CN114594721B - Centrifugal machine fault diagnosis device - Google Patents
Centrifugal machine fault diagnosis device Download PDFInfo
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- CN114594721B CN114594721B CN202210165863.9A CN202210165863A CN114594721B CN 114594721 B CN114594721 B CN 114594721B CN 202210165863 A CN202210165863 A CN 202210165863A CN 114594721 B CN114594721 B CN 114594721B
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- 238000003745 diagnosis Methods 0.000 title claims abstract description 16
- 238000012545 processing Methods 0.000 claims abstract description 37
- 238000004458 analytical method Methods 0.000 claims abstract description 22
- 238000004891 communication Methods 0.000 claims abstract description 19
- 230000001133 acceleration Effects 0.000 claims abstract description 14
- 230000003993 interaction Effects 0.000 claims abstract description 5
- 230000000087 stabilizing effect Effects 0.000 claims description 5
- 238000001228 spectrum Methods 0.000 claims description 3
- 230000006641 stabilisation Effects 0.000 claims 2
- 238000011105 stabilization Methods 0.000 claims 2
- 230000005540 biological transmission Effects 0.000 abstract description 3
- 238000010586 diagram Methods 0.000 description 11
- 238000012423 maintenance Methods 0.000 description 4
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 4
- 239000000306 component Substances 0.000 description 3
- 230000003321 amplification Effects 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
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- 238000003199 nucleic acid amplification method Methods 0.000 description 2
- 230000002093 peripheral effect Effects 0.000 description 2
- 229910052697 platinum Inorganic materials 0.000 description 2
- 230000002159 abnormal effect Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
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- 238000000926 separation method Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
Classifications
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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
-
- 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- 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 fault diagnosis device of a centrifugal machine, which comprises: network communication interface, centrifuge control cabinet, acceleration vibration sensor, the high-speed vibration acquisition circuit who is connected with acceleration vibration sensor, temperature sensor, the temperature acquisition circuit who is connected with temperature sensor, photoelectric sensor, the rotational speed acquisition circuit who is connected with photoelectric sensor, be equipped with PLC in the centrifuge control cabinet, the network communication interface carries out data interaction with PLC in the centrifuge control cabinet, be equipped with data processing and analysis module in the centrifuge control cabinet, data processing and analysis module and network communication interface connection, the data transmission that high-speed vibration acquisition circuit, temperature acquisition circuit, rotational speed acquisition circuit gathered is handled and is analyzed to data processing and analysis module. According to the invention, various parameters of the centrifugal machine are fed back in time, and fault parts of the centrifugal machine are judged 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. Under the complex working conditions of speed change, load change and the like, the moving parts are extremely easy to generate fatigue damage and performance decline, equipment faults are caused, the operation reliability of the equipment is seriously affected, the preventive maintenance method for the fixed maintenance period cannot predict the development trend and the service life of the equipment faults because the real-time health state information of the equipment is not fully excavated and utilized, and the over/under maintenance problem is difficult to solve.
The running state parameters of the current centrifugal machine are obtained from a control module PLC of the current centrifugal machine, and comprise the current working procedure parameters of the centrifugal machine, the set rotating speed parameters of the frequency converter, the working state parameters of components of the centrifugal machine and the like, the running state parameters can feed back the running information of the current centrifugal machine, an alarm signal can be sent out when a fault occurs, and emergency shutdown can be carried out when a serious fault occurs.
However, since the fault feedback information is not comprehensive, the emergency stop can cause disorder of production order and unnecessary loss, and the fault diagnosis device of the centrifugal machine can solve the problems.
Disclosure of Invention
The invention aims to provide a fault diagnosis device for a centrifugal machine, which solves the technical problems that fault response is incomplete and the centrifugal machine is stopped in an emergency due to faults.
