CN113358150A - Method for avoiding equipment failure caused by production fluctuation - Google Patents
Method for avoiding equipment failure caused by production fluctuation Download PDFInfo
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- CN113358150A CN113358150A CN202110045950.6A CN202110045950A CN113358150A CN 113358150 A CN113358150 A CN 113358150A CN 202110045950 A CN202110045950 A CN 202110045950A CN 113358150 A CN113358150 A CN 113358150A
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- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D21/00—Measuring or testing not otherwise provided for
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Abstract
A method for avoiding equipment faults caused by production fluctuation relates to the technical field of equipment fault avoidance, and the structure of the method is as follows: the method comprises three steps of data acquisition, data threshold value judgment and fault comprehensive analysis; synchronously acquiring data and waveforms of motor current X, motor voltage Y, motor vibration D and reducer vibration C; the fluctuation of the motor current X during production and operation fluctuates under the production condition; the motor voltage Y is in a constant state during production and operation; the motor vibration D is the gravity acceleration change of the motor in the running process, and the fluctuation source is the running stress and the fault of the motor; the reducer vibration C is the change of the gravity acceleration of the reducer in the running process. The invention has the beneficial effects that: the equipment change is determined through the current and voltage changes, the shaft and tooth breaking faults are determined through data overrun and map content, the operation condition of the equipment is accurately grasped in real time, early warning is found in advance, the equipment faults are effectively avoided, and the production efficiency is improved.
Description
Technical Field
The invention relates to the technical field of equipment fault avoidance, in particular to an avoiding method for equipment faults caused by production fluctuation.
Background
The cement factory has great production fluctuation in the production process, such as material change, grindability change, yield, temperature change and air volume change, in the process, the influence of the production fluctuation on equipment is serious, the load is weighted slightly to cause pressure on the equipment, the equipment is locked seriously, the production running condition and the equipment running condition supplement each other, the avoidance or the solution is carried out by depending on the experience of equipment management personnel all the time, and the effect is not good.
Disclosure of Invention
In order to overcome the defects in the prior art, the invention provides a method for avoiding equipment faults caused by production fluctuation, which analyzes the current change caused by the production fluctuation and the faults of broken shafts of electrical equipment and broken teeth of a gear box by comprehensively analyzing data acquisition, thereby avoiding the faults in advance and adjusting the process.
The invention provides a method for avoiding equipment faults caused by production fluctuation, which comprises the following steps: data acquisition, data threshold judgment and comprehensive fault analysis;
the first step is as follows: data acquisition
And synchronously acquiring data and waveforms of motor current X, motor voltage Y, motor vibration D and reducer vibration C.
The second step is that: data threshold determination
Judging a data threshold value according to the characteristics of the motor current X, the motor voltage Y, the motor vibration D and the reducer vibration C;
the motor current X is characterized in that: expressing the condition of power consumption of a motor when equipment runs, wherein the fluctuation of the motor during production running is fluctuated by the production condition, and when increasing/decreasing the production, the data can be fed back and changed immediately; but the condition of production fluctuation cannot be directly deduced in a reverse mode due to the change of secondary data;
the motor voltage Y is characterized in that: expressing the voltage used by the equipment during operation, wherein the voltage is in a constant state during production operation and is 0 during shutdown;
the motor vibrates D: expressing the gravity acceleration change of equipment parts in the production and operation process of the motor, wherein the fluctuation source is the operation stress and the fault of the motor;
the reducer vibrates C: expressing the change of the gravity acceleration of the speed reducer in the running process;
the fluctuation of the motor current X during production and operation is fluctuated by the production condition, the smaller the resistance of the production surface is, the smaller the X change is, and the larger the resistance of the production surface is, the larger the X change is;
the motor voltage Y is in a constant state during production and operation, has no fluctuation and large-range change, and is used as a parameter value.
The third step: comprehensive analysis of faults
When in production and operation, the motor voltage Y is in a constant state without fluctuation and large-range change and is used as a parameter value to be added into an algorithm;
during production, the fluctuation of the motor current X fluctuates under the production condition, the smaller the resistance of the production surface is, the smaller the change of the X is, and the larger the resistance of the production surface is, the larger the change of the X is;
the motor vibration D is the gravity acceleration change of the motor in the running process, the fluctuation source is the running stress and the fault of the motor, and the vibration acceleration data, the time domain waveform change and the frequency domain spectrum change are shown;
the vibration C of the speed reducer is the change of the gravity acceleration of the speed reducer in the operation process, and the fluctuation source of the vibration C is the meshing of a mechanical structure and the operation stress and the fault.
