CN114720872A - Fault diagnosis method and system for motor load transmission mechanism - Google Patents

Fault diagnosis method and system for motor load transmission mechanism Download PDF

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Publication number
CN114720872A
CN114720872A CN202210294762.1A CN202210294762A CN114720872A CN 114720872 A CN114720872 A CN 114720872A CN 202210294762 A CN202210294762 A CN 202210294762A CN 114720872 A CN114720872 A CN 114720872A
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China
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motor
transmission mechanism
period
load
active power
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CN202210294762.1A
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任家友
唐丽
赵忠
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Shenzhen Shuanghe Electric Co ltd
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Shenzhen Shuanghe Electric Co ltd
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Priority to CN202210294762.1A priority Critical patent/CN114720872A/en
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
    • G01R31/34—Testing dynamo-electric machines
    • G01R31/343—Testing dynamo-electric machines in operation
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M13/00—Testing of machine parts
    • G01M13/02—Gearings; Transmission mechanisms
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
    • G01R31/34—Testing dynamo-electric machines
    • 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
    • Y04—INFORMATION OR COMMUNICATION TECHNOLOGIES HAVING AN IMPACT ON OTHER TECHNOLOGY AREAS
    • Y04S—SYSTEMS INTEGRATING TECHNOLOGIES RELATED TO POWER NETWORK OPERATION, COMMUNICATION OR INFORMATION TECHNOLOGIES FOR IMPROVING THE ELECTRICAL POWER GENERATION, TRANSMISSION, DISTRIBUTION, MANAGEMENT OR USAGE, i.e. SMART GRIDS
    • Y04S10/00—Systems supporting electrical power generation, transmission or distribution
    • Y04S10/50—Systems or methods supporting the power network operation or management, involving a certain degree of interaction with the load-side end user applications
    • Y04S10/52—Outage or fault management, e.g. fault detection or location

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)
  • Control Of Electric Motors In General (AREA)

Abstract

The invention provides a method and a system for diagnosing faults of a transmission mechanism of a motor load, wherein the method comprises the following steps: collecting voltage and current signals of a motor which works periodically in one period; calculating an active power curve in the period according to the acquired voltage and current signals; and comparing and analyzing the active power curve in the period with the historical active power curve, and judging whether the transmission mechanism of the motor load has a fault according to the comparison and analysis result. By adopting the technical scheme of the invention, the health monitoring can be efficiently carried out on the transmission mechanism of the motor load, the operation and maintenance personnel can be scientifically guided to arrange a shutdown maintenance plan in time, the production efficiency is improved, and the operation and maintenance cost of equipment is reduced.

