CN113916366A - Vibration signal-based method and device for monitoring operation of impeller of vortex crusher - Google Patents
Vibration signal-based method and device for monitoring operation of impeller of vortex crusher Download PDFInfo
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- 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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Abstract
The embodiment of the application discloses a method and equipment for monitoring the running of an impeller of a vortex crusher based on vibration signals, which are used for solving the problem that the running state of the impeller of the vortex crusher is difficult to monitor in the prior art. Acquiring an impeller vibration signal acquired by a vibration sensor; the vibration sensor is embedded in an impeller shaft corresponding to an impeller of the vortex crusher; determining an impeller vibration signal corresponding to the current time period from the obtained impeller vibration signals according to a preset time interval; generating a vibration signal curve corresponding to the current time period according to the impeller vibration signal corresponding to the current time period; determining the running state of the impeller in the current time period based on the vibration signal curve corresponding to the current time period; and controlling the operation of an impeller in the vortex crusher according to the operation state. By the method, the purpose of monitoring the running state of the impeller of the vortex crusher is achieved.
Description
Technical Field
The application relates to the technical field of signal processing, in particular to a method and equipment for monitoring the operation of an impeller of a vortex crusher based on vibration signals.
Background
In industries such as ore mining and coal mining, a vortex crusher is needed to crush and transmit materials. The vortex crusher is internally provided with an impeller and a material channel, the impeller rotates at a high speed, and the vortex effect is formed, so that materials are crushed by mutual collision in the material channel, and the crushed materials are smoothly transferred to a discharge hole.
In such operating environments, the impeller is susceptible to damage, which can cause abnormal operation of the scroll crusher and which can be found to exacerbate damage in time.
However, in the prior art, the running state of the impeller of the vortex crusher is difficult to monitor, so that the damage condition of the impeller is difficult to find in time.
Disclosure of Invention
The embodiment of the application provides a method and equipment for monitoring the running state of an impeller, which are used for solving the problem that the running state of the impeller of a vortex crusher is difficult to monitor in the prior art.
The embodiment of the application adopts the following technical scheme:
the embodiment of the application provides a method for monitoring the operation of an impeller of a vortex crusher based on a vibration signal. Acquiring an impeller vibration signal acquired by a vibration sensor; the vibration sensor is embedded in an impeller shaft corresponding to an impeller of the vortex crusher; determining an impeller vibration signal corresponding to the current time period from the obtained impeller vibration signals according to a preset time interval; generating a vibration signal curve corresponding to the current time period according to the impeller vibration signal corresponding to the current time period; determining the running state of the impeller in the current time period based on the vibration signal curve corresponding to the current time period; and controlling the operation of the impeller in the vortex crusher according to the operation state.
The vibration sensor who locates in the impeller shaft through the embedding gathers the vibration signal of impeller, avoids on the one hand placing vibration sensor in the blade, influences blade work efficiency's problem. On the other hand, the running state of the impeller can be analyzed in real time according to the acquired vibration signals, and faults occurring in the running process of the impeller can be found in time. In addition, the embodiment of the application generates a vibration signal curve by using the acquired vibration signal, and determines different running states of the impeller according to the change of the curve. The problem of just can detect the impeller under the condition of scroll breaker inoperative is solved, guarantee that scroll breaker can normally work.
In an implementation manner of the present application, determining an operation state of an impeller in a current time period based on a vibration signal curve corresponding to the current time period specifically includes: determining a maximum wave peak value and a minimum wave valley value in a vibration signal curve; determining that the impeller is in a normal operation state in the current time period under the condition that the maximum wave peak value is smaller than or equal to a first preset value and the minimum wave trough value is larger than or equal to a second preset value; determining that the impeller is in an abnormal operation state in the current time period under the condition that a wave peak value larger than a first preset value exists in the vibration signal curve or a wave valley value smaller than a second preset value exists in the vibration signal curve; wherein, the abnormal operation state includes: large particles impact and damage the impeller.
According to the embodiment of the application, the operating state of the impeller can be obtained by analyzing the obtained impeller vibration signal curve in the current time period. According to the embodiment of the application, the wave peak value and the wave trough value of the vibration bright signal curve are used, so that the fluctuation of the impeller in operation can be visually seen, different abnormal states of the impeller can be determined by analyzing the wave peak value and the wave trough value, the operation of the current impeller is controlled, and the damage speed of the impeller is reduced.
In an implementation manner of the present application, determining that an impeller is in an abnormal operation state in a current time period when a peak value greater than a first preset value exists in a vibration signal curve or a valley value smaller than a second preset value exists in the vibration signal curve specifically includes: determining a difference value between adjacent wave crests in a vibration signal curve corresponding to the current time period as a wave crest difference value, or determining a difference value between adjacent wave troughs as a wave trough difference value; determining whether a peak difference value or a trough difference value larger than a third preset value exists; and under the condition that the peak difference value or the trough difference value larger than the third preset value exists, determining that the running state of the impeller is large particle impact.
In one implementation of the present application, the method further comprises: under the condition that the peak difference value or the trough difference value larger than a third preset value does not exist, calculating a first peak average value or a first trough average value of the vibration signal curve of the current time period; acquiring a vibration signal curve of the previous time period, and calculating a second peak average value or a second trough average value of the vibration signal curve of the previous time period; determining that the running state of the impeller is impeller damage under the condition that the difference value of the first peak average value and the second peak average value is greater than a fourth preset value; or determining that the running state of the impeller is impeller breakage under the condition that the difference value between the first trough average value and the second trough average value is smaller than a fifth preset value.
