CN112710474B - Diesel engine state evaluation method based on real-time vibration data - Google Patents
Diesel engine state evaluation method based on real-time vibration data Download PDFInfo
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Abstract
The invention discloses a diesel engine state evaluation method based on real-time vibration data, and belongs to the technical field of diesel engine running state monitoring. Firstly, preliminarily determining a sensor arrangement scheme, secondly, determining a characteristic channel through sensitivity analysis, then selecting a characteristic parameter based on the characteristic channel, then establishing a state evaluation key index according to the characteristic channel and the characteristic parameter, and establishing an index reference of dynamic self-adaptive iterative update; and finally, evaluating the state of the diesel engine based on the established state evaluation index and index standard. The invention can quickly evaluate the instantaneous running state of the diesel engine only by real-time vibration data, finds the fault symptoms of the diesel engine in advance and effectively avoids malignant faults and casualties.
Description
Technical Field
The invention belongs to the technical field of monitoring of running states of diesel engines, and particularly relates to a diesel engine state evaluation method based on real-time vibration data.
Background
The rapid development of global economy accelerates the development of marine industry, so that the marine transportation capacity is greatly increased, and the marine diesel engine serving as a main power device of a ship has an inseparable relationship with marine transportation. With the continuous introduction of technologies such as computer, data communication and automatic control in the world, the diesel engine system is developing towards intellectualization and energy conservation, the automation level of the system is greatly improved, the personnel dependence is greatly reduced, and therefore the failure probability is greatly increased. Once the diesel engine breaks down, the safety of the ship sailing on the sea is directly influenced, catastrophic personal injuries and disastrous equipment damages can be seriously caused, and immeasurable losses are caused. According to statistics, the diesel engine fault accounts for 45% of the mechanical faults and 22% of the whole ship fault.
At present, a diesel engine state evaluation method based on vibration data is mainly vibration spectrum analysis based on fourier transform, and researchers analyze different vibration test information to obtain a fault diagnosis result of a diesel engine. For example, the present inventors propose to integrate the wear state and vibration information of the diesel engine to realize the comprehensive diagnosis and reasoning of two kinds of information on the fault of the diesel engine. Aiming at the characteristic that the sensitivity of various diagnostic features is different, the Thailand of the university of Sian traffic, rayas and the like provide a novel fault diagnosis method based on feature evaluation and a neural network, apply the novel fault diagnosis method to the diagnosis of the friction fault of the flue gas turbine, and verify the effectiveness and the robustness of the provided method. However, most of the research methods are used for fault diagnosis, real-time state evaluation is not considered, and the method belongs to post analysis. The diagnosis model provided by the Zhang Yingtang only utilizes certain specific characteristic parameters as the basis for diagnosing and analyzing the running state, has great limitation, needs similar faults as comparison, and is difficult to have a complete fault model in practical engineering application; the fault diagnosis method based on the neural network proposed by the reyas usually has higher requirements on training samples, and is not easy to change after the training is completed. However, the diesel engine belongs to a typical fault mode which mainly adopts performance degradation, the use environment and the operation working condition are severe and changeable, and the fault diagnosis method has low adaptability.
In addition, the existing diesel engine state evaluation method depends on human experience to a certain extent, and the false alarm rate is high. For various types of diesel engines with different types and structures, the selection of the optimal vibration measuring point theoretically needs complicated transmission path analysis deduction, the practicability is not strong, and the method often depends on artificial experience; the existing vibration analysis indexes are numerous, the enumeration method is time-consuming and labor-consuming, and the selection is often carried out by depending on human experience. In addition, the benchmark of state evaluation needs to be dynamically adjusted according to the performance running-in and the actual operation condition of the diesel engine, while the existing scheme is often set according to experience or initial conditions, and once the setting is not allowed to be modified in real time, the self-adaptive updating capability is lacked. Therefore, although the state evaluation of the diesel engine is applied in many occasions, the existing vibration acquisition scheme and state analysis method have certain blindness, and informatization and intelligent improvement based on the principles of mechanical dynamics, statistics and informatics methods is urgently needed.
Disclosure of Invention
In view of the above, the invention provides a method for evaluating the state of a diesel engine based on real-time vibration data, which makes full use of the current large-capacity data storage, large data mining, high-speed operation technology and high-speed low-delay communication technology to realize that the instantaneous operating state of the diesel engine can be quickly evaluated only through the real-time vibration data, so that the fault symptom of the diesel engine can be found in advance, and the occurrence of malignant faults and casualties can be effectively avoided.
