CN111927750B - Nondestructive monitoring system and method for diaphragm of diaphragm compressor - Google Patents
Nondestructive monitoring system and method for diaphragm of diaphragm compressor Download PDFInfo
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- CN111927750B CN111927750B CN202010676383.XA CN202010676383A CN111927750B CN 111927750 B CN111927750 B CN 111927750B CN 202010676383 A CN202010676383 A CN 202010676383A CN 111927750 B CN111927750 B CN 111927750B
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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
- F04B51/00—Testing machines, pumps, or pumping installations
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01H—MEASUREMENT OF MECHANICAL VIBRATIONS OR ULTRASONIC, SONIC OR INFRASONIC WAVES
- G01H17/00—Measuring mechanical vibrations or ultrasonic, sonic or infrasonic waves, not provided for in the preceding groups
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/14—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object using acoustic emission techniques
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/44—Processing the detected response signal, e.g. electronic circuits specially adapted therefor
- G01N29/46—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by spectral analysis, e.g. Fourier analysis or wavelet analysis
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Abstract
The application belongs to the technical field of compressors, and particularly relates to a diaphragm compressor diaphragm nondestructive monitoring system and method. When the diaphragm compressor compresses gas at negative pressure to work, namely the suction pressure and the exhaust pressure are both smaller than the atmospheric pressure, and the pressure of a cavity between the diaphragms is always smaller than the atmospheric pressure under the condition that the diaphragms are broken, a pressure alarm used by the diaphragm monitoring scheme cannot be triggered, and the existing method fails. The application provides a diaphragm compressor diaphragm nondestructive monitoring system includes cylinder, diaphragm subassembly, hydro-cylinder and data acquisition processing subassembly in proper order, the diaphragm subassembly sticiss to prop up admittedly in the cylinder with between the hydro-cylinder, diaphragm monitoring sensing subassembly sets up in sticising the district of propping up admittedly, diaphragm monitoring sensing subassembly with data acquisition processing subassembly is connected. During the operation of the diaphragm compressor, the vibration or acoustic emission signal of the diaphragm is monitored, and therefore the operation health state of the diaphragm compressor can be monitored and diagnosed in a nondestructive mode.
Description
Technical Field
The application belongs to the technical field of compressors, and particularly relates to a diaphragm compressor diaphragm nondestructive monitoring system and method.
Background
The diaphragm compressor is a special device for compressing gas without leakage in a compression cavity. Because the sealing performance provided by the gas compressor is good, the pressure range is wide, and the compression ratio is large, the gas compressor is widely applied to compressing and conveying various high-purity gases, precious rare gases, toxic and harmful gases and corrosive gases in the fields of hydrogenation stations and petrochemical industry. The diaphragm is the core part of the diaphragm compressor, the piston pushes working oil in the oil cavity of the cylinder, and then the diaphragm is pushed to reciprocate in the diaphragm cavity so as to change the working volume of the air cavity, and a leakage-free periodic working process is realized under the matching of the suction valve and the exhaust valve. In the high-pressure compression diaphragm compressor, a diaphragm serves as an isolator between hydraulic oil and compressed gas, and is a medium for coupling multiple physical fields of the hydraulic oil and the compressed gas, and the motion synchronization, momentum and energy transfer, heat conduction and the like between the hydraulic oil and the gas depend on the diaphragm.
Vibration or acoustic emission is the most effective tool for diagnosing mechanical structure damage, dynamic monitoring of vibration or acoustic emission of a diaphragm compressor is the most direct method for improving reliability and safety of operation of the compressor, and monitoring of the operation state of equipment is also a strong demand of designers and users of the diaphragm compressor. The upper limit of the pressure output of the diaphragm compressor can reach 300MPa, and in order to ensure the normal work of the diaphragm compressor, the vulnerable parts must be supervised. The monitoring of the diaphragm dynamic signal of the diaphragm compressor is an effective method for improving the reliability and safety of the operation of equipment, and the monitoring of the operation state of the equipment is also a strong demand of designers and users of the diaphragm compressor.