In one implementation manner of the present application, after determining that the operating state of the impeller is the impeller breakage, the method further includes: searching a peak average value of a vibration signal curve of the current time period in a preset impeller tachometer, and obtaining a corresponding first standard rotating speed; the preset impeller rotating speed meter comprises a plurality of average wave peak values and standard rotating speeds of impellers respectively corresponding to the average wave peak values; determining the preset lowest rotating speed of the impeller when the material is crushed according to the material information of the current material to be crushed; converting the current rotating speed of the impeller into a first standard rotating speed under the condition that the first standard rotating speed is greater than or equal to a preset lowest rotating speed; and controlling the impeller to stop running under the condition that the first standard rotating speed is less than the preset lowest rotating speed.
According to the embodiment of the application, the standard rotating speed corresponding to the impeller in the damaged state is determined according to the peak average value. And determining the minimum rotating speed required by the impeller when the material is crushed according to the material information. The minimum rotating speed is replaced by the standard rotating speed, so that the impeller in the current damage state can continue to finish the residual crushing work, and the material can be guaranteed to be damaged in time. And the standard rotating speed is lower than the current rotating speed, so that the further damage of the impeller can be reduced, the service life of the impeller is prolonged, the replacement frequency of the impeller is reduced, and the cost is reduced.
In one implementation of the present application, after determining that the impeller is in the normal operation state in the current time period, the method further includes: calculating a third wave peak average value or a third wave valley average value of the vibration signal curve of the current time period; acquiring a vibration signal curve of the previous time period, and calculating a fourth wave peak average value or a fourth wave valley average value of the vibration signal curve of the previous time period; calculating a peak difference value between the average value of the third wave peak and the average value of the fourth wave peak, or calculating a trough difference value between the average value of the third wave trough and the average value of the fourth wave trough; determining the impeller abrasion degree of the current time period according to the wave crest difference value or the wave trough difference value; and comparing the abrasion degree of the impeller in the current time period with the abrasion degree of the impeller in the previous time period, and controlling the impeller to normally operate under the condition that the abrasion degree accords with a preset abrasion rule.
In one implementation of the present application, after determining that the impeller is in the normal operation state in the current time period, the method further includes: acquiring vibration signal curves corresponding to impellers of the same model in a normal operation state and in an initial state and a normal operation state respectively; acquiring each vibration signal curve, and respectively corresponding abrasion degree of the impeller; comparing each vibration signal curve with a vibration signal curve corresponding to an impeller in a preset maintenance state to obtain a wear degree difference value; determining the residual operation time of the impeller corresponding to the vibration signal curve according to the abrasion degree difference; wherein the residual operation time is the residual operation time of the impeller in the normal operation state; and training a preset neural network model through a vibration signal curve, the abrasion degree of the impeller and the residual running time to obtain an impeller running time prediction model.
According to the embodiment of the application, the preset neural network model is trained through the acquired vibration signal curve, the abrasion degree of the impeller and the residual running time, and the impeller running time prediction model is obtained. The running time of the current impeller can be predicted, so that the quantity of the crushed materials is increased, and the control of the material crushing progress is improved.
In one implementation of the present application, after obtaining the impeller operation duration prediction model, the method further includes: inputting a vibration signal curve of the current time period into an impeller operation duration prediction model; acquiring the operation time of the impeller from the current wear state to the maintenance state according to the impeller operation time prediction model; and generating corresponding prompt information according to the running time of the impeller from the current wear state to the maintenance state, and sending the prompt information to a corresponding management terminal of the vortex crusher.
In one implementation manner of the present application, after generating a vibration signal curve corresponding to a current time period according to an impeller vibration signal corresponding to the current time period, the method further includes: determining the corresponding average vibration frequency of the impeller in the current time period according to the vibration signal curve of the current time period; acquiring a set rotating speed of the impeller in the current time period, and determining a standard vibration frequency corresponding to the set rotating speed according to the information of the impeller; calculating a frequency difference between the standard vibration frequency and the average vibration frequency; and under the condition that the frequency difference value is greater than a sixth preset value, determining that the current rotating speed of the impeller is less than the set rotating speed, and sending alarm information under the condition that the current rotating speed of the impeller is less than the set rotating speed.
The embodiment of the application provides a vortex breaker's impeller operation monitoring facilities based on vibration signal, includes: at least one processor; and a memory communicatively coupled to the at least one processor; wherein the memory stores instructions executable by the at least one processor to cause the at least one processor to: acquiring an impeller vibration signal acquired by a vibration sensor; the vibration sensor is embedded in an impeller shaft corresponding to an impeller of the vortex crusher; determining an impeller vibration signal corresponding to the current time period from the obtained impeller vibration signals according to a preset time interval; generating a vibration signal curve corresponding to the current time period according to the impeller vibration signal corresponding to the current time period; determining the running state of the impeller in the current time period based on the vibration signal curve corresponding to the current time period; and controlling the operation of the impeller in the vortex crusher according to the operation state.
