CN102619684B

CN102619684B - Fault diagnosis method and system

Info

Publication number: CN102619684B
Application number: CN201110034115.9A
Authority: CN
Inventors: 陈卓; 蔡旋; 杨松; 苏丽营
Original assignee: Sinovel Wind Group Co Ltd
Current assignee: Sinovel Wind Group Co Ltd
Priority date: 2011-01-31
Filing date: 2011-01-31
Publication date: 2014-07-09
Anticipated expiration: 2031-01-31
Also published as: CN102619684A

Abstract

The invention discloses a fault diagnosis method and system which are used for solving the problems that equipment is started and stopped frequently in the prior art and the like. The fault diagnosis method comprises the following steps of: acquiring redundant measurement data; processing the redundant measurement data and performing fault diagnosis; triggering a fault program and running a restarting program; and setting a threshold value and a restarting hysteresis value during fault diagnosis. According to the method, a fan cannot be started normally after failing until an actually measured value of a part to be measured does not trigger the threshold value added with the restarting hysteresis value, so that the equipment safety is guaranteed, and a phenomenon that the fan is frequently started and stopped because of the same fault is avoided; when a key value of a wind driven power generator set is measured, unnecessary fault alarm can be well avoided by adopting a redundancy technology, so that manmade mistakes are avoided, alarm halt caused by hardware fault of a measurement sensor is reduced, the accuracy of a measured value is improved, and the wind driven power generator set has relatively high performance under a severe condition.

Description

Method for diagnosing faults and system

Technical field

The present invention relates to a kind of fault diagnosis technology, relate in particular to a kind of method for diagnosing faults for wind power generating set redundant measurement and system.

Background technique

The fault diagnosis of wind power generating set is the important component part of its electric control system, automatical control system carrys out the state of various peripheral unit, Interface Module and software program in supervisory system by fault diagnosis, thereby the running state of controlled system, in case of abnormal conditions can provide alarm automatically, hardware device in Protection control system, thereby ensure the working life of key components and parts, for operator provide fault prompting easily, be convenient to related commissioning and maintenance; At present, in industry, measure and also do not adopt widely redundancy for wind power generating set critical quantity, just use single-sensor composition measuring system to measure critical quantity; What existing scheme fault diagnosis technology mainly adopted is the mode of scan round major error flag bit array, this mode refers in software program, unit electric control system out of order generation all by fault flag of corresponding triggering, be a major error Mark Array by these flag bit unified definitions, the each program cycle of PLC controller is by this array of scanning, the flag bit position that obtains being triggered in array and corresponding failure code, and it is saved and is sent to operation screen and upper-position unit shows.When operator are shielded by operation and fault is resetted upper-position unit, exception handles is called, and now system is carried out reset operation, and the zero clearing that major error flag bit array is carried out by turn resets.

Such scheme mainly contains following shortcoming:

1), aspect the measurement of blower fan critical quantity, existing scheme is not also used redundancy on a large scale, causes system to cause disorderly closedown because of the fault of sensor or measurement error, has reduced the mean time between failures of blower fan.

2) each fault treatment is all by fault position is resetted; be not adjusted to the time of normal state to corresponding equipment; can cause like this failure reset rear fan to start very soon; but due to identical mistake disorderly closedown again; start and stop meeting increasing device to a great extent and the wearing and tearing of parts so frequently; reduce its working life, thereby reduce working life and the mean time between failures of blower fan, the benefit of fan has been brought very large impact.

Summary of the invention

The invention provides a kind of method for diagnosing faults and system, in order to solve defect of the prior art, realize and reducing the disorderly closedown frequency, extension device working life and the Mean time to failure that cause because of measurement error.