At present, in domestic and foreign industries, a diaphragm of a diaphragm compressor adopts a three-layer metal diaphragm structure. Based on a leakage detection system formed by a three-layer diaphragm structure, a middle diaphragm is processed with radial scribed lines communicated with a gas collection cavity. When a rupture of the membrane occurs on either the oil or gas side, the corresponding medium will penetrate between the gas and oil side diaphragms, pressurizing the chamber between the diaphragms, which is connected to a pressure switch or contact manometer, triggering a diaphragm failure alarm system. When the diaphragm compressor compresses gas at negative pressure to work, namely the suction pressure and the exhaust pressure are both smaller than the atmospheric pressure, and the pressure of a cavity between the diaphragms is always smaller than the atmospheric pressure under the condition that the diaphragms are broken, a pressure alarm used by the diaphragm monitoring scheme cannot be triggered, and the existing method fails.
Disclosure of Invention
1. Technical problem to be solved
When the diaphragm compressor is used for compressing gas under negative pressure, namely the suction pressure and the exhaust pressure are both smaller than the atmospheric pressure, and the pressure of a cavity between the diaphragms is always smaller than the atmospheric pressure under the condition that the diaphragms are broken, so that a pressure alarm used by a diaphragm monitoring scheme cannot be triggered.
2. Technical scheme
In order to reach foretell purpose, this application provides a diaphragm compressor diaphragm nondestructive monitoring system, include cylinder, diaphragm subassembly, hydro-cylinder and data acquisition processing subassembly in proper order, the diaphragm subassembly sticis solid in the cylinder with between the hydro-cylinder, diaphragm monitoring sensing subassembly sets up in sticising solid branch district, diaphragm monitoring sensing subassembly with data acquisition processing subassembly is connected.
Another embodiment provided by the present application is: including sensing subassembly installation passageway, the diaphragm subassembly is including the gas side diaphragm, middle diaphragm and the oil side diaphragm that arrange in proper order, sensing subassembly installation passageway is close to gas side diaphragm one side, diaphragm monitoring sensing subassembly sets up in the O type circle outside, O type circle set up in the cylinder with between the diaphragm subassembly.
Another embodiment provided by the present application is: the diaphragm monitoring and sensing assembly is connected with one end of an elastic component, the other end of the elastic component is connected with the air side cylinder cover, and the diaphragm monitoring and sensing assembly is tightly pressed on the air side diaphragm through a spring component.
Another embodiment provided by the present application is: the elastic component is a spring.
Another embodiment provided by the present application is: the diaphragm monitoring and sensing component is an acoustic emission sensor or a vibration sensor.
Another embodiment provided by the present application is: the data acquisition and processing assembly comprises a photoelectric sensing unit and a signal acquisition unit, the photoelectric sensing unit comprises a flywheel, the flywheel is arranged corresponding to the photoelectric sensor, the signal acquisition unit is connected with the diaphragm monitoring and sensing assembly, and the signal acquisition unit is connected with the photoelectric sensor; the signal acquisition unit is connected with the data processing unit.
Another embodiment provided by the present application is: the data processing unit is an intelligent terminal.
The application also provides a nondestructive monitoring method for the diaphragm of the diaphragm compressor, which comprises the following steps:
step 1, synchronously acquiring a voltage signal output by a photoelectric sensor and a monitoring signal output by a diaphragm monitoring sensing assembly through a signal acquisition unit, simultaneously converting the voltage signal into a first digital signal for storage, and converting the monitoring signal into a second digital signal for storage;
step 2, judging the start-stop time of a complete period according to the first digital signal;
and 3, processing the second digital signal according to the starting and stopping time of the complete cycle.
Another embodiment provided by the present application is: the monitoring signal is an acoustic emission signal or a vibration signal.
Another embodiment provided by the present application is: and 3, mapping the acquired monitoring signal to a time-frequency two-dimensional plane by adopting a short-time Fourier transform (STFT) method.
3. Advantageous effects
Compared with the prior art, the diaphragm compressor diaphragm nondestructive monitoring system that this application provided has:
the application provides a diaphragm compressor diaphragm nondestructive monitoring system for a diaphragm compressor diaphragm nondestructive monitoring system, during the diaphragm compressor operation, realizes diaphragm running state and health condition.