The embodiment of the application adopts at least one technical scheme which can achieve the following beneficial effects: the vibration sensor who locates in the impeller shaft through the embedding gathers the vibration signal of impeller, avoids on the one hand placing vibration sensor in the blade, influences blade work efficiency's problem. On the other hand, the running state of the impeller can be analyzed in real time according to the acquired vibration signals, and faults occurring in the running process of the impeller can be found in time. In addition, the vibration signal curve is generated through the acquired vibration signals, and different running states of the impeller are determined according to changes of the curve. The problem of just can detect the impeller under the condition of scroll breaker inoperative is solved to the guarantee scroll breaker can normally work.
Drawings
In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings needed to be used in the description of the embodiments or the prior art will be briefly introduced below, it is obvious that the drawings in the following description are only some embodiments described in the present application, and for those skilled in the art, other drawings can be obtained according to the drawings without any creative effort. In the drawings:
FIG. 1 is a flow chart of a method for monitoring operation of an impeller of a vortex crusher based on a vibration signal according to an embodiment of the present disclosure;
fig. 2 is a vibration signal graph corresponding to a normal operating state of an impeller provided by an embodiment of the present application;
FIG. 3 is a graph illustrating vibration signals corresponding to an impeller in a large particle collision state according to an embodiment of the present disclosure;
fig. 4 is a graph illustrating a vibration signal when an impeller is in a damaged state according to an embodiment of the present disclosure;
FIG. 5 is a schematic illustration of a scroll crusher according to an embodiment of the present application;
FIG. 6 is a cross-sectional view of a scroll crusher provided in an embodiment of the present application;
fig. 7 is a schematic structural diagram of an impeller operation monitoring device of a vortex crusher based on a vibration signal according to an embodiment of the present application.
Detailed Description
The embodiment of the application provides a method and equipment for monitoring the operation of an impeller of a vortex crusher based on a vibration signal.
In order to make those skilled in the art better understand the technical solutions in the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are only a part of the embodiments of the present application, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without making any inventive step based on the embodiments of the present disclosure, shall fall within the scope of protection of the present application.
In industries such as ore mining and coal mining, a vortex crusher is needed to crush and transmit materials. The vortex crusher is internally provided with an impeller and a material channel, the impeller rotates at a high speed, and the vortex effect is formed, so that materials are crushed by mutual collision in the material channel, and the crushed materials are smoothly transferred to a discharge hole.
In such operating environments, the impeller is susceptible to damage, which can cause abnormal operation of the scroll crusher and which can be found to exacerbate damage in time.
However, in the prior art, the running state of the impeller of the vortex crusher is difficult to monitor, so that the damage condition of the impeller is difficult to find in time.
In order to solve the above problems, embodiments of the present application provide a method and an apparatus for monitoring the operation of an impeller of a scroll crusher based on a vibration signal. The vibration sensor who locates in the impeller shaft through the embedding gathers the vibration signal of impeller, avoids on the one hand placing vibration sensor in the blade, influences blade work efficiency's problem. On the other hand, the running state of the impeller can be analyzed in real time according to the acquired vibration signals, and faults occurring in the running process of the impeller can be found in time. In addition, the vibration signal curve is generated through the acquired vibration signals, and different running states of the impeller are determined according to changes of the curve. The problem of just can detect the impeller under the condition of scroll breaker inoperative is solved to the guarantee scroll breaker can normally work.
The technical solutions proposed in the embodiments of the present application are described in detail below with reference to the accompanying drawings.
Fig. 1 is a flowchart of an impeller operation monitoring method of a vortex crusher based on a vibration signal according to an embodiment of the present application. As shown in fig. 1, the method for monitoring the operation of the impeller includes the following steps:
s101, the server acquires an impeller vibration signal acquired by the vibration sensor.
In one embodiment of the present application, the server obtains an impeller vibration signal collected by a vibration sensor. Wherein, the vibration sensor is embedded in an impeller shaft corresponding to an impeller of the vortex crusher.
Specifically, the impeller of the vortex crusher rotates at a high speed, and the materials collide with each other in the material channel to be crushed by the vortex effect, and the crushed materials are smoothly transferred to the discharge port. Therefore, in order to reduce the influence of the vibration sensor on the impeller, the impeller is fitted into an impeller shaft corresponding to the impeller of the scroll crusher. The motor drives the impeller shaft to rotate, and the impeller shaft drives the blades in the impeller to rotate, so that an eddy current effect is formed.
Further, the vibration sensor is used for collecting vibration signals generated in the rotation process of the impeller, and the vibration signals generated by the impeller in different states are different. The vibration sensor transmits the acquired vibration signal to the server to analyze the vibration signal, so that the current running state of the impeller is obtained.
S102, the server determines an impeller vibration signal corresponding to the current time period from the obtained impeller vibration signals according to a preset time interval.
In one embodiment of the present application, the server acquires the vibration signal of the impeller at preset time intervals. For example, the server may acquire the vibration signal of the impeller once every t seconds.
S103, the server generates a vibration signal curve corresponding to the current time period according to the impeller vibration signal corresponding to the current time period.
In an embodiment of the application, after the server acquires the impeller vibration signal corresponding to the current time period, in order to more intuitively acquire the operating state of the impeller in the current time period, the impeller vibration signal needs to be converted into a vibration signal curve.
