CN114167842B - Fault prediction and health management method based on vibration active control system - Google Patents
Fault prediction and health management method based on vibration active control system Download PDFInfo
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- CN114167842B CN114167842B CN202111491852.1A CN202111491852A CN114167842B CN 114167842 B CN114167842 B CN 114167842B CN 202111491852 A CN202111491852 A CN 202111491852A CN 114167842 B CN114167842 B CN 114167842B
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
- G05B23/0243—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults model based detection method, e.g. first-principles knowledge model
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/20—Pc systems
- G05B2219/24—Pc safety
- G05B2219/24065—Real time diagnostics
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- Engineering & Computer Science (AREA)
- Automation & Control Theory (AREA)
- Measurement Of Mechanical Vibrations Or Ultrasonic Waves (AREA)
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Abstract
A fault prediction and health management method based on a vibration active control system determines the vibration active control system, and is used for sensing the installation position and quantity of a sensor for the vibration of a controlled object; in the long-term operation of the controlled object, vibration continuous monitoring and data processing are kept, and an operation feature library of the controlled object is established and updated appropriately according to operation and use habits, so that fault misinformation caused by the operation feature library is avoided; in the data processing, the conditions such as frequency and amplitude abnormality are aimed at; under the condition that the controlled object is suspected to have faults, the vibration active control system is used as a test system, and the faults caused by loosening, unbalance and the like are diagnosed by utilizing the input pulse of an actuator, sine or other excitation beneficial to judging the fault type, the acquisition of a sensor and the processing of a controller; for the faults, the output of the active control system actuator is automatically adjusted, and the vibration of the controlled object is restrained; the operation is reliable.
Description
Technical Field
The invention relates to the technical field of equipment fault prediction and health management, in particular to a fault prediction and health management method based on a vibration active control system.
Background
Currently, in the military field, in order to improve the sound stealth performance of a ship, reduce the probability of being found by enemy sonar, and improve the detection performance of the enemy sonar at the same time, it is very important to control mechanical noise on the ship, and in the case that conventional vibration isolation, vibration absorption, sound insulation and other means have been fully excavated, active means are adopted to control vibration, so that the reduction of sound radiation becomes increasingly important. In order to improve the comfort of surrounding personnel, the working accuracy and the reliability of equipment and reduce the failure risk caused by fatigue, the application of the vibration active control technology is also becoming wider and wider.
Predictive and health management (Prognostic and Health Management, PHM) uses a vast amount of state monitoring data and a priori knowledge to assess the health of management equipment by means of statistical algorithms or models. The PHM can predict potential faults in advance, and provide maintenance decisions by combining various equipment information, so that the PHM can realize the maintenance according to conditions, thereby improving the safety of the production process and reducing the maintenance cost.
The complete vibration active control system comprises a vibration sensor, a controller, a power amplifier and an actuator, and the complete PHM system comprises equipment characteristic sensing elements such as the vibration sensor and a data processing and analyzing unit. It can be seen that the two systems overlap to a certain extent, if the two systems are independently built, time and effort are consumed, and the hardware arrangement positions can be in conflict.
Disclosure of Invention
The applicant provides a fault prediction and health management method based on a vibration active control system aiming at the defects in the prior art, so that the fault prediction and health management can be realized by only adding corresponding functions on software, the cost of a whole period is saved, the reliability of the system is improved, the maintenance requirement is reduced, the fault diagnosis accuracy is improved, the fault is ensured not to be further deteriorated after the fault occurs, and the loss is minimized.