Description

Fault diagnosis method and system for motor load transmission mechanism
Technical Field
The invention relates to the field of motor fault diagnosis, in particular to a fault diagnosis method and system for a motor load transmission mechanism.
Background
Motors are widely used in industrial fields such as power generation, chemical industry, ships, steel, cement, and the like, and loads of the motors, whether asynchronous motors or servo motors, are generally screw mechanisms, synchronous pulley mechanisms, rack and pinion structures, disc structures, long arm structures, and the like. The transmission mechanisms or operation mechanisms work in various complex environments for a long time, transmission parts such as shaft pins, gears, chains and the like are lack of lubrication and are easy to wear out, and after the transmission mechanisms or operation mechanisms run for a period of time, the phenomena of corrosion, jamming, distortion, fracture, movement rejection and the like of the mechanical mechanisms often occur. The travel of the electric operating mechanism is not sensitive easily, broken teeth of a transmission gear and the temperature of the mechanism rises, and serious potential safety hazards are caused, and even the operation is stopped or the operation cannot be carried out. The normal production of the enterprise is directly influenced, the overhaul cost is increased, and the economic benefit of the enterprise is further influenced.
At present, most motor monitoring and diagnosing methods are used for monitoring and diagnosing a motor body, such as faults of a motor stator short circuit, a rotor broken bar, a bearing and the like. Occasionally, a method for analyzing the fault of the motor load mechanism by monitoring the voltage and current changes in the working period of the motor and the working time of each period is provided, but other judgment methods are too simple, the load generally changes in a nonlinear manner in the working process of the motor, and the abnormal phenomena of corrosion, jamming and the like of the mechanical part of the load mechanism are difficult to find.
The traditional motor mainly diagnoses the motor body, and the motor transmission mechanism is rarely involved. At present, the transmission mechanism in industrial and mining enterprises generally has a problem that the transmission mechanism is failed and can not work continuously to be repaired or manually checked during regular maintenance, so that the efficiency is low.
Disclosure of Invention
The invention mainly aims to provide a method and a system for diagnosing the fault of a transmission mechanism of a motor load with high efficiency.
In order to achieve the purpose, the invention adopts the following technical scheme:
a method of diagnosing a failure of a drive mechanism of a motor load, comprising:
collecting voltage and current signals of a motor in a period of a periodic work system;
calculating an active power curve in the period according to the acquired voltage and current signals;
and comparing and analyzing the active power curve in the period with the historical active power curve, and judging whether the transmission mechanism of the motor load has a fault according to the comparison and analysis result.
Wherein, according to the voltage, the active power curve in this cycle of signal calculation of electric current gathered, include:
carrying out Fourier decomposition on the acquired voltage and current signals to obtain fundamental wave voltage and current signals;
and calculating active power by adopting fundamental wave voltage and current signals.
Wherein, carry out contrastive analysis with historical active power curve with the active power curve in this cycle, include:
comparing the active power value at each moment to obtain curve similarity;
comparing the time sequence shapes of the data in the same time period to obtain the time sequence similarity;
and calculating the stability index of the load transmission mechanism according to the curve similarity and the time sequence similarity.
Wherein, calculate load drive mechanism smoothness index according to curve similarity and time series similarity, include:
and calculating the arithmetic mean of the curve similarity and the time series similarity, and taking the arithmetic mean as a smoothness index of the load transmission mechanism.
Wherein, calculate load drive mechanism smoothness index according to curve similarity and time series similarity, include:
and calculating the square average of the curve similarity and the time series similarity, and taking the square average as a smoothness index of the load transmission mechanism.
And judging whether the transmission mechanism of the motor load has a fault or not according to whether the smoothness index is larger than a set threshold value or not.
The method for diagnosing the fault of the transmission mechanism of the motor load further comprises the following steps:
and issuing a motor transmission mechanism diagnosis report according to the analysis result.
Wherein the motor drive mechanism diagnostic report comprises: the motor starting time, the stopping time, the maximum power, the voltage minimum effective value, the current maximum effective value, the motor maximum torque, the motor power consumption in the period, the stability index and the motor load transmission mechanism maintenance guidance suggestion are obtained.
And judging the starting time of the motor in the current period according to the rated current of the motor when the effective value of the current sampling value is increased to be more than 0.05 times.
And judging the stop time of the current period of the motor according to the rated current of which the effective value of the current sampling value is reduced to be less than 0.05 times.
Furthermore, the invention also provides a system for diagnosing the fault of the transmission mechanism of the motor load, which adopts the method for diagnosing the fault of the transmission mechanism of the motor load when the fault of the transmission mechanism of the motor load is diagnosed.
Compared with the prior art, the motor load transmission mechanism fault diagnosis method provided by the invention is used for analyzing and judging whether the motor transmission mechanism is abnormal or not by comprehensively evaluating the curve similarity and the time sequence similarity of active function power curves in different periods according to the principle that the load change trend is constant in each period and the energy consumption is basically constant in the industrial and mining process that the periodic working time of the motor is fixed, so that the problem that the motor load transmission mechanism cannot be found in time due to the hidden troubles of corrosion, jamming, abrasion, component damage, movement rejection and the like is solved, the safety production is effectively ensured, operation and maintenance personnel are scientifically guided to arrange a shutdown maintenance plan in time, the production efficiency is improved, and the equipment operation and maintenance cost is reduced.
Drawings
Fig. 1 is a flowchart of an embodiment of a method for diagnosing a failure of a motor-loaded transmission according to the present invention.
Fig. 2 is a flow chart of another embodiment of the motor loaded transmission fault diagnosis method of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
The following detailed description of implementations of the invention refers to specific embodiments,
referring to fig. 1, a method for diagnosing a failure of a motor-loaded transmission according to an embodiment of the present invention includes steps S1-S6, which will be described in detail below.
Step S1: the motor is started.
And acquiring voltage and current data of the motor in real time, and judging that the motor is started when the effective value of the current sampling value is more than 0.05 times of the rated current of the motor.