For example, fig. 2 is a graph of a vibration signal corresponding to a normal operating state of an impeller provided in an embodiment of the present application. As can be seen from fig. 2, in the coordinate axis where the vibration signal curve is located, the abscissa is time, and the ordinate is the amplitude corresponding to the vibration signal curve. Through the vibration signal curve graph, the vibration amplitude of the impeller corresponding to different moments can be seen, and therefore the vibration condition of the impeller is determined. And determining the current running state of the impeller according to the vibration condition of the impeller.
S104, the server determines the running state of the impeller in the current time period based on the vibration signal curve corresponding to the current time period.
In one embodiment of the present application, the server determines the maximum peak value and the minimum valley value in the vibration signal curve. And under the condition that the maximum wave peak value is less than or equal to a first preset value and the minimum wave trough value is greater than or equal to a second preset value, the server determines that the impeller is in a normal operation state in the current time period.
Specifically, the vibration signal curve includes a plurality of peaks and troughs, and the amplitude of the current impeller vibration can be seen from the peak value and the trough value. The larger the wave crest value is, the smaller the wave trough value is, and the more violent the impeller vibration is. The smaller the difference between the wave peak value and the wave trough value is, the weaker the impeller vibration is.
Further, the server determines the maximum peak value and the minimum valley value of the impeller vibration signal curve corresponding to the current time period. And comparing the maximum wave peak value with a first preset value, and determining whether the maximum wave peak value is less than or equal to the first preset value. And the server compares the minimum wave peak value with a second preset value to determine whether the minimum wave peak value is greater than or equal to the second preset value. The first preset value and the second preset value are vibration signals in a normal running state of the impeller, and the maximum amplitude value corresponding to a generated vibration signal curve is obtained.
Further, the server determines that the impeller is in a normal operation state in the current time period under the condition that the maximum wave crest value is smaller than or equal to the first preset value and the minimum wave trough value is larger than or equal to the second preset value. For example, a first preset value is set as a, that is, the maximum amplitude of the vibration curve corresponding to the normal operation state of the impeller is set as a, and a second preset value is set as e, that is, the minimum amplitude of the vibration curve corresponding to the normal operation state of the impeller is set as e. And determining that the maximum wave crest value of the current impeller vibration signal curve is b, the minimum wave trough value is c, and at the moment, the maximum wave crest value b is smaller than a first preset value a, and the minimum wave trough value c is larger than a second preset value e, so that the current impeller is in a normal operation state.
For example, fig. 2 is a graph of a vibration signal corresponding to a normal operating state of an impeller provided in an embodiment of the present application. The peak value and the trough value in the vibration signal curve in fig. 2 are stable, and the difference between adjacent peak values and trough values is small, that is, the vibration is weak in the operation process of the impeller, and the operation is stable.
In one embodiment of the present application, in a case where a peak value greater than a first preset value exists in a vibration signal curve or a valley value smaller than a second preset value exists, it is determined that the impeller is in an abnormal operation state in a current time period. Wherein, the abnormal operation state includes: large particles impact and damage the impeller.
Specifically, the server determines a difference between adjacent peaks in a vibration signal curve corresponding to the current time period as a peak difference, or determines a difference between adjacent troughs as a trough difference. The server determines whether a peak difference or a trough difference greater than a third preset value exists. And under the condition that the peak difference value or the trough difference value larger than the third preset value exists, determining that the running state of the impeller is large particle impact.
For example, assume that the third preset value is f, that is, the difference between two adjacent peak values in the corresponding vibration signal curve is f at most in the normal operating state of the impeller. And calculating that the difference value between adjacent wave crests in the vibration signal curve in the current time period is h, and the difference value h is greater than a third preset value f, so that the impeller is in a large-particle collision state.
Fig. 3 is a graph of a vibration signal corresponding to an impeller in a large particle collision state according to an embodiment of the present application. As can be seen from fig. 3, the abscissa of the graph is the vibration time and the ordinate is the vibration amplitude. In fig. 3, when the difference value between two adjacent peak values is large, the difference value between the peak values is compared with a preset third preset value, and when the peak value is larger than the third preset value, it is determined that the impeller is currently in a large particle collision state.
In one embodiment of the present application, when the impeller is in a large particle collision state, it indicates that the current crushing degree of the material is not satisfactory. Large particles generated after the materials are crushed can continuously impact the impeller, so that the impeller is damaged. In addition, the large granule of production is difficult to be carried out the discharge gate, is piled up in impeller the place ahead, influences impeller operation effect. Therefore, when the impeller is in a large particle collision state for a plurality of times, the air speed of the air inlet of the vortex crusher can be properly increased, and the collision extrusion of the materials in the material conveying channel is increased, so that the breakage degree of the materials is improved.
In one embodiment of the present application, in the absence of a peak difference value or a trough difference value greater than a third preset value, the server calculates a first peak average value or a first trough average value of the vibration signal curve of the current time period. And acquiring a vibration signal curve of the previous time period, and calculating a second peak average value or a second trough average value of the vibration signal curve of the previous time period.
Further, the server determines that the running state of the impeller is impeller breakage under the condition that the difference value between the first peak average value and the second peak average value is larger than a fourth preset value. Or the server determines that the running state of the impeller is impeller breakage under the condition that the difference value between the first trough average value and the second trough average value is smaller than a fourth preset value.