When the current X of the motor rises by 20 percent and a fixed threshold value is triggered, calculating whether the waveforms and the conversion frequency of the vibration D of the motor and the vibration C of the speed reducer are normal or not;
the calculation method is as follows: main frequency is positioned and amplitude is read, and if the vibration D amplitude of the motor exceeds 60%, an alarm is given to 'the motor bearing pretightening force is too large, and the risk of shaft breakage is caused'; c amplitude is over 40% and natural frequency debugging frequency number is 4 and above, then report to the police "gear meshing atress is uneven, has disconnected tooth risk".
When the motor voltage Y exceeds 20%, triggering by a fixed threshold, calculating whether the waveform and the frequency conversion of the motor vibration D are normal;
the calculation method is as follows: and (3) positioning the main frequency, namely the rotation speed/60 of the equipment is the main frequency of the equipment, reading the amplitude, polling the main frequency by two-frequency multiplication, three-frequency multiplication and four-frequency multiplication, wherein the two times of the main frequency are two-frequency multiplication, the three times of the main frequency are three-frequency multiplication, and the like, and if the frequency multiplication amplitude is increased by 20% and the frequency conversion amplitude is increased by 40%, alarming that the pretightening force of the motor bearing is overlarge and the shaft breakage risk exists.
The invention has the beneficial effects that: the equipment change is determined through the current and voltage changes, the shaft and tooth breaking faults are determined through data overrun and map content, the operation condition of the equipment is accurately grasped in real time, early warning is found in advance, the equipment faults are effectively avoided, and the production efficiency is improved.
Drawings
FIG. 1 is a data acquisition waveform of the present invention;
fig. 2 shows time domain waveforms and frequency domain waveforms according to the present invention.
Detailed Description
Embodiment 1, as shown in fig. 1-2, the present invention provides a method for circumventing a failure of equipment due to a production fluctuation, comprising: data acquisition, data threshold judgment and comprehensive fault analysis;
the first step is as follows: data acquisition
And synchronously acquiring data and waveforms of motor current X, motor voltage Y, motor vibration D and reducer vibration C.
The second step is that: data threshold determination
Judging a data threshold value according to the characteristics of the motor current X, the motor voltage Y, the motor vibration D and the reducer vibration C;
the motor current X is characterized in that: expressing the condition of power consumption of a motor when equipment runs, wherein the fluctuation of the motor during production running is fluctuated by the production condition, and when increasing/decreasing the production, the data can be fed back and changed immediately; but the condition of production fluctuation cannot be directly deduced in a reverse mode due to the change of secondary data;
the motor voltage Y is characterized in that: expressing the voltage used by the equipment during operation, wherein the voltage is in a constant state during production operation and is 0 during shutdown;
the motor vibrates D: expressing the gravity acceleration change of equipment parts in the production and operation process of the motor, wherein the fluctuation source is the operation stress and the fault of the motor;
the reducer vibrates C: expressing the change of the gravity acceleration of the speed reducer in the running process;
the fluctuation of the motor current X during production and operation is fluctuated by the production condition, the smaller the resistance of the production surface is, the smaller the X change is, and the larger the resistance of the production surface is, the larger the X change is;
the motor voltage Y is in a constant state during production and operation, has no fluctuation and large-range change, and is used as a parameter value.
The third step: comprehensive analysis of faults
When in production and operation, the motor voltage Y is in a constant state without fluctuation and large-range change and is used as a parameter value to be added into an algorithm;
during production, the fluctuation of the motor current X fluctuates under the production condition, the smaller the resistance of the production surface is, the smaller the change of the X is, and the larger the resistance of the production surface is, the larger the change of the X is;
the motor vibration D is the gravity acceleration change of the motor in the running process, the fluctuation source is the running stress and the fault of the motor, and the vibration acceleration data, the time domain waveform change and the frequency domain spectrum change are shown;
the vibration C of the speed reducer is the change of the gravity acceleration of the speed reducer in the operation process, and the fluctuation source of the vibration C is the meshing of a mechanical structure and the operation stress and the fault.
When the current X of the motor rises by 20 percent and a fixed threshold value is triggered, calculating whether the waveforms and the conversion frequency of the vibration D of the motor and the vibration C of the speed reducer are normal or not;
the calculation method is as follows: main frequency is positioned and amplitude is read, and if the vibration D amplitude of the motor exceeds 60%, an alarm is given to 'the motor bearing pretightening force is too large, and the risk of shaft breakage is caused'; c amplitude is over 40% and natural frequency debugging frequency number is 4 and above, then report to the police "gear meshing atress is uneven, has disconnected tooth risk".
