CN106089754B - Immersible pump real-time fault diagnosis and method for maintaining based on " internet+" - Google Patents
Immersible pump real-time fault diagnosis and method for maintaining based on " internet+" Download PDFInfo
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- CN106089754B CN106089754B CN201610531397.6A CN201610531397A CN106089754B CN 106089754 B CN106089754 B CN 106089754B CN 201610531397 A CN201610531397 A CN 201610531397A CN 106089754 B CN106089754 B CN 106089754B
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D15/00—Control, e.g. regulation, of pumps, pumping installations or systems
- F04D15/0088—Testing machines
Abstract
The invention discloses the immersible pump real-time fault diagnosis and method for maintaining that are based on " internet+".Process of the invention are as follows: pressure sensor, turbine flowmeter, Speed sensing formula sensor, vibrating sensor and current sensor are installed in immersible pump pump group and pipe-line system；Operation is based on the immersible pump real-time fault diagnosis and maintenance system of " internet+"；The signal issued using each sensor of data collecting module collected, and establish the data communication between immersible pump real-time fault diagnosis and maintenance system and PLC；Real-time data analysis and diagnosis are carried out to the data-signal of reading, the failure being diagnosed to be is saved in Mishap Database, and provide optimal fault solution, issues fault pre-alarming notice；Maintenance effect is estimated, and breakdown maintenance scheme is saved in maintenance management database.The present invention effectively combines " internet+" technology and fault diagnosis technology, realizes the long-range initial failure early warning and maintenance of immersible pump, reduces the downtime.
Description
Technical field
The invention belongs to fluid machinery Intelligent Diagnosis Technology field, the immersible pump for refering in particular to be related to being based on " internet+" is real-time
Fault diagnosis and method for maintaining.
Background technique
The industry internet epoch have arrived, the utilization and analysis of big data, and digitlization, networking and intelligence have become
The important feature of water pump industry development is the Main way of water pump Future Development of Enterprise.The development in " internet+water pump " future is fought
It slightly, is sufficiently to be merged " internet+" technology in each stage such as design, research and development, manufacture, marketing, maintenance with water pump,
To improve the efficiency of operation of entire water pump industry.Water pump real-time fault diagnosis and maintenance based on " internet+", exactly use
" internet+" technology, data analysis and fault diagnosis technology are measured in real time to water pump and failure anticipation, takes for pump maintenance
Business personnel provide maintenance opinion, to make water pump assembly safe and stable operation.
Currently, Pump Fault Diagnosis and method for maintaining based on " internet+" are also immature, such as: master thesis " base
Studied in power plant's water pump vibration online monitoring of industry internet " (in June, 2014) using data under industry internet networking
The on-line monitoring and expert diagnosis of power plant's water pump vibration signal are realized, but the failure of water pump is not only temperature caused by vibrating
Degree and electric current are likely to cause fault of water pump；Utility model patent " the thermal power plant turbine pumping unit failure based on industry internet
Early warning and inspection optimization system " (application number: 201520176105.2) describe a kind of thermal power plant turbine based on industry internet
Pumping unit fault pre-alarming and inspection optimization system, which is only applicable to thermal power plant's pump, and the system is according only to historical data
Carry out breakdown judge.
Summary of the invention
(1) technical problems to be solved
The problem of for above-mentioned existing Pump Fault Diagnosis Internet-based and method for maintaining, the present invention is directed to
A kind of immersible pump real-time fault diagnosis and method for maintaining being based on " internet+" is provided.
