CN107942878B - Self-learning fault monitoring and alarming system of three-foot centrifuge - Google Patents
Self-learning fault monitoring and alarming system of three-foot centrifuge Download PDFInfo
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- CN107942878B CN107942878B CN201711362425.7A CN201711362425A CN107942878B CN 107942878 B CN107942878 B CN 107942878B CN 201711362425 A CN201711362425 A CN 201711362425A CN 107942878 B CN107942878 B CN 107942878B
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/048—Monitoring; Safety
Abstract
The invention discloses a self-learning fault monitoring and alarming system of a three-legged centrifuge, wherein an acceleration sensor is arranged on a motor of the centrifuge or a base near the motor, a temperature sensor is arranged on the side surface in the centrifuge body, data of the acceleration sensor and the temperature sensor are collected by a data acquisition card and transmitted to an industrial personal computer, and the industrial personal computer operates a fault monitoring and alarming system to monitor the centrifuge in real time. The invention has the advantages that the vibration and temperature judgment threshold value is automatically set through the vibration and temperature signal acquisition when the centrifugal machine is just put into use; vibration data of the centrifuge after working for a period of time is collected, and the vibration threshold of the centrifuge in the next period of time is predicted through self-learning, so that misjudgment caused by the fact that the initial threshold is set to be harsh is avoided.
Description
Technical Field
The invention relates to a self-learning fault monitoring and alarming system of a three-leg centrifuge.
Background
The centrifugal machine is a machine which uses centrifugal force to accelerate the separation of different materials to be separated. The centrifugal machine is divided into a filtering type centrifugal machine, a sedimentation type centrifugal machine and the like, consists of a centrifugal tube, a tube sleeve, a centrifugal bottle and other parts, and is widely applied to chemical industry, petroleum, food, pharmacy, mineral separation, coal, water treatment, ships and other departments.
The three-leg centrifuge is named because the bottom support is three column feet which are arranged in an evenly-divided triangular mode. The three-leg centrifuge is a solid-liquid separation equipment, mainly suitable for solid-liquid two-phase separation. The working principle is as follows: centrifuge is through high-speed rotation, produces powerful centrifugal force, its centrifugation coefficient is usually hundreds of times of acceleration of gravity, last thousand times, consequently the separating rate is very fast, but because different material nature differences are very big, so formed the centrifuge of various different specifications, the centrifuge rotational speed that general solid and liquid separated is below 3000 revolutions, the granule is thinner, the mixed liquid that the density difference is less then needs the centrifuge of rotational speed between 8000 ~ 30000 to separate, and the centrifuge of higher rotational speed is then needed like the concentrated separation of uranium. The three-leg centrifuge is the most widely used centrifuge, starting from the first centrifuge, widely used in various industries, and is still popular worldwide today.
Common faults of the three-leg centrifuge are increased in noise and overhigh in temperature rise, and if the state of the centrifuge is not monitored in real time in the working process, the damage of the centrifuge is easily caused once the fault occurs.
Any machine can generate vibration during working, the vibration is the root of noise generated by the centrifugal machine, and the actual state of the centrifugal machine can be reflected. When the three-leg centrifuge works abnormally, the vibration amplitude and the vibration waveform generally change remarkably. Therefore, according to the measurement and analysis of the vibration signal, whether the fault exists in the centrifuge can be grasped and identified in real time in the operation process of the centrifuge.
In the measurement and analysis of vibrations, sensors are generally used which convert mechanical energy into electrical energy, causing the sensor to generate an electrical signal which is a function of the mechanical vibrations. Then recording and reality by zooming in. There are many types of vibration transducers, three types being commonly used: a displacement sensor for sensing vibration displacement, a velocity sensor for sensing vibration velocity, and an acceleration sensor for sensing vibration acceleration. The vibration displacement, the speed and the acceleration have a relation of differentiation and integration, and only one of the three is needed to be obtained, so that the other two parameters can be obtained through conversion. In the invention, the most common acceleration sensor is adopted to measure the vibration signal, and the abnormal vibration is judged according to the parameters such as amplitude and the like.
