CN116660107A - Online wear detection anti-bubble interference method and device - Google Patents
Online wear detection anti-bubble interference method and device Download PDFInfo
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- 238000001514 detection method Methods 0.000 title claims abstract description 268
- 238000000034 method Methods 0.000 title claims abstract description 57
- 239000002245 particle Substances 0.000 claims abstract description 182
- 230000005284 excitation Effects 0.000 claims abstract description 37
- 238000003384 imaging method Methods 0.000 claims abstract description 23
- 230000009471 action Effects 0.000 claims abstract description 17
- 230000005484 gravity Effects 0.000 claims abstract description 17
- 230000008569 process Effects 0.000 claims abstract description 4
- 239000003921 oil Substances 0.000 claims description 330
- 239000006061 abrasive grain Substances 0.000 claims description 33
- 230000002159 abnormal effect Effects 0.000 claims description 30
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- 230000002572 peristaltic effect Effects 0.000 claims description 22
- 239000007788 liquid Substances 0.000 claims description 17
- 238000001228 spectrum Methods 0.000 claims description 17
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- 239000011521 glass Substances 0.000 claims description 15
- 238000005086 pumping Methods 0.000 claims description 13
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- 238000005299 abrasion Methods 0.000 claims description 10
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- 238000012545 processing Methods 0.000 description 8
- 239000012530 fluid Substances 0.000 description 5
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- 238000013461 design Methods 0.000 description 3
- 230000002411 adverse Effects 0.000 description 2
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- 238000004364 calculation method Methods 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 238000013209 evaluation strategy Methods 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 239000010687 lubricating oil Substances 0.000 description 2
- 101150030330 MAJIN gene Proteins 0.000 description 1
- 230000003321 amplification Effects 0.000 description 1
- 239000002518 antifoaming agent Substances 0.000 description 1
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Abstract
The invention belongs to the technical field of mechanical equipment fault diagnosis and discloses an online wear detection anti-bubble interference method and device. According to the method and the device, the oil duct of the detection unit is vertically arranged, so that working oil flows through the oil duct of the detection unit from top to bottom during online detection; in the flowing process, abrasive particles in oil are laterally adsorbed and deposited in the detection unit by the excitation device so as to carry out imaging detection, meanwhile, working oil flows out from the bottom of an oil duct of the detection unit under the combined action of a pump suction device and gravity and then enters an online working pipeline, so that the abrasive particles are separated from the oil and bubbles, imaging detection is carried out in air, and the problems that the detection unit is horizontally placed and the abrasive particles directly have bubble interference in the working oil during the imaging detection are avoided. The method and the device have the advantages of stable bubble removal effect, accurate and reliable detection, simple structure, small volume, low cost, flexible and efficient operation and strong universality of the adopted equipment.
Description
Technical Field
The invention belongs to the technical field of mechanical equipment fault diagnosis, in particular to the technical field of oil abrasive particle online detection, and particularly relates to an online abrasion detection anti-bubble interference method and device.
Background
The online detection of the lubricating oil abrasive particles is based on detection analysis of working oil of the equipment. The detecting element of current online detecting instrument of fluid grit is horizontal imaging detection, and detecting element oil duct that detecting element inside set up promptly is placed horizontally, and after online working fluid was let in detecting element oil duct, the grit was carried out imaging detection through this medium of working fluid, and often contains a large amount of bubbles in the working fluid, can often cause serious interference to the detection, can't develop the detection even.
Currently, the method for eliminating the bubble interference comprises the following steps: (1) Standing for defoaming, wherein the defoaming period of the lubricating oil liquid is too long, and the detection effect is difficult to ensure; (2) The defoaming agent is used, so that the normal use of working oil can be influenced, and the method is not suitable for on-line instruments; (3) The special defoaming device is used, such as vacuumizing or ultrasonic wave, the cost of the method is high, and the design and implementation of hardware equipment required by online application are complex; (4) The method is suitable for image analysis scenes, but only can identify bubbles appearing in the images, and can not identify whether abrasive particles are blocked by the bubbles, so that the accuracy of detection results is difficult to guarantee.
