CN106438310A - 一种基于监控输出压力防止柱塞泵抽空的方法 - Google Patents
一种基于监控输出压力防止柱塞泵抽空的方法 Download PDFInfo
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
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Abstract
本发明涉及柱塞泵监控技术领域,尤其涉及一种基于监控输出压力防止柱塞泵抽空的方法。其包括柱塞泵及出口管路,其特征在于,在出口管路上设有压力数据采集控制装置,数据的处理方法如下:1)、获得输出压力平均值P0:设定输出压力设定公差ΔP,在P0+ΔP线以上称为峰域;在P0‑ΔP线以下称为谷域;并分别设定峰域计数器A和谷域计数器B;设定A和B的允许差值为数值C;A和B超差次数计数器D及上线E;2)、采集压力数据Px,3)、剔除异常数据;4)、计算Px落入峰域谷域次数;5)、判断A和B差值超差的次数D是否超过预设值E,如果是,发出抽空警报.本发明与现有技术的检测方法相比,方法准确、可靠,无误报警。
Description
技术领域
本发明涉及柱塞泵监控技术领域,尤其涉及一种基于监控输出压力防止柱塞泵抽空的方法。
背景技术
柱塞泵是工业生产中普遍使用的泵送设备,其可以泵送很高的压力,但一旦抽空则会对泵造成直接损坏。如在L-CNG加气站中,储罐内的低温低压LNG液体由柱塞泵加压至20MPa左右,然后通过高压汽化器与空气换热,转换成常温高压的气体,由顺序控制盘进行分配至高压储气瓶组存储,最后经CNG加气机对车载储气瓶进行加气。柱塞泵是LNG由液体转换为气体的关键设备。
目前,行业内应用L-CNG柱塞泵普遍存在故障率高、稳定性较差的问题,其中最突出的便是泵抽空现象。若泵在长时间内抽空,则直接导致泵损坏,影响加气站的运营。
以检测柱塞泵电流、压差等方法判断柱塞泵是否抽空存在一定的缺陷,特别是在泵运行中发生抽空时,泵出口压力较高且变化较小,上述方法无法进行准确判断。
发明内容
本发明针对上述现有技术的不足,提供一种准确可靠、便于实施的基于监控输出压力防止柱塞泵抽空的方法。
本发明解决上述技术问题的技术方案如下:一种基于监控输出压力防止柱塞泵抽空的方法,包括柱塞泵及出口管路,其特征在于,在所述出口管路上设有压力数据采集控制装置,对所采集压力数据的处理方法如下:
1)、获得输出压力平均值P0:连续采集一组压力数据,去掉其中最大值和最小值,其余求平均值得到P0;设定输出压力设定公差ΔP,正常输出压力范围为:上限P0+ΔP,在P0+ΔP线以上称为峰域;下限P0-ΔP;在P0-ΔP线以下称为谷域;并分别设定峰域计数器A和谷域计数器B;设定A和B的允许差值为数值C;设定A和B的差值超过C的次数计数器D,设定E为计数器D的上限值,即连续出现的偏离预期次数超过E时,发出抽空警告;
2)、采集压力数据Px;
3)、Px异常吗?如果异常则返回到步骤2);否则转入步骤4);
4)、Px在峰域和谷域之间吗?如果是则返回到步骤2);否则转入步骤5)
5)、Px落入峰域吗?如果是则给峰域计数器A加1;否则给谷域计数器B加1;
6)、判断A和B的绝对差值是否大于C,如果不是将计数器D清零,然后转入步骤2);如果大于C,则转入步骤7);
7)、给计数器D加1,并判断计数器D的值是否大于设定值E,如果是,发出抽空警报,同时转入步骤2)继续监控;如果否,则直接转入步骤2)。
本发明的有益效果是:与现有技术的检测方法相比,本检测方法准确、可靠,无误报警,较好的对柱塞泵进行了保护。
在上述技术方案的基础上,本发明还可以做如下改进。
进一步,还包括当采集压力数据Px连续在峰域和谷域之内,而不出现在峰域和谷域之外的脉动数据情况判断:即
在上述步骤4)中,Px在峰域和谷域之间吗?如果是则经过对持续落入峰域和谷域之内的次数进行判断后再返回到步骤2),设定Px在峰域和谷域之内的次数计数器W,W数据达到的设定限值为M;具体步骤如下:
8)、如果Px在峰域和谷域之外,则使计数器W清零;如果Px在峰域和谷域之内,则使W加1,并判断W是否大于M,如果W≥M,则转入步骤9);否则直接转如步骤2)
9)、发出抽空警报后转入步骤2)。
采用上述进一步方案的有益效果是,使监控抽空更全面,即若泵后压力值持续在P0+ΔP和P0-ΔP之间变化(即长时间不出现脉动性),也确认为柱塞泵已经抽空。
进一步,所述输出压力平均值P0为动态平均值,即在选定输出压力平均值的计算步长后,每个新值被采集后,最前面的一个值会被替代。
采用上述进一步方案的有益效果是,动态平均值可以适应系统因素的变化,如估计系统需要压力调高或调低,这时本发明可以使平均值及时跟进,避免由于平均值偏差而出现误判。
进一步,步骤3)所述的Px异常为明显不该出现的数据,包括外界电磁干扰数据。
采用上述进一步方案的有益效果是,可以把非检测因素导致的数据过滤掉。
进一步,所述数据采集控制装置包括压力传感器。
进一步,所述柱塞泵为多个,多个所述柱塞泵并排设置,其输出端汇总到输出管路中,所述压力传感器安装在所述总管上。
采用上述进一步方案的有益效果是,当柱塞泵为多个并联时,输出管路也能出现周期性波动的特性,因此也适合于本发明的监控方法。
进一步,所述柱塞泵为柱塞缸,所述出口管路为所述柱塞缸出口。
采用上述进一步方案的有益效果是,当一个柱塞泵具有多个缸时,可以分别在每个柱塞缸出口设本发明监控系统,即可以具体判断哪个柱塞缸抽空。
进一步,所述柱塞泵为多个,多个所述柱塞泵并排设置,在每个柱塞泵的输出管路上分别设有压力数据采集控制装置。
采用上述进一步方案的有益效果是,通过分别设压力数据采集控制装置可以得知哪个泵被抽空。
进一步,还包括对峰域计数器A和谷域计数器B的清零,即当出现抽空警报时将A、B清零,重新开始计数。
采用上述进一步方案的有益效果是,可以去除系统误差来计算A和B的差值,以判断是否超过设定差额C。因此通过阶段性清零,有保证准确判断。
附图说明
图1为本发明一种实施例的步骤框图;
图2为本发明另一种实施例的步骤框图;
图3为本发明的压力和时间分布示意图。
具体实施方式
以下结合附图对本发明的原理和特征进行描述,所举实例只用于解释本发明,并非用于限定本发明的范围。
实施例1
如图1和图2所示,一种基于监控输出压力防止柱塞泵抽空的方法,包括柱塞泵及出口管路,其特征在于,在所述出口管路上设有压力数据采集控制装置,对所采集压力数据的处理方法如下:
1)、获得输出压力平均值P0:连续采集一组压力数据,去掉其中最大值和最小值,其余求平均值得到P0;设定输出压力设定公差ΔP,则正常输出压力范围为:上限P0+ΔP,在P0+ΔP线以上称为峰域;(指P0大于P0+ΔP);下限P0-ΔP;在P0-ΔP线以下称为谷域(指P0小于(P0-ΔP));并分别设定峰域计数器A和谷域计数器B;设定A和B的允许差值为数值C;设定A和B的差值超过C的次数计数器D,设定E为计数器D的上限值,即连续出现的偏离预期次数超过E时,发出抽空警告;
2)、采集压力数据Px;
3)、Px异常吗?如果异常则返回到步骤2);否则转入步骤4);
4)、Px在峰域和谷域之间吗?如果是则返回到步骤2);否则转入步骤5)
5)、Px落入峰域吗?如果是则给峰域计数器A加1;否则给谷域计数器B加1;
6)、判断A和B的绝对差值是否大于C,如果不是将计数器D清零,然后转入步骤2);如果大于C,则转入步骤7);
7)、给计数器D加1,并判断计数器D的值是否大于设定值E,如果是,发出抽空警报,同时转入步骤2)继续监控;如果否,则直接转入步骤2)。
所述输出压力平均值P0为动态平均值,即在选定输出压力平均值的计算步长后,每个新值被采集后,最前面的一个值会被替代。
步骤3)所述的Px异常为明显不该出现的数据,包括外界电磁干扰数据。
所述数据采集控制装置包括压力传感器。
所述柱塞泵为多个,多个所述柱塞泵并排设置,其输出端汇总到输出管路中,所述压力传感器安装在所述总管上。
所述出口管路为所述柱塞缸出口。
作为另一种监控方式,所述柱塞泵为多个,多个所述柱塞泵并排设置,在每个柱塞泵的输出管路上分别设有压力数据采集控制装置。
还包括对峰域计数器A和谷域计数器B的清零,即当出现抽空警报时将A、B清零,重新开始计数。
实施例2
如图2和图3所示,本实施例作为另一种判断抽空的思路,在实施例1的方案基础上:还包括当采集压力数据Px连续在峰域和谷域之内,而不出现在峰域和谷域之外的脉动数据情况判断:即
在上述步骤4)中,Px在峰域和谷域之间吗?如果是则经过对持续落入峰域和谷域之内的次数进行判断后再返回到步骤2),设定Px在峰域和谷域之内的次数计数器W,W数据达到的设定限值为M;具体步骤如下:
8)、如果Px在峰域和谷域之外,则使计数器W清零;如果Px在峰域和谷域之内,则使W加1,并判断W是否大于M,如果W≥M,则转入步骤9);否则直接转如步骤2)
9)、发出抽空警报后转入步骤2)。
其余与实施例1相同,不再赘述。
本发明的监控原理如下:
以LNG用柱塞泵为例,其柱塞泵活塞缸一般为双缸或者三缸,交错运动。在柱塞泵的活塞缸交错运行时,泵出口压力呈现周期性波动,即具有脉动特性,如图2所示。图中的小点代表随机采集的数据。在峰域和谷域之外的数据显示出了数据的脉动特性。柱塞泵实际运行时,其输出压力有脉动特性,波动较大,会比较对称的出现大于P0+ΔP的值和小于P0-ΔP的值,此时,柱塞泵是正常运行的。
有两种情况可以判定为柱塞泵抽空:
1);虽然分别有大于P0+ΔP的值和小于P0-ΔP的值随机出现,但两者出现较大的次数差额时,即出现在峰域和谷域的次数严重不对称时,则判为柱塞泵已经抽空;
2)、若泵后压力值持续在P0+ΔP和P0-ΔP之间变化(即长时间不出现脉动性),柱塞泵已经抽空。
从宏观上讲,进行周期性的数据采集,柱塞泵出口压力数据出现在波峰区域之外和波谷区域之外的概率是相等的。在已经采集存储的数据中,舍去偏离度较大的数据,将剩余数据求平均值P0,再将新采集的数据与之进行比较。
设定输出压力设定公差ΔP,则正常输出压力范围为:上限P0+ΔP,在P0+ΔP线以上称为峰域;下限P0-ΔP;在P0-ΔP线以下称为谷域;在确定时间段内,计算出出现在“峰域”数据的次数A和“谷域”的数据次数B,当A和B之差值比较大时,则说明柱塞泵工作状态偏离正常状态,这时再判断是否连续偏差,如果是连续偏差再确定连续偏差次数,当该次数超过预设值D时,将以此判定为泵抽空。
泵出口压力数据是实时采集并更新的,每个新值被采集后,都有一个最早采集的数据被替换,因此泵抽空检测是实时在线的。
关于设定公差ΔP,可以通过经验数据获得,即把除过异常数据之外的所有数据作为一个样本空间,取中间占40%-80%的数据作为峰域和谷域内的数据,此时设定公差ΔP就可以测算出了。
以上所述仅为本发明的较佳实施例,并不用以限制本发明,凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (9)
1.一种基于监控输出压力防止柱塞泵抽空的方法,包括柱塞泵及出口管路,其特征在于,在所述出口管路上设有压力数据采集控制装置,对所采集压力数据的处理方法如下:
1)、获得输出压力平均值P0:连续采集一组压力数据,去掉其中最大值和最小值,其余求平均值得到P0;设定输出压力设定公差ΔP,正常输出压力范围为:上限P0+ΔP,在P0+ΔP线以上称为峰域;下限P0-ΔP;在P0-ΔP线以下称为谷域;并分别设定峰域计数器A和谷域计数器B;设定A和B的允许差值为数值C;设定A和B的差值超过C的次数计数器D,设定E为计数器D的上限值,即连续出现的偏离预期次数超过E时,发出抽空警告;
2)、采集压力数据Px;
3)、Px异常吗?如果异常则返回到步骤2);否则转入步骤4);
4)、Px在峰域和谷域之间吗?如果是则返回到步骤2);否则转入步骤5)
5)、Px落入峰域吗?如果是则给峰域计数器A加1;否则给谷域计数器B加1;
6)、判断A和B的绝对差值是否大于C,如果不是将计数器D清零,然后转入步骤2);如果大于C,则转入步骤7);
7)、给计数器D加1,并判断计数器D的值是否大于设定值E,如果是,发出抽空警报,同时转入步骤2)继续监控;如果否,则直接转入步骤2)。
2.根据权利要求1所述的基于监控输出压力防止柱塞泵抽空的方法,其特征在于,还包括当采集压力数据Px连续在峰域和谷域之内,而不出现在峰域和谷域之外的脉动数据情况判断:即
在上述步骤4)中,Px在峰域和谷域之间吗?如果是则经过对持续落入峰域和谷域之内的次数进行判断后再返回到步骤2),设定Px在峰域和谷域之内的次数计数器W,W数据达到的设定限值为M;具体步骤如下:
8)、如果Px在峰域和谷域之外,则使计数器W清零;如果Px在峰域和谷域之内,则使W加1,并判断W是否大于M,如果W≥M,则转入步骤9);否则直接转如步骤2);
9)、发出抽空警报后转入步骤2)。
3.根据权利要求1或2所述的基于监控输出压力防止柱塞泵抽空的方法,其特征在于,所述输出压力平均值P0为动态平均值,即在选定输出压力平均值的计算步长后,每个新值被采集后,最前面的一个值会被替代。
4.根据权利要求1或2所述的基于监控输出压力防止柱塞泵抽空的方法,其特征在于,步骤3)所述的Px异常为明显不该出现的数据,包括外界电磁干扰数据。
5.根据权利要求1或2所述的基于监控输出压力防止柱塞泵抽空的方法,其特征在于,所述数据采集控制装置包括压力传感器。
6.根据权利要求1或2所述的基于监控输出压力防止柱塞泵抽空的方法,其特征在于,所述柱塞泵为多个,多个所述柱塞泵并排设置,其输出端汇总到输出管路中,所述压力传感器安装在所述总管上。
7.根据权利要求1或2所述的基于监控输出压力防止柱塞泵抽空的方法,其特征在于,所述柱塞泵为柱塞缸,所述出口管路为所述柱塞缸出口。
8.根据权利要求1或2所述的基于监控输出压力防止柱塞泵抽空的方法,其特征在于,所述柱塞泵为多个,多个所述柱塞泵并排设置,在每个柱塞泵的输出管路上分别设有压力数据采集控制装置。
9.根据权利要求1或2所述的基于监控输出压力防止柱塞泵抽空的方法,其特征在于,还包括对峰域计数器A和谷域计数器B的清零,即当出现抽空警报时将A、B清零,重新开始计数。
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