(2) technical solution
In order to solve the above technical problems, the technical scheme adopted by the invention is that: based on " internet+" exploitation immersible pump fortune
Row condition monitoring and diagnostic system, the signal issued using each sensor of data collecting module collected, using PLC
(Programmable Logic Controller) technology converts the signals into digital signal, establishes diving pump operation shape
Data communication between state monitor and diagnosis system and PLC, the data of reading data in real-time acquisition module, and to the data of reading
Signal carries out real-time data analysis and operational diagnostics, pre-alert notification is issued after being diagnosed to be the failure being likely to occur, with SMS
Mode notify maintenance personal to overhaul, finally the immersible pump operating status after maintenance is monitored in real time, estimates maintenance
Effect, and breakdown maintenance scheme is saved in maintenance management database.The specific steps of which are as follows:
(1) pressure sensor, turbine flowmeter, Speed sensing formula sensing are installed in immersible pump pump group and pipe-line system
Device, vibrating sensor and current sensor.The no-load loss that immersible pump submersible motor is measured using electrical measuring method, draws out iron loss
It is consumed with machinery.The revolving speed n of immersible pump is obtained by inductosyn measurement, and flow Q is by the whirlpool in submersible pump outlet pipe-line system
Flowmeters measurement obtains, and submersible pump outlet pressure Po is obtained by the pressure sensor measurement of pump discharge pipe road.Submersible motor
It is obtained with the vibration severity of immersible pump by vibrating sensor measurement.The pressure sensor, speed probe, vibrating sensor and
Current sensor needs to do water-proofing treatment, prevents water from entering in sensor, to ensure the sensitivity of sensor.
(2) it using WinCC design immersible pump running state monitoring and diagnostic system, is realized using PLC technology to immersible pump
The process control of operating status.A VPN service is set up in the Intranet resource of immersible pump running state monitoring and diagnostic system
Device.The remote of immersible pump operating status is realized by the mobile 2G/3G/4G network of mobile phone or mobile phone wireless network linking vpn server
Range monitoring.Communication data between vpn server and cell phone is encrypted, to guarantee the safety of data transmission.
(3) it is passed using data collecting module collected pressure sensor, turbine flowmeter, Speed sensing formula sensor, vibration
The current signal for 4~20mA that sensor and current sensor issue.Data are carried out using current signal of the PLC technology to acquisition to turn
It changes.A/D is carried out by PLC and is converted into digital signal, while being established between immersible pump running state monitoring and diagnostic system and PLC
Data communication.The lift H of immersible pump is calculated by the pressure Po of 2 times away from pump discharge flange calibers,Wherein ρ
For the density of centrifugal pump pumped (conveying) medium, g is acceleration of gravity, and the unit of g=9.8, g are m/s2；Unloaded according to submersible motor
Iron loss and mechanical consumption, the submersible motor output power after calculating load test, i.e. the input power P of immersible pump；Efficiency eta is by public affairs
Formula η=ρ gQH/P is calculated.To the data such as flow, pressure, revolving speed, lift, power, efficiency, vibration, electric current carry out storage and
Backup.
(4) data such as flow, pressure, revolving speed, lift, power, efficiency, the electric current read in step (3) are carried out real-time
Trend analysis and spectrum analysis.Wavelet decomposition is carried out to the vibration signal that step (3) are read, the wavelet coefficient of high band is used
Hlibert-Huang transformation carries out Envelope Analysis, then the envelope signal that Envelope Analysis is obtained using Empirical mode decomposition into
Row decomposes.It is diagnosed to be supercurrent, bearing damage, rotor misalignment, the loosening of pump group foundation bolt, damage in impeller or impeller and the pump housing
After the failure that contact etc. is likely to occur, using the popularization of mobile Internet, efficient and rational failure is searched in the world
Solution, and failure pre-alert notification is issued, failure and fault solution are notified into maintenance personal in a manner of SMS.
(5) the immersible pump operating status after maintenance is monitored in real time, estimates maintenance effect, and by breakdown maintenance scheme
It is saved in maintenance management database.
(3) beneficial effect
The present invention has the advantages that
(1) " internet+" technology and fault diagnosis technology are effectively combined, the early stage for realizing diving failure of pump is pre-
Alert and maintenance, so that pump group safe and stable operation.
(2) failure that line real time diagnosis proof submersible sand discharging pump is likely to occur can not only reduce submersible sewage failure of pump and stop
The machine time, moreover it is possible to provide technical support for maintenance personal, reduce maintenance cost.
