CN114323607A - Overspeed test device and method for aluminum alloy closed impeller - Google Patents
Overspeed test device and method for aluminum alloy closed impeller Download PDFInfo
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Abstract
The application discloses aluminum alloy closed impeller overspeed test device and test method, including operation platform, power unit, protection machanism and monitoring mechanism, power unit is located protection machanism, and power unit is used for providing the power of device operation, and protection machanism is used for the protection of device operation in-process, and monitoring mechanism includes sensor and camera for the real-time supervision of each parameter of device operation process has following advantage: various sensors are installed in the test device, various parameters of the test device during operation can be collected in real time, vibration is monitored in real time, the operation picture and damage of the overspeed test are monitored in real time, the parameters can be used for evaluating the overspeed test result of the impeller and monitoring the operation of equipment and energy consumption, failure analysis can be carried out after a test piece is broken, and the effectiveness of the overspeed test is improved.
Description
Technical Field
The invention relates to an impeller overspeed test device and a test method, in particular to an aluminum alloy closed impeller overspeed test device and a test method.
Background
The impeller is the most central moving part of the turbo machine, and when the impeller operates, fluid does work to provide pressurization for various fluid flows, and overspeed and fatigue tests are generally required to verify the operation stability of the impeller.
The existing overspeed test method is used for judging whether the impeller is qualified or not by observing whether cracks exist at the welding seams, cover plates, blades and the like of the impeller and measuring whether the dimensional change exceeds a required value before and after overspeed after the overspeed test is finished. In the test process, various parameters of the overspeed machine during operation are not usually acquired, or real-time vibration values are mainly acquired, when the impeller fails, analysis can be performed only according to crack conditions, physical and chemical analysis results of the impeller, tool structures and the like, reference analysis is performed on actual operation parameters of the overspeed machine and real-time pictures before and after the failure, so that the effectiveness of failure analysis is low, the true cause of the failure is difficult to determine, and the risk of repeated failure occurrence exists.
Disclosure of Invention
Aiming at the defects, the invention provides an aluminum alloy closed impeller overspeed test device and a test method, wherein various sensors are arranged in the test device, and can acquire various parameters of the test device in operation in real time, monitor vibration in real time, monitor the operation picture of the overspeed test in real time, take pictures of damage in instant, the parameters can be used for evaluating the impeller overspeed test result and monitoring the equipment operation and energy consumption, and failure analysis can be carried out after a test piece is broken, so that the effectiveness of the overspeed test is improved;
through the overspeed test and the fatigue test of the impeller, the running state of the impeller under various working conditions can be simulated, the performance limit of an impeller workpiece can be explored by combining the deformation condition and the internal defect condition detection, and the method has guiding significance on the improvement of the subsequent design and processing of the impeller and the like.
In order to solve the technical problems, the invention adopts the following technical scheme:
an aluminum alloy closed impeller overspeed test device comprises an operation platform, a power mechanism, a protection mechanism and a monitoring mechanism, wherein the power mechanism is positioned in the protection mechanism and used for providing power for the operation of the device;
the control system is used for controlling the starting and stopping of the power mechanism and monitoring the running parameters of the device in real time, and allows a user to set different running curves by adjusting the rotating speed, the acceleration and the running time.
Further, protection mechanism includes inlayer guard shield and outer guard shield, and inlayer guard shield and outer guard shield quantity all are two to relative setting, the inlayer guard shield is located outer guard shield inboard, is circular-arcly, and power unit is located between two inlayer guard shields, is equipped with the observation hole on the inlayer guard shield.
Furthermore, the power mechanism comprises a driving motor connected with a power transmission device, a pneumatic tire clutch is mounted on the power transmission device, the power transmission device is connected with a transmission main shaft and provides power for an overspeed test for equipment, and an overspeed test piece is mounted on the transmission main shaft.
Further, noise sensor, camera and temperature sensor are installed to the inboard of outer guard shield, and noise sensor is used for monitoring the inboard noise size of outer guard shield, and the camera is located outer guard shield inboard, and the observation hole of inlayer guard shield is aimed at to the camera, carries out real-time supervision to the process of speeding through the observation hole of the inboard guard shield of arc, takes a candid photograph the testing device internal conditions when appearing unusually, and temperature sensor is used for check out test set cavity temperature.