A diesel engine state evaluation method based on real-time vibration data comprises the following implementation steps:
the method comprises the following steps: preliminarily determining a sensor arrangement scheme;
step two: determining a characteristic channel through sensitivity analysis;
step three: selecting characteristic parameters based on the characteristic channels;
step four: establishing a state evaluation key index according to the characteristic channel and the characteristic parameter;
step five: constructing an index reference of dynamic self-adaptive iterative updating;
step six: and performing diesel engine state evaluation based on the established state evaluation indexes and index standards.
Further, the process of determining the sensor arrangement scheme in the first step includes: according to the structural characteristics of a target diesel engine, three-direction vibration measuring points capable of directly reflecting dynamic response characteristics of moving parts of the diesel engine are selected, an acceleration sensor with the measuring range being 3-5 times larger than the maximum vibration level of the target measuring points is selected according to the vibration magnitude of the actual measuring points, and multi-channel vibration data acquisition of the diesel engine in a real-time running state is carried out on the basis of the configuration.
Further, the characteristic channel determination process of the second step includes: taking 20% of rated power of the diesel engine as an initial value, taking 1% of the rated power as incremental change, and gradually increasing the load level until the rated power is cut off; each load condition is kept running for 10 seconds, and the time domain peak value of the vibration signal is calculated; calculating the average value of the absolute value of the peak-to-peak value change under the condition of gradually increasing load, defining the average value as the peak-to-peak value load change rate, and using the peak-to-peak value load change rate as an index for evaluating the channel vibration signal sensitivity; and taking 5 signal channels with the maximum peak load change rate as feature sensitive test channels.
Further, the initial power, the power increment, the cut-off power, the time length for maintaining the operation of the characteristic load condition and the number of finally selected signal channels in the second step are all adjusted according to actual requirements.
Further, the process of selecting the characteristic parameters in the third step includes: designing a cyclic operation map containing 5 typical operation states according to the actual operation condition of the diesel engine, performing two cyclic operation tests, and synchronously acquiring vibration signals of the 5 characteristic sensitive test channels determined in the second step; respectively calculating effective value, variance, peak-to-peak value, skewness and kurtosis of an original vibration signal of each channel, amplitude spectral mean value, average frequency, spectral variance, spectral peak value and spectral kurtosis of an original signal after Fourier transform, effective value, variance, peak-to-peak value, skewness and kurtosis of an amplitude envelope signal of the original signal, amplitude spectral mean value, average frequency, spectral variance, spectral peak value and spectral kurtosis of the amplitude envelope signal after Fourier transform, and totaling 20 characteristic parameter indexes; according to the principle of minimum characteristic difference under the same working condition and maximum characteristic difference under different working conditions, the basis for evaluating the characteristic parameter indexes is designed, and 5 optimal vibration characteristic parameters capable of effectively reflecting the running state of the diesel engine are preferably selected for each channel.
Furthermore, the number of the running states, the number of the cycle tests, the number and the types of the characteristic parameter indexes and the number of the optimal vibration characteristic parameters in the third step can be properly adjusted according to actual requirements.
Further, the process of establishing the state evaluation key index in the fourth step includes: and removing channels and parameters with the same type and similar effects based on the selected diesel engine characteristic sensitivity test channel in the step two and the optimized vibration characteristic parameter of each channel in the step three, normalizing and multiplying the characteristic parameters of the rest channels, and fusing the characteristic parameters into a key evaluation index.
Further, the construction process of the index reference in the fifth step includes: taking the health state of the diesel engine as an initial state, taking 20% of rated power of the diesel engine as an initial value, taking 1% of the rated power as an increment, and gradually increasing the load level until the rated power is cut off. And (4) keeping running for 5 minutes under each load condition, and calculating a corresponding state evaluation index as an initial index reference. In the actual running process of the diesel engine, state evaluation index calculation is carried out on the vibration data collected in real time, and the latest index reference is calculated again every 10 minutes on the basis of the running state data of the latest 10 minutes, so that the dynamically self-adaptive iterative updated index reference is formed.
Furthermore, the initial power, the power increment, the cut-off power, the specific load maintaining operation time and the index reference updating time in the fifth step are all properly adjusted according to actual requirements.
