CN113916366B - Method and equipment for monitoring operation of impeller of vortex breaker based on vibration signal - Google Patents
Method and equipment for monitoring operation of impeller of vortex breaker based on vibration signal Download PDFInfo
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- CN113916366B CN113916366B CN202111227944.9A CN202111227944A CN113916366B CN 113916366 B CN113916366 B CN 113916366B CN 202111227944 A CN202111227944 A CN 202111227944A CN 113916366 B CN113916366 B CN 113916366B
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- 238000000034 method Methods 0.000 title claims abstract description 40
- 238000012544 monitoring process Methods 0.000 title claims abstract description 19
- 239000000463 material Substances 0.000 claims description 59
- 238000005299 abrasion Methods 0.000 claims description 50
- 239000002245 particle Substances 0.000 claims description 15
- 230000002159 abnormal effect Effects 0.000 claims description 14
- 238000012423 maintenance Methods 0.000 claims description 14
- 238000003062 neural network model Methods 0.000 claims description 5
- 238000012806 monitoring device Methods 0.000 claims description 3
- 238000012549 training Methods 0.000 claims description 3
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- 239000003245 coal Substances 0.000 description 2
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01H—MEASUREMENT OF MECHANICAL VIBRATIONS OR ULTRASONIC, SONIC OR INFRASONIC WAVES
- G01H17/00—Measuring mechanical vibrations or ultrasonic, sonic or infrasonic waves, not provided for in the preceding groups
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
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Abstract
The embodiment of the application discloses an impeller operation monitoring method and equipment of a vortex breaker based on vibration signals, which are used for solving the problem that the operation state of the impeller of the vortex breaker 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 the 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 breaker according to the operation state. By the method, the purpose of monitoring the running state of the impeller of the vortex breaker is achieved.
Description
Technical Field
The application relates to the technical field of signal processing, in particular to an impeller operation monitoring method and equipment of a vortex breaker based on vibration signals.
Background
In industries such as ore mining and coal mining, vortex crushers are required to crush and transport materials. The vortex crusher has the advantages that the impeller and the material channel exist, the impeller rotates at a high speed, the vortex effect is formed, materials are crashed in the material channel in a collision mode, and the crashed materials are smoothly transferred to the discharge hole.
In such a working environment, the impeller is easily damaged, which may cause abnormal operation of the vortex breaker, and failure of the impeller is aggravated by untimely discovery.
However, the prior art is difficult to monitor the running state of the impeller of the vortex breaker, so that the damage condition of the impeller is difficult to discover 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 breaker is difficult to monitor in the prior art.
The embodiment of the application adopts the following technical scheme:
The embodiment of the application provides an impeller operation monitoring method of a vortex breaker based on vibration signals. Acquiring an impeller vibration signal acquired by a vibration sensor; the vibration sensor is embedded in an impeller shaft corresponding to the impeller of the vortex breaker; 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 a vibration signal curve corresponding to the current time period; and controlling the operation of the impeller in the vortex breaker according to the operation state.
According to the embodiment of the application, the vibration sensor embedded in the impeller shaft is used for collecting the vibration signal of the impeller, so that the problem that the working efficiency of the blade is affected due to the fact that the vibration sensor is arranged on the blade is avoided. On the other hand, the running state of the impeller can be analyzed in real time according to the obtained 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 obtained vibration signal, and determines different running states of the impeller according to the change of the curve. The problem that the impeller can be detected only under the condition that the vortex crusher stops running is solved, and the normal operation of the vortex crusher can be ensured.
In one implementation manner of the present application, determining an operation state of the impeller in the current time period based on a vibration signal curve corresponding to the current time period specifically includes: determining a maximum crest value and a minimum trough value in a vibration signal curve; determining that the impeller is in a normal running 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 running state in the current time period under the condition that a crest value larger than a first preset value exists in the vibration signal curve or a trough value smaller than a second preset value exists in the vibration signal curve; wherein the abnormal operation state includes: large particles strike and the impeller is broken.
According to the embodiment of the application, the operation 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, through the peak value and the trough value of the vibration bright signal curve, fluctuation in the operation of the impeller can be intuitively seen, and different abnormal states of the impeller can be determined through analyzing the peak value and the trough value, so that the operation of the current impeller is controlled, and the damage speed of the impeller is slowed down.
