CN109488630B - Centrifugal fan rotor misalignment fault diagnosis method based on harmonic relative index - Google Patents

Centrifugal fan rotor misalignment fault diagnosis method based on harmonic relative index Download PDF

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CN109488630B
CN109488630B CN201811346611.6A CN201811346611A CN109488630B CN 109488630 B CN109488630 B CN 109488630B CN 201811346611 A CN201811346611 A CN 201811346611A CN 109488630 B CN109488630 B CN 109488630B
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centrifugal fan
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CN109488630A (en
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刘晗
胡剑威
王小兵
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Shanghai Jinyi Inspection Technology Co ltd
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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
    • F04D27/00—Control, e.g. regulation, of pumps, pumping installations or pumping systems specially adapted for elastic fluids
    • F04D27/001—Testing thereof; Determination or simulation of flow characteristics; Stall or surge detection, e.g. condition monitoring
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/72—Wind turbines with rotation axis in wind direction

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  • Structures Of Non-Positive Displacement Pumps (AREA)
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Abstract

The invention discloses a centrifugal fan rotor misalignment fault diagnosis method based on harmonic relative indexes. The invention has the advantages of easy understanding and convenient explanation of the expression form, overcomes the defects that the traditional vibration spectrum analysis method is easily affected by manual work and a large number of characteristic parameters are jointly judged, and can effectively reflect the change of centering faults by the extracted relative indexes, thereby improving the accuracy of diagnosis.

Description

Centrifugal fan rotor misalignment fault diagnosis method based on harmonic relative index
Technical Field
The invention relates to the field of mechanical fault diagnosis, in particular to a centrifugal fan rotor misalignment fault diagnosis method based on harmonic relative indexes.
Background
The centrifugal fan is important auxiliary equipment in the industries of metallurgy, electric power and the like, has the main functions of ensuring full combustion of fuel and smooth discharge of waste gas, and has good operation working conditions, so that the fan is an essential condition for safe and stable operation of a host unit, and the centrifugal fan is used for monitoring and diagnosing the operation state of the centrifugal fan, and is an important content for equipment maintenance and management in the industries of metallurgy and electric power. The same as other rotary machines is characterized in that the core component of the fan is a rotor, most of fault behaviors of the fan are related to the rotor and components of the rotor, and therefore, diagnosis and identification of the rotor faults are the core content of monitoring and diagnosis of the centrifugal fan.
For a centrifugal fan system supported by rolling bearings, the main structural form is a motor direct-connected fan, the rotating speed of the fan is the same as that of the motor, and for the metallurgical industry, most fans are in cantilever structures, namely, a main shaft impeller is positioned at a position other than two bearings, and vibration measuring points are radial vibration and axial vibration on a bearing seat. Researches show that the power frequency faults of the fan main shaft rotor relate to the faults of main shaft rotation frequency and harmonic waves thereof, mainly comprise impeller unbalance faults, main shaft and coupling misalignment faults and loosening faults, and due to the cantilever structure mode, the axial vibration in an unbalanced state is larger, the axial vibration is often misjudged with the centering faults, and the harmonic wave components of the radial vibration also cause the centering faults to be similar to the loosening faults. The prior art mainly relies on manual analysis of the spectrum changes, which results in different results that may be obtained by different people. Although the frequency spectrum characteristics of the power frequency faults in a single direction (such as horizontal) are similar, the vibration mechanism shows that the excitation response of the non-centering faults is different from other faults in different directions (vertical, horizontal and axial) of the cross section, but the multi-directional characteristic analysis can lead to the extraction of a plurality of harmonic characteristic components, so that the difficulty of setting a threshold value is greatly increased, and therefore, based on the harmonic components of the multi-measuring point frequency spectrum, relative indexes are constructed on the basis of the frequency conversion and the harmonic characteristics thereof to effectively reflect the difference of the faults, thereby realizing the diagnosis of the non-centering faults and reducing the influence of personnel experience on diagnosis results.