Specifically, the server calculates a difference between an average peak value corresponding to the current time period and an average peak value corresponding to the previous time period, and determines that the impeller is in the impeller damage state when the difference is large and the difference is greater than a fourth preset value. And under the condition of the fourth preset value, the maximum value of the peak average difference value corresponding to two adjacent time periods is obtained under the normal running state of the impeller. Or the server calculates the difference between the average valley value corresponding to the current time period and the average valley value corresponding to the previous time period, and determines that the impeller is in the impeller damage state under the condition that the difference is a negative number and is smaller than a fifth preset value.
For example, if the fourth preset value is D, the average crest value corresponding to the current time period is a, the average crest value corresponding to the previous time period is B, the crest difference between the two values is C, and the crest difference C is greater than the fourth preset value D, it may be determined that the operation state of the impeller in the current time period is a damaged state. Similarly, assuming that the fifth preset value is E, and the fifth preset value E is a negative number, the average valley value corresponding to the current time period is F, the average peak value corresponding to the previous time period is G, the trough difference value between the two values is H, and the trough difference value H is smaller than the fourth preset value E, at this time, it can be determined that the operation state of the impeller in the current time period is a damaged state.
For example, fig. 4 is a graph of a vibration signal corresponding to an impeller in a damaged state according to an embodiment of the present application. As shown in fig. 4, the abscissa of the graph is the vibration time and the ordinate is the vibration amplitude. In fig. 3, the peak values are all larger, the trough values are all smaller, and the difference between the adjacent peak values and the trough values is larger, which indicates that the current impeller vibrates more severely.
According to the embodiment of the application, the wave peak value and the wave trough value of the vibration bright signal curve are used, so that the fluctuation of the impeller in operation can be visually seen, different abnormal states of the impeller can be determined by analyzing the wave peak value and the wave trough value, the operation of the current impeller is controlled, and the damage speed of the impeller is reduced.
In an embodiment of the present application, the server determines, according to the vibration signal curve of the current time period, an average vibration frequency corresponding to the impeller in the current time period. The server obtains the set rotating speed of the impeller in the current time period, and determines the standard vibration frequency corresponding to the set rotating speed according to the information of the impeller.
Specifically, the server obtains an impeller vibration signal curve of the current time period, a corresponding average vibration frequency, and a preset rotation speed of the impeller in the current time period. And obtaining information of the impeller, such as the model, size, rated rotating speed and the like of the impeller, so as to determine the corresponding standard vibration frequency when the impeller operates based on the current set rotating speed.
Further, the server calculates a frequency difference between the standard vibration frequency and the average vibration frequency. And under the condition that the frequency difference value is greater than a sixth preset value, determining that the current rotating speed of the impeller is less than the set rotating speed, and sending alarm information under the condition that the current rotating speed of the impeller is less than the set rotating speed.
Specifically, the server calculates a frequency difference between the standard vibration frequency and the average vibration frequency. If the frequency difference is larger than the preset value, it is described that the average vibration frequency is lower, the current impeller rotating speed is slower, and the target rotating speed cannot be reached. For example, the motor fails and cannot drive the rotating shaft to rotate at a set speed. At this time, the rotating speed of the impeller is low, the material crushing cannot reach the expected standard, and an alarm, such as an audible alarm or a light alarm, is sent out at this time.
This application embodiment obtains current impeller rotational speed and whether reaches the rotational speed of setting for through the vibration frequency who obtains the vibration signal curve to prevent to appear because of the lower unqualified problem of material breakage that causes of rotational speed. Meanwhile, whether the motor corresponding to the impeller breaks down or not can be acquired, the motor is maintained in time, and normal operation of the vortex crusher is guaranteed.
And S105, controlling the operation of an impeller in the vortex crusher by the server according to the operation state.
In one embodiment of the present application, in a case where it is determined that the current operating state of the impeller is the damaged state of the impeller, it is necessary to determine whether the impeller can still continue to operate in the currently damaged state.
In an embodiment of the application, the server searches a peak average value of a vibration signal curve of the current time period in a preset impeller tachometer, and the corresponding first standard rotating speed is obtained. The preset impeller revolution meter comprises a plurality of average wave peak values and standard revolution speeds of impellers respectively corresponding to the average wave peak values. And determining the preset lowest rotating speed of the impeller when the material is crushed according to the material information of the current material to be crushed.
Specifically, the server may search, according to the peak average value corresponding to the current damage state, the first standard rotation speed corresponding to the peak average value in a preset impeller rotation speed table. And, according to the material information of the current material to be crushed, for example, the type of the material, the quantity of the material, the specification of the crushed material, the crushing time and other information, the preset minimum rotating speed which the impeller needs to reach when the current material to be crushed is determined.
It should be noted that the first standard rotation speed is the maximum rotation speed that can be reached by the impeller in the current damaged state under the condition of delaying the aggravation of the damaged state. And the first standard rotation speed is lower than the current rotation speed.
And converting the current rotating speed of the impeller into the first standard rotating speed under the condition that the first standard rotating speed is greater than or equal to the preset lowest rotating speed. And controlling the impeller to stop running under the condition that the first standard rotating speed is less than the preset lowest rotating speed.
For example, if the first standard rotating speed is 2000r/min and the minimum rotating speed is 1500r/min, the current rotating speed can be replaced by the first standard rotating speed, so that the material crushing can reach the standard, the damage speed of the impeller can be reduced, and the service life of the impeller can be prolonged. For another example, the first standard rotating speed is 2000r/min, the lowest rotating speed is 2500r/min, and at this time, the first standard rotating speed is lower than the lowest rotating speed, the current rotating speed cannot be replaced by the first standard rotating speed, and the impeller needs to be controlled to stop running.