(3) popularization for utilizing mobile Internet, can search efficient and rational fault solution in the world, into
One step improves trouble diagnosibility and maintenance effect.
Detailed description of the invention
Fig. 1 is based on the immersible pump running state monitoring of " internet+" and the schematic diagram of repair method；
In figure, 1- water pump vibrating sensor, 2- proof submersible sand discharging pump, 3- induction type speed probe, 4- motor oscillating sensing
Device, 5- submersible motor, 6- pump discharge pressure sensor, 7- current sensor, 8- immersible pump running state monitoring and diagnostic system,
9- turbine flowmeter, 10- export gate valve.
Specific embodiment
With reference to the accompanying drawings and examples, specific embodiments of the present invention will be described in further detail.Implement below
Example is not intended to limit the scope of the invention for illustrating the present invention.
Embodiment: the WQK25-40-7.5 type proof submersible sand discharging pump (Fig. 1) that a specific revolution is 54.6, design discharge Qd
=25m3/h, rated lift Hd=40m, revolving speed n=2860r/min.Specific step is as follows:
(1) pressure sensor, turbine flowmeter, Speed sensing formula sensing are installed in immersible pump pump group and pipe-line system
Device, vibrating sensor and current sensor.The no-load loss that immersible pump submersible motor is measured using electrical measuring method, draws out iron loss
It is consumed with machinery.The revolving speed n of immersible pump is obtained by inductosyn measurement, and flow Q is by the whirlpool in submersible pump outlet pipe-line system
Flowmeters measurement obtains, and submersible pump outlet pressure Po is obtained by the pressure sensor measurement of pump discharge pipe road.Submersible motor
It is obtained with the vibration severity of immersible pump by vibrating sensor measurement.The pressure sensor, speed probe, vibrating sensor and
Current sensor needs to do water-proofing treatment, prevents water from entering in sensor, to ensure the sensitivity of sensor.As the flow Q of pump
When=27.1m3/h, revolving speed n=2866r/min, outlet pressure Po=0.38MPa, motor oscillating speed is 0.94mm/s, pump vibration
Dynamic speed is 0.82mm/s.
(2) it using WinCC design immersible pump running state monitoring and diagnostic system, is realized using PLC technology to immersible pump
The process control of operating status.A VPN service is set up in the Intranet resource of immersible pump running state monitoring and diagnostic system
Device.The remote of immersible pump operating status is realized by the mobile 2G/3G/4G network of mobile phone or mobile phone wireless network linking vpn server
Range monitoring.Communication data between vpn server and cell phone is encrypted, to guarantee the safety of data transmission.
(3) it is passed using data collecting module collected pressure sensor, turbine flowmeter, Speed sensing formula sensor, vibration
The current signal for 4~20mA that sensor and current sensor issue.Data are carried out using current signal of the PLC technology to acquisition to turn
It changes.A/D is carried out by PLC and is converted into digital signal, while being established between immersible pump running state monitoring and diagnostic system and PLC
Data communication.The lift H of immersible pump is calculated by the pressure Po of 2 times away from pump discharge flange calibers,Wherein ρ
For the density of centrifugal pump pumped (conveying) medium, g is acceleration of gravity, and the unit of g=9.8, g are m/s2；Unloaded according to submersible motor
Iron loss and mechanical consumption, the submersible motor output power after calculating load test, i.e. the input power P of immersible pump；Efficiency eta is by public affairs
Formula η=ρ gQH/P is calculated.By above-mentioned formula it can be calculated that as Q=27.1m3/h, n=2866r/min, H=
39.9m, P=6.5kW, η=61.3%.The data such as flow, pressure, revolving speed, lift, power, efficiency, vibration, electric current are carried out
Storage and backup.