In one implementation manner of the present application, when a crest value greater than a first preset value exists in the vibration signal curve or a trough value smaller than a 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 includes: determining a difference value between adjacent wave peaks or a difference value between adjacent wave troughs in a vibration signal curve corresponding to the current time period as a wave peak 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 crest difference value or the trough difference value larger than the third preset value exists, determining the running state of the impeller to be large particle collision.
In one implementation of the present application, the method further comprises: calculating a first peak average value or a first trough average value of the vibration signal curve in the current time period under the condition that the peak difference value or the trough difference value which is larger than a third preset value does not exist; obtaining 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 breakage under the condition that the difference value between the first crest average value and the second crest average value is larger than a fourth preset value; or 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.
In one implementation of the present application, after determining that the operational state of the impeller is an impeller failure, the method further includes: searching a peak average value of a vibration signal curve in the current time period in a preset impeller tachometer, and corresponding to a first standard rotating speed; the preset impeller rotating speed meter comprises a plurality of average wave peak values and standard rotating speeds of impellers corresponding to the plurality of average wave peak values respectively; determining a preset minimum rotation speed of the impeller when crushing materials according to the material information of the current materials to be crushed; converting the current rotation speed of the impeller into the first standard rotation speed under the condition that the first standard rotation speed is larger than or equal to the preset minimum rotation speed; and controlling the impeller to stop running under the condition that the first standard rotating speed is smaller than the preset minimum 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 rotation speed required to be reached by the impeller when crushing the material according to the material information. The standard rotating speed is used for replacing the lowest rotating speed, so that the impeller in the current damaged state can continuously complete the residual crushing work, and the materials are ensured 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 slowed down, the service life of the impeller is prolonged, the replacement frequency of the impeller is further reduced, and the cost is reduced.
In one implementation of the present application, after determining that the impeller is in a normal operating state during the current time period, the method further includes: calculating a third peak average value or a third trough average value of the vibration signal curve in the current time period; obtaining a vibration signal curve of the previous time period, and calculating a fourth crest average value or a fourth trough 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 in the current time period according to the crest difference value or the trough difference value; 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 a normal operating state during the current time period, the method further includes: obtaining vibration signal curves corresponding to impellers of the same model in a normal running state respectively in an initial state and a normal running state; acquiring the wear degree of each vibration signal curve and corresponding impeller respectively; comparing each vibration signal curve with the vibration signal curve corresponding to the 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 value; the residual operation time is the residual operation time of the impeller in a normal operation state; training a preset neural network model through the vibration signal curve, the abrasion degree of the impeller and the residual operation time length to obtain an impeller operation time length prediction model.
According to the embodiment of the application, the preset neural network model is trained through the obtained vibration signal curve, the abrasion degree of the impeller and the residual operation time length, so that an impeller operation time length prediction model is obtained. The running time of the current impeller can be predicted, so that the quantity of crushed materials and the control of the material crushing progress are improved.
In one implementation of the present application, after obtaining the impeller operation time length prediction model, the method further includes: inputting a vibration signal curve of the current time period into an impeller operation time length prediction model; acquiring the running time of the impeller from the current abrasion state to the maintenance state according to the running time prediction model of the impeller; and generating corresponding prompt information according to the running time of the impeller from the current wearing state to the maintenance state, and sending the prompt information to a corresponding management terminal of the vortex breaker.
In one implementation of the present application, after generating the vibration signal curve corresponding to the current time period according to the impeller vibration signal corresponding to the current time period, the method further includes: determining the average vibration frequency corresponding to 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 a 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 larger than a sixth preset value, determining that the current rotating speed of the impeller is smaller than the set rotating speed, and sending out alarm information under the condition that the current rotating speed of the impeller is smaller than the set rotating speed.
The embodiment of the application provides impeller operation monitoring equipment of a vortex breaker based on a vibration signal, which comprises the following components: 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, the instructions being 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 the impeller of the vortex breaker; 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 a vibration signal curve corresponding to the current time period; and controlling the operation of the impeller in the vortex breaker according to the operation state.