According to the embodiment of the application, the standard rotating speed corresponding to the impeller in the damaged state is determined according to the peak average value. And determining the minimum rotating speed required by the impeller when the material is crushed according to the material information. The minimum rotating speed is replaced by the standard rotating speed, so that the impeller in the current damage state can continue to finish the residual crushing work, and the material can be guaranteed to be damaged in time. And the standard rotating speed is lower than the current rotating speed, so that the further damage of the impeller can be reduced, the service life of the impeller is prolonged, the replacement frequency of the impeller is reduced, and the cost is reduced.
In an embodiment of the application, if the server determines that the impeller is in a normal operation state in the current time period, the server determines the current abrasion degree of the impeller to determine whether an excessive abrasion condition occurs to the impeller.
Specifically, the server calculates a third peak average value or a third valley average value of the vibration signal curve of the current time period. And acquiring the vibration signal curve of the previous time period, and calculating the fourth peak average value or the fourth valley average value of the vibration signal curve of the previous time period. And calculating a peak difference value between the average value of the third wave peak and the average value of the fourth wave peak, or calculating a trough difference value between the average value of the third wave trough and the average value of the fourth wave trough. And determining the impeller abrasion degree of the current time period according to the wave crest difference value or the wave trough difference value.
Further, the server may obtain the vibration intensity of the impeller in the current time period according to the third peak average value and the third valley average value corresponding to the current time period, where the larger the third peak average value is, the smaller the third valley average value is, the more intense the vibration is. And obtaining the vibration intensity of the impeller in the last time period according to the average value of the fourth wave peak or the average value of the fourth wave valley. According to the change of the vibration intensity of the impeller in the current time period and the previous time period, the abrasion degree of the impeller can be obtained. Along with the accumulation of the use time of the impeller, the abrasion degree of the impeller is gradually increased, the more serious the abrasion degree is, the more unstable the running state of the impeller is, and the more violent the vibration is, so that the larger the peak average value in the acquired vibration signal curve is, the smaller the trough average value is.
Further, the server compares the abrasion degree of the impeller in the current time period with the abrasion degree of the impeller in the previous time period, and controls the impeller to normally operate under the condition that the abrasion degree accords with a preset abrasion rule.
Further, under the condition that the impeller is kept in a normal operation state, normal abrasion can be generated, and the normal abrasion value corresponding to the adjacent time period is small. And arranging the normal wear sequence in each time period, namely the corresponding preset wear rule when the impeller operates in a normal state.
For example, assuming that the degree of wear of the impeller in the current time period is 2.1% and the degree of wear of the impeller in the previous time period is 1.7%, the difference between the degrees of wear of the current time period and the previous time period can be calculated to be 0.4%. If the difference value of the abrasion degrees in the adjacent time periods is less than 2 percent, the normal abrasion rule is assumed, then the abrasion degree of the impeller in the current time period accords with the abrasion rule, and the impeller can be controlled to normally run. If the abrasion degree of the impeller in the current time period is 3% and is larger than the normal abrasion rule by 2%, the abrasion degree of the impeller is too large at the moment, the impeller breaks down, and the impeller needs to be controlled to stop so as to be checked by workers.
In one embodiment of the application, after determining that the impeller is in a normal operation state in the current time period, the server predicts the time length that the impeller can still operate according to the normal state.
Specifically, the server obtains vibration signal curves corresponding to impellers of the same model in the normal operation state and corresponding to the impellers in the initial state and the normal operation state respectively. And acquiring the vibration signal curves and the abrasion degrees of the corresponding impellers respectively.
Specifically, the server obtains vibration signal curves corresponding to a plurality of impellers which are currently in a normal operation state and have the same type as the monitored impellers and are respectively in an initial state. And a plurality of vibration signal curves corresponding to a plurality of time periods of the impeller in a normal operation state. And acquiring the abrasion degree of the impeller corresponding to each vibration signal curve.
And the server compares each vibration signal curve with a vibration signal curve corresponding to the impeller in the preset maintenance state to obtain a wear degree difference value. And determining the residual running time of the impeller corresponding to the vibration signal curve according to the abrasion degree difference. Wherein the residual operation time is the residual operation time of the impeller in the normal operation state.
Specifically, the impeller in the preset maintenance state is an impeller needing to be maintained, and a vibration signal curve corresponding to the impeller in the preset maintenance state is obtained. And the server compares each vibration signal curve with a vibration signal curve corresponding to the impeller in the preset maintenance state so as to obtain the difference between the impeller abrasion degree and the impeller abrasion degree in the maintenance state. And according to the wear degree difference and the preset impeller wear rule, the time length required for the impeller corresponding to each wear degree to operate to the maintenance state can be obtained.
Further, training a preset neural network model through a vibration signal curve, the abrasion degree of the impeller and the residual running time to obtain an impeller running time prediction model.
In one embodiment of the present application, the vibration signal profile for the current time period is input to the impeller operation duration prediction model. And acquiring the running time of the impeller from the current wear state to the maintenance state according to the impeller running time prediction model. And generating corresponding prompt information according to the running time of the impeller from the current wear state to the maintenance state, and sending the prompt information to a corresponding management terminal of the vortex crusher.
