CN111998690B - Fault alarm method for smoke exhaust fan of low-temperature kiln - Google Patents
Fault alarm method for smoke exhaust fan of low-temperature kiln Download PDFInfo
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- CN111998690B CN111998690B CN202010859887.5A CN202010859887A CN111998690B CN 111998690 B CN111998690 B CN 111998690B CN 202010859887 A CN202010859887 A CN 202010859887A CN 111998690 B CN111998690 B CN 111998690B
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D21/00—Arrangements of monitoring devices; Arrangements of safety devices
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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
- F04D27/004—Control, e.g. regulation, of pumps, pumping installations or pumping systems specially adapted for elastic fluids by varying driving speed
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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
- F04D27/008—Stop safety or alarm devices, e.g. stop-and-go control; Disposition of check-valves
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D19/00—Arrangements of controlling devices
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D21/00—Arrangements of monitoring devices; Arrangements of safety devices
- F27D21/04—Arrangements of indicators or alarms
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2270/00—Control
- F05D2270/30—Control parameters, e.g. input parameters
- F05D2270/303—Temperature
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D21/00—Arrangements of monitoring devices; Arrangements of safety devices
- F27D2021/0057—Security or safety devices, e.g. for protection against heat, noise, pollution or too much duress; Ergonomic aspects
- F27D2021/0071—Security or safety devices, e.g. for protection against heat, noise, pollution or too much duress; Ergonomic aspects against explosions
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Waste-Gas Treatment And Other Accessory Devices For Furnaces (AREA)
Abstract
The invention discloses a fault alarm method of a smoke exhaust fan of a low-temperature kiln, which relates to the technical field of low-temperature kilns and comprises the following steps that when a differential pressure value cannot be stabilized at a set value, a control module automatically detects whether a differential pressure sensor is normal or not, and if the differential pressure sensor fails, the control module automatically switches to a power frequency operation state of the smoke exhaust fan while sending out an audible and visual alarm; when the differential pressure sensor has no fault, whether the smoke exhaust fan motor is normal or not is automatically detected, the control module is provided with a data communication interface and can be associated with the emergency shutdown function of the low-temperature kiln temperature control combustion system, if the smoke exhaust fan motor is damaged, the control module can send out an audible and visual alarm and simultaneously can emergently stop the work of a burner so as to prevent unsmooth smoke exhaust and explosion of the low-temperature kiln; when the motor of the smoke exhaust fan is normal, the control module detects whether the smoke exhaust temperature is lower than the set temperature again. After the system fault self-checking is completed, the system is restored to an automatic operation state.
Description
Technical Field
The invention relates to the technical field of low-temperature kilns, in particular to a fault alarm method for a smoke exhaust fan of a low-temperature kiln.
Background
The kiln is a common key energy consumption device in industrial and mining enterprises. At present, enterprises in China have a large number of low-temperature kilns with the exhaust gas temperature lower than 250 ℃, and the heat loss of the exhaust gas is an important factor influencing the thermal efficiency of equipment of the type. Most enterprises only know whether the kilns of the enterprises can meet the requirements of the production process, and little is known about whether the smoke exhaust fans and the burners of the enterprises are matched and the heat efficiency. And once the motor of the smoke exhaust fan breaks down, the failure can not be known in time, the combustor in the kiln continues to work, the discharge in the kiln is not smooth, and the low-temperature kiln can be possibly exploded.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides a fault alarm method for a smoke exhaust fan of a low-temperature kiln.
The purpose of the invention is realized by the following technical scheme:
a fault alarm method for a smoke exhaust fan of a low-temperature kiln comprises the following steps:
step 1, a control module acquires the flue gas temperature at the input end of a smoke exhaust fan through a temperature sensor;
step 2, judging whether the temperature of the flue gas is lower than a set temperature; if the temperature of the flue gas acquired by the control module is lower than the set temperature, controlling the power frequency of the smoke exhaust fan to operate; otherwise, executing step 3;
step 3, the control module utilizes a differential pressure sensor to collect the pressure difference between the input end and the output end of the smoke exhaust fan, and adjusts the rotating speed of the smoke exhaust fan through PID (proportion integration differentiation) to ensure that the differential pressure value is constant at a set value;
step 4, when the differential pressure value cannot be stabilized at a set value, judging whether the differential pressure sensor is normal, if the differential pressure sensor is abnormal, the control module automatically switches to a power frequency operation state of the smoke exhaust fan while sending out an audible and visual alarm, and otherwise, executing step 5;
and 5, automatically detecting whether the motor of the smoke exhaust fan is normal by the control module, if the motor of the smoke exhaust fan is abnormal, giving out an audible and visual alarm by the control module, and emergently stopping the work of the burner, otherwise, returning to the step 2.