The technical scheme adopted by the invention is as follows:
a fault prediction and health management method based on a vibration active control system comprises the following operation steps:
step one: determining a vibration active control system, wherein the vibration active control system is used for sensing the mounting positions and the quantity of sensors for vibrating a controlled object;
judging whether a sensor currently used for the vibration active control system meets the requirements of fault prediction and health management or not according to the angles of fault prediction and health management and by combining the fault mechanism, mode and influence of a controlled object, and carrying out overall arrangement and proper adjustment;
step two: in the long-term operation of the controlled object, vibration continuous monitoring and data processing are kept, and an operation feature library of the controlled object is established and updated appropriately according to operation and use habits, so that fault misinformation caused by the operation feature library is avoided;
step three: in data processing, pre-warning and diagnosing potential faults are carried out according to abnormal frequency and amplitude and the like and common fault information of equipment, and prediction is carried out on the residual service life of a controlled object according to the gradual change conditions of the frequency and the amplitude;
step four: under the condition that the controlled object is suspected to have faults, the vibration active control system is used as a test system, and the faults caused by loosening, unbalance and the like are diagnosed by utilizing the input pulse of an actuator, sine or other excitation beneficial to judging the fault type, the acquisition of a sensor and the processing of a controller;
step five: for the faults, the output of the active control system actuator is automatically adjusted, the vibration of the controlled object is restrained, the faults are prevented from being further deteriorated, and the faults are prevented from being transmitted to other peripheral equipment, so that other equipment is damaged.
The further technical scheme is as follows:
in the first step, the sensors are added appropriately when the requirements of fault prediction and health management are not met.
In the first step, vibration monitoring is a useful means for fault prediction and health management, but from the two viewpoints of fault prediction and health management and vibration control, the positions and the number of the installed sensors are necessarily different, so vibration control is taken into account, fault prediction and health management are considered, and the installation positions and the number of the sensors are comprehensively arranged.
In the second step, the controlled object feature library established based on long-term monitoring and operation and use habits is mainly amplitude-frequency characteristics under the normal operation condition of each working condition and corresponding amplitude-frequency characteristics during switching between working conditions, threshold intervals are respectively set according to the long-term operation condition, and then self-adaptive updating is carried out according to the operation characteristics of the controlled object.
And thirdly, for the gradual or progressive faults, observing the change trend of an amplitude-frequency curve of the acquired data, confirming the trend by comparing the trend with the previous characteristics, giving an early warning, and for the sudden faults, observing the sudden faults through the sudden change of the amplitude or frequency.
In the third step, by combining common fault information of equipment provided by a manufacturer, a fault diagnosis result can be given, and the residual service life of the controlled object is predicted according to a performance reduction curve of the controlled object provided by the manufacturer or based on monitoring data by a machine learning or deep learning method.
In the fourth step, the theoretical basis is that when the equipment is normal and has loose, unbalanced and unbalanced faults, different response curves exist under specific excitation, so that after the faults are found, the faults are further diagnosed by means of an active control system.
In the fifth step, after the fault occurs, the vibration of the equipment is more intense, so that the fault of the equipment is worsened, and other peripheral equipment is damaged, so that the vibration of the equipment is restrained through the active control system, and the loss is automatically and timely reduced until the equipment is stopped.
The beneficial effects of the invention are as follows:
the invention has convenient operation, fully utilizes the hardware system of the vibration driving system, realizes the fault prediction and health management of the rotating and reciprocating machinery, saves the installation cost and the operation and maintenance cost, increases the fault diagnosis means, reduces the fault loss and improves the fault prediction and health management level.
The invention fully utilizes the hardware system of the vibration active control system, reduces the cost for additionally constructing the PHM system, increases the means of fault diagnosis and fault loss reduction through the organic fusion of the two systems, and improves the PHM level.
Firstly, determining the installation positions and the quantity of sensors used for sensing the vibration of a controlled object by a vibration active control system, and then judging whether the current sensor used for the vibration active control system meets the requirements of the fault prediction and the health management or not by combining the fault mechanism, the mode and the influence of the controlled object from the angles of the fault prediction and the health management, if not, comprehensively considering the installation positions and the quantity of the sensors; then, in the long-term operation of the controlled object, vibration continuous monitoring and data processing are kept, and an operation feature library of the controlled object is established and updated appropriately according to operation and use habits and the like, so that fault misinformation caused by the operation feature library is avoided. In the data processing, the potential faults are early-warned and diagnosed according to the conditions of abnormal frequency, amplitude and the like and the common fault information of equipment provided by manufacturers, and the residual service life of a controlled object can be predicted according to the performance degradation curve provided by the manufacturers or according to the slowly-changing conditions of the frequency, the amplitude and the like by a data mining method.