In order to achieve the technical purpose and meet the technical requirements, the invention adopts the technical scheme that: a centrifuge failure diagnosis device, comprising: network communication interface, centrifuge control cabinet, acceleration vibration sensor, the high-speed vibration acquisition circuit who is connected with acceleration vibration sensor, temperature sensor, the temperature acquisition circuit who is connected with temperature sensor, photoelectric sensor, the rotational speed acquisition circuit who is connected with photoelectric sensor, be equipped with PLC in the centrifuge control cabinet, the network communication interface carries out data interaction with PLC in the centrifuge control cabinet, be equipped with data processing and analysis module in the centrifuge control cabinet, data processing and analysis module and network communication interface connection, the data transmission that high-speed vibration acquisition circuit, temperature acquisition circuit, rotational speed acquisition circuit gathered is handled and is analyzed to data processing and analysis module.
As an optimal technical scheme, the acceleration vibration sensor is respectively arranged in the x, y and z directions of a bearing shaft seat of the centrifugal machine.
As an advantageous solution, the vibration data are used to obtain vibration characteristic values of the centrifuge bearings and the rotor components through a data processing and analyzing module, wherein the vibration characteristic values are core data for representing faults of the centrifuge equipment.
As an optimized technical scheme, the temperature sensors are respectively arranged at the front end and the rear end of the outside of the centrifugal machine bearing, and the temperature acquisition circuit acquires front and rear shaft temperature data of the bearing to the data processing and analyzing module for subsequent data processing and analysis.
As an preferable technical scheme, the real-time rotation speed data is different from the set theoretical rotation speed, and the real-time rotation speed data is combined with the vibration data to obtain real-time frequency spectrum data.
As a preferable technical scheme, the network communication interface comprises a hundred mega ethernet chip and a hundred mega ethernet chip connected with the network transformer.
As an optimal technical scheme, 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 zero-stabilizing bipolar operational amplifier integrated circuit and a fully differential operational amplifier.
As a preferred solution, the data processing and analysis module is a highly integrated system on chip.
As an optimal 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 beneficial effects of the invention are as follows:
(1) All information data of the centrifuge during operation can be collected to a data processing and analyzing module, the data comprise operation state parameters of centrifuge equipment, including actual rotation speed, front and rear shaft temperature, vibration and the like, the data can comprehensively represent fault characteristics of the centrifuge after being processed by an algorithm, fault occurrence reasons are accurately locked, fault inquiry time is shortened, and time cost is saved;
(2) The device in the fault diagnosis device of the centrifugal machine has small volume, strong anti-interference capability of signal acquisition and stable and reliable data transmission;
(3) The data processing and analyzing module is combined with a special data processing algorithm to deeply mine out special characteristic signals aiming at the centrifugal machine, so that the accuracy of analysis results is high, the fault analysis difficulty is reduced, and the maintenance efficiency is improved.
Drawings
FIG. 1 is a first portion of a network communication interface wiring diagram;
FIG. 2 is a second portion of a network communication interface wiring diagram;
FIG. 3 is a third portion of a network communication interface wiring diagram;
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 a high-speed vibration acquisition circuit;
FIG. 6 is a third portion of a wiring diagram of a high-speed vibration acquisition circuit;
FIG. 7 is a first portion of a wiring diagram of a data processing and analysis module;
FIG. 8 is a second portion of a wiring diagram of a data processing and analysis module;
FIG. 9 is a first portion of a wiring diagram of a temperature acquisition circuit;
fig. 10 is a second portion of a wiring diagram of a temperature acquisition circuit.
Detailed Description
The invention is further described below with reference to the accompanying drawings.
Referring to fig. 1 to 10, a fault diagnosis apparatus for a centrifuge 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 performs data interaction with the PLC in the centrifuge control cabinet, 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 analysis; the content of data interaction comprises all state parameters of the centrifuge running, including voltage, current, actual rotation 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, which part parameter is abnormal, and therefore which part is diagnosed, meanwhile, the system can be connected with an early warning system, early warning is started before the state of the centrifuge reaches a critical value, and an operator is reminded of which parts of the centrifuge need to be replaced or maintained, so that safety accidents are prevented.
As shown in fig. 1-10, in some embodiments, the acceleration vibration sensor is respectively installed in the x, y and z directions of the bearing shaft seat of the centrifugal machine, and the high-speed vibration acquisition circuit is connected with the acceleration vibration sensor to acquire real-time vibration data of the centrifugal machine to the data processing and analysis module for subsequent data processing and analysis.
