CN102123177A - Fault detection system for rotary machine based on network and on-line detection method thereof - Google Patents
Fault detection system for rotary machine based on network and on-line detection method thereof Download PDFInfo
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- CN102123177A CN102123177A CN201110068815XA CN201110068815A CN102123177A CN 102123177 A CN102123177 A CN 102123177A CN 201110068815X A CN201110068815X A CN 201110068815XA CN 201110068815 A CN201110068815 A CN 201110068815A CN 102123177 A CN102123177 A CN 102123177A
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Abstract
The invention relates to the technical field of signal processing, in particular relating to a fault detection system for a rotary machine based on a network and an on-line detection method thereof. The system comprises an enterprise monitoring station, an enterprise monitoring center and a remote diagnostic center; the enterprise monitoring station consists of a data acquisition device, a sensor and a master-control computer; the enterprise monitoring center consists of an enterprise server and a database server; the input end of the data acquisition device is connected with a field device through the sensor and used for collecting device information, and the output end of the data acquisition device outputs vibration data to the master-control computer through a VXI (VMEbus eXtensions for Instrument) protocol; the master-control computer outputs the vibration data to the database server and enterprise server of the enterprise monitoring center respectively; and the remote diagnostic center acquires the vibration data through a web server and can be used for carrying out on-line detection. Through the data acquisition of a field vibration signal, the Ethernet data communication and the processing of a six-frequency-band energy analysis alarm, the on-line detection and quick and effective alarm to the running state of the rotary machine are realized.
Description
Technical field
What the present invention relates to is the device and method in a kind of signal processing technology field, specifically is a kind of rotating machinery fault detection system and online test method thereof of realization Network Based.
Background technology
Equipment condition monitoring and fault diagnosis technology originate from the U.S. the earliest, 1967, under the initiating of NASA (NASA), have set up the U.S. " mechanical breakdown prevention group (MFPG) " by USN research department (ONR) hosting.Existing condition monitoring and failure diagnosis system be mainly three kinds of canonical forms: periodic monitoring and diagnostic system, the online malfunction monitoring of unit and diagnostic system and distributed monitoring and diagnostic system, the deficiency of these systems is analyzed as follows:
1) periodic monitoring and diagnostic system: periodic monitoring and diagnostic system be by monitoring sensor collecting device operation information, analyzed and diagnosed by computer.More when the plant equipment quantity of needs monitorings, but when not belonging to key equipment, can adopt this type systematic.Its advantage is economical, flexible.But the inefficiency of system, take great amount of manpower and material resources, and because periodic monitoring just, so generally can not monitor the break down signal of front and back of unit, thereby do not have " black box " effect, be difficult to the operation trend of correct failure judgement and forecast unit.
2) online malfunction monitoring of unit and diagnostic system: each equipment is installed a set of fault monitoring diagnosis system.This mode real-time is good, the reliability height.This pattern is suitable for early stage semiworks.It is the system of a sealing, and information only flows and processing in internal system, and information is difficult to share between each monitoring diagnosis system, along with the expansion of plant layout, and the increase of number of devices, this type systematic more and more demonstrates its limitation.
3) distributed monitoring and diagnostic system: along with the appearance of large-scale corporation and giant mechanical and electrical equipment, online malfunction monitoring of unit and diagnostic system can not satisfy the production needs, people have realized the distributed monitoring and the diagnostic system of technology Network Based according to the function distribution of equipment and the characteristics of Regional Distribution.This type systematic is formed local area network (LAN) with the computer of each monitoring point, realizes resource-sharing, decentralized supervisory control and concentrates diagnosis, has improved the efficient of system, is a relative open system.Weak point is that each enterprise all sets up relatively independent monitoring and diagnosis local area network (LAN), only can accomplish the information sharing of each monitoring diagnosis system of enterprises, and unrelated between the enterprise.
Simultaneously, in current rotating machinery on-line monitoring and diagnosis application evolution, the fault alarm problem of equipment is the bottleneck problem of puzzlement on-line monitoring machine fault diagnosis technology development always, the relatively extensively ripe method of traditional application has the vibrational energy warning that exceeds standard, vibration effective value warning etc., these methods all exist fault insensitive, and alarm response waits shortcoming slowly.