The above at least one technical scheme adopted by the embodiment of the application can achieve the following beneficial effects: according to the embodiment of the application, the vibration sensor embedded in the impeller shaft is used for collecting the vibration signal of the impeller, so that the problem that the working efficiency of the blade is affected due to the fact that the vibration sensor is arranged on the blade is avoided. On the other hand, the running state of the impeller can be analyzed in real time according to the obtained 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 through the acquired vibration signal, and determines different running states of the impeller according to the change of the curve. The problem that the impeller can be detected only under the condition that the vortex crusher stops running is solved, so that the vortex crusher can work normally is guaranteed.
Drawings
In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments described in the present application, and other drawings can be obtained according to the drawings without inventive effort for a person skilled in the art. In the drawings:
FIG. 1 is a flow chart of a method for monitoring the operation of an impeller of a vortex breaker based on vibration signals, which is provided by an embodiment of the application;
fig. 2 is a graph of vibration signals corresponding to a normal running state of an impeller according to an embodiment of the present application;
FIG. 3 is a graph of vibration signals corresponding to a large particle collision state of an impeller according to an embodiment of the present application;
Fig. 4 is a graph of vibration signals corresponding to an impeller in an impeller damaged state according to an embodiment of the present application;
Fig. 5 is a schematic structural view of a vortex breaker according to an embodiment of the present application;
FIG. 6 is a cross-sectional view of a vortex breaker provided by an embodiment of the present application;
Fig. 7 is a schematic structural diagram of an impeller operation monitoring device of a vortex breaker based on vibration signals 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 breaker based on a vibration signal.
In order to make the technical solution of the present application better understood by those skilled in the art, the technical solution of the present application will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present application, and it is apparent that the described embodiments are only some embodiments of the present application, not all embodiments. All other embodiments, which can be made by one of ordinary skill in the art based on the embodiments herein without making any inventive effort, shall fall within the scope of the present application.
In industries such as ore mining and coal mining, vortex crushers are required to crush and transport materials. The vortex crusher has the advantages that the impeller and the material channel exist, the impeller rotates at a high speed, the vortex effect is formed, materials collide and crush in the material channel, and crushed materials are smoothly transferred to the discharge hole.
In such a working environment, the impeller is easily damaged, which may cause abnormal operation of the vortex breaker, and failure of the impeller is aggravated by untimely discovery.
However, the prior art is difficult to monitor the running state of the impeller of the vortex breaker, so that the damage condition of the impeller is difficult to discover in time.
In order to solve the problems, the embodiment of the application provides a method and equipment for monitoring the operation of an impeller of a vortex breaker based on vibration signals. According to the embodiment of the application, the vibration sensor embedded in the impeller shaft is used for collecting the vibration signal of the impeller, so that the problem that the working efficiency of the blade is affected due to the fact that the vibration sensor is arranged on the blade is avoided. On the other hand, the running state of the impeller can be analyzed in real time according to the obtained 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 through the acquired vibration signal, and determines different running states of the impeller according to the change of the curve. The problem that the impeller can be detected only under the condition that the vortex crusher stops running is solved, so that the vortex crusher can work normally is guaranteed.
The following describes the technical scheme provided by the embodiment of the application in detail through the attached drawings.
Fig. 1 is a flowchart of a method for monitoring operation of an impeller of a vortex breaker based on a vibration signal according to an embodiment of the present application. As shown in fig. 1, the impeller operation monitoring method includes the steps of:
S101, acquiring impeller vibration signals acquired by a vibration sensor by a server.
In one embodiment of the application, the server obtains the impeller vibration signal acquired by the vibration sensor. Wherein, the vibration sensor is embedded in the impeller shaft corresponding to the impeller of the vortex breaker.
Specifically, the impeller of the vortex crusher makes the materials collide with each other in the material channel for crushing through high-speed rotation and form vortex effect, and smoothly transfers the crushed materials 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 vortex breaker. The motor drives the impeller shaft to rotate, and the impeller shaft drives blades in the impeller to rotate, so that an eddy 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 collected 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 application, the server obtains 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 one embodiment of the present application, after the server obtains the impeller vibration signal corresponding to the current time period, in order to obtain the running state of the impeller in the current time period more intuitively, the impeller vibration signal needs to be converted into a vibration signal curve.