Step S2: motor data is analyzed in real time.
The collected voltage and current data are calculated in real time, and the characteristic quantities such as active power, effective values of voltage and current, motor torque and the like are mainly calculated. Before the active power is calculated, Fourier decomposition is carried out on the collected voltage and current signals to obtain fundamental voltage and current signals, and the active power is calculated by adopting the fundamental voltage and current signals to prevent harmonic interference.
Step S3: motor data is saved.
And storing the real-time sampling data and the analyzed characteristic quantity of the period into a file so as to be convenient for analysis after the period is finished.
Step S4: the motor ends the run.
And judging that the motor finishes the work of the period when the effective value of the current sampling value is less than 0.05 times of rated current.
And step S5, fault diagnosis and analysis.
And calculating the electric energy of the period through the stored active power data of the current period, and simultaneously reading historical active data for comparison and analysis to obtain a stability index. And calculating the maximum current according to the stored effective current value. And calculating the maximum torque of the motor according to the saved motor voltage, current and motor parameters. And when the obtained stability index is higher than the set threshold value, judging that the transmission mechanism of the motor load has a fault, and giving an alarm to process by a technician.
In the embodiment of the present invention, the motor load transmission mechanism refers to a mechanical structure such as a screw mechanism, a synchronous pulley mechanism, a rack and pinion structure, a disc structure, and a long arm structure, and is generally referred to as a motor load transmission mechanism in the present application. The transmission mechanism utilizes a mechanical mode to transmit power and motion transmission.
The periodic working type motor has basically constant load change trend in each period, basically fixed working period duration, and when a transmission mechanism of a motor load has fault hidden dangers of corrosion, jamming, abrasion and the like in a certain working period, the active power of the load relatively changes, which is mainly reflected in that the electric energy consumption changes in the period, so that an active power curve can be adopted to reflect the change phenomenon, and whether the transmission mechanism of the motor load is abnormal or not can be judged by comparing the active power curve in each period.
And step S6, outputting a fault diagnosis report.
The fault diagnosis report includes: the motor starting time, the stopping time, the maximum power, the maximum effective value of current, the minimum effective value of voltage, the maximum torque of the motor, the electric energy consumed by the motor in the period, the smoothness index, the maintenance guidance suggestion of the motor load transmission mechanism and the like. The stability index is a main evaluation index for evaluating whether the motor load transmission mechanism is abnormal, and the larger the stability index is, the better the state of the engine load transmission mechanism is. The starting time, the stopping time, the maximum power, the maximum effective value of the current, the maximum torque of the motor and the consumed electric energy of the motor in the period are compared with the historical report to serve as auxiliary judgment indexes.
As shown in fig. 2, the process of the motor load transmission mechanism fault diagnosis method provided in another embodiment of the present invention is as follows:
after the motor is started, firstly judging the type of the motor, and if the type of the motor is the direct current motor, directly calculating the active power of the motor. If the motor is an alternating current motor, accumulating a cycle of wave data, and then calculating the active power of the motor. And meanwhile, the calculated active power value is directly written into a file and is stored as historical data. And simultaneously, the characteristic quantities of voltage, effective value of current, motor torque and the like calculated in real time are written into a file.
When the motor stops working in the period, historical active power data and active power data in the period are read for comparative analysis, active power values of two active power curves at each moment are compared to obtain curve similarity, and time sequence similarity is obtained for time sequence shapes of data in the same time period. And considering that the common curve contrast algorithm cannot distinguish the shape similarity and cannot reflect the similarity of the trend dynamic change amplitude, calculating the sequence similarity by adopting a DTW algorithm.
And analyzing and judging whether the motor transmission mechanism is abnormal or not through the comprehensive evaluation of the two indexes, and giving a stability index of the motor transmission mechanism. Specifically, an arithmetic mean of the curve similarity and the time-series similarity may be calculated as a smoothness index of the load transmission mechanism, and a square mean of the curve similarity and the time-series similarity may be calculated as a smoothness index of the load transmission mechanism.
The minimum voltage and the maximum current are calculated by reading the stored effective values of the voltage and the current, and the maximum motor torque is calculated. And outputting a diagnosis report, wherein the report contents comprise the starting time, the stopping time, the maximum power, the maximum effective value of current, the maximum torque of the motor, the electric energy consumed by the motor in the period, the smoothness index and the maintenance guidance suggestion of the motor load transmission mechanism. And report and save this as historical data. The operator can check the running condition of the motor load transmission mechanism according to the report content and make a maintenance plan.
Furthermore, the invention also provides a system for diagnosing the fault of the transmission mechanism of the motor load, which adopts the method for diagnosing the fault of the transmission mechanism of the motor load when the fault of the transmission mechanism of the motor load is diagnosed.
In conclusion, by adopting the motor load transmission mechanism fault diagnosis method, whether the motor transmission mechanism is abnormal or not is analyzed and judged by comprehensively evaluating the curve similarity and the time sequence similarity of active function power curves in different periods according to the principle that the load change trend is constant in each period and the energy consumption is basically constant in the industrial and mining environment with fixed period time when the motor works periodically, the problem that the motor load transmission mechanism cannot be found in time due to the fault hidden dangers such as corrosion, jamming, abrasion, component damage, refusal and the like is solved, the safety production is effectively ensured, operation and maintenance personnel are scientifically guided to arrange a shutdown maintenance plan in time, the production efficiency is improved, and the equipment operation and maintenance cost is reduced.
The above description is only a preferred embodiment of the present invention, and is not intended to limit the present invention, and various modifications and changes may be made to the embodiment of the present invention by those skilled in the art. Any modification, equivalent replacement, improvement and the like made within the spirit and principle of the embodiments of the present invention should be included in the protection scope of the embodiments of the present invention.