Disclosure of Invention
The invention aims to solve the technical problem of providing a centrifugal fan rotor misalignment fault diagnosis method based on harmonic relative indexes, which overcomes the defects of the existing frequency spectrum analysis technology, and can effectively reflect fault changes by establishing judgment indexes based on frequency conversion and harmonic characteristics so as to realize the diagnosis and identification of two rotor misalignment faults.
In order to solve the technical problems, the centrifugal fan rotor misalignment fault diagnosis method based on harmonic relative indexes comprises the following steps:
step one, collecting vibration speed signals in three directions on a rolling bearing seat of a centrifugal fan, wherein the vertical direction is set as x v (t) the horizontal direction is y h (t) and the axial direction is z a (t)；
Step two, calculating the frequency spectrum of the vibration speed signal, and extracting the frequency conversion and the fourth harmonic amplitude thereof through frequency spectrum correction, wherein the frequency conversion f in the vertical direction v Amplitude is of
Figure BDA0001863903790000021
The amplitudes from double frequency to quadruple frequency are respectively +.>
Figure BDA0001863903790000022
And->
Figure BDA0001863903790000023
Frequency f is converted in horizontal direction h Amplitude is +.>
Figure BDA0001863903790000024
The amplitudes from double frequency to quadruple frequency are respectively +.>
Figure BDA0001863903790000025
And->
Figure BDA0001863903790000026
Frequency f is turned up in the axial direction a Amplitude is +.>
Figure BDA0001863903790000027
The amplitudes from double frequency to quadruple frequency are respectively +.>
Figure BDA0001863903790000028
And->
Figure BDA0001863903790000029
Step three, calculating a relative index K according to the extracted three frequency conversion harmonic component amplitudes 0 And K 1 For measuring the variation of the harmonics in the vertical and horizontal directions;
Figure BDA00018639037900000210
Figure BDA00018639037900000211
step four, calculating an axial relative vibration index K based on horizontal vibration 2 ；
Figure BDA00018639037900000212
Step five, for judging the magnitude of the axial harmonic component, calculating a relative index K for evaluating the frequency doubling component 3 ；
Figure BDA00018639037900000213
Step six, when
Figure BDA00018639037900000214
Or->
Figure BDA00018639037900000215
And K is 0 <0.5，K 1 <0.5, a serious unbalance state condition of the centrifugal fan impeller is adopted, and if the serious unbalance state condition is judged not to be met, a serious unbalance fault is eliminated;
step seven, when K 1 <0.3, the spectrum structure is mainly frequency conversion, then the horizontal vibration is based, when the axial vibration is greater than half of the horizontal vibration, namely K 2 >0.5, judging that the rotor is not centered;
step eight, when K 1 When larger, it is indicated that there is a harmonic component in the horizontal vibration, the determination is made in the following order:
1) The ratio of the axial frequency doubling harmonic component is higher than a set threshold, namely K 3 >0.7, and K 1 >0.3, judging that the rotor is not centered;
2) When the ratio of the axial frequency doubling harmonic component is lower than the set threshold value and the axial vibration is greater than the horizontal vibration, namely K 3 <0.7 and K 1 >0.3 and K 2 >1, a rotor misalignment failure is determined.
The centrifugal fan rotor misalignment fault diagnosis method based on the harmonic relative index adopts the technical scheme that the method calculates the frequency spectrum of the multi-measuring-point vibration speed signal of the rolling bearing seat of the centrifugal fan, obtains accurate frequency conversion and two to four times frequency characteristic amplitude of the frequency conversion through frequency spectrum correction, establishes a misalignment relative judgment index by utilizing the frequency conversion and harmonic components thereof, and realizes the distinction between the misalignment fault and unbalance and loosening fault of the centrifugal fan through the joint change condition of the relative judgment index. The invention has the advantages of easy understanding and convenient explanation of the expression form, overcomes the defects that the traditional vibration spectrum analysis method is easily affected by manual work and a large number of characteristic parameters are jointly judged, and can effectively reflect the change of centering faults by the extracted relative indexes, thereby improving the accuracy of diagnosis.