The embodiment of the present invention provides a kind of method for diagnosing faults, comprising:

Step 1, all establishes at least one sensor in each measuring point, and the survey data of described sensor is carried out respectively to interval collection;

Step 2, judges that through data processor this survey data is whether within the scope of described sensor settings by the survey data of above-mentioned collection; If obtaining measured value also by this measured value input fault determining program; If do not sending measurement alarm signal;

Step 21, judgement is arranged on the number of the described sensor of single measuring point;

Step 22, reads survey data and enters described data processor if described sensor is one; This data processor judges whether this survey data meets setting range; To obtain measured value and enter fault determining program; No, send failure alarm signal;

Step 23, reads respectively survey data and enters described data processor if sensor is two; Judge described survey data whether in setting range separately and difference whether in setting range;

Step 24, if having one in setting range in two described survey data, taking this survey data as measured value enters described fault determining program send the measurement failure alarm signal of sensor of another survey data of output; If two described survey data all in setting range separately, enter fault determining program taking the mean value of two described survey data as measured value; If two described survey data all not in setting range or the difference of two described survey data not in setting range, send the measurement failure alarm signal of two described sensors;

Step 3, input fault word in malfunction routine; Described malfunction routine comprises major error program and modular program, difference input fault word in described modular program, and major error program is obtained respectively described fault word from described modular program;

Step 4, whether the measured value that whether meets the limit value corresponding with described fault word and this input according to the measured value of last time input meets limit value that described fault word is corresponding and restarts stagnant ring value sum and judge whether to trigger described malfunction routine and enter reset routine;

Step 41, judges whether last measured value has triggered this fault word;

Step 42, if this fault word is not triggered, judges whether this measured value meets the limit value that this fault word is corresponding; Satisfied trigger this fault word, do not meet and enter program cycle;

Step 43, if this fault word is triggered, judges whether this measured value meets the limit value that this fault word is corresponding and restart stagnant ring value sum; Satisfied lock described reset routine; After reset operation instruction, carry out reset routine this fault word in described major error program is resetted receiving if do not meet, and restart program and start blower fan receiving to carry out after restart command.

A kind of fault diagnosis system, comprises at least two sensors and the PLC controller being connected with described sensor by data acquisition channel respectively, and the corresponding measuring point setting of every two described sensors, is characterized in that, described PLC controller comprises:

Trouble unit, shows tracing trouble for triggering according to fault judging unit the fault word being arranged in this trouble unit;

Reset unit, is connected with described trouble unit and restart unit, for moving according to the judged result of described fault judging unit;

Described restart unit, for according to the action executing restart command of described reset unit;

Data processing unit, connects described data acquisition channel and fault judging unit, inputs to described fault judging unit for the survey data of described data acquisition channel collection being processed to the measured value obtaining;

Described fault judging unit, be connected with described trouble unit, follow the limit value that this fault word is corresponding and the comparative result of restarting stagnant ring value sum to judge the action of reset unit for whether trigger the measured value of this fault word and this input according to the measured value of last time input.

Wherein, described trouble unit comprises major error unit and function module, and described function module connects described fault judging unit and described major error unit; Described function module is provided with the input end for inputting described fault word, and described major error unit is provided with the display modular for showing the described fault word being triggered.

Further, described data processing unit comprises:

Reading unit, is connected with described data acquisition channel, for reading the survey data of described sensor;

Judging unit, is connected with described reading unit, for judging that described survey data is whether in the setting range of described sensor;

Output unit, is connected with described fault judging unit and judging unit, for according to the judged result outputting measurement value of judging unit to described fault judging unit;

Alarm unit, is connected with described judging unit, sends alarm signal for the judged result according to described judging unit.

Method for diagnosing faults provided by the invention and system, in the measurement of wind power generating set critical quantity, use redundancy can finely evade unnecessary malfunction alarm, avoiding people is misoperation, for example, in various temperature, the variable of pressure and liquid level uses redundancy both can reduce the warning being caused by measuring transducer hardware fault in detecting and shuts down, can improve again the degree of accuracy of measured value, make Wind turbine can under severe situation, also give play to good performance, redundancy detection and fault diagnosis and in wind power generating set be applied as wind power generating set in real time, accurately control sound assurance is provided, in fault determining program, in limit value corresponding to fault word, add and restart stagnant ring value and judge, report to the police if the last time, this fault (as: generator drive side shaft temperature is too high) did not occur, restart stagnant ring value inoperative, if the last time has been triggered this fault, in the time that fan starting fault judges, add and restart stagnant ring value, that is: make the high limit of generator drive side shaft temperature become T2 (T2 < T1), blower fan wants the necessary wait of normal startup generator drive side shaft temperature drop to T2 like this, so both ensured the Security of equipment, also avoided blower fan because of identical faults frequent start and stop.