As shown in fig. 1-10, the vibration data are used for obtaining vibration characteristic values of the centrifugal machine bearing and the rotor component through a data processing and analyzing module of the PLC, wherein the vibration characteristic values are core data used for representing faults of centrifugal machine equipment.
As shown in fig. 1-10, the temperature sensors are respectively installed at the front end and the rear end outside the centrifuge bearing, the temperature acquisition circuit acquires 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 important state parameters of the centrifuge core component bearing.
As shown in fig. 1-10, the real-time rotation speed data is different from the set theoretical rotation speed, and meanwhile, the real-time rotation speed data is combined with the vibration data to obtain real-time frequency spectrum data, so that whether the centrifuge equipment is in normal operation can be more perfectly represented.
As shown in fig. 1-10, the network communication interface includes a hundred mega ethernet chip, a hundred mega ethernet chip connected with a network transformer, further, the hundred mega ethernet chip is IP101GR, and the type: ethernet Transceivers 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 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, wherein the differential four-channel digital control analog switch is a CD4052BM, has two binary control input ends and an INH input end of A, B, has low on-resistance and very low off-leakage current, and can control a digital signal with an amplitude of 4.5V-20V to an analog signal with a peak-to-peak value of 20V. Here used to control the selection of signals;
the three-terminal adjustable constant current source device is LM334, and the adjustable range ratio of the constant current source in the working current is 10000:1, and has a wide dynamic voltage range of 1V-40V, and has 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 three binary control input ends and INH input ends, has low on-resistance and very low off leakage current, and can control analog signals from peak to 20V by digital signals with the amplitude of 4.5V-20V. The invention is used for selecting corresponding measuring range and switching of the filter;
the bipolar operational amplifier integrated circuit with non-chopper stabilized is an Op07 chip and has the characteristic of low noise, and because the OP07 has very low input offset voltage (25 mu V for OP07A at maximum), the OP07 does not need extra zeroing measures in many application occasions. The OP07 has the characteristics of low input bias current (OP 07A is +/-2 nA) and high open loop gain (300V/mV for the OP 07A), and the characteristics of low offset and high open loop gain lead the OP07 to be particularly suitable for the aspects of measuring equipment with high gain, weak signals of an amplifying sensor and the like;
the fully differential operational amplifier is THS4521, has very low power characteristics, and 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 present invention is used for differential signal amplification;
because the circuit diagram is large, the high-speed vibration acquisition circuit is split into three parts, namely fig. 4, 5 and 6.
As shown in fig. 1-10, the data processing and analyzing module is a highly integrated system on chip, further, the highly integrated system on chip is a sigmasar SSD201, which is based on an arm Cortex-A7 dual core and integrates peripheral devices for intelligent display applications, such as an h.264/h.265 video decoder, a 2D graphics engine, a TTL/mipi display and an adjustable image quality engine. The system includes 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 scaled when the main system clock is off, and the h.264/h.265 engine decodes video streams from the network and sends them to the display subsystem. The brightness/contrast/saturation/sharpness may be used to provide the best image quality before output to the TTL or MIPI TX panel. NOR or NAND flash memory is a core device that is typically reserved for operating systems and applications, and in addition, other peripheral devices, such as SAR ADC, audio support ADC/DAC, UARTs, PWMs, GPIOS, and spi, enable maximum flexibility of application programs, and the invention is used 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 stabilizing source, a differential four-channel digital control analog switch, and a single 8-channel digital control analog switch, further, the high-precision instrumentation amplifier is an AD620, only one external resistor is needed to set the gain, and the gain range is 1-10000. AD620 has high accuracy (maximum nonlinearity 40 ppm), low offset voltage (maximum 50 μV) and low offset drift (maximum 0.6 μV/DEG C), low noise, low input bias current and low power consumption, and is used for signal amplification;
the controllable precise voltage stabilizing source is TL431, the output voltage of the controllable precise voltage stabilizing source can be set to any value ranging from Vref (2.5V) to 36V by using two resistors, and the typical dynamic impedance of the device is 0.2 omega;
the four-channel digital control analog switch is CD4052BM, which has A, B two binary control input ends and INH input ends, has low on-resistance and very low off leakage current, and the digital signal with the amplitude of 4.5V-20V can control the analog signal from peak to peak value to 20V;
the differential four-channel digital control analog switch is CD4051, has A, B, C three binary control input ends and INH input ends, has low on-resistance and very low off leakage current, and can control analog signals from peak to 20V by 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 wiring terminal b and a platinum resistor wiring terminal c, a thermocouple or a platinum resistor is adopted to sense temperature, then the temperature acquisition circuit acquires temperature data, the temperature acquisition circuit also 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, y and z directions of the bearing shaft seat of the centrifugal machine, 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 of the outside of the centrifugal machine bearing, 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 subjected to algorithm processing through a data processing and analyzing module, data representing fault characteristics of the centrifugal machine are obtained, and then fault diagnosis results are obtained through label comparison of fault characteristic sets.
