CN114594721A - Centrifuge fault diagnosis device - Google Patents
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- CN114594721A CN114594721A CN202210165863.9A CN202210165863A CN114594721A CN 114594721 A CN114594721 A CN 114594721A CN 202210165863 A CN202210165863 A CN 202210165863A CN 114594721 A CN114594721 A CN 114594721A
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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
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
- G05B19/054—Input/output
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D21/00—Measuring or testing not otherwise provided for
- G01D21/02—Measuring two or more variables by means not covered by a single other subclass
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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
- G05B2219/10—Plc systems
- G05B2219/13—Plc programming
- G05B2219/13142—Debugging, tracing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The invention provides a centrifuge fault diagnosis device, comprising: the centrifuge control cabinet is provided with a PLC, the network communication interface and the PLC in the centrifuge control cabinet are in data interaction with each other, a data processing and analyzing module is arranged in the centrifuge control cabinet, the data processing and analyzing module is connected with the network communication interface, and the data collected by the high-speed vibration collecting circuit, the temperature collecting circuit and the rotating speed collecting circuit are transmitted to the data processing and analyzing module to be processed and analyzed. The invention feeds back various parameters of the centrifuge in time and judges the fault part of the centrifuge according to the data.
Description
Technical Field
The invention relates to the field of centrifuge diagnosis, in particular to a centrifuge fault diagnosis device.
Background
The centrifugal machine is a device for realizing solid-liquid separation by utilizing centrifugal force, and is widely used in the fields of pharmacy and chemical industry. When the centrifugal machine operates under complex working conditions of speed change, load change and the like, moving parts are easy to generate fatigue damage and performance decline to cause equipment failure, the operation reliability of the equipment is seriously influenced, the development trend and the usable service life of the equipment failure cannot be predicted due to the fact that the real-time health state information of the equipment is not fully excavated and utilized in the preventive maintenance method for fixing the overhaul period, and the problem of over/under maintenance is difficult to solve.
The operation state parameters of the existing centrifuge are obtained from a control module PLC of the existing centrifuge, wherein the operation state parameters comprise current process parameters of the centrifuge, set rotating speed parameters of a frequency converter, working state parameters of components of the centrifuge and the like, the operation state parameters can feed back the operation information of the existing centrifuge, when a fault occurs, an alarm signal can be sent, and when a serious fault occurs, the centrifuge can be stopped emergently.
However, because the failure feedback information is not comprehensive, the emergency shutdown will cause the disorder of the production order and cause unnecessary loss, and the centrifuge failure diagnosis device can solve the above problems.
Disclosure of Invention
The invention aims to provide a fault diagnosis device for a centrifugal machine, which solves the technical problems that the fault reaction is not comprehensive and the centrifugal machine is stopped emergently due to the fault.
In order to achieve the technical purpose and achieve the technical requirements, the invention adopts the technical scheme that: a centrifuge failure diagnosis apparatus comprising: the centrifuge control cabinet is provided with a PLC, the network communication interface and the PLC in the centrifuge control cabinet are in data interaction with each other, a data processing and analyzing module is arranged in the centrifuge control cabinet, the data processing and analyzing module is connected with the network communication interface, and the data collected by the high-speed vibration collecting circuit, the temperature collecting circuit and the rotating speed collecting circuit are transmitted to the data processing and analyzing module to be processed and analyzed.
As a preferable technical scheme, the acceleration vibration sensors are respectively installed in the x direction, the y direction and the z direction of a bearing shaft seat of the centrifugal machine.
According to a preferable technical scheme, the vibration data are processed by a data processing and analyzing module to obtain vibration characteristic values of a bearing and a rotor component of the centrifuge, and the vibration characteristic values are core data used for representing equipment faults of the centrifuge.
As a preferred technical scheme, the temperature sensors are respectively arranged at the front end and the rear end outside the bearing of the centrifuge, and the temperature acquisition circuit acquires the front and rear shaft temperature data of the bearing to the data processing and analyzing module for subsequent data processing and analysis.
As a preferred technical scheme, the real-time rotating speed data is different from a set theoretical rotating speed, and the real-time rotating speed is combined with the vibration data to obtain real-time frequency spectrum data.
As a preferred technical solution, the network communication interface includes a hundred-mega ethernet chip and a hundred-mega ethernet chip connected to the network transformer.
As a preferable technical scheme, the high-speed vibration acquisition circuit comprises a differential four-channel digital control analog switch, a three-end adjustable constant current source device, a single 8-channel digital control analog switch, a non-chopper-stabilized bipolar operational amplifier integrated circuit and a fully differential operational amplifier.