According to the embodiment of the application, the preset neural network model is trained through the acquired vibration signal curve, the abrasion degree of the impeller and the residual running time, and the impeller running time prediction model is obtained. The running time of the current impeller can be predicted, so that the quantity of the crushed materials is increased, and the control of the material crushing progress is improved.
Fig. 5 is a schematic structural diagram of a vortex crusher provided in an embodiment of the present application. FIG. 6 is a cross-sectional view of a scroll crusher according to an embodiment of the present application. As shown in fig. 5 and 6, the scroll crusher includes:
the device comprises a material conveying channel 1, a motor 2, a discharge hole 3, an air inlet 4, a feed inlet 5, a discharge channel 6, an impeller 7, an impeller shaft sleeve 8 and an impeller shaft 9.
The material passes through the feed inlet 5 of vortex breaker, carries to material transmission passageway 1, blows to material transmission passageway 1 in through air intake 4, makes the material move to impeller 7 end. The impeller shaft 9 is connected with the impeller 7, and the motor 2 drives the impeller shaft 9 to rotate, so that the impeller shaft 9 drives the impeller 7 to rotate. The impeller 7 rotates at a high speed, and the materials collide with each other in the material channel 1 to be crushed by the vortex effect, and the crushed materials are smoothly transferred to the discharge hole 3. The crushed material is conveyed out of the vortex crusher through the discharge channel 1.
The embodiment of the application can acquire the running state of the impeller by monitoring the impeller. When the impeller breaks down, the impeller can be maintained or replaced in time, so that the crushing quality of the materials can meet the requirement.
Fig. 7 is a schematic structural diagram of an impeller operation monitoring device of a vortex crusher based on a vibration signal according to an embodiment of the present application. As shown in fig. 5, the apparatus includes:
at least one processor; and the number of the first and second groups,
a memory communicatively coupled to the at least one processor; wherein the content of the first and second substances,
the memory stores instructions executable by the at least one processor to enable the at least one processor to:
acquiring an impeller vibration signal acquired by a vibration sensor; the vibration sensor is embedded in an impeller shaft corresponding to an impeller of the vortex crusher;
determining an impeller vibration signal corresponding to the current time period from the obtained impeller vibration signals according to a preset time interval;
generating a vibration signal curve corresponding to the current time period according to the impeller vibration signal corresponding to the current time period;
determining the running state of the impeller in the current time period based on the vibration signal curve corresponding to the current time period;
and controlling the operation of an impeller in the vortex crusher according to the operation state.
The embodiments in the present application are described in a progressive manner, and the same and similar parts among the embodiments can be referred to each other, and each embodiment focuses on the differences from the other embodiments. In particular, for the embodiments of the apparatus, the device, and the nonvolatile computer storage medium, since they are substantially similar to the embodiments of the method, the description is simple, and for the relevant points, reference may be made to the partial description of the embodiments of the method.
The foregoing description of specific embodiments of the present application has been presented. Other embodiments are within the scope of the following claims. In some cases, the actions or steps recited in the claims may be performed in a different order than in the embodiments and still achieve desirable results. In addition, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results. In some embodiments, multitasking and parallel processing may also be possible or may be advantageous.
The above description is only an example of the present application and is not intended to limit the present application. Various modifications and changes may occur to those skilled in the art to which the embodiments of the present application pertain. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the embodiments of the present application should be included in the scope of the claims of the present application.
Claims (10)
1. A method of monitoring operation of an impeller of a scroll crusher based on a vibration signal, the method comprising:
acquiring an impeller vibration signal acquired by a vibration sensor; the vibration sensor is embedded in an impeller shaft corresponding to an impeller of the vortex crusher;
determining an impeller vibration signal corresponding to the current time period from the obtained impeller vibration signals according to a preset time interval;
generating a vibration signal curve corresponding to the current time period according to the impeller vibration signal corresponding to the current time period;
determining the running state of the impeller in the current time period based on the vibration signal curve corresponding to the current time period;
and controlling the operation of an impeller in the vortex crusher according to the operation state.
2. The method for monitoring the operation of the impeller of the vortex crusher based on the vibration signal according to claim 1, wherein the determining the operation state of the impeller in the current time period based on the vibration signal curve corresponding to the current time period specifically comprises:
determining a maximum wave peak value and a minimum wave valley value in the vibration signal curve;
determining that the impeller is in a normal operation state in the current time period under the condition that the maximum wave crest value is smaller than or equal to a first preset value and the minimum wave trough value is larger than or equal to a second preset value;
determining that the impeller is in an abnormal operation state in the current time period under the condition that a wave peak value larger than the first preset value exists in the vibration signal curve or a wave valley value smaller than the second preset value exists in the vibration signal curve;
wherein the abnormal operation state includes: large particles impact and damage the impeller.
3. The method for monitoring the operation of the impeller of the vibration signal-based scroll crusher according to claim 2, wherein in the case that a peak value greater than the first preset value or a valley value smaller than the second preset value exists in the vibration signal curve, determining that the impeller is in an abnormal operation state in the current time period specifically comprises:
determining a difference value between adjacent wave crests in a vibration signal curve corresponding to the current time period as a wave crest difference value, or determining a difference value between adjacent wave troughs as a wave trough difference value;
determining whether a peak difference value or a trough difference value larger than a third preset value exists;
and under the condition that the peak difference value or the trough difference value larger than the third preset value exists, determining that the running state of the impeller is large particle impact.