Chinese patent document CN115165684a discloses an electromagnetic oil abrasive grain on-line monitoring device, which comprises an excitation source, an electromagnetic sensor for detecting abrasive grains, an analog signal processing module for amplifying and extracting abrasive grain signals, a digital signal processing module for analyzing and processing abrasive grain signals, and an upper computer for displaying abrasive grain on-line detection data, which are connected in sequence; when the power is on, the output of the sensor without abrasive particles is a normal carrier signal; when the abrasive particles pass through, a differential signal is generated, the differential signal enters an analog signal processing module for amplification and filtering, the abrasive particle signal is extracted and transmitted to a digital signal processing module, the digital signal processing module adopts a limiting filtering method to extract abrasive particle data characteristics, and a processing result is sent to an upper computer, and at the moment, the upper computer displays the number, the size and the type of the abrasive particles; the method can not be easily interfered by bubbles and vibration in the monitoring process, and does not need to be cleaned regularly. However, the method does not consider the interference of bubbles in the oil liquid on the detection of abrasive particles, does not treat the bubbles in the oil liquid, and the accuracy and reliability of the detection result are difficult to ensure.
The Chinese patent document CN112017109A discloses a method for eliminating bubbles in an online ferrograph video image, wherein an image when oil liquid does not enter the online ferrograph is used as a background image, the video image after the oil liquid enters the online ferrograph is an original online ferrograph video image, the original ferrograph image is converted into a gray level image, and then the gray level image is subjected to bubble identification treatment; removing micro bubble noise by using improved Gaussian filtering, detecting a moving object of the processed video image by using a frame difference method, binarizing a difference value by using an Ojin method to obtain a pixel position where the bubble noise is located, and replacing noise pixels in the video image after Gaussian filtering by using the same pixel position of a background image; and then, performing the Majin binarization processing on the image with the bubbles eliminated, so that the image is suitable for online ferrographic video images with bubbles of different sizes, and the problem of bubble noise interference when the online ferrographic video images are used for carrying out abrasive particle identification is solved. However, the method adopts an image analysis method to shield bubbles, cannot identify whether abrasive particles are shielded by the bubbles, and partially detects the abrasive particles shielded by the bubbles, so that the accuracy and reliability of a detection result are affected.
Disclosure of Invention
Aiming at least one technical problem in the background technology, the invention aims to provide an online abrasion detection anti-bubble interference method and device, which have the characteristics of stable bubble removal effect, accurate and reliable detection, simple structure, small volume, low cost, flexible and efficient operation and strong universality of the adopted equipment.
In order to achieve the technical purpose, the invention adopts the following technical scheme:
the online abrasion detection anti-bubble interference method is used for detecting and analyzing working oil of equipment online through an abrasive particle detection mechanism, wherein the abrasive particle detection mechanism comprises an abrasive particle detector, a pipeline mechanism and an industrial personal computer; the industrial personal computer is used for controlling the operation of the abrasive particle detector and the pipeline mechanism, and the pipeline mechanism is used for introducing working oil into the abrasive particle detector; the abrasive grain detector is internally provided with a detection unit, the detection unit comprises an excitation device, and the excitation device is used for adsorbing and depositing abrasive grains in working oil liquid for detection by the detection unit;
the method comprises the following steps:
step S1: introducing online working oil into the detection unit, so that the working oil flows through an oil duct of the detection unit from top to bottom;
step S2: and (3) abrasive particle deposition: energizing an excitation device in the detection unit to laterally adsorb and deposit abrasive particles in the working oil in the detection unit; meanwhile, working oil flows out from the bottom of an oil duct of the detection unit and enters an online working pipeline under the combined action of a pump suction and gravity;
step S3: closing an oil inlet pipeline, opening a gas circuit pipeline, stopping oil inlet and introducing air into the detection unit;
step S4: defoaming time delay: waiting time t 0 Detecting defoaming delay to ensure that working oil retained in the detection unit is continuously discharged out of an oil duct of the detection unit together with bubbles under the combined action of pumping suction force and gravity;
step S5: and (3) abrasive particle map acquisition and analysis: stopping pumping, and performing imaging detection on the deposited abrasive particles by a detection unit to obtain an abrasive particle map and transmitting the abrasive particle map to an industrial personal computer; the industrial personal computer analyzes the abrasive particle patterns to obtain abrasive particle characteristic data;
step S6: the exciting device in the detecting unit is powered off and abrasive particles are released; and simultaneously, closing the gas path pipeline, opening the oil inlet pipeline, continuously introducing working oil into the detection unit, and repeating the steps S1-S5 to perform the next working oil on-line detection.