In addition, under the condition that the controlled object is suspected to have faults, the vibration active control system can be used as a test system, and the faults caused by looseness, unbalance and the like are diagnosed by utilizing the input pulse of an actuator, sine or other excitation beneficial to judging the fault type and the acquisition of a sensor and the processing of a controller. Finally, for the faults, the output of the active control system actuator can be automatically adjusted, the vibration of the controlled object is restrained, the faults are prevented from further deteriorating, and the faults are prevented from being conducted to other peripheral equipment, so that other equipment is damaged.
Aiming at the rotary or reciprocating machinery needing to control vibration, the invention fully utilizes the hardware of the vibration control system, can realize fault prediction and health management only by adding corresponding functions on software, saves the cost of the whole period, improves the reliability of the system, reduces the maintenance requirement, not only improves the fault diagnosis accuracy, but also can ensure that the fault is not further deteriorated after the fault occurs, and reduces the loss to the minimum.
Detailed Description
The following describes specific embodiments of the present invention.
The fault prediction and health management method based on the vibration active control system of the embodiment comprises the following operation steps:
step one: determining a vibration active control system, wherein the vibration active control system is used for sensing the mounting positions and the quantity of sensors for vibrating a controlled object;
judging whether a sensor currently used for the vibration active control system meets the requirements of fault prediction and health management or not according to the angles of fault prediction and health management and by combining the fault mechanism, mode and influence of a controlled object, and carrying out overall arrangement and proper adjustment;
step two: in the long-term operation of the controlled object, vibration continuous monitoring and data processing are kept, and an operation feature library of the controlled object is established and updated appropriately according to operation and use habits, so that fault misinformation caused by the operation feature library is avoided;
step three: in data processing, pre-warning and diagnosing potential faults are carried out according to abnormal frequency and amplitude and the like and common fault information of equipment, and prediction is carried out on the residual service life of a controlled object according to the gradual change conditions of the frequency and the amplitude;
step four: under the condition that the controlled object is suspected to have faults, the vibration active control system is used as a test system, and the faults caused by loosening, unbalance and the like are diagnosed by utilizing the input pulse of an actuator, sine or other excitation beneficial to judging the fault type, the acquisition of a sensor and the processing of a controller;
step five: for the faults, the output of the active control system actuator is automatically adjusted, the vibration of the controlled object is restrained, the faults are prevented from being further deteriorated, and the faults are prevented from being transmitted to other peripheral equipment, so that other equipment is damaged.
In the first step, the sensors are added appropriately when the requirements of fault prediction and health management are not met.
In the first step, vibration monitoring is a useful means for the present embodiment of fault prediction and health management, but from the two viewpoints of fault prediction and health management and vibration control, the positions and the number of the installed sensors are necessarily different, so vibration control is mainly required, and the fault prediction and health management are considered, so that the installation positions and the number of the sensors are comprehensively arranged.
In the second step, the controlled object feature library established based on long-term monitoring and operation and use habits is mainly amplitude-frequency characteristics under the normal operation condition of each working condition and corresponding amplitude-frequency characteristics during switching between working conditions, threshold intervals are respectively set according to the long-term operation condition, and then self-adaptive updating is carried out according to the operation characteristics of the controlled object.
And thirdly, for the gradual or progressive faults, observing the change trend of an amplitude-frequency curve of the acquired data, confirming the trend by comparing the trend with the previous characteristics, giving an early warning, and for the sudden faults, observing the sudden faults through the sudden change of the amplitude or frequency.
In the third step, by combining common fault information of equipment provided by a manufacturer, a fault diagnosis result can be given, and the residual service life of the controlled object is predicted according to a performance reduction curve of the controlled object provided by the manufacturer or based on monitoring data by a machine learning or deep learning method.