Further, a temperature sensor is mounted on the power transmission device and used for detecting the temperature of the body;
and a vibration sensor is arranged on one side of the transmission main shaft, which is close to the impeller test piece, and is used for detecting the vibration condition in the operation process.
Furthermore, control system includes PLC, and PLC is connected with noise sensor, camera, vibrations sensor, driving motor, temperature sensor and touch-sensitive screen to carry out information storage, sharing through ethernet, USB flash disk, the touch-sensitive screen is installed on the operation panel, and the user can set up different operation curves on the touch-sensitive screen.
An overspeed test method for an aluminum alloy closed impeller comprises a real-time monitoring method, an impeller overspeed test method, an impeller fatigue test method, an impeller deformation condition detection method and an impeller internal defect monitoring method.
Further, the real-time monitoring method comprises the following steps:
step S101, starting the test of the overspeed test device, and entering step S102 after the test is finished;
step S102, the PLC controls the vibration sensor, the temperature sensor, the camera and the noise sensor to monitor the test device in real time, and uploads monitoring data to the PLC, and the step S103 is executed after the monitoring data are completed;
step S103, judging whether the monitoring value is in the maximum allowable value requirement range of the setting parameter, if the monitoring value meets the requirement, entering step S104, and if the monitoring value exceeds the upper limit, entering step S105;
step S105, cutting off a power supply of a driving motor, shooting the impeller state by a camera 20 times per second, if the impeller fails, accurately capturing an impeller picture at the moment of impeller failure by the camera, conveniently analyzing the impeller failure, and entering step S104 after the impeller failure is completed;
step S104, carrying out overspeed test according to a set program, and entering step S106 after the overspeed test is finished;
and step S106, reducing the rotating speed to 0, and finishing the test.
Further, the impeller overspeed test method comprises the following steps:
step S201, determining test conditions, and entering step S202 after the test conditions are completed;
step S202, installing an impeller test workpiece in an overspeed test device, and entering step S203 after the impeller test workpiece is installed;
step S203, inputting an impeller running curve in an operation console to control the acceleration, deceleration and running time of the impeller, and entering step S204 after the acceleration, deceleration and running time are controlled;
and step S204, carrying out an impeller overspeed test, wherein the impeller overspeed test is carried out at the rotating speed of 120% of the rated rotating speed, plastic deformation possibly occurs in part of the impeller during the process, and the operation time is usually 3-5 min.
Further, the impeller fatigue test method comprises the following steps:
the method comprises the following steps of simulating each special working condition when an impeller runs by adopting an overspeed testing device, wherein the special working conditions comprise starting and stopping working conditions and rotating speed fluctuation working conditions, and the starting and stopping working conditions are the reciprocating loading process of adjusting the power of a motor to enable the impeller to rotate at the rotating speed of 0-working rotating speed-0; the rotation speed fluctuation is a phenomenon of simulating the rotation speed fluctuation of the impeller, and an operation curve of the impeller under a special working condition is determined.
Further, the impeller deformation condition detection method comprises the following steps:
step S301, detecting the size of a machining part of the impeller used for compressor assembly before testing by using three coordinates, scanning the blade shape of the impeller before testing by using a joint arm scanner, and entering step S302 after completing;
step S302, performing overspeed test on the impeller by adopting an overspeed test device, and entering step S303 after the overspeed test is completed;
step S303, detecting the size of a machining part of the tested impeller for assembling the compressor by using three coordinates, scanning the blade shape of the tested impeller by using a joint arm scanner, and entering step S304 after the detection is finished;
step S304, comparing and analyzing the measurement results of the impeller before and after the overspeed test, and entering step S305 after the comparison is completed;
step S305, judging whether the size change of the impeller is within an allowable range before and after the test, if so, the impeller is a qualified product, if not, the impeller is unqualified, and the impeller deforms after the test, so that the position with the largest deformation quantity of the impeller after the test can be determined, and a basis is provided for later-stage impeller shape and performance improvement.