Further, the step S1 specifically includes:
step S1: introducing online working oil into the abrasive particle detector to enable the working oil to flow through an oil duct of the detection unit from top to bottom; and (3) continuously introducing oil for a certain time, so that the oil duct of the detection unit is filled with the oil sample, and the original residual oil sample in the oil duct is replaced.
Further, in the step S2, the pump is provided by a peristaltic pump provided on the detection unit oil discharge line.
Further, in the step S4, the defoaming delay waiting time t is determined according to the oil flow characteristics and the oil viscosity for different oils 0 。
Further, the step S5 further includes a map anomaly investigation, specifically:
step S51: and (3) abrasive particle map acquisition: stopping pumping, and performing imaging detection on the deposited abrasive particles by a detection unit to obtain an abrasive particle map and transmitting the abrasive particle map to an industrial personal computer;
step S52: the industrial personal computer analyzes the abrasive particle patterns to obtain abrasive particle characteristic data;
if the characteristic data of the abrasive particles are normal, the step S6 is carried out, and the next online detection of the working oil is continued;
if the characteristic data of the abrasive particles are abnormal, marking the characteristic data of the abrasive particles, and turning to a step S53 for carrying out abnormal investigation of the map;
step S53: delay waiting time t 1 Then, a detection unit in the abrasive grain detector performs imaging detection again, grabs an abrasive grain map and transmits the abrasive grain map to the industrial personal computer, and the industrial personal computer performs secondary detection analysis;
if the analysis data of the second detection is normal, removing the abrasive particle spectrum result of the first detection, and retaining the abrasive particle spectrum result of the second detection; then, turning to step S6, and continuing to perform online detection on the next working oil;
if the second detection data is still abnormal, selecting a result of the detection data, which is close to a normal value, from the two detection results as a current detection result; and then, turning to step S6, continuously carrying out online detection of the next working oil, and carrying out early warning and investigation on equipment faults by combining the online detection results of the next or subsequent working oil.
Meanwhile, the invention also provides an online abrasion detection anti-bubble interference abrasive grain detector, which comprises an oil gas pipeline, a detection unit and a peristaltic pump;
the detection unit comprises an excitation device, an optical imaging device, an oil duct and a deposition observation window; an oil inlet port of the oil duct is arranged on one side of the upper end of the oil duct, an oil outlet port of the oil duct is arranged on one side of the lower end of the oil duct, two oppositely arranged glass sheets are vertically embedded in the oil duct, working oil flowing into the oil duct flows through a cavity between the two glass sheets from top to bottom, and the two glass sheets form the deposition observation window; the excitation device and the optical imaging device are respectively connected to two sides of the oil duct and are arranged in parallel and opposite to the deposition observation window in the oil duct;
the oil gas pipeline comprises an oil inlet pipeline and an air inlet pipeline, the oil inlet pipeline and the air inlet pipeline are connected in parallel and summarized to a first pipeline, the first pipeline is connected with an oil inlet port of an oil duct, the oil outlet port of the oil duct is connected with a peristaltic pump through a second pipeline, and the peristaltic pump is connected with an oil discharge pipeline.
Further, the oil inlet pipeline is sequentially provided with an oil way electromagnetic valve, a tee joint and an air way electromagnetic valve;
the tee joint comprises two inlets and an outlet, wherein one inlet is connected with the oil circuit electromagnetic valve, and the other inlet is connected with the gas circuit electromagnetic valve to form a gas circuit pipeline; and an outlet of the tee joint is connected with a first pipeline.
Further, when working oil flows between two glass sheets of the deposition observation window from top to bottom, the exciting device adsorbs and deposits abrasive particles in the working oil on the glass sheets close to one side of the exciting device, and the working oil and bubbles in the working oil flow downwards to drain an oil duct under the action of the suction force of a peristaltic pump and gravity; after the working oil liquid and the bubbles are completely discharged, the optical imaging device carries out imaging detection on the abrasive particles in the deposition observation window.