The application provides a diaphragm compressor diaphragm nondestructive monitoring system, at the diaphragm compressor operation duration, the vibration or the acoustic emission signal of monitoring diaphragm, and then realize diaphragm compressor's operation health status nondestructive monitoring and diagnosis.
Drawings
FIG. 1 is a schematic structural diagram of a non-destructive monitoring system for diaphragm compressor diaphragms of the present application;
FIG. 2 is a schematic diagram of a non-destructive monitoring system for diaphragm compressor diaphragms of the present application;
in the figure: the device comprises a gas side diaphragm 1, a middle diaphragm 2, an oil side diaphragm 3, a first O-shaped ring 4, a diaphragm monitoring sensing assembly 5, an elastic component 6, a signal acquisition unit 7, a flywheel 8, a photoelectric sensor 9 and a data processing unit 10.
Detailed Description
Hereinafter, specific embodiments of the present application will be described in detail with reference to the accompanying drawings, and it will be apparent to those skilled in the art from this detailed description that the present application can be practiced. Features from different embodiments may be combined to yield new embodiments, or certain features may be substituted for certain embodiments to yield yet further preferred embodiments, without departing from the principles of the present application.
Under normal working conditions and with high cleanliness of the compressed gas, the service life of the metal diaphragm is about 3000 to 5000 hours. Greater lifetimes are achieved in continuous operation (24 hours) and lower lifetimes are achieved in batch operation. The motion state and the service life of the diaphragm directly influence the working efficiency and the service life of the diaphragm compressor, and the easy breakage and the short service life of the diaphragm are the common problems in the application scene of the global diaphragm compressor.
Referring to fig. 1-2, the application provides a diaphragm compressor diaphragm nondestructive monitoring system which characterized in that: include cylinder, first O type circle 4, diaphragm subassembly, second O type circle, hydro-cylinder and data acquisition processing subassembly in proper order, the diaphragm subassembly sticiss to prop up admittedly in the cylinder with between the hydro-cylinder, the 4 outsides of first O type circle are provided with diaphragm monitoring sensing subassembly 5, diaphragm monitoring sensing subassembly 5 sets up in sticising the solid district of propping up admittedly, diaphragm monitoring sensing subassembly 5 with data acquisition processing subassembly is connected.
Further, including sensing subassembly installation passageway, the diaphragm subassembly is including the gas side diaphragm 1, middle diaphragm 2 and the oil side diaphragm 3 that arrange in proper order, sensing subassembly installation passageway is close to gas side diaphragm 1 one side, diaphragm monitoring sensing subassembly 5 sets up in the 4 outsides of O type circle, O type circle 4 set up in the cylinder with between the diaphragm subassembly.
Furthermore, the diaphragm monitoring and sensing assembly 5 is connected with one end of an elastic component 6, the other end of the elastic component 6 is connected with a gas-side cylinder cover, and the diaphragm monitoring and sensing assembly 5 is tightly pressed on the gas-side diaphragm 1 through the spring component 6.
Further, the elastic member 6 is a spring.
Further, the diaphragm monitoring and sensing component 5 is an acoustic emission sensor or a vibration sensor.
Furthermore, the data acquisition and processing assembly comprises a photoelectric sensing unit and a signal acquisition unit 7, the photoelectric sensing unit comprises a flywheel 8, the flywheel 8 is arranged corresponding to the photoelectric sensor 9, the signal acquisition unit 7 is connected with the diaphragm monitoring and sensing assembly 5, and the signal acquisition unit 7 is connected with the photoelectric sensor 9; the signal acquisition unit 7 is connected with the data processing unit 10.
Further, the data processing unit 10 is an intelligent terminal.
The application also provides a nondestructive monitoring method for the diaphragm of the diaphragm compressor, which comprises the following steps:
step 1, synchronously acquiring a voltage signal output by a photoelectric sensor 9 and a monitoring signal output by a diaphragm monitoring and sensing assembly 5 through a signal acquisition unit 7, converting the voltage signal into a first digital signal for storage, and converting the monitoring signal into a second digital signal for storage;
step 2, judging the start-stop time of a complete period according to the first digital signal;
and 3, processing the second digital signal according to the starting and stopping time of the complete cycle.