For example, fig. 2 is a graph of vibration signals corresponding to a normal operation state of an impeller according to 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. The vibration signal graph can be used for finding the vibration amplitude values of the corresponding impellers at different moments so as to determine the vibration condition of the impellers. The current running state of the impeller is determined according to the vibration condition of the impeller.
And 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 application, the server determines a maximum peak value and a minimum trough value in the vibration signal curve. And 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, the server determines that the impeller is in a normal running state in the current time period.
Specifically, the vibration signal curve comprises a plurality of wave crests and wave troughs, and the amplitude of the current impeller vibration can be seen from the wave crest value and the wave trough value. The larger the peak value, the smaller the trough value, and the more intense the impeller vibration. The smaller the difference between the peak value and the trough value, the weaker the impeller vibration is.
Further, the server determines maximum peak and minimum trough values of the impeller vibration signal curve corresponding to the current time period. And comparing the maximum peak value with a first preset value, and determining whether the maximum peak value is smaller than or equal to the first preset value. And comparing the minimum peak value with a second preset value by the server, and determining whether the minimum peak value is larger 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 corresponding to the generated vibration signal curve is obtained.
Further, the server determines that the impeller is in a normal running state in the current time period when 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. For example, a first preset value is set as a, that is, a 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, a minimum amplitude of the vibration curve corresponding to the normal operation state of the impeller is set as e. The maximum wave peak value b and the minimum wave trough value c of the current impeller vibration signal curve are determined, and at the moment, the maximum wave peak 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 running state.
For example, fig. 2 is a graph of vibration signals corresponding to a normal operation state of an impeller according to 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 the adjacent peak value and the trough value is small, i.e. the vibration is weak and the operation is stable in the operation process of the impeller.
In one embodiment of the present application, in the case that there is a peak value greater than a first preset value or there is a trough value less than a second preset value in the vibration signal curve, it is determined that the impeller is in an abnormal operation state in the current period. Wherein the abnormal operation state includes: large particles strike and the impeller is broken.
Specifically, the server determines, in the vibration signal curve corresponding to the current time period, a difference value between adjacent peaks as a peak difference value or a difference value between adjacent valleys as a valley difference value. The server determines whether there is a peak difference or a trough difference greater than a third preset value. And under the condition that the crest difference value or the trough difference value larger than the third preset value exists, determining the running state of the impeller to be large particle collision.
For example, assume that the third preset value is f, that is, the difference between two adjacent peak values in the corresponding vibration signal curves is f at maximum in the normal running state of the impeller. And calculating that the difference value between adjacent wave peaks in the vibration signal curve in the current time period is h, wherein the difference value h is larger than a third preset value f, and at the moment, the impeller is in a large particle collision state.
Fig. 3 is a graph of vibration signals corresponding to a large particle collision state of an impeller according to an embodiment of the present application. As can be seen from fig. 3, the abscissa in the figure is the vibration time, and the ordinate is the vibration amplitude. In fig. 3, when the difference between two adjacent wave crest values is larger, the wave crest value difference is compared with a preset third preset value, and when the wave crest value is larger than the third preset value, the current large particle collision state of the impeller is determined.
In one embodiment of the present application, when the impeller is in a large particle collision state, it is indicated that the current crushing degree of the material does not meet the requirement. Large particles generated after the materials are crushed can continuously strike the impeller, so that the impeller is damaged. In addition, the large particles are difficult to convey out of the discharge hole and are accumulated in front of the impeller, so that the operation effect of the impeller is affected. Therefore, when the impeller is in the large particle collision state for a plurality of times, the wind speed of the air inlet of the vortex crusher can be properly increased, and the collision extrusion of the material in the material conveying channel is increased, so that the breakage degree of the material is improved.
In one embodiment of the present application, the server calculates a first peak average value or a first trough average value of the vibration signal curve of the current time period in the absence of a peak difference value or a trough difference value greater than a third preset value. 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 when the difference between the first peak average value and the second peak average value is greater 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 the difference between the average peak value corresponding to the current time period and the average peak value corresponding to the previous time period, and determines that the impeller is in an impeller breakage state when the difference is larger and the difference is larger than a fourth preset value. The fourth preset value is the maximum value of the peak average value difference value corresponding to the two adjacent time periods in the normal running state of the impeller. Or the server calculates the difference value between the average trough value corresponding to the current time period and the average trough value corresponding to the last time period, and determines that the impeller is in an impeller breakage state under the condition that the difference value is negative and smaller than a fifth preset value.