Further, the state evaluation process of the sixth step includes: based on the established state evaluation index and the dynamically self-adaptive iterative updated index standard, carrying out real-time vibration data acquisition and rapid index calculation on the diesel engine, and comparing the real-time vibration data acquisition and rapid index calculation with the real-time index standard; when the real-time state evaluation index value exceeds 10% of the current standard, judging that the diesel engine is abnormal, and performing state early warning; and analyzing the original vibration data corresponding to the abnormal moment by using a time-frequency analysis technology, and diagnosing the abnormal reason so as to guide the real-time state evaluation of the diesel engine.
Has the advantages that:
1. compared with the prior art, the diesel engine state evaluation method based on real-time vibration data provided by the invention obviously reduces the deviation caused by human intervention. The method does not depend on manual experience to select the measuring points and the characteristic indexes of the diesel engine, but automatically selects the measuring points and the evaluation indexes which are most sensitive to state change based on the self vibration characteristics of the diesel engine to be measured, thereby improving the accuracy of state evaluation.
2. Compared with the prior art, the diesel engine state evaluation method based on real-time vibration data can effectively reduce the false alarm rate. In the actual operation process of the diesel engine, the vibration characteristic changes along with the assembly condition of parts and the running-in of contact parts, and the overall vibration characteristic also has the characteristic of nonlinear change even under the condition of no fault. On the premise of fixing the index reference, false alarm is easy to occur. The method provided by the invention updates the index reference at regular time without human intervention, and can integrate the performance change information of the diesel engine into the state evaluation flow, thereby reducing the false alarm rate.
Drawings
FIG. 1 is a flow chart of the steps of a method for diesel engine state estimation based on real-time vibration data in accordance with the present invention;
FIG. 2 is a schematic diagram of a preferred process of a sensing channel;
FIG. 3 is a schematic diagram of a characteristic indicator optimization process;
FIG. 4 is a diagram illustrating reference setup and update.
Detailed Description
The invention is described in detail below by way of example with reference to the accompanying drawings.
As shown in fig. 1, the invention provides a method for evaluating the state of a diesel engine based on real-time vibration data, which comprises the following implementation steps:
step 1: preliminarily determining a sensor arrangement scheme; according to the structural characteristics of a target diesel engine, three-direction vibration measuring points such as a cylinder cover, a bearing seat and a machine foot which can directly reflect the dynamic response characteristics of moving parts of the diesel engine are selected, an acceleration sensor with the measuring range being 3-5 times larger than the maximum vibration level of the target measuring point is selected according to the vibration magnitude of the actual measuring point, and a sensor bolt connection installation mode is selected for ensuring the testing quality and safety. Based on the configuration, multichannel vibration data acquisition of the diesel engine in a real-time running state is carried out.
Preferably, in step 1, other common vibration measuring points can be selected, and the measuring range and the installation mode of the sensor can be set according to actual requirements.
And 2, step: determining a characteristic channel through sensitivity analysis; and taking 20 percent of rated power of the diesel engine as an initial value and 1 percent of rated power as incremental change, and gradually increasing the load level until the rated power is cut off. Each load condition was maintained for 10 seconds and the time domain peak to peak value of the vibration signal segment was calculated. And (4) calculating the average value of the absolute values of the peak-to-peak value changes under the condition of gradually increasing loads, defining the average value as the peak-to-peak value load change rate, and using the peak-to-peak value load change rate as an index for evaluating the channel vibration signal sensitivity. And taking 5 signal channels with the maximum peak load change rate as feature sensitive test channels.
Preferably, the initial power, the power increment, the cut-off power, the time length for maintaining the operation of the characteristic load condition and the number of the finally selected signal channels in the step 2 can be properly adjusted according to actual requirements.
And step 3: selecting characteristic parameters based on the characteristic channels; and designing a cyclic operation map containing 5 typical operation states according to the actual operation conditions of the diesel engine, performing two cyclic operation tests, and synchronously acquiring the vibration signals of the 5 characteristic sensitive test channels determined in the step two. The 20 characteristic parameter indexes of each channel are respectively calculated. According to the principle of minimum characteristic difference under the same working condition and maximum characteristic difference under different working conditions, the basis for evaluating the characteristic parameter indexes is designed, and 5 optimal vibration characteristic parameters capable of effectively reflecting the running state of the diesel engine are preferably selected for each channel.
Preferably, the number of the running states, the number of the cycle tests, the number and the types of the characteristic parameter indexes, and the number of the optimal vibration characteristic parameters in the step 3 can be properly adjusted according to actual requirements.