Preferably, the set value of the differential pressure sensor is an optimal differential pressure value determined by an excess air ratio at the exhaust smoke.
Preferably, the control module is provided with a data communication interface, the data communication interface is associated with an emergency shutdown function of temperature control of the low-temperature kiln, and when the motor of the smoke exhaust fan is damaged, the control module can emergently stop the work of the combustor while giving out sound and light alarm.
Preferably, the control module regulates and controls the rotating speed of the smoke exhaust fan of the low-temperature kiln through a PID (proportion integration differentiation) regulation technology to stabilize the pressure difference in a state of minimum excess air coefficient at the smoke exhaust position.
Preferably, the control module is provided with a data receiving unit, a storage unit and a judging unit, and the method for judging whether the differential pressure sensor is normal is that,
step 1, storing a corresponding relation table of the motor rotating speed and the differential pressure value of the smoke exhaust fan in a storage unit;
step 2, when the differential pressure value cannot be stabilized at a set value, the control module adjusts the rotating speed of the motor and simultaneously receives signals of the differential pressure sensor in real time through the data receiving unit;
and 3, matching the differential pressure value detected by the differential pressure sensor with the rotating speed of the motor according to a corresponding relation table in the storage unit through the judgment unit, judging that the differential pressure sensor is normal if the rotating speed of the motor is adjusted to different ranges by the control module every time and the differential pressure value is always matched with the rotating speed of the motor, and otherwise judging that the differential pressure sensor is abnormal.
Preferably, the process of the control module automatically detecting the motor of the smoke exhaust fan comprises the following steps,
step 1: the method comprises the steps that a temperature measuring sensor is adopted to detect the bearing temperature of a motor to obtain temperature information, a current measuring sensor is adopted to detect the working current of the motor to obtain current information, and a rotating speed measuring sensor is adopted to detect the rotating speed of the motor to obtain rotating speed information;
step 2: the processor judges the state or the performance of the motor according to the temperature information, the current information and the rotating speed information by combining a preset judgment algorithm in the processor;
the preset judgment algorithm comprises the following steps:
step 1: comparing the temperature information with a standard temperature, and judging that a bearing of the motor is in a damaged state when the temperature information gradually deviates from the standard temperature; when the temperature information is continuously higher than a preset temperature value within a preset temperature time, judging that a bearing of the motor needs to be replaced or overhauled;
step 2: comparing the current information with a standard current, and judging that a motor of the motor is in a damaged state when the current information gradually deviates from the standard current; when the current information is continuously higher than a preset current value within a preset current time, judging that a motor of the motor needs to be replaced or overhauled;
and step 3: when the rotating speed information changes, whether the temperature information and the current information are normal or not is checked firstly, if the temperature information and the current information are normal, the abnormal condition of the rotating speed is reported, and the ventilation opening or the ventilation environment is reminded to be checked.
The invention has the beneficial effects that:
the system has the functions of fault self-checking and audible and visual alarming, normal production of enterprises cannot be influenced due to faults of the system, a communication interface for damaging an emergency stop burner by a smoke exhaust fan motor is reserved, the safety of low-temperature kiln operation is improved, and the risk of kiln explosion can be effectively avoided.
Drawings
FIG. 1 is a flow chart of a smoke exhaust fan fault detection method of the present invention;
FIG. 2 is a flow chart of a differential pressure sensor fault detection method of the present invention;
fig. 3 is a flow chart of the motor fault detection method of the smoke exhaust fan of the present invention.
Detailed Description
The technical solutions of the present invention are further described in detail below with reference to the accompanying drawings, but the scope of the present invention is not limited to the following.