For example, assuming that the fourth preset value is D, the average peak value corresponding to the current time period is a, and the average peak value corresponding to the previous time period is B, at this time, the peak difference between the two values is C, and the peak difference C is greater than the fourth preset value D, at this time, it can be determined that the running state of the impeller in the current time period is a damaged state. Similarly, assuming that the fifth preset value is E, the fifth preset value E is a negative number, the average trough value corresponding to the current time period is F, the average trough value corresponding to the previous time period is G, at this time, the trough difference between the two values is H, and the trough difference H is smaller than the fourth preset value E, at this time, the running state of the impeller in the current time period can be determined to be a damaged state.
For example, fig. 4 is a graph of vibration signals corresponding to an impeller in a broken state according to an embodiment of the present application. As shown in fig. 4, the abscissa in the figure is vibration time, and the ordinate is vibration amplitude. In fig. 3, the peak values are larger, the trough values are 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, through the peak value and the trough value of the vibration bright signal curve, fluctuation in the operation of the impeller can be intuitively seen, and different abnormal states of the impeller can be determined through analyzing the peak value and the trough value, so that the operation of the current impeller is controlled, and the damage speed of the impeller is slowed down.
In one embodiment of the application, the server determines the average vibration frequency corresponding to the impeller in the current time period according to the vibration signal curve of 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 acquires an impeller vibration signal curve in the current time period, the average vibration frequency corresponding to the curve, and the preset rotating speed of the impeller in the current time period. And obtaining information of the impeller, such as information of the model, the size, the rated rotation 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 rotation 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 larger than a sixth preset value, determining that the current rotating speed of the impeller is smaller than the set rotating speed, and sending out alarm information under the condition that the current rotating speed of the impeller is smaller 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, 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 the spindle cannot be driven to rotate at a set speed. At this time, the rotation speed of the impeller is low, so that the material cannot be crushed to reach the expected standard, and an alarm, such as an audible alarm or a light alarm, can be sent out at this time.
According to the embodiment of the application, whether the current impeller rotating speed reaches the set rotating speed is obtained by obtaining the vibration frequency of the vibration signal curve, so that the problem that materials are broken and disqualified due to lower rotating speed is prevented. Meanwhile, whether the motor corresponding to the impeller fails or not can be obtained, the motor is maintained in time, and the normal operation of the vortex crusher is ensured.
And S105, the server controls the operation of the impeller in the vortex breaker according to the operation state.
In one embodiment of the present application, in the case where it is determined that the current operation state of the impeller is the broken state of the impeller, it is necessary to determine whether the impeller can continue to operate in the current broken state.
In one embodiment of the application, the server searches a peak average value of a vibration signal curve in the current time period in a preset impeller tachometer, and the peak average value corresponds to a first standard rotating speed. The preset impeller rotating speed meter comprises a plurality of average wave peak values and standard rotating speeds of impellers corresponding to the plurality of average wave peak values respectively. And determining the preset minimum rotation speed of the impeller when the materials are crushed according to the material information of the current materials to be crushed.
Specifically, the server may find, according to the peak average value corresponding to the current damaged state, a first standard rotation speed corresponding to the peak average value in a preset impeller rotation speed table. And determining a preset minimum rotation speed required to be reached by the impeller when the current material to be crushed is crushed according to the material information of the current material to be crushed, such as the type of the material, the quantity of the material, the specification of the crushed material, the crushing time and the like.
The first standard rotation speed is the highest rotation speed which can be achieved under the condition that the damage state is delayed and aggravated. And the first standard rotational speed is lower than the current rotational speed.
And under the condition that the first standard rotating speed is larger than or equal to the preset minimum rotating speed, converting the current rotating speed of the impeller into the first standard rotating speed. And controlling the impeller to stop running under the condition that the first standard rotating speed is smaller than the preset minimum rotating speed.