Further, the method for monitoring the internal defect of the impeller comprises the following steps:
s401, carrying out flaw detection on the whole impeller before testing by using X-ray real-time imaging equipment, and entering S402 after the flaw detection is finished;
step S402, judging whether the requirement is met, if so, entering step S403, and if not, determining that the impeller is an unqualified product;
step S403, performing overspeed test on the impeller by using an overspeed test device, and entering step S404 after the overspeed test is completed;
s404, carrying out flaw detection on the whole tested impeller by using X-ray real-time imaging equipment, and entering S405 after the flaw detection is finished;
and S405, judging whether the requirement is met, if so, determining the impeller to be a qualified product, and if not, determining the impeller to be an unqualified product.
By adopting the technical scheme, compared with the prior art, the invention has the following technical effects:
the vibration value and the temperature of the main shaft can be collected through various sensors in the equipment; running noise and air temperature of the ultra-speed machine cavity; the motor current can form various parameter curves in the test process, and form a test report for evaluating the impeller overspeed test result and monitoring the equipment operation and energy consumption.
The vibration is monitored in real time, the machine is stopped when the vibration exceeds a specified value, the impeller is prevented from continuously running to cause larger damage to workpieces and equipment after local deformation or breakage, overspeed pictures can be monitored through the camera, and running pictures and damage are monitored in real time and taken pictures instantly.
After the impeller is subjected to overspeed test, whether cracks exist in welding seams, wheel rows, wheel covers and the like of the impeller is checked, the size change conditions before and after overspeed are measured, surface linearity discontinuity or cracks are checked, penetration flaw detection can be performed in an area, failure analysis can be performed after a test piece is broken, the effectiveness of the overspeed test is improved, and outflow of risk impellers is avoided.
The impeller overspeed testing machine is a horizontal workbench, the running state of the impeller overspeed testing machine is close to the use state of the impeller, and the impeller overspeed testing machine can be used for simulating the running condition of the impeller. Through the overspeed test and the fatigue test of the impeller, the running state of the impeller under various working conditions can be simulated. The performance limit of the impeller workpiece can be explored by combining deformation condition and internal defect condition detection, and the method has guiding significance for improvement of subsequent design and processing of the impeller and the like.
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In order to more clearly illustrate the detailed description of the invention or the technical solutions in the prior art, the drawings that are needed in the detailed description of the invention or the prior art will be briefly described below. Throughout the drawings, like elements or portions are generally identified by like reference numerals. In the drawings, elements or portions are not necessarily drawn to scale.
FIGS. 1 and 2 are schematic views showing the construction of an overspeed testing apparatus according to the present invention;
FIG. 3 is a block diagram of a control system within the operating platform of the present invention;
FIG. 4 is a flow chart of a real-time monitoring method of the present invention;
FIG. 5 is a flow chart of a method of the impeller overspeed test of the present invention;
FIG. 6 is a flow chart of a method of fatigue testing of an impeller according to the present invention;
FIG. 7 is a flow chart of a method for detecting deformation of an impeller according to the present invention;
FIG. 8 is a flow chart of a method for monitoring internal defects of an impeller according to the present invention;
in the figure:
1-operation platform, 2-outer layer shield, 3-inner layer shield, 4-noise sensor, 5-camera 6-temperature sensor, 7-power transmission device, 8-overspeed test piece, 9-driving motor, 10-transmission main shaft, 11-pneumatic tire clutch and 12-vibration sensor
Detailed Description
Embodiment 1, as shown in fig. 1 and 2, an aluminum alloy closed impeller overspeed test apparatus includes an operation platform 1, an outer shroud 2, an inner shroud 3, a transmission main shaft 10, a drive motor 9, a pneumatic tire clutch 11, a power transmission device 7, and a vibration sensor 12.
The operating platform 1 is internally provided with a control system, the control system is used for monitoring equipment operation and parameters in real time, and a user is allowed to set different operating curves by adjusting the rotating speed, the acceleration and the operating time.
As shown in fig. 3, the control system includes a PLC, the PLC is connected to a noise sensor 4, a camera 5, a vibration sensor 12, a driving motor 9, a temperature sensor 6, and a touch screen, and performs information storage and sharing through an ethernet and a usb disk, and a user can set different operation curves on the touch screen.
The outer-layer shield 2 is positioned on the outermost side of the main part of the equipment and is used for guaranteeing the operation safety of the equipment and preventing fragments generated by breakage in the overspeed process of the impeller from flying out.
