing and so on slowly changes in time.

Computing formula: $X_{\mathrm{rms}}=\sqrt{\frac{1}{N}\underset{i=1}{\overset{N}{\mathrm{\Σ}}}{X}_i^2}$

(4) kurtosis index Kv

The kurtosis index definition is a kurtosis and the ratio of the bipyramid of root-mean-square value.Its reflection departs from another index of normal distribution degree, and is responsive especially to the impact composition in the signal.When equipment state just often, record signal amplitude and be normal distribution, the kurtosis desired value is 3, too high kurtosis index has reflected local defect usually, and overall fault and distribution defect can make the kurtosis index reduce.

Computing formula: $K_v=\frac{{\left(\frac{1}{N}\underset{i=1}{\overset{N}{\mathrm{\Σ}}}{X}_i\right)}^4}{X_{\mathrm{rms}}^4}$

Step 2, make the following choice according to the judged result of step 1:

Containing in the judged result of step 1 has potential faults, sends early warning;

Or,

Be non-fault hidden danger in the judged result of step 1, finish.

The embodiment of the invention can be carried out comprehensive diagnos to the running status of intermittent low-speed heave-load device in conjunction with four kinds of detection methods, has good complementarity, if four testing results are all normal, can judge that pressure box runs well, and does not break down; If wherein the result of one or more detections occurs unusually, then can determine trouble location to the monitoring target primary part observation of this detection mode, can reach the purpose of early warning.

Grease detects and is mainly used in the initial failure detection as can be seen from Figure 4, and acoustic emission and temperature detection are mainly used in fault mid-term and late period.

The inventive method is effective especially to the intermittent exercise monitoring of equipment of (big as noise, vibration source is many, external interference is obvious) under low-speed heave-load, the rugged surroundings, other monitoring method such as vibration monitoring, behavior in service monitoring technology incomparable superiority.

Claims (4)

1. method that is used to detect intermittent low-speed heave-load device potential faults, it is characterized in that: it comprises:

Step 1, the step that detects and judge;

The result who judges is for having potential faults or non-fault hidden danger;

Step 2, make the following choice according to the judged result of step 1:

Containing in the judged result of step 1 has potential faults, sends early warning;

Or,

Be non-fault hidden danger in the judged result of step 1, finish;

Described step 1 comprises at least: regularly detect oil sample and the step that judges and detected temperatures and the step that judges in real time;

The step that regularly detects oil sample and judge is specially:

Step 1.1.1, regularly extract the step of oil sample in the intermittent low-speed heave-load device parts;

The step of galling thing composition, content in step 1.1.2, the detection oil sample;

The step of step 1.1.3, judgement; Be specially:

The content of the arbitrary composition in the oil sample in the galling thing surpasses setting value, and the result of judgement is for there being potential faults;

The content of none composition in the oil sample in the galling thing surpasses setting value, and the result of judgement is a non-fault hidden danger;

Real-time detected temperatures and the step that judges are specially:

Step 1.2.1, detect the step of intermittent low-speed heave-load device part temperatures in real time;

Step 1.2.2, the step of drawing temperature-time curve according to the testing result of step 1.2.1;

The step of step 1.2.3, judgement; Be specially: temperature-time curve and setting curve that step 1.2.2 is drawn mate;

Do not match, the result of judgement is for there being potential faults;

Coupling, the result of judgement is a non-fault hidden danger.

2. the method for claim 1, it is characterized in that: described step 1 also comprises real-time detection strain and the step that judges, and is specially:

Step 1.3.1, detect the step of intermittent low-speed heave-load device parts shell strain in real time; Strain detecting point is two or more;

The step of step 1.3.2, judgement; Be specially:

Arbitrary strain value in each strain detecting value surpasses setting value, and the result of judgement is for there being potential faults;

None surpasses setting value each strain detecting value, and the result of judgement is a non-fault hidden danger.

3. method as claimed in claim 1 or 2 is characterized in that: described step 1 also comprises real-time detection FEATURE PARAMETERS OF ACOUSTIC EMISSION and the step that judges, and is specially:

Step 1.4.1, detect the step of intermittent low-speed heave-load device parts FEATURE PARAMETERS OF ACOUSTIC EMISSION in real time;

The step of step 1.4.2, judgement; Be specially:

Arbitrary parameter in each FEATURE PARAMETERS OF ACOUSTIC EMISSION surpasses setting value, and the result of judgement is for there being potential faults;

None surpasses setting value each FEATURE PARAMETERS OF ACOUSTIC EMISSION, and the result of judgement is a non-fault hidden danger.

4. method as claimed in claim 3, it is characterized in that: FEATURE PARAMETERS OF ACOUSTIC EMISSION comprises: Ring-down count, root-mean-square value, signal amplitude and kurtosis coefficient value.

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