Summary of the invention
The present invention is directed to the prior art above shortcomings, a kind of rotating machinery fault detection system and online test method thereof of realization Network Based are provided, by data acquisition to on-the-spot vibration signal, Ethernet data communication, the processing that six band energy analyses are reported to the police realizes the on-line monitoring of rotating machinery operation conditions and warning fast and effectively.
The present invention is achieved by the following technical solutions:
The present invention relates to a kind of rotating machinery fault detection system of realization Network Based, comprise: enterprise monitoring station, monitoring center of enterprise and remote diagnostic center, wherein: the enterprise monitoring station is made up of data acquisition unit, transducer and main control computer, and monitoring center of enterprise is become with database servers group by enterprise servers; The input of data acquisition unit links to each other with field apparatus and collecting device information by transducer, the output of data acquisition unit exports vibration data to main control computer by the VXI agreement, main control computer exports vibration data the database server and the enterprise servers of monitoring center of enterprise to respectively, and remote diagnostic center obtains vibration data and realizes online detection by the web server.
Described data acquisition unit is the data acquisition control computer with data collecting card.
Described remote diagnostic center comprises: remote diagnosis database and web server, wherein: remote diagnostic center will be with the diagnostic device data to send into the remote diagnosis database by the web server and diagnose, simultaneously diagnostic result is published to diagnose on the internet shared.
The present invention relates to the online test method of said detecting system, may further comprise the steps:
The first step, the frequency domain vector of vibration signal is carried out normalization operation, the energy and the upper limit thereof that define six frequency ranges are respectively one times to five frequency multiplication energy.
The second warning limit value that goes on foot, is provided with above-mentioned six frequency ranges is respectively 0.4,0.2,0.1,0.3,0.6 and 0.4 times of energy and relatively can whether has fault by checkout equipment by six frequency range calculating energies and warning limit value to image data.
Advantage of the present invention is:
1) carries out data communication by Ethernet between enterprise monitoring station, monitoring center of enterprise, the remote fault diagnosis center, he can make full use of the internet network of public character, switched telephone network or integrated services digital network (ISDN) etc., not only construction cost and operating cost are all very low, produce simultaneously, installation and maintenance management be very simple, be easy to popularize.
2) solved enterprises expert limited amount problem.Because the enterprises professional and technical personnel is fewer, the expert tended to because the delay of time causes enormous economic loss again owing to the region reason can not be in time when equipment broke down.And take this economy of remote diagnosis, easy method field data in time to be delivered in expert's hand by computer, just can judge accurately and timely at the scene, adopt an effective measure and deal with problems as the expert.
3) realized sharing of diagnostic knowledge, avoided knowledge repeat obtain.In large-scale global enterprise, enterprise with like device often is distributed in different regions, they can use the identical diagnostic system based on knowledge fully, in the course of the work, the new regulation of finding in an enterprise may be unknown for another enterprise fully, this will cause same knowledge acquisition process to repeat in many different areas, and the time has been wasted.And native system can make the on-the-spot and same diagnostic center foundation of different monitoring, diagnosings get in touch, all diagnostic messages all can be obtained by network, the user who makes in different enterprises shares same diagnostic knowledge, can collect knowledge as much as possible by Internet, only need obtain diagnostic knowledge and once just can make all enterprises all use it.
4) six band energies that propose of the present invention divide alarm method, have overcome that traditional failure diagnosis alarm method is insensitive to fault, alarm response waits shortcoming slowly, can effectively reach accurate identification rotating machinery fault state, make warning.
Description of drawings
Fig. 1 is a structural representation of the present invention.
Fig. 2 is the pie graph of enterprise monitoring station.
Fig. 3 is the pie graph of monitoring center of enterprise.
Fig. 4 is a remote fault diagnosis center schematic diagram.
Embodiment
Below embodiments of the invention are elaborated, present embodiment is being to implement under the prerequisite with the technical solution of the present invention, provided detailed execution mode and concrete operating process, but protection scope of the present invention is not limited to following embodiment.