Currently, the working state of the three-leg centrifuge is mainly judged through subjective feeling and working experience of an operator. The disadvantages are that:
1) different people do not have the same perception on the vibration, the subjective feelings of the people are different, and misjudgment may exist;
2) abnormal vibration cannot be found in time, and the solution thereof is delayed.
This is where the application needs to be greatly improved
Disclosure of Invention
The invention aims to solve the technical problem of providing a self-learning fault monitoring and alarming system of a three-legged centrifuge, which can automatically learn the vibration characteristics of the centrifuge according to the life cycle of the centrifuge, actively adjust the judgment threshold value and avoid misjudgment.
In order to solve the technical problems, the invention provides a self-learning fault monitoring and alarming system of a three-legged centrifuge, wherein an acceleration sensor is arranged on a motor of the centrifuge or a base near the motor, a temperature sensor is arranged on the side surface in the centrifuge body, data of the acceleration sensor and the temperature sensor are collected by a data collecting card and transmitted to an industrial personal computer, and the industrial personal computer operates the fault monitoring and alarming system to monitor the centrifuge in real time, and the self-learning fault monitoring and alarming system comprises the following steps:
1) after the three-foot centrifuge works, the system is started;
2) judging whether the system is used for the first time or whether the centrifugal machine is put into use immediately, and judging whether the vibration speed root mean square value and the temperature threshold value are set or not;
if no vibration speed root mean square value and no temperature threshold are set, entering 3);
if the root mean square value of the vibration speed and the temperature threshold value are set, entering 5);
3) collecting vibration signals of the centrifuge in 1 minute when the centrifuge works, calculating an effective value of vibration speed, and setting the effective value of vibration speed as a threshold value for judging the vibration signals;
4) collecting temperature signals of the centrifuge in 20 minutes when the centrifuge works, calculating the average value of the temperature, and setting the average value of the temperature as a threshold value for judging the temperature signals;
5) operating a fault monitoring and alarming system on an industrial personal computer, and acquiring a vibration acceleration signal on a centrifuge body and a temperature signal in the centrifuge body in real time through a data acquisition card;
6) the system takes 2s as a calculation period to calculate the effective value of the vibration speed in the period, and takes 10s as a calculation period to calculate the average value of the temperature in the period;
7) judging whether the effective value of the vibration speed and the average value of the temperature exceed set thresholds or not;
if the threshold value is exceeded, 8) is entered;
if not, returning to 5);
8) sending an alarm signal to remind the centrifuge to be overhauled;
9) and storing the calculated effective value of the vibration speed and the temperature mean value into a database of the system.
The self-learning fault monitoring and alarming system of the three-legged centrifuge further comprises a self-learning automatic threshold updating and judging method, and the method comprises the following steps:
a) extracting effective values of vibration speed measured every day from a database of the system;
b) performing least square fitting on the data of the current day;
c) predicting a future vibration threshold of the centrifuge;
d) judging whether the vibration threshold value exceeds the vibration limit value of the centrifuge;
if yes, entering g);
if not, enter e).
e) Comparing the vibration threshold value with a vibration threshold value currently set in the system;
if yes, entering f);
if the number is less than the preset value, no operation is performed;
f) updating a vibration threshold in the system;
g) and sending an alarm signal to remind an operator to overhaul the centrifuge.
The invention has the following advantages: automatically setting a vibration and temperature judgment threshold value through vibration and temperature signal acquisition when the centrifugal machine is just put into use; vibration data of the centrifuge after working for a period of time is collected, and the vibration threshold of the centrifuge in the next period of time is predicted through self-learning, so that misjudgment caused by the fact that the initial threshold is set to be harsh is avoided.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:
FIG. 1 is a functional block diagram of the present invention;
FIG. 2 is a control flow chart of the present invention.
Detailed Description
The embodiments of the invention will be described in detail below with reference to the drawings, but the invention can be implemented in many different ways as defined and covered by the claims.
Embodiments of the present invention will be described in detail below with reference to the accompanying drawings.