Claims (10)

1. A method of diagnosing a failure of a drive mechanism of a motor load, comprising:
collecting voltage and current signals of a motor which works periodically in one period;
calculating an active power curve in the period according to the acquired voltage and current signals;
and comparing and analyzing the active power curve in the period with the historical active power curve, and judging whether the transmission mechanism of the motor load has a fault according to the comparison and analysis result.
2. The method of claim 1, wherein calculating the active power curve for the cycle based on the collected voltage and current signals comprises:
carrying out Fourier decomposition on the acquired voltage and current signals to obtain fundamental wave voltage and current signals;
and calculating active power by adopting fundamental wave voltage and current signals.
3. The method of claim 1, wherein comparing the active power curve during the period to historical active power curves comprises:
comparing the active power value at each moment to obtain curve similarity;
comparing the time sequence shapes of the data in the same time period to obtain the time sequence similarity;
and calculating the stability index of the load transmission mechanism according to the curve similarity and the time sequence similarity.
4. The method of diagnosing a failure in a motor-loaded drive train of claim 3, wherein calculating a load drive train smoothness index based on curve similarity and time series similarity comprises:
and calculating the arithmetic mean of the curve similarity and the time series similarity, and taking the arithmetic mean as a smoothness index of the load transmission mechanism.
5. The method of diagnosing a failure in a motor-loaded drive train of claim 3, wherein calculating a load drive train smoothness index based on curve similarity and time series similarity comprises:
and calculating the square average of the curve similarity and the time series similarity, and taking the square average as a smoothness index of the load transmission mechanism.
6. The method of claim 3, wherein the determining whether the transmission of the motor load is faulty is based on whether the smoothness index is greater than a predetermined threshold.
7. The motor-loaded transmission fault diagnostic method of claim 1, further comprising:
and issuing a motor transmission mechanism diagnosis report according to the analysis result.
8. The motor-loaded transmission mechanism fault diagnosis method according to claim 7, characterized in that:
the motor drive diagnostic report includes: the motor starting time, the stopping time, the maximum power, the voltage minimum effective value, the current maximum effective value, the motor maximum torque, the motor power consumption in the period, the stability index and the motor load transmission mechanism maintenance guidance suggestion are obtained.
9. The motor-loaded transmission failure diagnostic method according to claim 8,
and judging the starting time of the motor in the current period according to the rated current of the motor when the effective value of the current sampling value is increased to be more than 0.05 times.
And judging the stop time of the current period of the motor according to the rated current of which the effective value of the current sampling value is reduced to be less than 0.05 times.
10. A transmission failure diagnosis system for a motor load, characterized in that the transmission failure diagnosis method for a motor load according to any one of claims 1 to 9 is used when performing failure diagnosis of a transmission for a motor load.
CN202210294762.1A 2022-03-24 2022-03-24 Fault diagnosis method and system for motor load transmission mechanism Pending CN114720872A (en)

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Application Number Priority Date Filing Date Title
CN202210294762.1A CN114720872A (en) 2022-03-24 2022-03-24 Fault diagnosis method and system for motor load transmission mechanism

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Application Number Priority Date Filing Date Title
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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116027724A (en) * 2022-09-23 2023-04-28 河北东来工程技术服务有限公司 Ship equipment risk monitoring method and system
CN116381490A (en) * 2023-06-05 2023-07-04 江苏铭星智能家居有限公司 Push rod motor performance detection system and method based on data analysis

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116027724A (en) * 2022-09-23 2023-04-28 河北东来工程技术服务有限公司 Ship equipment risk monitoring method and system
CN116027724B (en) * 2022-09-23 2024-01-12 河北东来工程技术服务有限公司 Ship equipment risk monitoring method and system
CN116381490A (en) * 2023-06-05 2023-07-04 江苏铭星智能家居有限公司 Push rod motor performance detection system and method based on data analysis
CN116381490B (en) * 2023-06-05 2023-08-11 江苏铭星智能家居有限公司 Push rod motor performance detection system and method based on data analysis

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