Drawings
The invention is described in further detail below with reference to the attached drawings and embodiments:
FIG. 1 is a flow diagram of the present method;
FIG. 2 is a schematic diagram of a centrifugal fan in an embodiment;
FIG. 3a is a schematic diagram of a vibration spectrum of a motor in a vertical direction on a load side in an embodiment;
FIG. 3b is a schematic diagram of a vibration spectrum of a motor on a load side in a horizontal direction according to an embodiment;
fig. 3c is a schematic diagram of a vibration spectrum in a motor load side axial direction in the embodiment;
FIG. 4a is a schematic diagram of a vibration spectrum of a centrifugal fan motor in a side vertical direction in an embodiment;
FIG. 4b is a schematic diagram of a vibration spectrum of a side horizontal direction of a centrifugal fan motor according to an embodiment;
fig. 4c is a schematic diagram of a vibration spectrum of a centrifugal fan motor in a lateral axial direction in an embodiment.
Detailed Description
The invention relates to a centrifugal fan rotor misalignment fault diagnosis method based on harmonic relative indexes, which comprises the following steps:
step one, collecting vibration speed signals in three directions on a rolling bearing seat of a centrifugal fan, wherein the vertical direction is set as x v (t) the horizontal direction is y h (t) and the axial direction is z a (t)；
Step two, calculating the frequency spectrum of the vibration speed signal, and extracting the frequency conversion and the fourth harmonic amplitude thereof through frequency spectrum correction, wherein the frequency conversion f in the vertical direction v Amplitude is of
Figure BDA0001863903790000041
The amplitudes from double frequency to quadruple frequency are respectively +.>
Figure BDA0001863903790000042
And->
Figure BDA0001863903790000043
Frequency f is converted in horizontal direction h Amplitude is +.>
Figure BDA0001863903790000044
The amplitudes from double frequency to quadruple frequency are respectively +.>
Figure BDA0001863903790000045
And->
Figure BDA0001863903790000046
Frequency f is turned up in the axial direction a Amplitude is +.>
Figure BDA0001863903790000047
The amplitudes from double frequency to quadruple frequency are respectively +.>
Figure BDA0001863903790000048
And->
Figure BDA0001863903790000049
Step three, calculating a relative index K according to the extracted three frequency conversion harmonic component amplitudes 0 And K 1 For measuring the variation of the harmonics in the vertical and horizontal directions;
Figure BDA00018639037900000410
Figure BDA00018639037900000411
step four, calculating an axial relative vibration index K based on horizontal vibration 2 ；
Figure BDA00018639037900000412
Step five, for judging the magnitude of the axial harmonic component, calculating a relative index K for evaluating the frequency doubling component 3 ；
Figure BDA00018639037900000413
Step six, when
Figure BDA00018639037900000414
Or->
Figure BDA00018639037900000415
And K is 0 <0.5，K 1 <0.5, a serious unbalance state condition of the centrifugal fan impeller is adopted, and if the serious unbalance state condition is judged not to be met, a serious unbalance fault is eliminated;
step seven, when K 1 <0.3, the spectrum structure is mainly frequency conversion, then the horizontal vibration is based, when the axial vibration is greater than half of the horizontal vibration, namely K 2 >0.5, judging that the rotor is not centered;
step eight, when K 1 When larger, it is indicated that there is a harmonic component in the horizontal vibration, the determination is made in the following order:
1) The ratio of the axial frequency doubling harmonic component is higher than a set threshold, namely K 3 >0.7, and K 1 >0.3, judging that the rotor is not centered;
2) When the ratio of the axial frequency doubling harmonic component is lower than the set threshold value and the axial vibration is greater than the horizontal vibration, namely K 3 <0.7 and K 1 >0.3 and K 2 >1, a rotor misalignment failure is determined.