Fig. 1 shows a schematic block diagram of an embodiment of the present invention, and fig. 2 shows a control flow diagram of an embodiment of the present invention. As shown in the figures 1 and 2, the invention provides a self-learning fault monitoring and alarming system of a three-legged centrifuge, wherein an acceleration sensor is arranged on a base of a centrifuge motor or near the motor, a temperature sensor is arranged on the side surface in the centrifuge body, data of the acceleration sensor and the temperature sensor are collected by a data collection card and transmitted to an industrial personal computer, and the industrial personal computer runs a fault monitoring and alarming system to monitor the centrifuge in real time, and the self-learning fault monitoring and alarming system comprises the following steps:
1) after the three-foot centrifuge works, the system is started;
2) judging whether the system is used for the first time or whether the centrifugal machine is put into use immediately, and judging whether the vibration speed root mean square value and the temperature threshold value are set or not;
if no vibration speed root mean square value and no temperature threshold are set, entering 3);
if the root mean square value of the vibration speed and the temperature threshold value are set, entering 5);
3) collecting vibration signals of the centrifuge in 1 minute when the centrifuge works, calculating an effective value of vibration speed, and setting the effective value of vibration speed as a threshold value for judging the vibration signals;
and collecting vibration acceleration signals by using a sampling frequency of 2048Hz, and carrying out real-time numerical integration calculation on the collected vibration acceleration time domain signals to obtain vibration speed signals. Numerical integration calculation using the complex trapezoidal method:
in the formula, ai-actually measuring the vibration acceleration signal, n-the number of trapezoids of the block, recommended to be 10, t1Lower limit of integration time, t2-integration time upper limit, recommends Δ t ═ t2-t1＝5ms
Then, an effective value of the vibration speed in 1 minute was calculated by the following equation.
In the formula, m is the number of vibration velocity sample points in 1 minute.
4) Collecting temperature signals of the centrifuge in 20 minutes when the centrifuge works, calculating the average value of the temperature, and setting the average value of the temperature as a threshold value for judging the temperature signals;
collecting a temperature signal when the centrifugal machine works at a sampling frequency of 1 Hz; then, the average temperature value over 20 minutes was calculated using the following formula:
in the formula, TkFor real-time temperature signals, n is the number of temperature sample points in 20 minutes.
5) Operating a fault monitoring and alarming system on an industrial personal computer, and acquiring a vibration acceleration signal on a centrifuge body and a temperature signal in the centrifuge body in real time through a data acquisition card;
6) the system takes 2s as a calculation period to calculate the effective value of the vibration speed in the period, and takes 10s as a calculation period to calculate the average value of the temperature in the period;
7) judging whether the effective value of the vibration speed and the average value of the temperature exceed set thresholds or not;
if the threshold value is exceeded, 8) is entered;
if not, returning to 5);
8) sending an alarm signal to remind the centrifuge to be overhauled;
9) and storing the calculated effective value of the vibration speed and the temperature mean value into a database of the system.
The working state of the three-leg centrifuge is monitored in real time, the centrifuge is a typical rotating machine, internal rotating parts can not avoid generating some abrasion along with longer and longer working time, and the vibration of the centrifuge can be slightly increased but is lower than the vibration when a fault occurs.
Aiming at the technical problems, the self-learning fault monitoring and alarming system of the three-legged centrifuge further comprises a method for automatically updating the judgment threshold value by self-learning, and the method comprises the following steps:
a) extracting effective values of vibration speed measured every day from a database of the system;
b) performing least square fitting on the data of the current day;
c) predicting a future vibration threshold of the centrifuge;
d) judging whether the vibration threshold value exceeds the vibration limit value of the centrifuge;
if yes, entering g);
if not, enter e).
e) Comparing the vibration threshold value with a vibration threshold value currently set in the system;
if yes, entering f);
if the number is less than the preset value, no operation is performed;
f) updating a vibration threshold in the system;
g) and sending an alarm signal to remind an operator to overhaul the centrifuge.