In the fourth step, the theoretical basis is that when the equipment is normal and has loose, unbalanced and unbalanced faults, different response curves exist under specific excitation, so that after the faults are found, the faults are further diagnosed by means of an active control system.
In the fifth step, after the fault occurs, the vibration of the equipment is more intense, so that the fault of the equipment is worsened, and other peripheral equipment is damaged, so that the vibration of the equipment is restrained through the active control system, and the loss is automatically and timely reduced until the equipment is stopped.
The specific operation flow and functions of the invention are as follows:
step one: determining the mounting positions and the quantity of sensors used for sensing the vibration of a controlled object by a vibration active control system; from the angles of fault prediction and health management, by combining the fault mechanism, mode and influence of the controlled object, whether the sensor currently used for the vibration active control system meets the requirements of fault prediction and health management or not is judged, and if the sensor does not meet the requirements, the sensor can be added appropriately.
Step two: in the long-term operation of the controlled object, vibration continuous monitoring and data processing are kept, and an operation feature library of the controlled object is established and updated appropriately according to operation and use habits and the like, so that fault misinformation caused by the operation feature library is avoided.
Step three: in the data processing, the potential faults are early-warned and diagnosed by combining common fault information of equipment provided by manufacturers or mining data aiming at the conditions of abnormal frequency, amplitude and the like. And predicting the residual service life of the controlled object by combining a performance degradation curve or mining data according to the slowly-changing conditions such as frequency, amplitude and the like.
Step four: under the condition that the controlled object is suspected to have faults, the vibration active control system can be used as a test system, and the faults caused by loosening, unbalance and the like can be diagnosed by inputting certain excitation to an actuator, collecting a sensor and processing by a controller.
Step five: for the faults, the output of the active control system actuator can be automatically adjusted, the vibration of the controlled object is restrained, the faults are prevented from being further deteriorated, and the faults are prevented from being conducted to other peripheral equipment, so that other equipment is damaged.
Aiming at the rotary or reciprocating machinery needing to control vibration, the invention fully utilizes the hardware of the vibration control system, can realize fault prediction and health management only by adding corresponding functions on software, saves the cost of the whole period, improves the reliability of the system, reduces the maintenance requirement, not only improves the fault diagnosis accuracy, but also can ensure that the fault is not further deteriorated after the fault occurs, and reduces the loss to the minimum.
The above description is intended to illustrate the invention and not to limit it, the scope of which is defined by the claims, and any modifications can be made within the scope of the invention.
Claims (7)
1. A fault prediction and health management method based on a vibration active control system is characterized in that: the method comprises the following operation steps:
step one: determining a vibration active control system, wherein the vibration active control system is used for sensing the mounting positions and the quantity of sensors for vibrating a controlled object;
judging whether a sensor currently used for the vibration active control system meets the requirements of fault prediction and health management or not according to the angles of fault prediction and health management and by combining the fault mechanism, mode and influence of a controlled object, and carrying out overall arrangement and proper adjustment;
step two: in the long-term operation of the controlled object, vibration continuous monitoring and data processing are kept, and an operation characteristic library of the controlled object is established and properly updated according to operation and use habits;
step three: in data processing, pre-warning and diagnosing potential faults are carried out according to abnormal conditions of frequency and amplitude and common fault information of equipment, and prediction is carried out on the residual service life of a controlled object according to slow-change conditions of the frequency and the amplitude;
step four: under the condition that the controlled object is suspected to have faults, the vibration active control system is used as a test system, and the faults caused by loosening, unbalance and misalignment are diagnosed by utilizing impulse input by an actuator and sinusoidal excitation and through the acquisition of a sensor and the processing of a controller;
step five: and for the faults, the output of the active control system actuator is automatically adjusted, and the vibration of the controlled object is restrained.