For example, if the first standard rotation speed is 2000r/min and the minimum rotation speed is 1500r/min, the current rotation speed can be replaced by the first standard rotation speed, so that the material crushing can reach the standard, the impeller breakage speed can be slowed down, and the impeller service life can be prolonged. For another example, the first standard rotation speed is 2000r/min, the lowest rotation speed is 2500r/min, at this time, the first standard rotation speed is lower than the lowest rotation speed, the current rotation speed cannot be replaced by the first standard rotation 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 rotation speed required to be reached by the impeller when crushing the material according to the material information. The standard rotating speed is used for replacing the lowest rotating speed, so that the impeller in the current damaged state can continuously complete the residual crushing work, and the materials are ensured 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 slowed down, the service life of the impeller is prolonged, the replacement frequency of the impeller is further reduced, and the cost is reduced.
In one embodiment of the present application, if the server determines that the impeller is in a normal operation state in the current time period, the server determines the wear degree of the current impeller to determine whether an excessive wear condition of the impeller occurs.
Specifically, the server calculates a third peak average value or a third trough average value of the vibration signal curve in the current time period. And acquiring a vibration signal curve of the previous time period, and calculating a fourth peak average value or a fourth trough average value of the vibration signal curve of the previous time period. A peak difference between the third peak average value and the fourth peak average value, or a trough difference between the third trough average value and the fourth trough average value, is calculated. And determining the impeller abrasion degree in the current time period according to the crest difference value or the trough difference value.
Further, the server can obtain the vibration intensity of the impeller in the current time period according to the third crest average value and the third trough average value corresponding to the current time period, and the larger the third crest average value is, the smaller the third trough average value is, and the more intense the vibration is. And according to the fourth crest average value or the fourth trough average value, the vibration intensity of the impeller in the previous time period can be obtained. And 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. The wear degree is increased gradually along with the accumulation of the service time of the impeller, the more serious the wear degree is, the more unstable the running state of the impeller is, and the more intense the vibration is, so that the larger the average value of wave peaks in the obtained vibration signal curve is, the smaller the average value of wave troughs 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 the normal operation of the impeller is controlled under the condition that the abrasion degree accords with a preset abrasion rule.
Further, under the condition that the impeller keeps in a normal running state, normal abrasion can be generated, and the normal abrasion value corresponding to the adjacent time period is smaller. And arranging the normal abrasion sequences in each time period to obtain the corresponding preset abrasion rules when the impeller operates in a normal state.
For example, assuming that the degree of wear of the impeller in the current period is 2.1% and the degree of wear of the impeller in the previous period is 1.7%, the difference between the degree of wear in the current period and the degree of wear in the previous period can be calculated to be 0.4%. And assuming that the difference value of the abrasion degree in the adjacent time period is less than 2% and is a normal abrasion rule, the abrasion degree of the impeller in the current time period accords with the abrasion rule, and the normal operation of the impeller can be controlled. If the abrasion degree of the impeller in the current time period is 3% and is more than 2% of the normal abrasion rule, the abrasion degree of the impeller is too large, faults occur in the impeller, and the impeller needs to be controlled to stop so as to enable staff to check.
In one embodiment of the application, the server predicts the time period for which the impeller can still operate according to the normal state after determining that the impeller is in the normal operation state in the current time period.
Specifically, the server acquires the vibration signal curves corresponding to impellers of the same model in the normal running state respectively in the initial state and the normal running state. And acquiring the wear degree of each vibration signal curve and the corresponding impeller respectively.
Specifically, the server acquires vibration signal curves corresponding to a plurality of impellers which are currently in a normal running state and have the same model as the monitored impellers in an initial state respectively. And vibration signal curves corresponding to a plurality of time periods of the impellers in the normal running state respectively. And the abrasion degree of the impeller corresponding to each vibration signal curve is obtained.
And the server compares each vibration signal curve with the vibration signal curve corresponding to the impeller in the preset maintenance state to obtain the abrasion degree difference value. And determining the residual operation time of the impeller corresponding to the vibration signal curve according to the abrasion degree difference value. 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 the impeller to be maintained, and a vibration signal curve corresponding to the impeller in the preset maintenance state is obtained. The server compares each vibration signal curve with the vibration signal curve corresponding to the impeller in the preset maintenance state, so as to obtain the difference value between the abrasion degree of each impeller and the abrasion degree of the impeller in the maintenance state. And obtaining the impeller corresponding to each abrasion degree according to the abrasion degree difference value and preset impeller abrasion rules, and running the impeller to a maintenance state for a required time.