Brief description of the drawings

Fig. 1 is method for diagnosing faults embodiment's of the present invention flowage structure block diagram.

Fig. 2 is fault diagnosis system embodiment's of the present invention structural representation.

Fig. 3 is the flow chart of data processor in method for diagnosing faults of the present invention.

Fig. 4 is the flow chart of fault determining program in method for diagnosing faults of the present invention.

Reference character:

10-sensor; 20-data acquisition channel; 30-data processing unit;

40-fault judging unit; 50-trouble unit; 60-reset unit;

70-restart unit.

Embodiment

For making object, technological scheme and the advantage of the embodiment of the present invention clearer, below in conjunction with the accompanying drawing in the embodiment of the present invention, technological scheme in the embodiment of the present invention is clearly and completely described, obviously, described embodiment is the present invention's part embodiment, instead of whole embodiments.Based on the embodiment in the present invention, those of ordinary skill in the art, not making the every other embodiment who obtains under creative work prerequisite, belong to the scope of protection of the invention.

Be illustrated in figure 1 method for diagnosing faults flow chart of the present invention, the invention provides a kind of redundant measurement method for diagnosing faults, step 1, establishes sensor in measuring point, and interval gathers the survey data of this sensor;

Step 2, judges the survey data of collection through data processor;

If this survey data obtains measured value also by this measured value input fault determining program within the scope of described sensor settings; If do not sending measurement alarm signal;

Step 3, input fault word in malfunction routine;

Step 4, whether the measured value that whether meets the limit value corresponding with described fault word and this input according to the measured value of last time input meets limit value that described fault word is corresponding and restarts stagnant ring value sum and judge whether to trigger described malfunction routine and enter reset routine.

Be illustrated in figure 2 fault diagnosis system structural representation, comprise peripheral unit and PLC controller for survey data, peripheral unit comprises at least two sensors 10, wherein every two sensors 10 corresponding measuring points (being environment, cabin cabinet, generator and gear-box in Fig. 2) arrange, sensor 10 is connected with PLC controller by data acquisition channel 20 respectively, and PLC controller comprises data processing unit 30, fault judging unit 40, trouble unit 50, reset unit 60 and restart unit 70.

Trouble unit 50, shows tracing trouble for triggering according to fault judging unit 40 the fault word being arranged in this trouble unit 50, comprise major error unit and function module, function module connects fault judging unit and major error unit, function module is provided with the input end for input fault word, and major error unit is provided with the display modular for showing the fault word being triggered, the function module here can be classified according to peripheral unit also can be according to controlling Function Classification, at this, it is classified according to peripheral unit, for example: gearbox module, generator module etc., these modules are respectively equipped with the fault word of oneself, at set intervals by gather survey data to carry out fault judgement, in the time breaking down, the fault word of Trigger Function module shows this fault word simultaneously in display modular, when fault treatment, only the fault word to major error unit carries out reset operation, the operation of the fault word of function module oneself is only determined in real time by the feedback of peripheral unit.

Reset unit 60 is connected with trouble unit 50 and restart unit 70, for moving according to the judged result of fault judging unit 40.

Restart unit 70, for according to the action executing restart command of reset unit 60.

Data processing unit 30, connection data acquisition channel 20 and fault judging unit 40, process for the survey data in sensor 10 setting ranges that data acquisition channel 20 is gathered the measured value obtaining and input to fault judging unit; The survey data gathering through data acquisition channel 20 is sent measurement failure alarm signal not in sensor 10 setting ranges time; Comprise reading unit, be connected with data acquisition channel 20, for the survey data of read sensor 10; Judging unit, is connected with reading unit, for judging that survey data is whether in the setting range of sensor 10; Output unit, is connected with fault judging unit 40 and judging unit, for according to the judged result outputting measurement value of judging unit to fault judging unit 40; Alarm unit, is connected with judging unit, sends alarm signal for the judged result according to judging unit.

Fault judging unit 40, be connected with trouble unit 50, follow the limit value that this fault word is corresponding and the comparative result of restarting stagnant ring value sum to judge the action of reset unit 60 for whether trigger the measured value of this fault word and this input according to the measured value of last time input.