The present method is described in further detail below with reference to the drawings and examples;
referring to FIG. 1, a misalignment fault is diagnosed according to the illustrated flow;
referring to FIG. 2, vibration measurements are performed on the illustrated centrifugal fan; in the figure, a motor 1 is connected with a fan rotating shaft 3 through a coupler 2, and a first rolling bearing seat 4 and a second rolling bearing seat 5 are arranged on the fan rotating shaft 3 at intervals;
referring to fig. 3a, 3b and 3c, a motor load side vibration velocity signal is obtained, and a frequency spectrum is calculated.
The centrifugal fan is subjected to misalignment fault diagnosis, and the process is as follows:
1) Collecting vibration speed signals in three directions on a rolling bearing seat, and setting the vertical direction as x v (t) the horizontal direction is y h (t) and the axial direction is z a (t)；
2) The frequency spectrum of the vibration velocity signal in three directions is subjected to frequency spectrum correction at the frequency conversion and the fourth harmonic thereof (the frequency spectrum correction method can be referred to: ding Kang and Jiang Liqi method for energy-centering of discrete spectrum [ J]Vibration engineering journal 2001,14 (3): 354-358.). Obtaining accurate amplitude, including amplitude of rotation in vertical direction
Figure BDA0001863903790000051
Frequency doubling amplitude
Figure BDA0001863903790000052
Triple frequency amplitude +.>
Figure BDA0001863903790000053
Four frequency multiplication amplitude +>
Figure BDA0001863903790000054
In the horizontal direction, the amplitude of the rotation frequency
Figure BDA0001863903790000055
Double frequency amplitude +.>
Figure BDA0001863903790000056
Triple frequency amplitude +.>
Figure BDA0001863903790000057
Four frequency multiplication amplitude +>
Figure BDA0001863903790000058
In the axial direction, the amplitude of the transition is +.>
Figure BDA0001863903790000059
Double frequency amplitude +.>
Figure BDA00018639037900000510
Triple frequency amplitude +.>
Figure BDA00018639037900000511
Four frequency multiplication amplitude +>
Figure BDA00018639037900000512
Wherein the frequency unit is Hz, and the amplitude unit is mm/s;
3) According to the extracted three frequency conversion harmonic component amplitudes, calculating a relative index K 0 And K 1 For measuring the variation of the harmonics in the vertical and horizontal directions;
Figure BDA00018639037900000513
Figure BDA00018639037900000514
4) Based on horizontal vibration, calculating an axial relative vibration index K 2 ；
Figure BDA00018639037900000515
5) To determine the magnitude of the axial harmonic component, a relative index K for evaluating the frequency-doubled component is calculated 3 ；
Figure BDA00018639037900000516
6) First, the influence of serious unbalance faults on the discrimination of the unbalance faults is removed, namely
Figure BDA00018639037900000517
Or (b)
Figure BDA00018639037900000518
And K is 0 <0.5，K 1 <0.5, which is a serious unbalance condition, and if the serious unbalance condition is judged not to be satisfied, eliminating serious unbalance faults;
7) When K is 1 <0.3, the spectrum structure is mainly frequency conversion, then the horizontal vibration is based, when the axial vibration is greater than half of the horizontal vibration, namely K 2 >0.5, rotor misalignment failure;
8) When K is 1 When the harmonic component is large, it is determined that the harmonic component exists in the horizontal vibration in the following order:
1) The ratio of the axial frequency doubling harmonic component is higher than a set threshold, namely K 3 >0.7, and K 1 >0.3, a rotor misalignment fault;
2) When the ratio of the axial frequency doubling harmonic component is lower than the set threshold value and the axial vibration is greater than the horizontal vibration, namely K 3 <0.7 and K 1 >0.3 and K 2 >1, a rotor misalignment fault.
In this embodiment of the present invention, the process is performed,
Figure BDA0001863903790000061
and->
Figure BDA0001863903790000062
The serious unbalance fault described in step 6 is eliminated.