Further, training a preset neural network model through the vibration signal curve, the abrasion degree of the impeller and the residual operation time length to obtain an impeller operation time length prediction model.
In one embodiment of the 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 abrasion state to the maintenance state according to the running time prediction model of the impeller. And generating corresponding prompt information according to the running time of the impeller from the current wearing state to the maintenance state, and sending the prompt information to a corresponding management terminal of the vortex breaker.
According to the embodiment of the application, the preset neural network model is trained through the obtained vibration signal curve, the abrasion degree of the impeller and the residual operation time length, so that an impeller operation time length prediction model is obtained. The running time of the current impeller can be predicted, so that the quantity of crushed materials and the control of the material crushing progress are improved.
Fig. 5 is a schematic structural view of a vortex breaker according to an embodiment of the present application. Fig. 6 is a cross-sectional view of a vortex breaker provided by an embodiment of the present application. As shown in fig. 5 and 6, the vortex breaker includes:
The device comprises a material conveying channel 1, a motor 2, a material outlet 3, an air inlet 4, a material inlet 5, a material outlet 6, an impeller 7, an impeller shaft sleeve 8 and an impeller shaft 9.
The material is conveyed to the material conveying channel 1 through a feed inlet 5 of the vortex crusher, and is blown into the material conveying channel 1 through an air inlet 4, so that the material moves towards the impeller 7. 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, forms a vortex effect, causes the materials to collide and crush each other in the material passage 1, and smoothly transfers the crushed materials to the discharge port 3. The crushed material is conveyed out of the vortex breaker through the discharge channel 1.
According to the embodiment of the application, the running state of the impeller can be obtained by monitoring the impeller. The impeller can be maintained or replaced in time when the impeller fails, so that the crushing quality of materials can be ensured to meet the requirement.
Fig. 7 is a schematic structural diagram of an impeller operation monitoring device of a vortex breaker based on vibration signals according to an embodiment of the present application. As shown in fig. 5, the apparatus 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 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 the 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 breaker according to the operation state.
The embodiments of the present application are described in a progressive manner, and the same and similar parts of the embodiments are all referred to each other, and each embodiment is mainly described in the differences from the other embodiments. In particular, for apparatus, devices, non-volatile computer storage medium embodiments, the description is relatively simple, as it is substantially similar to method embodiments, with reference to the section of the method embodiments being relevant.
The foregoing describes certain embodiments of the present application. Other embodiments are within the scope of the following claims. In some cases, the actions or steps recited in the claims can 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 are also possible or may be advantageous.
The foregoing is merely exemplary of the present application and is not intended to limit the present application. Various modifications and changes may be made to the embodiments of the application by those skilled in the art. 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 (8)
1. A method for monitoring the operation of an impeller of a vortex breaker based on vibration signals, the method comprising:
Acquiring an impeller vibration signal acquired by a vibration sensor; the vibration sensor is embedded in an impeller shaft corresponding to the 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;
Controlling the operation of an impeller in the vortex breaker according to the operation state;
the determining the running state of the impeller in the current time period based on the vibration signal curve corresponding to the current time period specifically comprises the following steps:
determining a maximum crest value and a minimum trough value in the vibration signal curve;
Determining that the impeller is in a normal running state in the current time period under the condition that the maximum crest value is smaller than or equal to a first preset value and the minimum 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 crest value larger than the first preset value exists in the vibration signal curve or a trough value smaller than the second preset value exists in the vibration signal curve;
wherein the abnormal operation state includes: large particles strike and the impeller is damaged;
after determining that the impeller is in a normal operating state for a current time period, the method further includes:
calculating a third peak average value or a third trough average value of the vibration signal curve in the current time period; and
Acquiring a vibration signal curve of the previous time period, and calculating a fourth peak average value or a fourth trough average value of the vibration signal curve of the previous time period;
Calculating a peak difference between the third peak average value and the fourth peak average value, or calculating a trough difference between the third trough average value and the fourth trough average value;
determining the impeller abrasion degree in the current time period according to the crest difference value or the trough difference value;
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.