Embodiment 1
As shown in Figure 1, present embodiment comprises: data acquisition unit, transducer, main control computer and remote diagnostic center, wherein: the input of data acquisition unit links to each other with field apparatus and collecting device information by transducer, the output of data acquisition unit exports vibration data to main control computer by the VXI agreement, main control computer exports vibration data to database and Web server respectively, and remote diagnostic center obtains vibration data and realizes online detection by the web server.
Described data acquisition unit comprises:
As shown in Figure 4, described remote diagnostic center comprises:
Present embodiment relates to the online test method of above-mentioned remote diagnostic center, may further comprise the steps:
The first step, the frequency domain vector of vibration signal is carried out normalization operation, the energy and the upper limit thereof that define six frequency ranges are respectively one times to five frequency multiplication energy.
The second warning limit value that goes on foot, is provided with above-mentioned six frequency ranges is respectively 0.4,0.2,0.1,0.3,0.6 and 0.4 times of energy and relatively can whether has fault by checkout equipment by six frequency range calculating energies and warning limit value to image data.
Bently rotor experimental bench RK4, critical piece comprises motor, base unit, arrangement for controlling motor speed, sensor device and some selectable units.Utilize this rotor test platform can simulate a lot of most common failures that produce rotor, the counterweight screws of 3.2mg is installed on rotor disk, come the imbalance fault of model rotor, by the signals collecting work station transmission of the vibration signal of this experimental bench is entered remote diagnostic center, at last signal is carried out six frequency range analyses, six band energies that draw are respectively 0.6,0.1,0.08,0.2,0.7,0.3 comparison threshold value is provided with band energy 1 and 5 as can be known and exceeds standard, and if use conventional frequency spectrum analysis method, can only judge that by virtue of experience this rotating machinery is in improper malfunction by artificial observation.
Embodiment 3
Utilize the Bently rotor experimental bench of embodiment 1, can simulate at the rotor side surface mounting screw and bump the fault of rubbing.By the step according to embodiment 1, six band energies that obtain at last are respectively 0.3,0.15,0.07,0.25,0.5,0.4 comparison threshold value this rotor signal as can be known is provided with band energy 2 and 4 and exceeds standard, present embodiment is successfully diagnosed the malfunction except rotating machinery as can be known.
Embodiment 4
The technical method that present embodiment proposed is applied to obtained good monitoring and diagnosis effect in the on-line monitoring and fault diagnosis system of certain iron and steel group coal coke-oven plant substantial equipment air blast.The scene has two air blast units, is out that one is equipped with in normal operation, and native system all is equipped with transducer on two air blasts, and there are two data acquisition units on-the-spot enterprise monitoring station, respectively two air blasts is carried out data acquisition.By the analysis to on-the-spot vibration data, six band energies of two air blasts are respectively 0.35,0.12,0.05,0.21,0.42,0.22 and 0.3,0.11,0.03,0.15,0.36 0.0.21 is with alarm threshold value contrast and exceeds standard, this blower unit does not break down as can be known.
The six band energy analytical techniques that provide by present embodiment, but the time enterprise effectively monitor for the fault of rotating machinery and judge, overcome the shortcoming of traditional diagnostic method that depends on attendant's experience, improved diagnosis efficiency greatly.
Claims (4)
1. the rotating machinery fault detection system of a realization Network Based, it is characterized in that, comprise: enterprise monitoring station, monitoring center of enterprise and remote diagnostic center, wherein: the enterprise monitoring station is made up of data acquisition unit, transducer and main control computer, and monitoring center of enterprise is become with database servers group by enterprise servers; The input of data acquisition unit links to each other with field apparatus and collecting device information by transducer, the output of data acquisition unit exports vibration data to main control computer by the VXI agreement, main control computer exports vibration data the database server and the enterprise servers of monitoring center of enterprise to respectively, and remote diagnostic center obtains vibration data and realizes online detection by the web server.