The above description is only a preferred embodiment of the present invention, and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (1)
1. The utility model provides a three-legged centrifuge self-learning fault monitoring and alarm system, installs acceleration sensor on centrifuge motor or near the base of motor, installs temperature sensor at the inside side-mounting of centrifuge organism, and data acquisition card gathers acceleration sensor and temperature sensor's data to convey the industrial computer, the industrial computer operation fault monitoring carries out real time monitoring with alarm system to centrifuge, includes following step:
1) after the three-foot centrifuge works, the system is started;
2) judging whether the system is used for the first time or whether the centrifugal machine is put into use immediately, and judging whether the vibration speed root mean square value and the temperature threshold value are set or not;
if no vibration speed root mean square value and no temperature threshold are set, entering 3);
if the root mean square value of the vibration speed and the temperature threshold value are set, entering 5);
3) collecting vibration signals of the centrifuge in 1 minute when the centrifuge works, calculating an effective value of vibration speed, and setting the effective value of vibration speed as a threshold value for judging the vibration signals;
4) collecting temperature signals of the centrifuge in 20 minutes when the centrifuge works, calculating the average value of the temperature, and setting the average value of the temperature as a threshold value for judging the temperature signals;
5) operating a fault monitoring and alarming system on an industrial personal computer, and acquiring a vibration acceleration signal on a centrifuge body and a temperature signal in the centrifuge body in real time through a data acquisition card;
6) the system takes 2s as a calculation period to calculate the effective value of the vibration speed in the period, and takes 10s as a calculation period to calculate the average value of the temperature in the period;
7) judging whether the effective value of the vibration speed and the average value of the temperature exceed set thresholds or not;
if the threshold value is exceeded, 8) is entered;
if not, returning to 5);
8) sending an alarm signal to remind the centrifuge to be overhauled;
9) storing the calculated effective value of the vibration speed and the temperature mean value into a database of the system;
the self-learning fault monitoring and alarming system also comprises a self-learning automatic threshold updating judgment method, and the method comprises the following steps:
a) extracting effective values of vibration speed measured every day from a database of the system;
b) performing least square fitting on the data of the current day;
c) predicting a future vibration threshold of the centrifuge;
d) judging whether the vibration threshold value exceeds the vibration limit value of the centrifuge;
if yes, entering g);
if not, entering e);
e) comparing the vibration threshold value with a vibration threshold value currently set in the system;
if yes, entering f);
if the number is less than the preset value, no operation is performed;
f) updating a vibration threshold in the system;
g) and sending an alarm signal to remind an operator to overhaul the centrifuge.
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| CN110085006B (en) * | 2019-03-13 | 2023-03-24 | 中交广州航道局有限公司 | Ship monitoring method, device and system and storage medium |
| CN110085005B (en) * | 2019-03-13 | 2023-03-24 | 中交广州航道局有限公司 | Ship generator monitoring method, device and system and storage medium |
| CN112040351B (en) * | 2020-08-25 | 2022-04-26 | 西安因联信息科技有限公司 | Mechanical equipment vibration alarm information pushing method |
| CN112965429A (en) * | 2021-01-14 | 2021-06-15 | 北京朗新明环保科技有限公司 | Pre-alarm method for intelligent water treatment system |
| CN112946471A (en) * | 2021-02-04 | 2021-06-11 | 郑州恩普特科技股份有限公司 | Variable frequency motor fault monitoring system |
| CN113092152B (en) * | 2021-04-09 | 2022-08-30 | 北京英华达电力电子工程科技有限公司 | Composite monitoring device and method for vibration temperature of mobile equipment |
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Effective date of registration: 20181225 Address after: 266400 No. 3316 Sansha Road, Huangdao District, Qingdao City, Shandong Province Applicant after: Qingdao Kehai Jiantang Biology Co., Ltd. Address before: No. 2528 Huancheng West Road, Fengxian District, Shanghai 201400 Applicant before: Shanghai Haijiantang Group Co., Ltd. Applicant before: Qingdao Hai Jian Tang Biological Technology Co., Ltd. Applicant before: Shanghai Yau Kou e-commerce Limited by Share Ltd |
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