Still further, the detection unit further includes a light source assembly including a first light source assembly and a second light source assembly;
the first light source component is integrally arranged on the optical imaging device;
the second light source assembly is arranged on one side of the oil duct close to the excitation device, the excitation device is arranged oppositely for the upper excitation assembly and the lower excitation assembly, and the second light source assembly irradiates the optical imaging device through a gap between the upper excitation assembly and the lower excitation assembly.
Still further, the abrasive grain detector further comprises a housing;
the oil gas pipeline, the detection unit and the peristaltic pump are all arranged in the shell.
In addition, the invention also provides an online abrasion detection anti-bubble interference abrasive grain detection mechanism, which comprises an abrasive grain detector, a pipeline mechanism and an industrial personal computer; the industrial personal computer is used for controlling the operation process of the abrasive particle detector and the pipeline mechanism, and the pipeline mechanism is used for introducing working oil into the abrasive particle detector;
the abrasive particle detector is any one of the abrasive particle detectors described above;
the industrial personal computer is internally integrated with an abrasive particle map analysis module and a map abnormality investigation module; the abrasive particle pattern analysis module is respectively connected with the pattern abnormality checking module and the detection unit of the abrasive particle detector;
the abrasive particle spectrum analysis module is used for analyzing the abrasive particle spectrum generated by the detection unit, and acquiring and storing detection data; when the detected data is abnormal, marking the abnormal detected data and transmitting the abnormal detected data to a map abnormal investigation module;
the map abnormality investigation module is used for controlling the detection unit to carry out map abnormality investigation.
Compared with the prior art, the invention has the beneficial effects that:
(1) According to the method and the device, working oil in the oil duct of the detection unit is emptied in a pump suction mode, so that abrasive particles are detected in the air as a medium, and interference of bubbles in the working oil on imaging detection of the abrasive particles is avoided; meanwhile, in order to thoroughly remove the working oil and bubbles in the oil, the method adopts the working oil to flow through the oil duct of the detection unit from top to bottom, and auxiliary oil discharge and bubbles are carried out under the action of gravity, and as the bubbles are suspended in the oil, the bubbles are free of the foundation after the oil is completely discharged, so that the abrasive particles can be thoroughly separated from the oil and the bubbles in the oil through the method; compared with the mode that the online detection of the oil abrasive particles is directly carried out in working oil in the prior art, the method and the device can more effectively eliminate the interference of bubbles in the oil, are more convenient for observing and detecting the abrasive particles, and have more accurate and reliable detection results;
(2) Compared with a method for eliminating bubbles by vacuumizing or ultrasonic waves, the method provided by the invention is more convenient to operate and more efficient to detect; meanwhile, compared with a method for shielding bubbles by image analysis, the method can avoid the situation that the image analysis cannot identify and detect the abrasive particles shielded by the bubbles, and the detection result is more accurate and reliable;
(3) According to the method, after the deposition of abrasive particles stops feeding oil, proper defoaming delay waiting time t is determined and set according to the flow characteristics of different oil liquids and the viscosity of the oil liquids 0 (avoid t 0 Too short results in failure of complete discharge of oil and bubbles to cause detection interference and t 0 Too long results in too low detection efficiency), and after the defoaming delay is finished, abrasive particle spectrum acquisition is performed, so that working oil can drive bubbles to fully and thoroughly flow out of an oil duct of a detection unit while the detection efficiency is considered, the bubble removal effect of different working oil under different application scenes and different working conditions is ensured, and the oil abrasive particle detection effect is improved;