Further, the monitoring signal is an acoustic emission signal or a vibration signal.
Further, the step 3 includes mapping the acquired monitoring signal onto a time-frequency two-dimensional plane by using a short-time fourier transform (STFT) method.
Examples
a. Constructing acoustic or vibration signal measurement systems
(1) Selecting a small acoustic emission sensor or a vibration sensor with proper size and model according to the material and the installation structure of the diaphragm;
(2) and cutting a sensor mounting channel on one side of the gas-side cylinder cover of the diaphragm compressor, which is close to the gas-side diaphragm 1, and mounting a small acoustic emission sensor or a vibration sensor. Because cylinder and hydro-cylinder are through the bolted connection of circumference equipartition in diaphragm compressor, the diaphragm subassembly is outer along being compressed tightly by cylinder and hydro-cylinder and firmly supporting, therefore the position of sensor and diaphragm contact is the diaphragm and receives oil/the cylinder to compress tightly the region of firmly supporting, and measure the sealed O type circle outside that is located, so this structure can not cause the leakage and little to cylinder intensity influence. The top of the sensor is pressed on the diaphragm through a spring so as to ensure the accuracy of signal monitoring.
(3) A photoelectric sensor 9 is arranged at the flywheel 8, and the initial value 0 of the crank angle theta of the compressor is determined according to the obtained outer dead center signal;
(4) and configuring a signal acquisition unit 7 which comprises an acquisition card and a signal conditioning module, setting data sampling frequency and a corresponding acquisition channel.
b. Signal acquisition
And (4) acquiring acoustic emission or vibration signals in the measurement system according to preset parameters in the step a. The analog signal output by the circuit is converted into the finally required digital signal by the data acquisition system and is stored in the hard disk of the computer for subsequent analysis and processing. The computer stores data, runs a data acquisition program, and controls signal sampling and display, such as setting sampling frequency and sample storage length. The data acquisition system realizes a series of functions of signal filtering, amplification, conditioning and A/D conversion.
c. Data processing
Mapping the collected acoustic emission or vibration time domain signal x (t) to a time-frequency two-dimensional plane by adopting a short-time Fourier transform (STFT) method:
wherein f is frequency, T represents time, x (T) is collected signal, window function h (T) selects hanning window, h (T) is 0.5/T (1-cos (T/T)), where T represents time, T represents period;
d. fault diagnosis
Establishing a fault diagnosis model, and determining a diaphragm diagnosis method:
judging the event through a burst type signal of an acoustic emission signal or a vibration signal when a diaphragm slaps an air cylinder or an oil cylinder;
when the diaphragm breaks and other faults which cause structural change occur, the mode of the diaphragm inevitably changes, so that acoustic emission signals or vibration signals can be measured and reflect the faults; in addition, when the diaphragm cracks and the cracks propagate, the amplitude of the diaphragm signal is increased in a high frequency band after the diaphragm signal is processed in the step c, and the amplitude is also used as a diaphragm crack diagnosis basis.
Fig. 2 is a specific flow of signal acquisition, and analog signals output by the acoustic emission or vibration sensor and the photoelectric sensor 9 are converted into finally required digital signals by the signal acquisition unit 7 and stored in a computer hard disk for subsequent analysis and processing. The computer stores data, runs a data acquisition program, and controls signal sampling and display, such as setting sampling frequency and sample storage length. The data acquisition system realizes a series of functions of signal filtering, amplification, conditioning and A/D conversion.
Although the present application has been described above with reference to specific embodiments, those skilled in the art will recognize that many changes may be made in the configuration and details of the present application within the principles and scope of the present application. The scope of protection of the application is determined by the appended claims, and all changes that come within the meaning and range of equivalency of the technical features are intended to be embraced therein.
Claims (7)
1. The utility model provides a diaphragm compressor diaphragm nondestructive monitoring system which characterized in that: the diaphragm monitoring and sensing device sequentially comprises an air cylinder, a diaphragm assembly, an oil cylinder and a data acquisition and processing assembly, wherein the diaphragm assembly is fixedly pressed between the air cylinder and the oil cylinder, the diaphragm monitoring and sensing assembly is arranged in a pressing and fixedly supporting area, and the diaphragm monitoring and sensing assembly is connected with the data acquisition and processing assembly; the air cylinder is characterized by comprising a sensing assembly mounting channel, wherein the sensing assembly mounting channel comprises an air side diaphragm, a middle diaphragm and an oil side diaphragm which are sequentially arranged, the sensing assembly mounting channel is close to one side of the air side diaphragm, the diaphragm monitoring sensing assembly is arranged on the outer side of an O-shaped ring and contacts with the air side diaphragm, and the O-shaped ring is arranged between the air cylinder and the diaphragm assembly; the diaphragm monitoring and sensing component is an acoustic emission sensor or a vibration sensor, the data acquisition and processing component acquires an acoustic emission signal or a vibration signal, the acoustic emission signal or the vibration signal is subjected to time-frequency domain analysis and processing, whether the diaphragm breaks down or not is diagnosed according to a data processing result, and the operation health state nondestructive monitoring and diagnosis of the diaphragm compressor are realized;
the diaphragm nondestructive monitoring system for the diaphragm compressor is applied to the diaphragm compressor when negative pressure compressed gas works.
2. The membrane compressor diaphragm nondestructive monitoring system of claim 1 wherein: the diaphragm monitoring and sensing assembly is connected with one end of an elastic component, the other end of the elastic component is connected with the air side cylinder cover, and the diaphragm monitoring and sensing assembly is tightly pressed on the air side diaphragm through the elastic component.
3. The membrane compressor diaphragm nondestructive monitoring system of claim 2 wherein: the elastic component is a spring.
4. The membrane compressor diaphragm nondestructive monitoring system of claim 1 wherein: the data acquisition and processing assembly comprises a photoelectric sensing unit and a signal acquisition unit, the photoelectric sensing unit comprises a flywheel, the flywheel is arranged corresponding to the photoelectric sensor, the signal acquisition unit is connected with the diaphragm monitoring and sensing assembly, and the signal acquisition unit is connected with the photoelectric sensor; the signal acquisition unit is connected with the data processing unit.
5. The membrane compressor diaphragm nondestructive monitoring system of claim 4 wherein: the data processing unit is an intelligent terminal.
6. A method of monitoring a non-destructive system of diaphragms of a diaphragm compressor according to claim 4, characterized in that: the method comprises the following steps:
step 1, synchronously acquiring a voltage signal output by a photoelectric sensor and a monitoring signal output by a diaphragm monitoring sensing assembly through a signal acquisition unit, simultaneously converting the voltage signal into a first digital signal for storage, and converting the monitoring signal into a second digital signal for storage;
step 2, judging the start-stop time of a complete period according to the first digital signal;
and 3, processing the second digital signal according to the starting and stopping time of the complete cycle.
7. The monitoring method of claim 6, wherein: and 3, mapping the acquired monitoring signal to a time-frequency two-dimensional plane by adopting a short-time Fourier transform (STFT) method.
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| CN202010676383.XA CN111927750B (en) | 2020-07-14 | 2020-07-14 | Nondestructive monitoring system and method for diaphragm of diaphragm compressor |
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| CN113153724B (en) * | 2021-04-15 | 2023-04-18 | 沈阳理工大学 | Diaphragm compressor diaphragm pulsation system fault diagnosis device based on industrial internet platform |
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| JP6362008B2 (en) * | 2015-02-09 | 2018-07-25 | Smc株式会社 | Pump system and pump abnormality detection method |
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| DE4027027A1 (en) * | 1990-08-27 | 1992-03-05 | Prominent Dosiertechnik Gmbh | Leak detector for diaphragm pump - uses laminate diaphragm with evacuated internal space connected to part with contacts which close if pressure arises because of leak |
| EP0732501A1 (en) * | 1995-03-16 | 1996-09-18 | W.L. GORE & ASSOCIATES, INC. | A pre-failure sensing diagram |
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