(4) data such as flow, pressure, revolving speed, lift, power, efficiency, the electric current read in step (3) are carried out real-time
Trend analysis and spectrum analysis.Wavelet decomposition is carried out to the vibration signal that step (3) are read, the wavelet coefficient of high band is used
Hlibert-Huang transformation carries out Envelope Analysis, then the envelope signal that Envelope Analysis is obtained using Empirical mode decomposition into
Row decomposes.It is diagnosed to be supercurrent, bearing damage, rotor misalignment, the loosening of pump group foundation bolt, damage in impeller or impeller and the pump housing
After the failure that contact etc. is likely to occur, using the popularization of mobile Internet, efficient and rational failure is searched in the world
Solution, and failure pre-alert notification is issued, failure and fault solution are notified into maintenance personal in a manner of SMS.
(5) the immersible pump operating status after maintenance is monitored in real time, estimates maintenance effect, and by breakdown maintenance scheme
It is saved in maintenance management database.
The above is only a preferred embodiment of the present invention, it is noted that for the ordinary skill people of the art
For member, without departing from the technical principles of the invention, several improvements and modifications can also be made, these improvements and modifications
Also it should be regarded as protection scope of the present invention.
Claims (6)
1. being based on the immersible pump real-time fault diagnosis and method for maintaining of " internet+", it is characterised in that the following steps are included:
(1) pressure sensor, turbine flowmeter, Speed sensing formula sensor, vibration are installed in immersible pump pump group and pipe-line system
Dynamic sensor and current sensor；
(2) operation is based on the immersible pump real-time fault diagnosis and maintenance system of " internet+"；
(3) signal issued using each sensor of data collecting module collected, converts the signal into digital letter using PLC technology
Number, and establish the data communication between immersible pump real-time fault diagnosis and maintenance system and PLC；
(4) real-time data analysis and diagnosis are carried out to the data-signal of reading, the failure being diagnosed to be are saved in Mishap Database,
And the failure being diagnosed to be is analyzed, optimal fault solution is provided, fault pre-alarming notice is issued；
(5) the immersible pump operating status after maintenance is monitored in real time, estimates maintenance effect, and breakdown maintenance scheme is saved
To maintenance management database；
Real-time data analysis and diagnosis are carried out to the data-signal of reading in the step (4), the failure being diagnosed to be is saved in
Mishap Database, and the failure being diagnosed to be is analyzed, optimal fault solution is provided, fault pre-alarming notice is issued
Specific step is as follows:
(A) real-time tendency is carried out to data such as flow, pressure, revolving speed, lift, power, efficiency, the electric currents read in step (3)
Analysis and spectrum analysis；
(B) wavelet decomposition is carried out to the vibration signal that step (3) are read, Hlibert- is used to the wavelet coefficient of high band
Huang transformation carries out Envelope Analysis, then is decomposed using Empirical mode decomposition to the envelope signal that Envelope Analysis obtains；
(C) failure being diagnosed to be is analyzed, and using the popularization of mobile Internet, searches efficiently close in the world
The fault solution of reason, and issue failure pre-alert notification；
The development procedure of immersible pump real-time fault diagnosis and maintenance system in the step (2) based on " internet+" is as follows:
(A) it using WinCC (Windows Control Center) design immersible pump running state monitoring and diagnostic system, utilizes
PLC technology realizes the process control to immersible pump operating status；
(B) vpn server is set up in the Intranet resource of immersible pump running state monitoring and diagnostic system, is moved by mobile phone
Dynamic 2G/3G/4G network or mobile phone wireless network linking vpn server realize the long-range monitoring of immersible pump operating status；
(C) communication data between vpn server and cell phone is encrypted.
2. the immersible pump real-time fault diagnosis and method for maintaining, feature according to claim 1 based on " internet+" exists
In:
Pressure sensor, turbine flowmeter, Speed sensing formula are installed in immersible pump pump group and pipe-line system in the step (1)
Specific step is as follows for sensor, vibrating sensor and current sensor:
(A) pressure sensor, turbine flowmeter, Speed sensing formula sensor, vibration are installed in immersible pump pump group and pipe-line system
Dynamic sensor and current sensor；
(B) no-load loss that immersible pump submersible motor is measured using electrical measuring method draws out iron loss and mechanical consumption；
(C) the revolving speed n of immersible pump is obtained by inductosyn measurement, and flow Q is by the turbine in submersible pump outlet pipe-line system
Flow measurement measures, and submersible pump outlet pressure Po is obtained by the pressure sensor measurement of pump discharge pipe road；
(D) vibration severity of submersible motor and immersible pump is obtained by vibrating sensor measurement.