Due to K 1 ＝0.82>0.3，K 3 ＝0.36<0.7，K 2 ＝1.57>1, according to 8.2, judging that the rotor fails to be misaligned, and matching with the actual failure.
The data verification shown in fig. 3a, 3b and 3c shows that the method can accurately diagnose the rotor misalignment fault of the centrifugal fan.
In addition, the unbalance faults shown in fig. 4a, 4b and 4c are verified, the frequency conversion and harmonic components thereof are obtained according to the illustrated vibration signal spectrum correction,
Figure BDA0001863903790000063
the calculated relative index is:
Figure BDA0001863903790000064
Figure BDA0001863903790000065
Figure BDA0001863903790000066
Figure BDA0001863903790000067
it is found that the condition is not satisfied, and the centering failure is not consistent with the actual situation.
The method constructs relative indexes on the basis of frequency conversion and harmonic characteristics thereof, can eliminate interference of factors such as working conditions and the like, and realizes more accurate fault identification with fewer characteristic components.

Claims (1)

1. A centrifugal fan rotor misalignment fault diagnosis method based on harmonic relative indexes is characterized by comprising the following steps:
step one, collecting vibration speed signals in three directions on a rolling bearing seat of a centrifugal fan, wherein the vertical direction is set as x v (t) the horizontal direction is y h (t) and the axial direction is z a (t)；
Step two, calculating the frequency spectrum of the vibration speed signal, and extracting the frequency conversion and the fourth harmonic amplitude thereof through frequency spectrum correction, wherein the frequency conversion f in the vertical direction v Amplitude is of
Figure FDA0004174477510000011
The amplitudes from double frequency to quadruple frequency are respectively +.>
Figure FDA0004174477510000012
And->
Figure FDA0004174477510000013
Frequency f is converted in horizontal direction h Amplitude is +.>
Figure FDA0004174477510000014
The amplitudes from double frequency to quadruple frequency are respectively +.>
Figure FDA0004174477510000015
And->
Figure FDA0004174477510000016
Frequency f is turned up in the axial direction a Amplitude is +.>
Figure FDA0004174477510000017
The amplitudes from double frequency to quadruple frequency are respectively +.>
Figure FDA0004174477510000018
And->
Figure FDA0004174477510000019
Step three, calculating a relative index K according to the extracted three frequency conversion harmonic component amplitudes 0 And K 1 For measuring the variation of the harmonics in the vertical and horizontal directions;
Figure FDA00041744775100000110
Figure FDA00041744775100000111
step four, calculating axial relative vibration based on horizontal vibrationIndex K 2 ；
Figure FDA00041744775100000112
Step five, for judging the magnitude of the axial harmonic component, calculating a relative index K for evaluating the frequency doubling component 3 ；
Figure FDA00041744775100000113
Step six, when
Figure FDA00041744775100000114
Or->
Figure FDA00041744775100000115
And K is 0 <0.5，K 1 <0.5, a serious unbalance state condition of the centrifugal fan impeller is adopted, and if the serious unbalance state condition is judged not to be met, a serious unbalance fault is eliminated;
step seven, when K 1 <0.3, the spectrum structure is mainly frequency conversion, then the horizontal vibration is based, when the axial vibration is greater than half of the horizontal vibration, namely K 2 >0.5, judging that the rotor is not centered;
step eight, when K 1 >0.3, it is indicated that there is a harmonic component in the horizontal vibration, and the determination is made in the following order:
1) The ratio of the axial frequency doubling harmonic component is higher than a set threshold, namely K 3 >0.7, and K 1 >0.3, judging that the rotor is not centered;
2) When the ratio of the axial frequency doubling harmonic component is lower than the set threshold value and the axial vibration is greater than the horizontal vibration, namely K 3 <0.7 and K 1 >0.3 and K 2 >1, a rotor misalignment failure is determined.
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