And 4, step 4: establishing a state evaluation key index according to the characteristic channel and the characteristic parameter; and removing channels and parameters with the same type and similar effects based on the selected diesel engine characteristic sensitivity test channel in the step two and the optimized vibration characteristic parameter of each channel in the step three, normalizing and multiplying the characteristic parameters of the rest channels, and fusing the characteristic parameters into 1 key evaluation index.
And 5: and constructing an index reference of dynamic self-adaptive iterative updating. And taking the health state of the diesel engine as an initial state, taking 20 percent of rated power of the diesel engine as an initial value, taking 1 percent of the rated power as an incremental change, and gradually increasing the load level until the rated power is cut off. And (4) keeping running for 5 minutes under each load condition, and calculating a corresponding state evaluation index as an initial index standard. In the actual running process of the diesel engine, the state evaluation index calculation is carried out on the vibration data collected in real time, and the latest index reference is calculated again every 10 minutes based on the running state data of the latest 10 minutes, so that the index reference of dynamic self-adaptive iterative updating is formed.
Preferably, the starting power, the power increment, the cut-off power, the specific load maintaining operation time and the index reference updating time in step 5 can be properly adjusted according to actual requirements.
And 6: index monitoring and state early warning are carried out. And based on the established state evaluation index and the dynamically self-adaptive iterative updated index reference, carrying out real-time vibration data acquisition and rapid index calculation on the diesel engine, and comparing the real-time vibration data acquisition and rapid index calculation with the real-time index reference. And when the real-time state evaluation index value exceeds 10% of the current reference, judging that the diesel engine is abnormal, and performing state early warning.
Preferably, the index threshold range can be properly adjusted according to actual requirements.
FIG. 2 is a schematic diagram of a preferred process for determining a characteristic channel by sensitivity analysis. First, a set of basic experiments was conducted with 20% of the rated power of the diesel engine as the starting value and 1% of the rated power as incremental changes to gradually increase the load level until the rated power cutoff was reached. Each load condition was maintained for 10 seconds and the time domain peak to peak value of the vibration signal segment was calculated. And averaging the absolute value of the peak-to-peak value change under the condition of gradually increasing load, defining the average value as the peak-to-peak value load change rate, and using the average value as an index for evaluating the channel vibration signal sensitivity. And taking 5 signal channels with the maximum peak load change rate as feature sensitive test channels. Preferably, the initial power, the power increment, the cut-off power, the duration of the characteristic load condition maintenance operation and the number of finally selected signal channels can be properly adjusted according to actual requirements.
Fig. 3 is a schematic diagram of a preferred process of feature index, which illustrates a detailed process of selecting feature parameters based on feature channels. Firstly, according to the actual operation condition of the diesel engine, a cyclic operation map containing 5 typical operation states is designed, two cyclic operation tests are carried out, and the vibration signals of the 5 characteristic sensitive test channels determined in the second step are synchronously acquired. The 20 characteristic parameter indexes of each channel are respectively calculated. According to the principle that the distance between the characteristic assemblies under the same working condition is minimum and the distance between the characteristic assemblies under different working conditions is maximum, the basis for evaluating the characteristic parameter indexes is designed, and 5 optimal vibration characteristic parameters capable of effectively reflecting the running state of the diesel engine are preferably selected for each channel. Preferably, the number of the running states, the number of the cycle tests, the number and the types of the characteristic parameter indexes and the number of the optimal vibration characteristic parameters can be properly adjusted according to actual requirements.
Fig. 4 is a diagram of reference setting and updating, which illustrates a specific process of constructing a dynamically adaptive iteratively updated index reference. And taking the health state of the diesel engine as an initial state, taking 20 percent of rated power of the diesel engine as an initial value, taking 1 percent of the rated power as an incremental change, and gradually increasing the load level until the rated power is cut off. And (3) keeping running for 10 minutes under each load condition, taking every 10 seconds as a section, and calculating a corresponding state evaluation index mean value as an initial index standard. In the actual running process of the diesel engine, state evaluation index calculation is carried out on the vibration data collected in real time, and the latest index reference is calculated again every 10 minutes on the basis of the running state data of the latest 10 minutes, so that the dynamically self-adaptive iterative updated index reference is formed. Preferably, the starting power, the power increment, the cut-off power, the specific load maintaining operation time and the index reference updating time can be properly adjusted according to actual requirements.