When the motor voltage Y exceeds 20%, triggering by a fixed threshold, calculating whether the waveform and the frequency conversion of the motor vibration D are normal;
the calculation method is as follows: and (3) positioning the main frequency, namely the rotation speed/60 of the equipment is the main frequency of the equipment, reading the amplitude, polling the main frequency by two-frequency multiplication, three-frequency multiplication and four-frequency multiplication, wherein the two times of the main frequency are two-frequency multiplication, the three times of the main frequency are three-frequency multiplication, and the like, and if the frequency multiplication amplitude is increased by 20% and the frequency conversion amplitude is increased by 40%, alarming that the pretightening force of the motor bearing is overlarge and the shaft breakage risk exists.
Claims (4)
1. A method for avoiding equipment failure caused by production fluctuation is characterized in that: the method comprises three steps of data acquisition, data threshold value judgment and fault comprehensive analysis;
the first step is as follows: data acquisition
Synchronously acquiring data and waveforms of motor current X, motor voltage Y, motor vibration D and reducer vibration C;
the second step is that: data threshold determination
Judging a data threshold value according to the characteristics of the motor current X, the motor voltage Y, the motor vibration D and the reducer vibration C;
the motor current X is characterized in that: expressing the condition of power consumption of a motor when equipment runs, wherein the fluctuation of the motor during production running is fluctuated by the production condition, and when increasing/decreasing the production, the data can be fed back and changed immediately; but the condition of production fluctuation cannot be directly deduced in a reverse mode due to the change of secondary data;
the motor voltage Y is characterized in that: expressing the voltage used by the equipment during operation, wherein the voltage is in a constant state during production operation and is 0 during shutdown;
the motor vibrates D: expressing the gravity acceleration change of equipment parts in the production and operation process of the motor, wherein the fluctuation source is the operation stress and the fault of the motor;
the reducer vibrates C: expressing the change of the gravity acceleration of the speed reducer in the running process;
the fluctuation of the motor current X during production and operation is fluctuated by the production condition, the smaller the resistance of the production surface is, the smaller the X change is, and the larger the resistance of the production surface is, the larger the X change is;
the motor voltage Y is in a constant state during production and operation, does not fluctuate or change in a large range, and is used as a parameter value to be added;
the third step: comprehensive analysis of faults
When in production and operation, the motor voltage Y is in a constant state without fluctuation and large-range change and is used as a parameter value to be added into an algorithm;
during production, the fluctuation of the motor current X fluctuates under the production condition, the smaller the resistance of the production surface is, the smaller the change of the X is, and the larger the resistance of the production surface is, the larger the change of the X is;
the motor vibration D is the gravity acceleration change of the motor in the running process, the fluctuation source is the running stress and the fault of the motor, and the vibration acceleration data, the time domain waveform change and the frequency domain spectrum change are shown;
the vibration C of the speed reducer is the change of the gravity acceleration of the speed reducer in the operation process, and the fluctuation source of the vibration is the meshing of a mechanical structure, the operation stress and the fault;
when the current X of the motor rises by 20 percent and a fixed threshold value is triggered, calculating whether the waveforms and the conversion frequency of the vibration D of the motor and the vibration C of the speed reducer are normal or not;
the calculation method is as follows: positioning the main frequency and reading the amplitude, and alarming when the amplitude of the motor vibration D exceeds 60 percent; c, if the amplitude exceeds 40% and the number of the natural frequency debugging frequencies is 4 or more, alarming;
when the motor voltage Y exceeds 20%, triggering by a fixed threshold, calculating whether the waveform and the frequency conversion of the motor vibration D are normal;
the calculation method is as follows: and (3) positioning the main frequency, namely the rotation speed/60 of the equipment is the main frequency of the equipment, reading the amplitude, polling the main frequency by two-frequency multiplication, three-frequency multiplication and four-frequency multiplication, wherein the two times of the main frequency is two-frequency multiplication, the three times of the main frequency is three-frequency multiplication, and the like, and alarming if the frequency multiplication amplitude is increased by more than 20% and the frequency conversion amplitude is increased by 40%.
2. An evading method for equipment failure caused by production fluctuation according to claim 1, wherein: the amplitude of the motor vibration D exceeds 60%, and the alarm content is that the pretightening force of a motor bearing is too large, so that the risk of shaft breakage exists.
3. An evading method for equipment failure caused by production fluctuation according to claim 1, wherein: the vibration C amplitude of the speed reducer exceeds 40% and the natural frequency debugging frequency number is 4 or more, the alarm content is 'uneven gear meshing stress and tooth breakage risk'.
4. An evading method for equipment failure caused by production fluctuation according to claim 1, wherein: and if the frequency multiplication amplitude increases by 20% and the frequency conversion amplitude increases by 40%, the alarm content is that the pre-tightening force of the motor bearing is too large and the shaft breakage risk exists.
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