3. the immersible pump real-time fault diagnosis and method for maintaining, feature according to claim 1 based on " internet+" exists
In:
The signal issued in the step (3) using each sensor of data collecting module collected is turned signal using PLC technology
It changes digital signal into, and establishes the specific steps of the data communication between immersible pump real-time fault diagnosis and maintenance system and PLC
It is as follows:
(A) data collecting module collected pressure sensor, turbine flowmeter, Speed sensing formula sensor, vibrating sensor are used
The current signal of the 4~20mA issued with current sensor；
(B) data conversion is carried out using current signal of the PLC technology to acquisition, A/D is carried out by PLC and is converted into digital signal,
The data communication between immersible pump running state monitoring and diagnostic system and PLC is established simultaneously；
(C) data processing；The lift H of immersible pump is calculated by the pressure Po of 2 times away from pump discharge flange calibers,
Wherein ρ is the density of centrifugal pump pumped (conveying) medium, and g is acceleration of gravity, and the unit of g=9.8, g are m/s2；According to submersible motor sky
The iron loss of load and mechanical consumption, the submersible motor output power after calculating load test, i.e. the input power P of immersible pump；Efficiency eta
It is calculated by formula η=ρ gQH/P；
(D) data such as flow, pressure, revolving speed, lift, power, efficiency, vibration, electric current are stored and is backed up.
4. the immersible pump real-time fault diagnosis and method for maintaining, feature according to claim 1 based on " internet+" exists
In: the failure being diagnosed to be supercurrent, bearing damage, rotor misalignment, pump group foundation bolt loosen, damage in impeller or
Impeller is contacted with the pump housing.
5. the immersible pump real-time fault diagnosis and method for maintaining according to claim 1 or 3 based on " internet+", special
Sign is: the pre-alert notification is that failure and fault solution are notified maintenance personal in a manner of SMS.
6. according to claim 1,2 and 3 described in any item immersible pump real-time fault diagnosis based on " internet+" and maintenance side
Method, it is characterised in that: the pressure sensor, speed probe, vibrating sensor and current sensor need to do water-proofing treatment,
Prevent water from entering in sensor.
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| CN108241346A (en) * | 2017-12-05 | 2018-07-03 | 北京智拓博科技有限公司 | Fluid machinery intelligent monitor system and its method |
| CN108412780B (en) * | 2018-03-13 | 2020-05-05 | 福建省福安市力德泵业有限公司 | Automatic coupling variable-speed pump and control method |
| CN108757502A (en) * | 2018-05-15 | 2018-11-06 | 江苏大学 | A kind of water pump assembly typical case's health status monitoring device and method based on Internet of Things |
| CN109538459B (en) * | 2018-10-17 | 2021-04-30 | 重庆川仪自动化股份有限公司 | Machine pump equipment fault monitoring operation and maintenance system and method based on networking |
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| CN111336100A (en) * | 2020-04-10 | 2020-06-26 | 中国恩菲工程技术有限公司 | Water pump fault diagnosis system |
| CN111980938A (en) * | 2020-08-22 | 2020-11-24 | 浙江水利水电学院 | Diagnosis technical route of flood control and drainage water pump unit |
| CN112377398A (en) * | 2020-12-01 | 2021-02-19 | 博利源科技(南京)有限公司 | Safety monitoring system of submersible pump |
| CN117570039B (en) * | 2024-01-16 | 2024-04-12 | 山东大洋矿用设备有限公司 | Mining flameproof submersible sand discharge electric pump fault monitoring system and method |
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| CN103016321A (en) * | 2011-09-20 | 2013-04-03 | 朗德华信（北京）自控技术有限公司 | System and method for managing and controlling water pump based on cloud computing |
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