The above examples are provided for the purpose of clearly illustrating the invention and are not to be construed as limiting the invention, and other variants and modifications of the various forms may be made by those skilled in the art based on the description, which are not intended to be exhaustive of all embodiments, and obvious variants or modifications of the invention may be found within the scope of the invention.
Claims (9)
1. A centrifuge failure diagnosis device, characterized by comprising: 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 performs data interaction with the PLC in the centrifuge control cabinet, 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 analysis;
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 bipolar operational amplifier integrated circuit with non-chopping zero stabilization and a fully differential operational amplifier, wherein the differential four-channel digital control analog switch is CD4052BM, has A, B two binary control input ends and INH input ends, has low on-resistance and very low off-leakage current, and digital signals with the amplitude of 4.5V-20V can control analog signals from peak to 20V;
the three-terminal adjustable constant current source device is LM334, and the adjustable range ratio of the constant current source in the working current is 10000:1 and has a wide dynamic voltage range of 1V-40V;
the single 8-channel digital control analog switch is CD4051, has A, B, C three binary control input ends and INH input ends, has low on-resistance and very low off leakage current, and can control analog signals from peak to 20V according to digital signals with the amplitude of 4.5V-20V;
the bipolar operational amplifier integrated circuit with non-chopping and zero stabilization is an Op07 chip;
the fully differential operational amplifier is THS4521.
2. The device for diagnosing faults of a centrifugal machine according to claim 1, wherein the acceleration vibration sensors are respectively installed in three directions of x, y and z of a bearing shaft seat of the centrifugal machine.
3. The fault diagnosis device for the centrifugal machine according to claim 2, wherein vibration data acquired by the high-speed vibration acquisition circuit are used for obtaining vibration characteristic values of the centrifugal machine bearing and the rotor component through the data processing and analyzing module, and the vibration characteristic values are core data used for representing faults of the centrifugal machine equipment.
4. A centrifuge fault diagnosis device according to claim 3 wherein the temperature sensors are mounted at the front and rear ends of the exterior of the centrifuge bearing respectively, and the temperature acquisition circuit acquires the front and rear shaft temperature data of the bearing to the data processing and analysis module for subsequent data processing and analysis.
5. The centrifuge failure diagnostic device of claim 4 wherein the rotational speed acquisition circuit is coupled to acquire real-time rotational speed data of the centrifuge device to the data processing and analysis module for subsequent data processing and analysis.
6. The device according to claim 5, wherein the real-time rotational speed data is different from a set theoretical rotational speed, and the real-time rotational speed is combined with the vibration data to obtain real-time spectrum data.
7. The centrifuge fault diagnosis device of claim 1 wherein the network communication interface comprises a hundred mega ethernet chip, a hundred mega ethernet chip connected to a network transformer.
8. The centrifuge failure diagnostic device of claim 1 wherein the data processing and analysis module is a highly integrated system on a chip.
9. The centrifuge fault diagnosis device of claim 1 wherein the temperature acquisition circuit comprises a high precision instrumentation amplifier, a controllable precision voltage stabilizing source, a differential four-channel digitally controlled analog switch, a single 8-channel digitally controlled analog switch.
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