The inner layer shield 3 is positioned on the inner side of the outer layer shield 2 and is arc-shaped, when the impeller is broken, fragments can move along a tangent line, a buffering effect is generated, and the overspeed test piece 8 is positioned between the inner layer shields 3.
Noise sensor 4, camera 5 are installed to outer guard shield 2's inboard, and noise sensor 4 is used for monitoring the inboard noise size of guard shield, and camera 5 is located outer guard shield inboard, and camera 5 aims at the observation hole of the inboard guard shield 3 of convex, carries out real-time supervision to the process of speeding through the observation hole of the inboard guard shield of convex, takes a candid photograph the testing device internal conditions when appearing unusually.
The driving motor 9 is connected with a power transmission device 7, a pneumatic tire clutch 11 is installed on the power transmission device 7, and the power transmission device 7 is connected with a transmission main shaft 10 to provide power for an overspeed test for equipment.
The overspeed test piece 8 is fixed on the transmission main shaft 10, and the vibration sensor 12 is positioned on the transmission main shaft 10 and close to one side of the impeller test piece and used for detecting the vibration condition in the operation process.
The overspeed test method for the aluminum alloy closed impeller comprises a real-time monitoring method, an impeller overspeed test method, an impeller fatigue test method, an impeller deformation condition detection method and an impeller internal defect monitoring method.
As shown in fig. 4, the real-time monitoring method includes the following steps:
step S101, starting the test of the overspeed test device, and entering step S102 after the test is finished;
step S102, the PLC controls the vibration sensor, the temperature sensor, the camera and the noise sensor to monitor the test device in real time, and uploads monitoring data to the PLC, and the step S103 is executed after the monitoring data are completed;
step S103, judging whether the monitoring value is in the maximum allowable value requirement range of the setting parameter, if the monitoring value meets the requirement, entering step S104, and if the monitoring value exceeds the upper limit, entering step S105;
step S105, cutting off a power supply of a driving motor, shooting the impeller state by a camera 20 times per second, if the impeller fails, accurately capturing an impeller picture at the moment of impeller failure by the camera, conveniently analyzing the impeller failure, and entering step S104 after the impeller failure is completed;
step S104, carrying out overspeed test according to a set program, and entering step S106 after the overspeed test is finished;
and step S106, reducing the rotating speed to 0, and finishing the test.
As shown in fig. 5, the impeller overspeed test method includes the steps of:
step S201, determining test conditions, and entering step S202 after the test conditions are completed;
step S202, installing an impeller test workpiece in an overspeed test device, and entering step S203 after the impeller test workpiece is installed;
step S203, inputting an impeller running curve in an operation console to control the acceleration, deceleration and running time of the impeller, and entering step S204 after the acceleration, deceleration and running time are controlled;
and step S204, carrying out an impeller overspeed test, wherein the impeller overspeed test is carried out at the rotating speed of 120% of the rated rotating speed, plastic deformation possibly occurs in part of the impeller during the process, and the operation time is usually 3-5 min.
As shown in fig. 6, the impeller fatigue test method includes the following steps:
the method comprises the following steps of simulating each special working condition when an impeller runs by adopting an overspeed testing device, wherein the special working conditions comprise starting and stopping working conditions and rotating speed fluctuation working conditions, and the starting and stopping working conditions are the reciprocating loading process of adjusting the power of a motor to enable the impeller to rotate at the rotating speed of 0-working rotating speed-0; the rotation speed fluctuation is a phenomenon of simulating the rotation speed fluctuation of the impeller, and an operation curve of the impeller under a special working condition is determined.
As shown in fig. 7, the method for detecting deformation of the impeller includes the following steps:
step S301, detecting the size of a machining part of the impeller used for compressor assembly before testing by using three coordinates, scanning the blade shape of the impeller before testing by using a joint arm scanner, and entering step S302 after completing;
step S302, performing overspeed test on the impeller by adopting an overspeed test device, and entering step S303 after the overspeed test is completed;
step S303, detecting the size of a machining part of the tested impeller for assembling the compressor by using three coordinates, scanning the blade shape of the tested impeller by using a joint arm scanner, and entering step S304 after the detection is finished;
step S304, comparing and analyzing the measurement results of the impeller before and after the overspeed test, and entering step S305 after the comparison is completed;
step S305, judging whether the size change of the impeller is within an allowable range before and after the test, if so, the impeller is a qualified product, if not, the impeller is unqualified, and the impeller deforms after the test, so that the position with the largest deformation quantity of the impeller after the test can be determined, and a basis is provided for later-stage impeller shape and performance improvement.