As a preferred technical solution, the data processing and analyzing module is a highly integrated system on chip.
As a preferred technical scheme, the temperature acquisition circuit comprises a high-precision instrument amplifier, a controllable precise voltage-stabilizing source, a differential four-channel digital control analog switch and a single 8-channel digital control analog switch.
The invention has the beneficial effects that:
(1) all information data during the operation of the centrifuge can be acquired to the data processing and analyzing module, the data comprises operation state parameters of centrifuge equipment, including actual rotating speed, front and rear shaft temperatures, vibration and the like, the data can comprehensively represent the fault characteristics of the centrifuge after being processed by an algorithm, the fault occurrence reason can be accurately locked, the fault inquiry time is reduced, and the time cost is saved;
(2) each device in the centrifuge fault diagnosis device has small volume, strong signal acquisition anti-interference capability and stable and reliable data transmission;
(3) the data processing and analyzing module is combined with a special data processing algorithm, special characteristic signals for the centrifuge are deeply excavated, the accuracy of an analysis result is high, the difficulty of fault analysis is reduced, and the maintenance efficiency is improved.
Drawings
FIG. 1 is a first portion of a wiring diagram of a network communications interface;
FIG. 2 is a second portion of a wiring diagram for a network communications interface;
FIG. 3 is a third portion of a wiring diagram for a network communications interface;
FIG. 4 is a first portion of a wiring diagram of a high speed vibration acquisition circuit;
FIG. 5 is a second portion of a wiring diagram of the high speed vibration acquisition circuit;
FIG. 6 is a third portion of a wiring diagram of the high speed vibration acquisition circuit;
FIG. 7 is a first portion of a wiring diagram for a data processing and analysis module;
FIG. 8 is a second portion of a wiring diagram for a data processing and analysis module;
FIG. 9 is a first portion of a wiring diagram of the temperature acquisition circuit;
fig. 10 is a second portion of a wiring diagram of the temperature acquisition circuit.
Detailed Description
The invention is further described below with reference to the accompanying drawings.
Referring to fig. 1 to 10, a centrifuge failure diagnosis apparatus includes: the system comprises a network communication interface, a centrifuge control cabinet, an acceleration vibration sensor, a high-speed vibration acquisition circuit connected with the acceleration vibration sensor, a temperature acquisition circuit connected with the temperature sensor, a photoelectric sensor and a rotating speed acquisition circuit connected with the photoelectric sensor, wherein a PLC is arranged in the centrifuge control cabinet, the network communication interface and the PLC in the centrifuge control cabinet perform data interaction, a data processing and analyzing module is arranged in the centrifuge control cabinet, the data processing and analyzing module is connected with the network communication interface, and data acquired by the high-speed vibration acquisition circuit, the temperature acquisition circuit and the rotating speed acquisition circuit are transmitted to the data processing and analyzing module for processing and analyzing; the data interaction content comprises all state parameters of the operation of the centrifuge, including voltage, current, actual rotating speed, front and rear shaft temperature, vibration frequency and the like, so that the state of the centrifuge can be monitored in real time, when the centrifuge breaks down, abnormal parameters of which parts are observed in time, and therefore the fault of which part is diagnosed, meanwhile, the data interaction content can also be connected with an early warning system, early warning is started before the state of the centrifuge reaches a critical value, operators are reminded of which parts of the centrifuge need to be replaced or maintained, and safety accidents are prevented.
As shown in fig. 1 to 10, in some embodiments, the acceleration vibration sensors are respectively installed in three directions x, y, and z of a bearing shaft seat of a centrifuge, and the high-speed vibration acquisition circuit is connected to the acceleration vibration sensors to acquire real-time vibration data of the centrifuge to the data processing and analyzing module for subsequent data processing and analysis.
As shown in fig. 1 to 10, the vibration data is processed and analyzed by the PLC module to obtain vibration characteristic values of the bearing and the rotor component of the centrifuge, which are core data for characterizing the failure of the centrifuge apparatus.
As shown in fig. 1 to 10, the temperature sensors are respectively installed at the front end and the rear end outside the bearing of the centrifuge, the temperature acquisition circuit acquires the front and rear shaft temperature data of the bearing to the data processing and analyzing module for subsequent data processing and analysis, and the temperature data is one of the important state parameters of the bearing of the core component of the centrifuge.
As shown in fig. 1 to 10, the real-time rotation speed data is different from a set theoretical rotation speed, and the real-time rotation speed is combined with the vibration data to obtain real-time frequency spectrum data, so that whether the centrifuge device operates normally can be more perfectly characterized.