2. the rotating machinery fault detection system of realization Network Based according to claim 1 is characterized in that, described data acquisition unit is the data acquisition control computer with data collecting card.
3. the rotating machinery fault detection system of realization Network Based according to claim 1, it is characterized in that, described remote diagnostic center comprises: remote diagnosis database and web server, wherein: remote diagnostic center will be with the diagnostic device data to send into the remote diagnosis database by the web server and diagnose, simultaneously diagnostic result is published to diagnose on the internet shared.
4. the online test method according to the described detection system of above-mentioned arbitrary claim is characterized in that, may further comprise the steps:
The first step, the frequency domain vector of vibration signal is carried out normalization operation, the energy and the upper limit thereof that define six frequency ranges are respectively one times to five frequency multiplication energy;
The second warning limit value that goes on foot, is provided with above-mentioned six frequency ranges is respectively 0.4,0.2,0.1,0.3,0.6 and 0.4 times of energy and relatively can whether has fault by checkout equipment by six frequency range calculating energies and warning limit value to image data.
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| CN102291278A (en) * | 2011-08-09 | 2011-12-21 | 上海辉格科技发展有限公司 | Remote test/calibration/service system and method of sensor or/and device |
| CN103200232A (en) * | 2013-03-04 | 2013-07-10 | 南京三埃工控股份有限公司 | Remote support system and remote support method of belt weigher |
| CN103905230A (en) * | 2012-12-28 | 2014-07-02 | 苏州工业园区进一科技有限公司 | Online abnormity management system |
| CN107218999A (en) * | 2017-06-08 | 2017-09-29 | 攀钢集团西昌钢钒有限公司 | Continuous annealing unit fan vibration diagnostic device |
| CN109102001A (en) * | 2018-07-16 | 2018-12-28 | 东南大学 | A kind of gene improve the rotor on-line fault diagnosis method of neural network |
| CN109470437A (en) * | 2018-10-19 | 2019-03-15 | 临沂矿业集团有限责任公司 | A kind of ground installation sensory perceptual system |
| CN109642853A (en) * | 2016-08-29 | 2019-04-16 | 韩国水力原子力株式会社 | Rotating device inline diagnosis/forecasting system |
| CN111259737A (en) * | 2020-01-08 | 2020-06-09 | 科大讯飞股份有限公司 | Method and device for predicting vehicle steering wheel fault, electronic equipment and storage medium |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN102291278A (en) * | 2011-08-09 | 2011-12-21 | 上海辉格科技发展有限公司 | Remote test/calibration/service system and method of sensor or/and device |
| CN103905230A (en) * | 2012-12-28 | 2014-07-02 | 苏州工业园区进一科技有限公司 | Online abnormity management system |
| CN103200232A (en) * | 2013-03-04 | 2013-07-10 | 南京三埃工控股份有限公司 | Remote support system and remote support method of belt weigher |
| CN103200232B (en) * | 2013-03-04 | 2015-10-28 | 南京三埃工控股份有限公司 | Belt conveyer scale remote support system and remote supporting method |
| CN109642853A (en) * | 2016-08-29 | 2019-04-16 | 韩国水力原子力株式会社 | Rotating device inline diagnosis/forecasting system |
| CN107218999A (en) * | 2017-06-08 | 2017-09-29 | 攀钢集团西昌钢钒有限公司 | Continuous annealing unit fan vibration diagnostic device |
| CN109102001A (en) * | 2018-07-16 | 2018-12-28 | 东南大学 | A kind of gene improve the rotor on-line fault diagnosis method of neural network |
| CN109470437A (en) * | 2018-10-19 | 2019-03-15 | 临沂矿业集团有限责任公司 | A kind of ground installation sensory perceptual system |
| CN111259737A (en) * | 2020-01-08 | 2020-06-09 | 科大讯飞股份有限公司 | Method and device for predicting vehicle steering wheel fault, electronic equipment and storage medium |
| CN111259737B (en) * | 2020-01-08 | 2023-07-25 | 科大讯飞股份有限公司 | Method and device for predicting failure of steering wheel of vehicle, electronic equipment and storage medium |
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Application publication date: 20110713 |