(4) The method comprises the steps of conducting abnormal investigation of the map, after the abrasive particle map is obtained, acquiring abrasive particle characteristic data according to abrasive particle map analysis, and conducting abnormal investigation of the map if calculation judges that the abrasive particle data are abnormal, wherein the current detected map possibly has interference such as bubbles: by delaying the waiting time t 1 Then, grabbing the abrasive particle patterns again and performing a second detection analysis (if bubbles exist under the condition that the oil duct of the detection unit is vertically arranged, the positions of the bubbles are always changed, and the probability that the two shot patterns are shot to the bubbles is smaller), and calculating the result according to the two detectionRemoving the results possibly having bubble interference, and taking the detection results with normal data or more similar to the normal data in the two results for recording; the probability of the abrasive particle map obtained by detection being interfered by bubbles can be further reduced by detecting and analyzing the bubble interference condition which can occur occasionally and with small probability again; meanwhile, a detection mode of drawing images twice is adopted only for the abnormal situation of abrasive particle data, so that the probability of bubble interference is greatly reduced and the real abnormal situation is avoided being ignored under the condition that the detection efficiency is basically not affected;
(5) When the equipment fault early warning and checking is carried out according to the map anomaly checking, the two-time map taking detection is adopted aiming at the condition of abrasive particle data anomaly, if the second detection analysis result is still anomaly, the next working oil liquid detection is immediately carried out, the equipment fault early warning and checking is carried out by combining the next or subsequent multiple working oil liquid online detection results, the equipment fault early warning state is comprehensively given through the working oil liquid detection and analysis evaluation strategy, the influence of accidental factors on the equipment state judgment accuracy is effectively avoided, and the high efficiency and reliability of the subsequent equipment fault diagnosis result are ensured;
(6) According to the device disclosed by the invention, oil is fed from the upper end of the oil duct of the detection unit and discharged from the bottom of the oil duct, so that working oil flows through the vertically placed deposition observation window in the oil duct from top to bottom, abrasive particles in the oil are laterally adsorbed in the deposition observation window by the excitation device, and the oil and bubbles in the oil flow downwards under the combined action of the pumping suction force and gravity to be discharged out of the oil duct, so that the abrasive particles are better separated from the working oil and the bubbles and are imaged and detected in the air, and adverse effects on imaging and detection of the abrasive particles caused by the bubbles in the working oil when the abrasive particles are horizontally placed and directly detected in the working oil are avoided;
(7) The device is simple and easy to obtain, the installation and fixation mode of the detection unit is simply adjusted on the basis of the original detection device, namely the original detection unit is horizontally installed and fixed and is vertically installed and fixed, and a tee joint and a gas circuit electromagnetic valve are additionally arranged, so that the influence on the structural adjustment of the original online detection instrument is small, the overall size change is small, the device is simple in structure, small in size and easy to realize, and the input cost is low; compared with devices such as vacuumizing or ultrasonic defoaming which are independently designed, the device provided by the invention has the advantages that the requirements on the overall size, input cost, design implementation difficulty and the like of a detection instrument are greatly reduced; and the flexibility is good, the universality is strong, can be widely applied to various oil media and working condition environments.
Drawings
FIG. 1 is a flow chart of the method of embodiment 1 of the present invention;
FIG. 2 is a flow chart of the method of embodiment 2 of the present invention;
FIG. 3 is a schematic view of the abrasive grain detector according to embodiment 3 of the present invention;
fig. 4 is a schematic structural diagram of a detection unit in embodiment 3 of the present invention;
the figure indicates:
1-an oil-way electromagnetic valve; 2-tee joint; 3-a gas circuit electromagnetic valve; a 4-detection unit; 5-peristaltic pump; 6-an oil inlet pipeline; 7-a first pipeline; 8-a second pipeline; 9-an oil discharge pipeline;
401-oil duct oil inlet port, 402-oil duct oil outlet port, 403-detection unit oil duct, 404-excitation device, 405-optical imaging device, 406-first light source component;
501-peristaltic pump oil inlet port; 502-peristaltic pump oil outlet port.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
In the description of the present invention, it should be understood that the terms "coaxial," "bottom," "one end," "top," "middle," "another end," "upper," "one side," "top," "inner," "front," "center," "two ends," etc. indicate orientations or positional relationships based on the orientation or positional relationships shown in the drawings, are merely for convenience in describing the present invention and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and thus should not be construed as limiting the present invention.