4. The method of monitoring operation of an impeller of a vibration signal-based scroll crusher according to claim 3, wherein after determining whether there is a peak difference or a valley difference greater than a third preset value, the method further comprises:
under the condition that the peak difference value or the trough difference value larger than the third preset value does not exist, calculating a first peak average value or a first trough average value of the vibration signal curve of the current time period; and
obtaining a vibration signal curve of a previous time period, and calculating a second peak average value or a second trough average value of the vibration signal curve of the previous time period;
determining that the running state of the impeller is impeller damage under the condition that the difference value of the first peak average value and the second peak average value is larger than a fourth preset value; or
And under the condition that the difference value between the first trough average value and the second trough average value is smaller than a fifth preset value, determining that the running state of the impeller is impeller breakage.
5. The method of claim 4, wherein the determining the operational status of the impeller is after the impeller is broken, the method further comprises:
searching a first peak average value of the vibration signal curve of the current time period in a preset impeller tachometer, and obtaining a corresponding first standard rotating speed; the preset impeller revolution meter comprises a plurality of peak average values and standard revolution speeds of the impeller, wherein the standard revolution speeds of the impeller correspond to the peak average values respectively;
determining the preset lowest rotating speed of the impeller when the material is crushed according to the material information of the current material to be crushed;
converting the current rotating speed of the impeller into the first standard rotating speed under the condition that the first standard rotating speed is greater than or equal to the preset lowest rotating speed;
and controlling the impeller to stop running under the condition that the first standard rotating speed is less than the preset lowest rotating speed.
6. The method of monitoring operation of an impeller of a vortex crusher based on a vibration signal according to claim 2, wherein after determining that the impeller is in a normal operation state for a current period of time, the method further comprises:
calculating a third wave peak average value or a third wave valley average value of the vibration signal curve of the current time period; and
obtaining a vibration signal curve of a previous time period, and calculating a fourth wave peak average value or a fourth wave valley average value of the vibration signal curve of the previous time period;
calculating a peak difference value between the third peak average value and the fourth peak average value, or calculating a trough difference value between the third trough average value and the fourth trough average value;
determining the impeller abrasion degree of the current time period according to the wave crest difference value or the wave trough difference value;
and comparing the abrasion degree of the impeller in the current time period with the abrasion degree of the impeller in the previous time period, and controlling the impeller to normally operate under the condition that the abrasion degree accords with a preset abrasion rule.
7. The method of monitoring operation of an impeller of a vibration signal-based scroll crusher according to claim 2, wherein after determining that the impeller is in a normal operation state for a current period of time, the method further comprises:
acquiring vibration signal curves corresponding to impellers of the same model in a normal operation state and in an initial state and a normal operation state respectively; and
obtaining each vibration signal curve, and respectively corresponding abrasion degree of the impeller;
comparing each vibration signal curve with a vibration signal curve corresponding to an impeller in a preset maintenance state to obtain a wear degree difference value;
determining the residual operation time length of the impeller corresponding to the vibration signal curve according to the abrasion degree difference value; wherein the residual operation time length is the residual operation time length of the impeller in a normal operation state;
and training a preset neural network model through the vibration signal curve, the abrasion degree of the impeller and the residual running time to obtain an impeller running time prediction model.
8. The vibration signal-based impeller operation monitoring method of a scroll crusher according to claim 7, wherein after obtaining the impeller operation duration prediction model, the method further comprises:
inputting a vibration signal curve of the current time period into the impeller operation duration prediction model;
acquiring the running time of the impeller from the current wear state to the maintenance state according to the impeller running time prediction model;
and generating corresponding prompt information according to the running time of the impeller from the current wear state to the maintenance state, and sending the prompt information to a corresponding management terminal of the vortex crusher.
9. The method of monitoring operation of an impeller of a vibration signal-based scroll crusher according to claim 1, wherein after generating a vibration signal profile corresponding to a current time period from the impeller vibration signal corresponding to the current time period, the method further comprises:
determining the corresponding average vibration frequency of the impeller in the current time period according to the vibration signal curve of the current time period;
acquiring a set rotating speed of the impeller in the current time period, and determining a standard vibration frequency corresponding to the set rotating speed according to the information of the impeller;
calculating a frequency difference between the standard vibration frequency and the average vibration frequency;
and under the condition that the frequency difference is larger than a sixth preset value, determining that the current rotating speed of the impeller is smaller than the set rotating speed, and sending alarm information under the condition that the current rotating speed of the impeller is smaller than the set rotating speed.
10. Vortex breaker's impeller operation monitoring facilities based on vibration signal includes:
at least one processor; and the number of the first and second groups,
a memory communicatively coupled to the at least one processor; wherein the content of the first and second substances,
the memory stores instructions executable by the at least one processor to enable the at least one processor to:
acquiring an impeller vibration signal acquired by a vibration sensor; the vibration sensor is embedded in an impeller shaft corresponding to an impeller of the vortex crusher;
determining an impeller vibration signal corresponding to the current time period from the obtained impeller vibration signals according to a preset time interval;
generating a vibration signal curve corresponding to the current time period according to the impeller vibration signal corresponding to the current time period;
determining the running state of the impeller in the current time period based on the vibration signal curve corresponding to the current time period;
and controlling the operation of an impeller in the vortex crusher according to the operation state.
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