2. The method for monitoring the operation of an impeller of a vortex breaker based on vibration signals according to claim 1, wherein in the case that there is a peak value greater than the first preset value or there is a trough value less than the second preset value in the vibration signal curve, determining that the impeller is in an abnormal operation state in the current period of time specifically comprises:
Determining a difference value between adjacent wave peaks or a difference value between adjacent wave troughs in a vibration signal curve corresponding to the current time period as a wave crest 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 crest difference value or the trough difference value which is larger than the third preset value exists, determining the running state of the impeller to be large particle collision.
3. The vibration signal based vortex breaker impeller operation monitoring method of claim 2 wherein after determining whether there is a crest difference or a trough difference greater than a third preset value, the method further comprises:
calculating a first peak average value or a first trough average value of the vibration signal curve in the current time period under the condition that the peak difference value or the trough difference value which is larger than the third preset value does not exist; 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;
Determining that the running state of the impeller is impeller breakage under the condition that the difference value between the first crest average value and the second crest average value is larger than a fourth preset value; or (b)
And 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.
4. The method of claim 3, wherein after determining that the operational state of the impeller is breakage of the impeller, the method further comprises:
searching a first peak average value of a vibration signal curve in the current time period in a preset impeller tachometer, and corresponding to a first standard rotating speed; the preset impeller rotating speed meter comprises a plurality of peak average values and standard rotating speeds of the impellers, wherein the standard rotating speeds correspond to the peak average values respectively;
Determining a preset minimum rotation speed of the impeller when crushing the materials according to the material information of the current materials to be crushed;
converting the current rotation speed of the impeller into the first standard rotation speed under the condition that the first standard rotation speed is larger than or equal to the preset minimum rotation speed;
And controlling the impeller to stop running under the condition that the first standard rotating speed is smaller than the preset lowest rotating speed.
5. The vibration signal based vortex breaker impeller operation monitoring method of claim 1 wherein after determining that the impeller is in a normal operating state for a current time period, the method further comprises:
Obtaining vibration signal curves corresponding to impellers of the same model in a normal running state respectively in an initial state and a normal running state; and
Acquiring the wear degree of the impeller corresponding to each vibration signal curve;
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; the residual operation time is the residual operation time 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 operation time length to obtain an impeller operation time length prediction model.
6. The method of claim 5, further comprising, after deriving the prediction model of the impeller operation time period:
Inputting a vibration signal curve of the current time period into the impeller operation time length prediction model;
acquiring the running time of the impeller from the current abrasion state to the maintenance state according to the running time prediction model of the impeller;
And generating corresponding prompt information according to the running time of the impeller from the current wearing state to the maintenance state, and sending the prompt information to a corresponding management terminal of the vortex breaker.
7. The method for monitoring the operation of an impeller of a vortex breaker based on vibration signals according to claim 1, wherein after generating a vibration signal curve corresponding to a current time period from an impeller vibration signal corresponding to the current time period, the method further comprises:
determining the average vibration frequency corresponding to 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 a 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 larger than a sixth preset value, determining that the current rotating speed of the impeller is smaller than the set rotating speed, and sending out alarm information under the condition that the current rotating speed of the impeller is smaller than the set rotating speed.
8. An impeller operation monitoring device of a vortex breaker based on vibration signals, comprising:
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 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 the 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;
Controlling the operation of an impeller in the vortex breaker according to the operation state;
the determining the running state of the impeller in the current time period based on the vibration signal curve corresponding to the current time period specifically comprises the following steps:
determining a maximum crest value and a minimum trough value in the vibration signal curve;
Determining that the impeller is in a normal running state in the current time period under the condition that the maximum crest value is smaller than or equal to a first preset value and the minimum 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 crest value larger than the first preset value exists in the vibration signal curve or a trough value smaller than the second preset value exists in the vibration signal curve;
wherein the abnormal operation state includes: large particles strike and the impeller is damaged;
after determining that the impeller is in a normal running state in the current time period, the method further comprises the following steps:
calculating a third peak average value or a third trough average value of the vibration signal curve in the current time period; and
Acquiring a vibration signal curve of the previous time period, and calculating a fourth peak average value or a fourth trough average value of the vibration signal curve of the previous time period;
Calculating a peak difference between the third peak average value and the fourth peak average value, or calculating a trough difference between the third trough average value and the fourth trough average value;
determining the impeller abrasion degree in the current time period according to the crest difference value or the trough difference value;
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.
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