In the present invention, unless explicitly specified and limited otherwise, the terms "mounted," "configured," "connected," "secured," "screwed," and the like are to be construed broadly and may be, for example, fixedly connected, detachably connected, or integrally formed; can be mechanically or electrically connected; either directly or indirectly through intermediaries, or in communication with each other or in interaction with each other, unless explicitly defined otherwise, the meaning of the terms described above in this application will be understood by those of ordinary skill in the art in view of the specific circumstances.
Example 1
As shown in fig. 1, the embodiment of the invention provides an online wear detection anti-bubble interference method, which is used for detecting and analyzing working oil of equipment online through an abrasive particle detection mechanism, wherein the abrasive particle detection mechanism comprises an abrasive particle detector, a pipeline mechanism and an industrial personal computer; the industrial personal computer is used for controlling the operation of the abrasive particle detector and the pipeline mechanism, and the pipeline mechanism is used for introducing working oil into the abrasive particle detector; the abrasive grain detector is internally provided with a detection unit, the detection unit comprises an excitation device, and the excitation device is used for adsorbing and depositing abrasive grains in working oil liquid for detection by the detection unit.
Wherein the method comprises the following steps:
step S1: introducing online working oil into the detection unit, so that the working oil flows through an oil duct of the detection unit from top to bottom; and the oil is continuously introduced for a certain time, so that the oil duct of the detection unit is filled with the oil sample, the original residual oil sample in the oil duct is replaced, and the bad interference of the residual oil sample to the detection of the online working oil sample at the current moment is avoided.
Step S2: and (3) abrasive particle deposition: energizing an excitation device in the detection unit to laterally adsorb and deposit abrasive particles in the working oil in the detection unit; meanwhile, a peristaltic pump is arranged on an oil discharge pipeline of the detection unit, and working oil flows out from the bottom of an oil duct of the detection unit and then enters an online working pipeline under the combined action of the pumping suction force of the peristaltic pump and gravity.
In the step S2, working oil in the oil duct of the detection unit is emptied by a pump suction mode, so that abrasive particles are detected in the air as a medium, and interference of bubbles in the working oil on imaging detection of the abrasive particles is avoided; meanwhile, in order to thoroughly remove the working oil and bubbles in the oil, the working oil flows through the oil duct of the detection unit from top to bottom, auxiliary oil discharge and bubbles are carried out under the action of gravity, and as the bubbles are suspended in the oil, the bubbles are free of the foundation after the oil is completely discharged, so that the abrasive particles can be thoroughly separated from the oil and the bubbles in the oil through the method.
Step S3: closing the oil inlet pipeline, opening the gas path pipeline, stopping oil inlet and introducing air into the detection unit.
Step S4: defoaming time delay: waiting time t 0 And detecting defoaming delay to ensure that working oil retained in the detection unit is continuously discharged out of the oil duct of the detection unit with bubbles under the combined action of the suction force of the pump and gravity.
In the step S4, the defoaming delay waiting time t is reasonably determined according to the flowing characteristic of the oil and the viscosity of the oil and considering the detection effect and the detection efficiency for different oils 0 Avoid t 0 Too short results in failure of complete discharge of oil and bubbles to cause detection interference and t 0 Too long influences the detection times to cause the detection efficiency to be too low; by setting reasonable defoaming delay waiting time t for different oil liquids 0 The abrasive particle spectrum collection is carried out after the defoaming delay is finished, so that the working oil drives bubbles to fully and thoroughly flow out of the oil duct of the detection unit while the detection efficiency is considered, the bubble removal effect of different working oil under different application scenes and different working conditions is ensured, and the oil abrasive particle detection effect is improved.
Step S5: and (3) abrasive particle map acquisition and analysis: stopping pumping, and performing imaging detection on the deposited abrasive particles by a detection unit to obtain an abrasive particle map and transmitting the abrasive particle map to an industrial personal computer; the industrial personal computer analyzes the abrasive particle patterns to obtain abrasive particle characteristic data;
step S6: the exciting device in the detecting unit is powered off and abrasive particles are released; and simultaneously, closing the gas path pipeline, opening the oil inlet pipeline, continuously introducing working oil into the detection unit, and repeating the steps S1-S5 to perform the next working oil on-line detection.