As shown in fig. 1 to 10, the network communication interface includes a hundred mega ethernet chip and a hundred mega ethernet chip connected to the network transformer, and further, the hundred mega ethernet chip is IP101GR, type: ethernet transmitters supply voltage: 3.3V interface type: MII, RMII, TP, Fiber Standard: 10/100/1000Base-T,100Base-TX Single Port 10/100M fast Ethernet Transceiver PHY. Here for data communication; the network transformer is HST-0041SAR, and RJ45 is a network cable interface.
As shown in fig. 1-10, the high-speed vibration acquisition circuit includes a differential four-channel digital control analog switch, a three-terminal adjustable constant current source device, a single 8-channel digital control analog switch, a non-chopper-stabilized bipolar operational amplifier integrated circuit, and a fully differential operational amplifier, further, the differential four-channel digital control analog switch is CD4052BM, has A, B two binary control input terminals and an INH input terminal, has low on-resistance and very low off-leakage current, and a digital signal with an amplitude of 4.5V-20V can control a peak-to-peak value to 20V analog signal. Here to control the selection of signals;
the three-end adjustable constant current source device is LM334, and the ratio of the adjustable range of the constant current source in the working current is 10000: 1, and has a wide dynamic voltage range of 1V-40V and very good constant current characteristics. Here to generate a 4-20mA signal;
the single 8-channel digital control analog switch is CD4051, has A, B, C binary control input ends and INH input ends, has low on-resistance and very low off-leakage current, and can control the peak-to-peak value to 20V analog signals by digital signals with the amplitude of 4.5V-20V. Here, the invention is used for controlling the selection of signals, selecting corresponding range of measuring range and the switching of the filter;
the non-chopper-stabilized bipolar operational amplifier integrated circuit is an Op07 chip and has the characteristic of low noise, and because the OP07 has a very low input offset voltage (the maximum is 25 mu V for the OP 07A), the OP07 does not need extra zero adjustment measures in many application occasions. The OP07 has the characteristics of low input bias current (OP07A is +/-2 nA) and high open-loop gain (for OP07A, 300V/mV), and the characteristics of low offset and high open-loop gain ensure that the OP07 is particularly suitable for the aspects of high-gain measuring equipment, amplification of weak signals of sensors and the like;
a fully differential operational amplifier, THS4521, with very low power, has a rail-to-rail output and an input common mode range including a negative supply rail. This amplifier is designed for low power data acquisition systems and high density applications where power dissipation is a critical parameter, the invention is used for differential signal amplification;
due to the fact that the circuit diagram is large, the high-speed vibration acquisition circuit is divided into three parts, namely fig. 4, fig. 5 and fig. 6.
As shown in fig. 1-10, the data processing and analyzing module is a highly integrated system on chip, and further, the highly integrated system on chip is a SigmaStar SSD201, which is based on an arm Cortex-a7 dual core and integrates h.264/h.265 video decoder, 2D graphics engine, TTL/mipi display and adjustable image quality engine, etc. as peripherals for smart display applications. The system comprises a connection module (Wi-Fi or ethernet) and a non-volatile memory (NOR flash, NAND flash or sd card). An external crystal driven Real Time Clock (RTC) at 32KHz frequency can keep time scaling when the main system clock is off, and the h.264/h.265 engine decodes the video streams from the network and sends them to the display subsystem. The information on brightness/contrast/saturation/sharpness may be used before output to a TTL or MIPI TX panel to provide the best image quality. NOR or NAND flash is a core device that is typically reserved for operating systems and application software, and in addition, other peripheral devices, such as SAR ADCs, audio support ADCs/DACs, UARTs, PWMs, GPIOS, and spi, achieve maximum flexibility for the application program, which the present invention uses to control data acquisition and output transfer.
As shown in fig. 1-10, the temperature acquisition circuit includes a high-precision instrumentation amplifier, a controllable precision voltage regulator, a differential four-channel digital control analog switch, and a single 8-channel digital control analog switch, further, the high-precision instrumentation amplifier is AD620, only one external resistor is needed to set a gain, and the gain range is 1 to 10000. The AD620 has the characteristics of high precision (the maximum nonlinearity is 40ppm), low offset voltage (the maximum is 50 muV) and low offset drift (the maximum is 0.6 muV/DEG C), and also has the characteristics of low noise, low input bias current and low power consumption, and the invention is used for signal amplification;
the controllable precise voltage-stabilizing source is TL431, the output voltage of the TL431 can be set to any value within the range from Vref (2.5V) to 36V by using two resistors, the typical dynamic impedance of the device is 0.2 omega, and the device is used for outputting reference voltage;
the four-channel digital control analog switch is CD4052BM, comprises A, B binary control input ends and INH input ends, has low on-resistance and very low off-leakage current, and can control the peak-to-peak value to 20V analog signals by digital signals with the amplitude of 4.5V-20V;
the differential four-channel digital control analog switch is CD4051, has A, B, C binary control input ends and INH input ends, has low on-resistance and very low off-leakage current, and can control the peak-to-peak value to 20V analog signals by using digital signals with the amplitude of 4.5V-20V.