As shown in fig. 1, a fault alarm method for a smoke exhaust fan of a low-temperature kiln comprises the following steps:
step 1, a control module acquires the flue gas temperature at the input end of a smoke exhaust fan through a temperature sensor;
step 2, judging whether the temperature of the flue gas is lower than a set temperature; if the temperature of the flue gas acquired by the control module is lower than the set temperature, controlling the power frequency of the smoke exhaust fan to operate; otherwise, executing step 3;
step 3, the control module utilizes a differential pressure sensor to collect the pressure difference between the input end and the output end of the smoke exhaust fan, and adjusts the rotating speed of the smoke exhaust fan through PID (proportion integration differentiation) to ensure that the differential pressure value is constant at a set value;
step 4, when the differential pressure value cannot be stabilized at a set value, judging whether the differential pressure sensor is normal, if the differential pressure sensor is abnormal, the control module automatically switches to a power frequency operation state of the smoke exhaust fan while sending out an audible and visual alarm, and otherwise, executing step 5;
and 5, automatically detecting whether the motor of the smoke exhaust fan is normal by the control module, if the motor of the smoke exhaust fan is abnormal, giving out an audible and visual alarm by the control module, and emergently stopping the work of the burner, otherwise, returning to the step 2.
As shown in fig. 1, when the differential pressure value cannot be stabilized at the set value, the system automatically detects whether the differential pressure sensor is normal, and if the differential pressure sensor fails, the system automatically switches to the power frequency operation state of the smoke exhaust fan while sending out an audible and visual alarm; when the differential pressure sensor has no fault, whether the smoke exhaust fan motor is normal or not is automatically detected, the system is provided with a data communication interface and can be associated with the emergency shutdown function of the low-temperature kiln temperature control combustion system, if the smoke exhaust fan motor is damaged, the system can send out an audible and visual alarm and simultaneously emergently stop the work of a burner so as to prevent unsmooth smoke exhaust and explosion of the low-temperature kiln; when the motor of the smoke exhaust fan is normal, the system detects whether the smoke exhaust temperature is lower than the set temperature again. After the system fault self-checking is completed, the system is restored to an automatic operation state.
It should be noted that the set value of the differential pressure sensor is an optimum differential pressure value determined by an excess air ratio at the exhaust smoke.
The control module regulates and controls the rotating speed of a smoke exhaust fan of the low-temperature kiln through a PID (proportion integration differentiation) regulation technology to stabilize the pressure difference in a state of minimum excess air coefficient at the smoke exhaust position.
A gas/oil low-temperature furnace kiln with the exhaust gas temperature lower than 250 ℃ is common key energy consumption equipment in the production process of industrial and mining enterprises in China. The kiln is used as key equipment in the production links of most enterprises, whether the kiln can meet the requirements of production processes is a primary concern of the enterprises, and the running states of the equipment are rarely known. In order to reserve sufficient allowance for the fluctuation of the production process of products, the smoke exhaust fan of the equipment is generally over-configured, so that the heat efficiency is low, and the phenomenon of serious energy waste exists. The thermal efficiency of the low-temperature kiln under the operating condition can be obtained according to an inverse equilibrium measurement method as follows:
η2=100-(q2+q3+q4+q5+q6+q7) (1)
wherein eta 2 is the thermal efficiency of the operation condition of the low-temperature kiln,%; q2 is heat loss from exhaust gas,%; q3 is gas incomplete combustion heat loss,%; q4 is solid incomplete combustion heat loss,%; q5 is heat loss,%; q6 represents physical heat loss of ash,%; q7 is limestone desulfurization heat loss percent. When the fuel used by the low-temperature kiln is non-solid fuel, q4, q6 and q7 are all 0.
TABLE 1.1 loss of heat from incomplete combustion of gas q3
The gas incomplete combustion heat loss q3 is shown in table 1.1, from which it is readily seen that q3 has a small influence on the thermal efficiency of the low temperature furnace and can be solved by adjusting the air-fuel ratio of the low temperature furnace. In addition, enterprises can reduce heat loss q5 by making insulation to the low temperature kiln. Therefore, the project designs an intelligent smoke exhaust system based on modern sensor technology and real-time dynamic feedback control, and on the premise of meeting the production process fluctuation and external production environment change of enterprise products, the heat loss q2 of exhaust smoke is reduced to improve the thermal efficiency of the enterprise low-temperature kiln.
The calculation formula of the exhaust heat loss q2 is as follows:
wherein m and n are both calculation coefficients, and Table 1.2 is the calculation coefficients of different types of fuel; alpha ds is the excess air coefficient at the exhaust; tds is the exhaust gas temperature, DEG C; and tca is the temperature of cold air entering the furnace, and is DEG C.