As shown in fig. 8, the method for monitoring the internal defect of the impeller comprises the following steps:
s401, carrying out flaw detection on the whole impeller before testing by using X-ray real-time imaging equipment, and entering S402 after the flaw detection is finished;
step S402, judging whether the requirement is met, if so, entering step S403, and if not, determining that the impeller is an unqualified product;
step S403, performing overspeed test on the impeller by using an overspeed test device, and entering step S404 after the overspeed test is completed;
s404, carrying out flaw detection on the whole tested impeller by using X-ray real-time imaging equipment, and entering S405 after the flaw detection is finished;
and S405, judging whether the requirement is met, if so, determining the impeller to be a qualified product, and if not, determining the impeller to be an unqualified product.
The description of the present invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to practitioners skilled in this art. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
Claims (10)
1. The utility model provides an aluminum alloy closed impeller overspeed test device which characterized in that: the device comprises an operation platform (1), a power mechanism, a protection mechanism and a monitoring mechanism, wherein the power mechanism is positioned in the protection mechanism and used for providing power for the operation of the device, the protection mechanism is used for protecting the device in the operation process, and the monitoring mechanism comprises a sensor and a camera (5) and is used for monitoring each parameter in the operation process of the device in real time;
install control system in operation platform (1), control system includes PLC, PLC is connected with power unit, sensor, camera (5) and touch-sensitive screen to carry out information storage, sharing through ethernet, USB flash disk, the touch-sensitive screen is installed on operation panel (1), the user can set up different operation curves on the touch-sensitive screen, control system is used for controlling opening of power unit and stops and the real-time supervision of device operating parameter, allow the user to set up different operation curves through adjustment rotational speed, acceleration and operating duration.
2. The closed impeller overspeed test device of aluminum alloy according to claim 1, wherein: protection machanism includes inlayer guard shield (3) and outer guard shield (2), and inlayer guard shield (3) and outer guard shield (2) quantity all are two to relative setting, inlayer guard shield (3) are located outer guard shield (2) inboardly, are circular-arcly, and power unit is located between two inlayer guard shields (3), is equipped with the observation hole on inlayer guard shield (3).
3. The closed impeller overspeed test device of aluminum alloy according to claim 1, wherein: the power mechanism comprises a driving motor (9), the driving motor (9) is connected with a power transmission device (7), a pneumatic tire clutch (11) is installed on the power transmission device (7), the power transmission device (7) is connected with a transmission main shaft (10) to provide power for an overspeed test for equipment, and an overspeed test piece (8) is installed on the transmission main shaft (10);
the drive motor (9) is also connected with a PLC, and the PLC controls the start and stop of the drive motor (9).
4. The closed impeller overspeed test device of aluminum alloy according to claim 2, wherein: noise sensor (4), camera (5) and temperature sensor (6) are installed to the inboard of outer guard shield (2), noise sensor (4) are used for monitoring the inboard noise size of outer guard shield, and camera (5) are located outer guard shield inboard, and the observation hole of inlayer guard shield (3) is aimed at in camera (5), and the process of speeding is carried out real-time supervision to the observation hole through the inboard guard shield of arc, takes a candid photograph test device internal conditions when appearing unusual, and temperature sensor (6) are used for check out test set cavity temperature.
5. The closed impeller overspeed test device of aluminum alloy according to claim 3, wherein: the power transmission device (7) is provided with a temperature sensor (6), and the temperature sensor (6) is used for detecting the temperature of the body;
and a vibration sensor (12) is arranged on one side, close to the impeller test piece, of the transmission main shaft (10) and used for detecting the vibration condition in the operation process.