As shown in fig. 1-10, the temperature sensor is a digital temperature sensor a, the temperature acquisition circuit comprises a thermocouple terminal b and a platinum resistor terminal c, the thermocouple or the platinum resistor is used for sensing the temperature, the temperature acquisition circuit acquires temperature data, the temperature acquisition circuit further comprises a D/a data conversion D, the output voltage is +/-5, and the digital temperature sensor a is connected with the temperature acquisition circuit.
The working principle of the invention is as follows:
the acceleration vibration sensor is respectively arranged in the x direction, the y direction and the z direction of a bearing shaft seat of the centrifuge, and the high-speed vibration acquisition circuit is connected with the acceleration vibration sensor; the temperature sensors are respectively arranged at the front end and the rear end outside the bearing of the centrifugal machine, and the temperature acquisition circuit is connected with the temperature sensors; the photoelectric sensor is arranged at the upper end of the centrifuge drum and is connected with the rotating speed acquisition circuit.
After all the data are processed through the algorithm by the data processing and analyzing module, data representing the fault characteristics of the centrifuge are obtained, and then the fault diagnosis result is obtained through the mark comparison of the fault characteristic set.
The foregoing examples are given solely for the purpose of illustrating the invention and are not to be construed as limiting the embodiments, and other variations and modifications in form thereof will be suggested to those skilled in the art upon reading the foregoing description, and it is not necessary or necessary to exhaustively enumerate all embodiments and all such obvious variations and modifications are deemed to be within the scope of the invention.
Claims (10)
1. A centrifuge failure diagnosis device characterized by comprising: the centrifuge control cabinet is provided with a PLC, the network communication interface and the PLC in the centrifuge control cabinet are in data interaction with each other, a data processing and analyzing module is arranged in the centrifuge control cabinet, the data processing and analyzing module is connected with the network communication interface, and the data collected by the high-speed vibration collecting circuit, the temperature collecting circuit and the rotating speed collecting circuit are transmitted to the data processing and analyzing module to be processed and analyzed.
2. The centrifuge failure diagnosis device according to claim 1, wherein the acceleration vibration sensors are respectively installed in x, y, z directions of a bearing shaft seat of the centrifuge.
3. The centrifuge fault diagnosis device according to claim 2, characterized in that the vibration data is processed by the data processing and analyzing module to obtain vibration characteristic values of the centrifuge bearing and the rotor component, and the vibration characteristic values are core data for characterizing the centrifuge equipment fault.
4. The centrifuge fault diagnosis device according to claim 3, wherein the temperature sensors are respectively installed at the front end and the rear end outside the centrifuge bearing, and the temperature acquisition circuit acquires the front and rear shaft temperature data of the bearing to the data processing and analyzing module for subsequent data processing and analysis.
5. The centrifuge fault diagnosis device according to claim 4, wherein the rotation speed acquisition circuit is connected to acquire real-time rotation speed data of the centrifuge device to the data processing and analyzing module for subsequent data processing and analysis.
6. The centrifuge failure diagnosis device according to claim 5, wherein the real-time rotation speed data is different from a set theoretical rotation speed, and the real-time rotation speed is combined with the vibration data to obtain real-time frequency spectrum data.
7. The centrifuge fault diagnosis device according to claim 1, wherein the network communication interface comprises a hundred mega Ethernet chip and a hundred mega Ethernet chip connected with a network transformer.
8. The centrifuge fault diagnosis device according to claim 1, wherein the high-speed vibration acquisition circuit comprises a differential four-channel digital control analog switch, a three-terminal adjustable constant current source device, a single 8-channel digital control analog switch, a non-chopper-stabilized bipolar operational amplifier integrated circuit, and a fully differential operational amplifier.
9. The centrifuge fault diagnosis device of claim 1, wherein the data processing and analyzing module is a highly integrated system on a chip.
10. The centrifuge fault diagnosis device according to claim 1, wherein the temperature acquisition circuit comprises a high-precision instrument amplifier, a controllable precision voltage-stabilizing source, a differential four-channel digital control analog switch and a single 8-channel digital control analog switch.
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