Describe the specific implementation process of the method for diagnosing faults shown in Fig. 1 in detail below in conjunction with the data processor flow chart shown in the fault diagnosis system structure shown in Fig. 2, Fig. 3, the fault determining program flow chart shown in Fig. 4.

Sensor 10 in the present embodiment all adopts temperature transducer, and temperature transducer (is ambient temperature I, ambient temperature II by the survey data gathering herein; Cabin cabinet temperature I, cabin cabinet temperature II; Generator axle temperature I, generator axle temperature II; Gear-box oil temperature I, gear-box oil temperature II) after data processor processing, input the fault determining program being located in PLC controller, data processor taking a measuring point as example, first judges the number of the sensor of single measuring point as shown in Figure 3; If sensor be one by the survey data of reading unit reading out data acquisition channel 20, judge that through judging unit this measured data values is whether in the setting range at this sensor; To be delivered to fault judging unit 40 with this survey data position measured value through output unit; No, send measurement failure alarm signal through alarm unit;

If sensor is two the data I and the data II that read respectively its measurement by reading unit through data acquisition channel, judging unit judges that data I, data II are whether all in the setting range of sensor separately, be, whether the difference that judges data I and data II in setting range, is that measured value is delivered to fault judging unit 40 through output unit at the mean value of fetch data I and data II; If data I is not in setting range, data II is in setting range, and the II that fetches data is that measured value is delivered to fault judging unit 40 through output unit, and sends the measurement failure alarm signal of the sensor of image data I through alarm unit; Data I is in setting range, and data II is scope in setting range not, and the I that fetches data is that measured value is delivered to fault judging unit 40 through output unit, and sends the measurement failure alarm signal of the sensor of image data II through alarm unit; Data I and data II, all not at zone of reasonableness, send two sensors through alarm unit and measure failure alarm signal.

Although the two cover hard ware measure equipment that the measurement of each key position all adopts, but which complete equipment of choice for use is measured as required, the selection of measuring equipment can be shielded with the control panel of upper-position unit and be operated by operation, calls unified data processor and carry out data screening and processing after data capture.Each measuring transducer all has the correct scope (being setting range) of measured value, if only have a measured data values in correct scope, this measured data values is measured value, and provide another sensor and have the warning of measuring fault, this warning is not shut down, and only serves as warning; If two described measured data values all in correct scope, also need to judge that its difference is whether in correct scope, if be measured value at the mean value of two described measured data values, if do not providing corresponding malfunction alarm; All use under normal circumstances two complete equipments to measure measuring point, data processor carries out examination according to the difference of its sensor type and setting to the measured value of every suit equipment, and examination scope comprises: its measured value whether in setting range, whether two groups of measured value differences in setting range; If measured value, not in setting range, can provide malfunction alarm and relevant information, if determine, measuring equipment existing problems can, by problematic device shutdown, be used normal device, if all fault needs more exchange device; If measured value in setting range, is got the mean value of two groups of measured values for sequential operation.

In environment module, establish fault word T10, in the module of cabin, establish fault word T20, in generator module, establish fault word T30, in gearbox module, establish fault word T40, introduce the concrete course of action of fault judging unit 40 as an example of the triggering of fault word T30 example, suppose the generator axle temperature I of two 10 first round of sensor image data through being located at generator measurement position, generator axle temperature I in generator axle temperature II, generator axle temperature II all in the setting range of sensor 10 simultaneously the difference of generator axle temperature I and generator axle temperature II also in setting range, after data processor, to obtain measured value be the mean value of generator axle temperature I and generator axle temperature II and be delivered in fault judging unit 40, first judge whether the last time trigger fault word T30, because therefore first round image data does not trigger fault word T30, judge whether this measured value meets the limit value T3 corresponding according to fault word T30, if satisfied trigger the fault word T30 in trouble unit 50, in the display modular of major error unit, show fault word T30, shut down being carried out fault treatment by diagnostic device, fault treatment is complete rear by manual operation reset routine, now fault determining program judgement is carried out reset routine the fault word T30 in major error unit display modular is resetted and removed, be located at fault word T30 in the generator module removing that can not be reset, send restart command by manual operation to restart unit 70, restart unit 70 is carried out this order and is restarted blower fan, in the time that second takes turns by sensor 10 generator axle temperature image data, suppose that generator axle temperature I is in sensor 10 setting ranges, be generator axle temperature I obtain measured value after data processor, generator axle temperature I is transferred to fault judging unit 40, first next program cycle judges whether last fault word T30 is triggered while scanning this fault determining program again, because the first opinion image data has triggered fault word T30, therefore, judge that whether this measured value generator axle temperature I meets that (T3 ' is herein negative deviation with restarting stagnant ring value T3 ' sum according to limit value T3 corresponding to fault word T30, therefore, (T3+T3 ') < T3, restart stagnant ring value and also can be set to overgauge, according to concrete parameter setting), this limit value equals former limit value and adds and restart stagnant ring value, if meet, fault treatment shut down can trigger again immediately after resetting this fault word, the removing that cannot reset of this fault word, therefore blower fan cannot start at once, if do not meet, carry out reset routine and then start shooting by restarting program, like this, blower fan wants normal startup after disorderly closedown must wait for that generator shaft temperature drop is low to moderate below (T3+T3 '), has avoided the frequent start-stop causing because of same fault in prior art, has ensured the Security of equipment.