6. An overspeed test method of an aluminum alloy closed impeller is characterized by comprising the following steps: the test method is carried out based on an overspeed test device and comprises a real-time monitoring method, and the real-time monitoring method comprises the following steps:
step S101, starting the test of the overspeed test device, and entering step S102 after the test is finished;
step S102, the PLC controls the vibration sensor, the temperature sensor, the camera and the noise sensor to monitor the test device in real time, and uploads monitoring data to the PLC, and the step S103 is executed after the monitoring data are completed;
step S103, judging whether the monitoring value is in the maximum allowable value requirement range of the setting parameter, if the monitoring value meets the requirement, entering step S104, and if the monitoring value exceeds the upper limit, entering step S105;
step S105, cutting off a power supply of a driving motor, shooting the impeller state by a camera 20 times per second, if the impeller fails, accurately capturing an impeller picture at the moment of impeller failure by the camera, conveniently analyzing the impeller failure, and entering step S104 after the impeller failure is completed;
step S104, carrying out overspeed test according to a set program, and entering step S106 after the overspeed test is finished;
and step S106, reducing the rotating speed to 0, and finishing the test.
7. The closed impeller overspeed test method of aluminum alloy according to claim 6, characterized in that: the method also comprises an impeller overspeed test method, and the impeller overspeed test method comprises the following steps:
step S201, determining test conditions, and entering step S202 after the test conditions are completed;
step S202, installing an impeller test workpiece in an overspeed test device, and entering step S203 after the impeller test workpiece is installed;
step S203, inputting an impeller running curve in an operation console to control the acceleration, deceleration and running time of the impeller, and entering step S204 after the acceleration, deceleration and running time are controlled;
and step S204, carrying out an impeller overspeed test, wherein the impeller overspeed test is carried out at the rotating speed of 120% of the rated rotating speed, plastic deformation possibly occurs in part of the impeller during the process, and the running time is 3-5 min.
8. The closed impeller overspeed test method of aluminum alloy according to claim 6, characterized in that: the impeller fatigue testing method comprises the following steps:
the method comprises the following steps of simulating each special working condition when an impeller runs by adopting an overspeed testing device, wherein the special working conditions comprise starting and stopping working conditions and rotating speed fluctuation working conditions, and the starting and stopping working conditions are the reciprocating loading process of adjusting the power of a motor to enable the impeller to rotate at the rotating speed of 0-working rotating speed-0; the rotation speed fluctuation is a phenomenon of simulating the rotation speed fluctuation of the impeller, and an operation curve of the impeller under a special working condition is determined.
9. The closed impeller overspeed test method of aluminum alloy according to claim 6, characterized in that: the method also comprises an impeller deformation condition detection method, and the impeller deformation condition detection method comprises the following steps:
step S301, detecting the size of a machining part of the impeller used for compressor assembly before testing by using three coordinates, scanning the blade shape of the impeller before testing by using a joint arm scanner, and entering step S302 after completing;
step S302, performing overspeed test on the impeller by adopting an overspeed test device, and entering step S303 after the overspeed test is completed;
step S303, detecting the size of a machining part of the tested impeller for assembling the compressor by using three coordinates, scanning the blade shape of the tested impeller by using a joint arm scanner, and entering step S304 after the detection is finished;
step S304, comparing and analyzing the measurement results of the impeller before and after the overspeed test, and entering step S305 after the comparison is completed;
step S305, judging whether the size change of the impeller is within an allowable range before and after the test, if so, the impeller is a qualified product, if not, the impeller is unqualified, and the impeller deforms after the test, so that the position with the largest deformation quantity of the impeller after the test can be determined, and a basis is provided for later-stage impeller shape and performance improvement.
10. The closed impeller overspeed test method of aluminum alloy according to claim 6, characterized in that: the method for monitoring the internal defects of the impeller further comprises the following steps:
s401, carrying out flaw detection on the whole impeller before testing by using X-ray real-time imaging equipment, and entering S402 after the flaw detection is finished;
step S402, judging whether the requirement is met, if so, entering step S403, and if not, determining that the impeller is an unqualified product;
step S403, performing overspeed test on the impeller by using an overspeed test device, and entering step S404 after the overspeed test is completed;
s404, carrying out flaw detection on the whole tested impeller by using X-ray real-time imaging equipment, and entering S405 after the flaw detection is finished;
step S405, judging whether the requirement is met, if so, determining the impeller to be a qualified product, and if not, determining the impeller to be an unqualified product.
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