2. The vibration-based active control system fault prediction and health management method of claim 1, wherein: in the first step, the sensors are added appropriately when the requirements of fault prediction and health management are not met.
3. The vibration-based active control system fault prediction and health management method of claim 1, wherein: in the first step, vibration control is taken into consideration mainly from two angles of fault prediction and health management and vibration control, and the installation positions and the number of the sensors are comprehensively arranged.
4. The vibration-based active control system fault prediction and health management method of claim 1, wherein: in the second step, the controlled object feature library established based on long-term monitoring and operation and use habits is mainly amplitude-frequency characteristics under the normal operation condition of each working condition and corresponding amplitude-frequency characteristics during switching between working conditions, threshold intervals are respectively set according to the long-term operation condition, and then self-adaptive updating is carried out according to the operation characteristics of the controlled object.
5. The vibration-based active control system fault prediction and health management method of claim 1, wherein: and thirdly, for the gradual or progressive faults, observing the change trend of an amplitude-frequency curve of the acquired data, confirming the trend by comparing the trend with the previous characteristics, giving an early warning, and for the sudden faults, observing the sudden faults through the sudden change of the amplitude or frequency.
6. The vibration-based active control system fault prediction and health management method of claim 1, wherein: in the third step, by combining common fault information of equipment provided by a manufacturer, a fault diagnosis result can be given, and the residual service life of the controlled object can be predicted based on monitoring data according to a performance degradation curve of the controlled object provided by the manufacturer or through machine learning.
7. The vibration-based active control system fault prediction and health management method of claim 1, wherein: in the fourth step, the theoretical basis is that when the equipment is normal and has loose, unbalanced and non-centering faults, different response curves are generated under specific excitation, so that after the faults are found, the faults are further diagnosed by means of an active control system.
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| CN115469643A (en) * | 2022-09-15 | 2022-12-13 | 中国核动力研究设计院 | Nuclear power station rotating machinery health management method, system and medium |
| CN115865731B (en) * | 2022-11-28 | 2024-04-09 | 四川天邑康和通信股份有限公司 | Gateway equipment and network set top box communication test system, method and storage medium |
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| JP4309919B2 (en) * | 2007-01-10 | 2009-08-05 | 本田技研工業株式会社 | Active vibration noise control device |
| US9174739B2 (en) * | 2014-01-13 | 2015-11-03 | The Boeing Company | Active vibration control system |
| US20170277995A1 (en) * | 2014-09-29 | 2017-09-28 | Sikorsky Aircraft Corporation | Vibration signatures for prognostics and health monitoring of machinery |
| CN107291475B (en) * | 2017-06-27 | 2020-06-12 | 中国电子产品可靠性与环境试验研究所 | Universal PHM application configuration method and device |
| CN109238443A (en) * | 2018-08-01 | 2019-01-18 | 中科振声（苏州）电子科技有限公司 | A kind of vibration noise intelligence reply system and a kind of vibration noise intelligence countermeasure |
| CN110376984A (en) * | 2019-07-15 | 2019-10-25 | 中国船舶科学研究中心（中国船舶重工集团公司第七0二研究所） | Adaptive vibration noise control management system |
| CN113391612A (en) * | 2020-03-13 | 2021-09-14 | 株洲中车时代电气股份有限公司 | Fault prediction and health management device and fault prediction method for vehicle transmission control system |
| JP2021160031A (en) * | 2020-03-31 | 2021-10-11 | セイコーエプソン株式会社 | Failure prediction method and device |
| CN112033666A (en) * | 2020-09-07 | 2020-12-04 | 上海辉度智能系统有限公司 | Speed reducer online fault prediction and diagnosis system based on mechanism model |
| CN112556828A (en) * | 2020-11-20 | 2021-03-26 | 国网天津市电力公司电力科学研究院 | Transformer winding loosening fault detection method |
| CN112465068A (en) * | 2020-12-15 | 2021-03-09 | 重庆忽米网络科技有限公司 | Rotating equipment fault feature extraction method based on multi-sensor data fusion |
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