In summary, the above description is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention. 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 (5)
1. A diesel engine state evaluation method based on real-time vibration data is characterized by comprising the following implementation steps of:
the method comprises the following steps: preliminarily determining a sensor arrangement scheme;
step two: determining a characteristic channel through sensitivity analysis;
step three: selecting characteristic parameters based on the characteristic channels;
step four: establishing a state evaluation key index according to the characteristic channel and the characteristic parameter;
step five: constructing an index reference of dynamic self-adaptive iterative updating;
step six: performing diesel engine state evaluation based on the established state evaluation indexes and index standards;
the characteristic channel determining process of the second step comprises the following steps: taking 20% of rated power of the diesel engine as an initial value, taking 1% of the rated power as an incremental change, and gradually increasing the load level to reach the rated power cut-off; each load condition is kept running for 10 seconds, and the time domain peak value of the vibration signal is calculated; calculating the average value of the absolute value of the peak-to-peak value change under the condition of gradually increasing load, defining the average value as the peak-to-peak value load change rate, and using the peak-to-peak value load change rate as an index for evaluating the channel vibration signal sensitivity; taking 5 signal channels with the maximum peak load change rate as feature sensitive test channels;
the process of selecting the characteristic parameters in the third step comprises the following steps: designing a cyclic operation map containing 5 typical operation states according to the actual operation condition of the diesel engine, performing two cyclic operation tests, and synchronously acquiring vibration signals of the 5 characteristic sensitive test channels determined in the second step; respectively calculating effective value, variance, peak-to-peak value, skewness and kurtosis of an original vibration signal of each channel, mean value, average frequency, spectral variance, spectral peak value and spectral kurtosis of an amplitude spectrum after Fourier transform of the original vibration signal, effective value, variance, peak-to-peak value, skewness and kurtosis of an amplitude envelope signal of the original vibration signal, mean value, average frequency, spectral variance, spectral peak value and spectral kurtosis of the amplitude spectrum after Fourier transform of the amplitude envelope signal, and totaling 20 characteristic parameter indexes; according to the principle that the characteristic difference of the same working condition is minimum and the characteristic difference of different working conditions is maximum, the basis for evaluating the characteristic parameter indexes is designed, and 5 optimal vibration characteristic parameters capable of effectively reflecting the running state of the diesel engine are selected for each channel.
2. The method for estimating a state of a diesel engine based on real-time vibration data according to claim 1, wherein the step one of determining the sensor arrangement scheme comprises: according to the structural characteristics of a target diesel engine, three-direction vibration measuring points capable of directly reflecting dynamic response characteristics of moving parts of the diesel engine are selected, an acceleration sensor with the measuring range being 3-5 times larger than the maximum vibration level of the target measuring points is selected according to the vibration magnitude of the actual measuring points, and multi-channel vibration data acquisition of the diesel engine in a real-time running state is carried out on the basis of the configuration.
3. The method for estimating the state of a diesel engine based on real-time vibration data according to claim 2, wherein the step four for establishing the key index for estimating the state comprises the steps of: and removing channels and parameters with the same type and similar effects based on the diesel engine characteristic sensitivity test channel selected in the step two and each channel vibration characteristic parameter selected in the step three, normalizing and multiplying all the characteristic parameters of the rest channels, and fusing the characteristic parameters into a key evaluation index.
4. The diesel engine state evaluation method based on real-time vibration data as set forth in claim 3, wherein the construction process of the index reference in the step five comprises: taking the health state of the diesel engine as an initial state, taking 20 percent of rated power of the diesel engine as an initial value, taking 1 percent of the rated power as incremental change, and gradually increasing the load level to reach the cutoff of the rated power; each load condition is kept running for 5 minutes, and corresponding state evaluation indexes are calculated and serve as initial index standards; in the actual running process of the diesel engine, the state evaluation index calculation is carried out on the vibration data collected in real time, and the latest index reference is calculated again every 10 minutes based on the running state data of the latest 10 minutes, so that the index reference of dynamic self-adaptive iterative updating is formed.
5. The diesel engine state estimation method based on real-time vibration data according to claim 4, wherein the state estimation process of the sixth step includes: based on the established state evaluation index and the dynamically self-adaptive iterative updated index reference, carrying out real-time vibration data acquisition and rapid index calculation on the diesel engine, and comparing the real-time vibration data acquisition and rapid index calculation with the real-time index reference; when the real-time state evaluation index value exceeds 10% of the current standard, judging that the diesel engine is abnormal, and performing state early warning; and analyzing the original vibration data corresponding to the abnormal moment by using a time-frequency analysis technology, and diagnosing the abnormal reason so as to guide the real-time state evaluation of the diesel engine.
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