TABLE 1.2 calculated coefficients for different fuels
Kind of fuel | Bituminous coal | Anthracite and lean coal | Oil, gas |
m | 0.4 | 0.3 | 0.5 |
n | 3.6 | 3.5 | 3.45 |
From the formula (2), when the fuel used by the low-temperature kiln of the enterprise is oil or gas, the heat loss of the exhaust smoke can be reduced by reducing the temperature difference between the exhaust smoke temperature tds and the temperature tca of the cold air entering the kiln and reducing the excess air coefficient α ds at the exhaust smoke. The exhaust gas temperature tds is only related to the temperature in the low-temperature kiln, when the production process of enterprise products is determined, the exhaust gas temperature tds is basically kept unchanged, and the furnace inlet cold air temperature tca is only related to the external environment where the low-temperature kiln burner is located. In order to meet the temperature requirements of the production process of enterprises, the fuel oil or gas low-temperature kiln usually automatically adjusts the fuel delivery rate according to the temperature of a kiln chamber, and the delivery rate of combustion air is also automatically adjusted according to the set air-fuel ratio.
Therefore, the pressure difference between the input end and the output end of the smoke exhaust fan is determined by utilizing the excess air coefficient alpha ds at the smoke exhaust part, and the rotating speed of the smoke exhaust fan of the low-temperature kiln is regulated and controlled based on the PID adjusting technology to maintain the optimal pressure difference, so that the influence of the fluctuation of the external environment on the operation stability of the system is avoided, the low-temperature kiln is kept in the temperature range required by the normal production process with less fuel consumption, the fuel is combusted more fully, the incomplete combustion heat loss q3 of the gas is reduced, and the purposes of saving energy and reducing consumption are achieved.
It should be noted that the control module is provided with a data communication interface, the data communication interface is associated with an emergency shutdown function of the low-temperature kiln temperature control, and when the smoke exhaust fan motor is damaged, the control module can give out sound and light alarm and simultaneously emergently stop the work of the burner.
Wherein, the control module is internally provided with a data receiving unit, a storage unit and a judging unit, and the method for judging whether the differential pressure sensor is normal is that, as shown in figure 2,
step 1, storing a corresponding relation table of the motor rotating speed and the differential pressure value of the smoke exhaust fan in a storage unit;
step 2, when the differential pressure value cannot be stabilized at a set value, the control module adjusts the rotating speed of the motor and simultaneously receives signals of the differential pressure sensor in real time through the data receiving unit;
and 3, matching the differential pressure value detected by the differential pressure sensor with the rotating speed of the motor according to a corresponding relation table in the storage unit through the judgment unit, judging that the differential pressure sensor is normal if the rotating speed of the motor is adjusted to different ranges by the control module every time and the differential pressure value is always matched with the rotating speed of the motor, and otherwise judging that the differential pressure sensor is abnormal.
It should be noted that, as shown in fig. 3, the process of the control module automatically detecting the motor of the smoke exhaust fan includes the following steps,
step 1: the method comprises the steps that a temperature measuring sensor is adopted to detect the bearing temperature of a motor to obtain temperature information, a current measuring sensor is adopted to detect the working current of the motor to obtain current information, and a rotating speed measuring sensor is adopted to detect the rotating speed of the motor to obtain rotating speed information;
step 2: the processor judges the state or the performance of the motor according to the temperature information, the current information and the rotating speed information by combining a preset judgment algorithm in the processor;
as shown in fig. 3, the preset judgment algorithm includes:
step 1: comparing the temperature information with a standard temperature, and judging that a bearing of the motor is in a damaged state when the temperature information gradually deviates from the standard temperature; when the temperature information is continuously higher than a preset temperature value within a preset temperature time, judging that a bearing of the motor needs to be replaced or overhauled;
step 2: comparing the current information with a standard current, and judging that a motor of the motor is in a damaged state when the current information gradually deviates from the standard current; when the current information is continuously higher than a preset current value within a preset current time, judging that a motor of the motor needs to be replaced or overhauled;
and step 3: when the rotating speed information changes, whether the temperature information and the current information are normal or not is checked firstly, if the temperature information and the current information are normal, the abnormal condition of the rotating speed is reported, and the ventilation opening or the ventilation environment is reminded to be checked.
The foregoing is merely a preferred embodiment of the invention, it being understood that the embodiments described are part of the invention, and not all of it. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention. The invention is not intended to be limited to the forms disclosed herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. And that modifications and variations may be effected by those skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (2)
1. A fault alarm method for a smoke exhaust fan of a low-temperature kiln is characterized by comprising the following steps:
step 1, a control module acquires the flue gas temperature at the input end of a smoke exhaust fan through a temperature sensor;
step 2, judging whether the temperature of the flue gas is lower than a set temperature; if the temperature of the flue gas acquired by the control module is lower than the set temperature, controlling the power frequency of the smoke exhaust fan to operate; otherwise, executing step 3;
step 3, the control module utilizes a differential pressure sensor to collect the pressure difference between the input end and the output end of the smoke exhaust fan, and adjusts the rotating speed of the smoke exhaust fan through PID (proportion integration differentiation) to ensure that the differential pressure value is constant at a set value;
step 4, when the differential pressure value cannot be stabilized at a set value, judging whether the differential pressure sensor is normal, if the differential pressure sensor is abnormal, the control module automatically switches to a power frequency operation state of the smoke exhaust fan while sending out an audible and visual alarm, and otherwise, executing step 5;
step 5, the control module automatically detects whether a motor of the smoke exhaust fan is normal, if the motor of the smoke exhaust fan is abnormal, the control module emergently stops the work of the burner while sending out audible and visual alarm, otherwise, the step 2 is returned;
the set value of the differential pressure sensor is the optimal differential pressure value determined by the excess air coefficient at the smoke exhaust position;
the control module is provided with a data communication interface which is associated with an emergency shutdown function of temperature control of the low-temperature kiln, and when a motor of the smoke exhaust fan is damaged, the control module can emergently stop the work of the burner while giving out sound and light alarm;
the control module regulates and controls the rotating speed of a smoke exhaust fan of the low-temperature kiln through a PID (proportion integration differentiation) regulation technology to stabilize the pressure difference in a state of minimum excess air coefficient at the smoke exhaust position;
the control module is internally provided with a data receiving unit, a storage unit and a judging unit, and the method for judging whether the differential pressure sensor is normal is that,
step 1, storing a corresponding relation table of the motor rotating speed and the differential pressure value of the smoke exhaust fan in a storage unit;
step 2, when the differential pressure value cannot be stabilized at a set value, the control module adjusts the rotating speed of the motor and simultaneously receives signals of the differential pressure sensor in real time through the data receiving unit;
and 3, matching the differential pressure value detected by the differential pressure sensor with the rotating speed of the motor according to a corresponding relation table in the storage unit through the judgment unit, judging that the differential pressure sensor is normal if the rotating speed of the motor is adjusted to different ranges by the control module every time and the differential pressure value is always matched with the rotating speed of the motor, and otherwise judging that the differential pressure sensor is abnormal.
2. The method for alarming faults of the smoke exhaust fan of the low-temperature kiln as claimed in claim 1, wherein the process of automatically detecting the motor of the smoke exhaust fan by the control module comprises the following steps,
step 1: the method comprises the steps that a temperature measuring sensor is adopted to detect the bearing temperature of a motor to obtain temperature information, a current measuring sensor is adopted to detect the working current of the motor to obtain current information, and a rotating speed measuring sensor is adopted to detect the rotating speed of the motor to obtain rotating speed information;
step 2: the processor judges the state or the performance of the motor according to the temperature information, the current information and the rotating speed information by combining a preset judgment algorithm in the processor;
the preset judgment algorithm comprises the following steps:
step 1: comparing the temperature information with a standard temperature, and judging that a bearing of the motor is in a damaged state when the temperature information gradually deviates from the standard temperature; when the temperature information is continuously higher than a preset temperature value within a preset temperature time, judging that a bearing of the motor needs to be replaced or overhauled;
step 2: comparing the current information with a standard current, and judging that the motor is in a damaged state when the current information gradually deviates from the standard current; when the current information is continuously higher than a preset current value within a preset current time, judging that the motor needs to be replaced or overhauled;
and step 3: when the rotating speed information changes, whether the temperature information and the current information are normal or not is checked firstly, if the temperature information and the current information are normal, the abnormal condition of the rotating speed is reported, and the ventilation opening or the ventilation environment is reminded to be checked.
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