The frequent start-stop coming because of fault reset strap for fear of blower fan has added stagnant ring control in fault judgement, can be both that blower fan safely and steadily runs, start and stop frequently while having avoided breaking down again.In the time of failure definition Rule of judgment, add a delay component to each Rule of judgment.For example: generator drive side shaft temperature during higher than T1 fan trouble shut down, if do not add delay component as existing program, blower fan opens machine after resetting, very fast generator drive side shaft temperature can cause higher than T1 again shutdown again.Concrete operation method: judge and add stagnant ring value in limit value in fault, report to the police if the last time, this fault (as: generator drive side shaft temperature is too high) did not occur, stagnant ring value is inoperative, if the last time has been triggered this fault, in the time that judging, fan starting fault adds stagnant ring value, that is: make generator drive side shaft temperature high limit become T2 (T2 < T1), blower fan wants the necessary wait of normal startup generator drive side shaft temperature drop to T2 like this.So both ensure the Security of equipment, and also avoided blower fan because of identical faults frequent start and stop.

Finally it should be noted that: above embodiment only, in order to technological scheme of the present invention to be described, is not intended to limit; Although the present invention is had been described in detail with reference to previous embodiment, those of ordinary skill in the art is to be understood that: its technological scheme that still can record aforementioned each embodiment is modified, or part technical characteristics is wherein equal to replacement; And these amendments or replacement do not make the essence of appropriate technical solution depart from the spirit and scope of various embodiments of the present invention technological scheme.

Claims

1. a method for diagnosing faults, is characterized in that, comprising:

Step 3, input fault word in malfunction routine;

2. method for diagnosing faults according to claim 1, is characterized in that, described step 2 comprises:

Step 24, if having one in setting range in two described survey data, taking this survey data as measured value enters described fault determining program send the measurement failure alarm signal of sensor of another survey data of output; If two described survey data all in setting range separately and the difference of two described survey data also in setting range, enter fault determining program taking the mean value of two described survey data as measured value; If two described survey data all in the scope of setting separately but the difference of two described survey data not in setting range or two described survey data all not in setting range, send the measurement failure alarm signal of two described sensors.

3. method for diagnosing faults according to claim 2, it is characterized in that, in step 3, described malfunction routine comprises the modular program that major error program and corresponding described measuring point arrange, difference input fault word in described modular program, major error program is obtained respectively described fault word from described modular program.

4. method for diagnosing faults according to claim 3, is characterized in that, described step 4 comprises:

Step 41, judges whether last measured value has triggered this fault word;

5. a fault diagnosis system, comprises at least two sensors and the PLC controller being connected with described sensor by data acquisition channel respectively, and the corresponding measuring point setting of every two described sensors, is characterized in that, described PLC controller comprises:

6. fault diagnosis system according to claim 5, is characterized in that, described trouble unit comprises major error unit and function module, and described function module connects described fault judging unit and described major error unit; Described function module is provided with the input end for inputting described fault word, and described major error unit is provided with the display modular for showing the described fault word being triggered.

7. fault diagnosis system according to claim 6, is characterized in that, described data processing unit comprises: