CN107725350A - State monitoring apparatus with the online efficiency evaluation and test of pump - Google Patents
State monitoring apparatus with the online efficiency evaluation and test of pump Download PDFInfo
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- CN107725350A CN107725350A CN201710929891.2A CN201710929891A CN107725350A CN 107725350 A CN107725350 A CN 107725350A CN 201710929891 A CN201710929891 A CN 201710929891A CN 107725350 A CN107725350 A CN 107725350A
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- 238000012544 monitoring process Methods 0.000 title claims abstract description 24
- 238000012360 testing method Methods 0.000 title claims abstract description 18
- 238000011156 evaluation Methods 0.000 title claims abstract description 11
- 238000003745 diagnosis Methods 0.000 claims abstract description 12
- 230000002159 abnormal effect Effects 0.000 claims abstract description 8
- 238000006243 chemical reaction Methods 0.000 claims abstract description 5
- 239000000284 extract Substances 0.000 claims abstract description 4
- 238000004804 winding Methods 0.000 claims description 15
- 238000005086 pumping Methods 0.000 claims description 9
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 6
- 229910052802 copper Inorganic materials 0.000 claims description 6
- 239000010949 copper Substances 0.000 claims description 6
- 238000005259 measurement Methods 0.000 claims description 6
- 238000000605 extraction Methods 0.000 claims description 4
- 238000013459 approach Methods 0.000 claims description 3
- 238000001914 filtration Methods 0.000 claims description 3
- 238000001595 flow curve Methods 0.000 claims description 3
- 230000001360 synchronised effect Effects 0.000 claims description 3
- 235000013399 edible fruits Nutrition 0.000 claims description 2
- 238000005265 energy consumption Methods 0.000 abstract description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 abstract description 4
- 238000005096 rolling process Methods 0.000 description 9
- 238000000034 method Methods 0.000 description 7
- 230000008859 change Effects 0.000 description 6
- 238000010586 diagram Methods 0.000 description 4
- 230000008569 process Effects 0.000 description 3
- 238000005070 sampling Methods 0.000 description 3
- 238000006073 displacement reaction Methods 0.000 description 2
- 239000000523 sample Substances 0.000 description 2
- 230000015556 catabolic process Effects 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 238000002405 diagnostic procedure Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000003862 health status Effects 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000000691 measurement method Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012806 monitoring device Methods 0.000 description 1
- 238000013139 quantization Methods 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 238000010183 spectrum analysis Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
Classifications
-
- 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
- F04B51/00—Testing machines, pumps, or pumping installations
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)
Abstract
The invention provides the state monitoring apparatus with the online efficiency evaluation and test function of pump, sets efficiency module in CMS gathers main frame, after gathering sensing data and carrying out Energy Efficiency Analysis, real-time energy efficiency analysis result is sent into software systems；After fault diagnosis module then carries out HILBERT conversion, rotating speed order analysis, fft analysis to filtered signal, extract energy amplitude corresponding to each abnormal aspect ratio, by each abnormal characteristic point energy percentage compared with thresholding, fault alarm is carried out more than threshold value.The application calculates the energy consumption and efficient state of motor, water pump and unit by the Energy Efficiency Analysis module carried in real time, and real-time online provides energy consumption analysis data and fault diagnosis data.
Description
Technical field
The present invention relates to pump on-line monitoring technique field, especially, be related to it is a kind of have the online efficiency evaluation and test of pump and
The state monitoring apparatus of fault diagnosis functions.
Background technology
Vibration, shaft displacement, rotating speed and the steering of current of electric, voltage, bear vibration, temperature, efficiency and pump, flow, pressure
Power, efficiency etc. are to reflect the important parameter of pump system current operating conditions.The health status of unit can be in above-mentioned signal upper table
Sign comes out., can be right by carrying out efficiency evaluation and test, status monitoring and accident analysis to operating pump key equipment, part
Monitored equipment carries out abnormity early warning, and primarily determining that causes equipment to produce the reason for abnormal and prevent in advance, predict maintenance
To ensure the safe and reliable and stable operation of unit.
At present, pump equipment operational energy efficiency and status monitoring need to rely on DCS (Distributed Control
System, dcs) or CMS (ConditionMonitoring System, on-line condition monitoring system) is in fact
It is existing.Such as waterworks, can be by disposing DCS system, installation vibration, pressure, flow, voltage, electric current, temperature polling instrument come
Obtain the operational energy efficiency and real-time status of pump.Such as power plant, can by disposing CMS system, install additional vibration, pressure, flow,
Voltage, electric current, temperature, speed probe etc. obtain the operational energy efficiency of pump and real-time status.
The CMS system major function of input commercial Application is to carry out online configuration graphical state to monitoring node to supervise
Checked depending on the change of, historical trend, Realtime Alerts early warning, not to each link energy consumption, the efficiency of monitored target (such as unit)
It is monitored.Its concrete function frame structure is as shown in figure 1, various kinds of sensors collects the vibration of monitored target, speed, temperature
After the DCS parameters such as degree, pressure, flow, electric, send to CMS and gather host computer system, CMS gathers host computer system again by number of passes
On-line analysis and record storage are carried out according to monitoring software is sent to.
But in the application of reality, consider from cost and mounting process, single unit is without flow measuring point and unit moment of torsion
Sensor, therefore the parameter states such as flow and shafting torque, the power of each pump can not be obtained, so as to cause DCS
System or CMS system can not realize real-time energy efficiency evaluation and test and comprehensive status monitoring.
The content of the invention
Present invention aims at provide a kind of status monitoring dress with the online efficiency evaluation and test of pump and fault diagnosis functions
Put, the parameter states such as flow, shafting torque and power can not be obtained to solve traditional pump condition monitoring system at present, it is impossible to enter
Row real-time energy efficiency is evaluated and tested and the technical problem of fault diagnosis.
To achieve the above object, the invention provides a kind of status monitoring dress with the online efficiency evaluation and test function of pump
Put, including the efficiency module being arranged in CMS collection main frames, the efficiency module gather sensing data and carry out Energy Efficiency Analysis
Afterwards, real-time energy efficiency analysis result is sent to software systems；
The shaft power of motor is calculated using loss analysis, under 20%-120% declared working condition, using pressure lift
The mode approached with total (pumping) head is counter to release current machine set outlet flow, and specific formula is as follows：
Machine winding resistance Rr=Rc* (235+Tr)/(235+Tc)
Motor stator copper loss Pcus=3*I*I*Rr/1000.0
Revolutional slip Sl=(N-n)/N
Rotor copper loss Pcur=(P1-PF-fPcu1) * Sl
Stray loss of motor Ps=(0.025-0.005lgPN) * P1 wherein, 1<PN<10000
Stray loss of motor Ps=0.005*P1 wherein, PN>10000
Motor shaft power P 2=P1-Pcus-Pcur-PF-Ps
Torque T=P2*1000/ (9550*n)
Inlet pressure lift Hi=Pi*102.0
Outlet pressure lift Ho=Po*102.0
Total (pumping) head H=Ho-Hi
Pump capacity Q=f (H) f (H) is the H-Q curves that equipment manufacturers provide
Water-horse power Pw=Q*Z/367.0
Electric efficiency η m=P2/P1
Pump power η p=Pw/P2
Unit efficiency η s=Pw/P1
Wherein：
Temperature during Tc-delivery test cold conditions winding resistance measurement, is provided by manufacturer
Line winding resistance during Rc-delivery test cold conditions winding resistance measurement, is provided by manufacturer
The motor winding temperature for Tr-measure in real time
I- motor actual time line current averages
N-current motor actual motion speed
The inlet pressure of Pi- pumps
The outlet pressure of Po- pumps
The total (pumping) head of H-pump
P1-power input to machine
N- motor synchronous rotational speeds, are provided by manufacturer
HQ curves-pump head flow curve, are provided by manufacturer
Pn-motor rated power, is provided by manufacturer.
Preferably, in addition to fault diagnosis functions, its step include：
A, sensor collection original vibration signal,
B, HILBERT conversion is carried out to filtered signal, carries out envelope extraction,
C, current rotating speed order analysis is carried out to the signal after demodulation, is angularly converted；
D, reciprocity angle signal carries out fft analysis, and extracts energy amplitude corresponding to each abnormal aspect ratio；
E, by each abnormal characteristic point energy percentage compared with thresholding, fault alarm is carried out more than threshold value.
Preferably, it is filtered into described in step B：Bandpass filtering is carried out to vibration signal, removes noise signal, background vibration letter
Number.
The invention has the advantages that：
Pump applicable industry scene at present, torque sensor is not installed between the motor and pump of most of unit, this
Sample can not just obtain the shaft power information (i.e. the input power of pump) of motor.So the efficiency of motor can not be obtained；Also, mostly
In the case of number, flowmeter only is installed in the inlet and outlet of total level of factory, without installing flowmeter on single unit, can not so be obtained
The water-horse power of single unit is obtained, the efficiency of pump can not be obtained.The present invention proposes a kind of state prison of the online efficiency evaluation and test of pump
Device is surveyed, without installing torque sensor and flowmeter, motor, water pump and machine are calculated by the Energy Efficiency Analysis module carried in real time
The energy consumption and efficient state of group, obtain the parameter state such as flow and shafting torque, power, and real-time online provides energy consumption analysis number
According to.
Also, at this stage, set state monitoring and Energy Efficiency Analysis are two sets of independent detecting systems, the present apparatus divides efficiency
Analysis function is directly embedded into CPU, directly can reach status monitoring and energy efficiency monitoring using the application device, use is more square
Just.The present apparatus also directly utilizes former DCS system resource, and the efficiency prison of monitoring device can be achieved without new plus sensor hardware etc.
Survey and comprehensive status monitoring.
The present invention, which proposes state monitoring apparatus, also has fault diagnosis functions, and fault diagnosis module can be shaken with continuous monitoring
Dynamic and procedure parameter, such as axle shakes (throw), watt shake, be eccentric, swollen poor, axial displacement, thermal expansion and rotating speed and temperature, pressure,
Can it is such as uneven for equipment breakdown, misalign, rotor rubbing, loosening and the discovery of bearing damage failure provide it is strong
Analyzing and diagnosing means, reliable protection is provided equipment.
In addition to objects, features and advantages described above, the present invention also has other objects, features and advantages.
Below with reference to figure, the present invention is further detailed explanation.
Brief description of the drawings
The accompanying drawing for forming the part of the application is used for providing a further understanding of the present invention, schematic reality of the invention
Apply example and its illustrate to be used to explain the present invention, do not form inappropriate limitation of the present invention.In the accompanying drawings：
Fig. 1 is the main flow CMS system structural representation of prior art；
Fig. 2 is the system structure of device schematic diagram of the preferred embodiment of the present invention；
Fig. 3 is the efficiency approximate algorithm and efficiency measurement method comparative graph of the preferred embodiment of the present invention；
Fig. 4 is the fault characteristic frequency order extraction block diagram of the preferred embodiment of the present invention；
Fig. 5 is the signal intensity schematic diagram when rolling bearing of the preferred embodiment of the present invention occurs damaged；
Fig. 6 is the fault diagnosis handling process schematic diagram of the preferred embodiment of the present invention.
Embodiment
Embodiments of the invention are described in detail below in conjunction with accompanying drawing, but the present invention can limit according to claim
Fixed and covering multitude of different ways is implemented.
Referring to Fig. 2, the online efficiency evaluation and test function of pump of the application state monitoring apparatus is by being arranged on CMS collection masters
What the efficiency module in machine was realized.After efficiency module gathers sensing data and carries out Energy Efficiency Analysis, real-time energy efficiency is analyzed and tied
Fruit is sent to software systems；
The shaft power of motor is calculated using loss analysis, under 20%-120% declared working condition, using pressure lift
The mode approached with total (pumping) head is counter to release current machine set outlet flow (pump capacity Q), and specific formula is as follows：
Machine winding resistance Rr=Rc* (235+Tr)/(235+Tc)
Motor stator copper loss Pcus=3*I*I*Rr/1000.0
Revolutional slip Sl=(N-n)/N
Rotor copper loss Pcur=(P1-PF-fPcu1) * Sl
Stray loss of motor Ps=(0.025-0.005lgPN) * P1 wherein, 1<PN<10000
Stray loss of motor Ps=0.005*P1 wherein, PN>10000
Motor shaft power P 2=P1-Pcus-Pcur-PF-Ps
Torque T=P2*1000/ (9550*n)
Inlet pressure lift Hi=Pi*102.0
Outlet pressure lift Ho=Po*102.0
Total (pumping) head H=Ho-Hi
Pump capacity Q=f (H) f (H) is the H-Q curves that equipment manufacturers provide
Water-horse power Pw=Q*H/367.0
Electric efficiency η m=P2/P1
Pump power η p=Pw/P2
Unit efficiency η s=Pw/P1
Wherein：
Temperature during Tc-delivery test cold conditions winding resistance measurement, is provided by manufacturer
Line winding resistance during Rc-delivery test cold conditions winding resistance measurement, is provided by manufacturer
The motor winding temperature for Tr-measure in real time
I- motor actual time line current averages
N-current motor actual motion speed
The inlet pressure of Pi- pumps
The outlet pressure of Po- pumps
The total (pumping) head of H-pump
P1-power input to machine
N- motor synchronous rotational speeds, are provided by manufacturer
HQ curves-pump head flow curve, are provided by manufacturer
Pn-motor rated power, is provided by manufacturer.
To sum up, the present apparatus need not install torque sensor and flowmeter, and the axle of motor can be calculated using loss analysis hair
Power, it is counter by the way of pressure lift approaches with total (pumping) head to release current unit and go out under 20% sharp -120% declared working condition
Mouthful flow is so as to calculating the water-horse power of pump.So as to obtain the efficiency of water pump.As shown in figure 3, the curve with square is use in figure
The Pump Efficiency Curve that efficiency algorithm in the present invention calculates, the curve with triangle are that water pump is having flowmeter and torque meter to survey
Type approval test curve under examination.It can be seen that the efficiency curve and pattern that are calculated using the approach method in the present invention
Trial curve error very little, status monitoring purposes can be used as.
Referring to Fig. 4, the present apparatus embeds automatic order tracking technique function, by off-note frequency quantization and with current real-time rotating speed
Association, forms fixed special type numerical value.The frequecy characteristic will not change with the change of rotating speed.Its fault characteristic frequency order
Abstraction function is as shown in Figure 4.
In Fig. 4, in a short time, it is believed that the speed (1. locating in Fig. 4) of unit is constant rotational speed, utilizes Edge check
(2. locating in Fig. 4) determines that rotary part reaches whole circle and determines the moment (3. locating in Fig. 4) and ask for currently practical velocity of rotation (Fig. 4
In 4.).According to the order resolution ratio () of resolution ratio rate control input setting and utilize lagrange-interpolation (Fig. 4 in Fig. 4 5.
In 4.) determine equiphase pulse signal () in Fig. 4 6..So as to complete the conversion for sampling equiangular sampling of constant duration
() in Fig. 4 8..Finally spectrum analysis is carried out to the angularly signal after sampling using FFT () in Fig. 4 9. and can obtain current letter
Number to the order analysis result unrelated with rotating speed.
Failure diagnostic process illustrates by taking pump front roll bearing-rolling element fault diagnosis as an example：Rolling bearing is as existed
When abnormal, its mechanical structure feature determine the outer ring of rolling bearing, inner ring, rolling element on vibration signals spectrograph there is with
Under spaced features frequency, as shown in Figure 5：
Outer ring spacing frequency fe=n/120 [1- (d/Dm)cosα]z
Inner ring spacing frequency fi=n/120 [1+ (d/Dm)cosα]z
Rolling element spacing frequency fo=(n/60) (Dm/d)[1-(d2/Dm 2)cos2α]
Wherein, n is the rotating speed of axle, and d is rolling element diameter, DmFor diameter, α is contact angle, and Z is rolling element number
Before failure occurs, vibration signal is small and very steady (1. locating in Fig. 5).When bearing roller occurs damaged (in Fig. 5
2. place), breakage can cause the high-frequency resonant (3. locating in Fig. 5) of sensor by being impacted caused by Sensor.Continuously
Two Secondary Shocks spacing frequencies are that rolling element fault characteristic frequency its numerical value is fo.In actual moving process, the rotating speed one of bearing
Directly in change (non-stationary), foAs n changes, but with n multiple proportion (Dm/d)[1-(d2/Dm 2)cos2α (order) will not become
Change.
Present apparatus signal transacting and fault diagnosis functions are as follows：
1st step:Original vibration signal is gathered from sensor, sees in Fig. 6 and 1. locates.
2nd step:Bandpass filtering is carried out to vibration signal, noise signal, background vibration signal is removed, sees in Fig. 6 and 2. locate.
3rd step:HILBERT conversion is carried out to filtered signal and carries out envelope extraction, sees in Fig. 6 and 3. locates.
4th step:Current rotating speed order analysis is carried out to the signal after demodulation, is angularly converted, seen in Fig. 6 4.
Place.
5th step:Reciprocity angle signal carries out fft analysis and extracts energy amplitude corresponding to each fault signature ratio.See in Fig. 6
5. locate.
6th step:By each characteristic point energy percentage compared with thresholding, more than i.e. progress fault alarm.See in Fig. 6 6.
Place.
The preferred embodiments of the present invention are the foregoing is only, are not intended to limit the invention, for the skill of this area
For art personnel, the present invention can have various modifications and variations.Within the spirit and principles of the invention, that is made any repaiies
Change, equivalent substitution, improvement etc., should be included in the scope of the protection.
Claims (3)
1. a kind of state monitoring apparatus with the online efficiency evaluation and test function of pump, it is characterised in that including being arranged on CMS collections
Efficiency module in main frame, after the efficiency module gathers sensing data and carries out Energy Efficiency Analysis, real-time energy efficiency is analyzed and tied
Fruit is sent to software systems；
The shaft power of motor is calculated using loss analysis, under 20%-120% declared working condition, using pressure lift and always
Mode that lift approaches is counter to release current machine set outlet flow, and specific formula is as follows：
Machine winding resistance Rr=Rc* (235+Tr)/(235+Tc)
Motor stator copper loss Pcus=3*I*I*Rr/1000.0
Revolutional slip Sl=(N-n)/N
Rotor copper loss Pcur=(P1-PF-fPcu1) * Sl
Stray loss of motor Ps=(0.025-0.005lgPN) * P1 wherein, 1<PN<10000
Stray loss of motor Ps=0.005*P1 wherein, PN>10000
Motor shaft power P 2=P1-Pcus-Pcur-PF-Ps
Torque T=P2*1000/ (9550*n)
Inlet pressure lift Hi=Pi*102.0
Outlet pressure lift Ho=Po*102.0
Total (pumping) head H=Ho-Hi
Pump capacity Q=f (H) f (H) is the H-Q curves that equipment manufacturers provide
Water-horse power Pw=Q*Z/367.0
Electric efficiency η m=P2/P1
Pump power η p=Pw/P2
Unit efficiency η s=Pw/P1
Wherein：
Temperature during Tc-delivery test cold conditions winding resistance measurement, is provided by manufacturer
Line winding resistance during Rc-delivery test cold conditions winding resistance measurement, is provided by manufacturer
The motor winding temperature for Tr-measure in real time
I- motor actual time line current averages
N-current motor actual motion speed
The inlet pressure of Pi- pumps
The outlet pressure of Po- pumps
The total (pumping) head of H-pump
P1-power input to machine
N- motor synchronous rotational speeds, are provided by manufacturer
HQ curves-pump head flow curve, are provided by manufacturer
Pn-motor rated power, is provided by manufacturer.
2. state monitoring apparatus according to claim 1, it is characterised in that also including fault diagnosis functions, its step bag
Include：
A, sensor collection original vibration signal,
B, HILBERT conversion is carried out to filtered signal, carries out envelope extraction,
C, current rotating speed order analysis is carried out to the signal after demodulation, is angularly converted；
D, reciprocity angle signal carries out fft analysis, and extracts energy amplitude corresponding to each abnormal aspect ratio；
E, by each abnormal characteristic point energy percentage compared with thresholding, fault alarm is carried out more than threshold value.
3. state monitoring apparatus according to claim 2, it is characterised in that be filtered into described in step B：Vibration signal is entered
Row bandpass filtering, remove noise signal, background vibration signal.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201710929891.2A CN107725350B (en) | 2017-10-09 | 2017-10-09 | State monitoring device with online energy efficiency evaluation of pump |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201710929891.2A CN107725350B (en) | 2017-10-09 | 2017-10-09 | State monitoring device with online energy efficiency evaluation of pump |
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| Publication Number | Publication Date |
|---|---|
| CN107725350A true CN107725350A (en) | 2018-02-23 |
| CN107725350B CN107725350B (en) | 2020-04-07 |
Family
ID=61208795
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|---|---|---|---|
| CN201710929891.2A Active CN107725350B (en) | 2017-10-09 | 2017-10-09 | State monitoring device with online energy efficiency evaluation of pump |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108916017A (en) * | 2018-06-01 | 2018-11-30 | 武汉船用机械有限责任公司 | A kind of turbine Cargo Oil Pump fault diagnosis system peculiar to vessel |
| CN109946603A (en) * | 2019-03-18 | 2019-06-28 | 四川托日工程技术有限公司 | A kind of pump on-line monitoring and fault diagnosis system |
| CN111577590A (en) * | 2020-05-12 | 2020-08-25 | 湖南信息职业技术学院 | Method for evaluating real-time energy efficiency of Internet of things machine pump |
| CN111578985A (en) * | 2020-04-21 | 2020-08-25 | 上海西派埃智能化系统有限公司 | Online evaluation system and method for energy efficiency of water treatment lifting pump set |
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| CN108916017A (en) * | 2018-06-01 | 2018-11-30 | 武汉船用机械有限责任公司 | A kind of turbine Cargo Oil Pump fault diagnosis system peculiar to vessel |
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| CN109946603A (en) * | 2019-03-18 | 2019-06-28 | 四川托日工程技术有限公司 | A kind of pump on-line monitoring and fault diagnosis system |
| CN111578985A (en) * | 2020-04-21 | 2020-08-25 | 上海西派埃智能化系统有限公司 | Online evaluation system and method for energy efficiency of water treatment lifting pump set |
| CN111577590A (en) * | 2020-05-12 | 2020-08-25 | 湖南信息职业技术学院 | Method for evaluating real-time energy efficiency of Internet of things machine pump |
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| Publication number | Publication date |
|---|---|
| CN107725350B (en) | 2020-04-07 |
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