Compared with the mode that in the prior art, oil abrasive particles are detected on line and directly in working oil, the method of the embodiment can effectively eliminate the interference of bubbles in the oil, is convenient for observing and detecting the abrasive particles, and has more accurate and reliable detection results.
Meanwhile, compared with a method for eliminating bubbles by vacuumizing or ultrasonic waves, the method of the embodiment is more convenient to operate and more efficient to detect; compared with the method for shielding bubbles by image analysis, the method of the embodiment can avoid the situation that the image analysis cannot identify and detect the abrasive particles shielded by the bubbles, and the detection result is more accurate and reliable.
Example 2
The embodiment of the invention provides an online abrasion detection anti-bubble interference method, which is further improved in step S5 on the basis of the embodiment 1.
As shown in fig. 2, the method of this embodiment specifically includes the following steps:
step S1: introducing online working oil into the detection unit, so that the working oil flows through an oil duct of the detection unit from top to bottom; and the oil is continuously introduced for a certain time, so that the oil duct of the detection unit is filled with the oil sample, the original residual oil sample in the oil duct is replaced, and the bad interference of the residual oil sample to the detection of the online working oil sample at the current moment is avoided.
Step S2: and (3) abrasive particle deposition: energizing an excitation device in the detection unit to laterally adsorb and deposit abrasive particles in the working oil in the detection unit; meanwhile, a peristaltic pump is arranged on an oil discharge pipeline of the detection unit, and working oil flows out from the bottom of an oil duct of the detection unit and then enters an online working pipeline under the combined action of the pumping suction force of the peristaltic pump and gravity.
In the step S2, working oil in the oil duct of the detection unit is emptied by a pump suction mode, so that abrasive particles are detected in the air as a medium, and interference of bubbles in the working oil on imaging detection of the abrasive particles is avoided; meanwhile, in order to thoroughly remove the working oil and bubbles in the oil, the working oil flows through the oil duct of the detection unit from top to bottom, auxiliary oil discharge and bubbles are carried out under the action of gravity, and as the bubbles are suspended in the oil, the bubbles are free of the foundation after the oil is completely discharged, so that the abrasive particles can be thoroughly separated from the oil and the bubbles in the oil through the method.
Step S3: closing the oil inlet pipeline, opening the gas path pipeline, stopping oil inlet and introducing air into the detection unit.
Step S4: defoaming time delay: waiting time t 0 And detecting defoaming delay to ensure that working oil retained in the detection unit is continuously discharged out of the oil duct of the detection unit with bubbles under the combined action of the suction force of the pump and gravity.
In the step S4, the defoaming delay waiting time t is reasonably determined according to the flowing characteristic of the oil and the viscosity of the oil and considering the detection effect and the detection efficiency for different oils 0 Avoid t 0 Too short results in failure of complete discharge of oil and bubbles to cause detection interference and t 0 Too long influences the detection times to cause the detection efficiency to be too low; by setting reasonable defoaming delay waiting time t for different oil liquids 0 The abrasive particle spectrum collection is carried out after the defoaming delay is finished, so that the working oil drives bubbles to fully and thoroughly flow out of the oil duct of the detection unit while the detection efficiency is considered, the bubble removal effect of different working oil under different application scenes and different working conditions is ensured, and the oil abrasive particle detection effect is improved.
Step S5: the abrasive particle spectrum collection and analysis method specifically comprises the following steps:
step S51: and (3) abrasive particle map acquisition: stopping pumping, and performing imaging detection on the deposited abrasive particles by a detection unit to obtain an abrasive particle map and transmitting the abrasive particle map to an industrial personal computer;
step S52: the industrial personal computer analyzes the abrasive particle patterns to obtain abrasive particle characteristic data;
if the characteristic data of the abrasive particles are normal, the step S6 is carried out, and the next online detection of the working oil is continued;
if the characteristic data of the abrasive particles are abnormal, marking the characteristic data of the abrasive particles, and turning to a step S53 for carrying out abnormal investigation of the map;
step S53: delay waiting time t 1 Then, a detection unit in the abrasive grain detector performs imaging detection again, grabs an abrasive grain map and transmits the abrasive grain map to the industrial personal computer, and the industrial personal computer performs secondary detection analysis;
if the analysis data of the second detection is normal, removing the abrasive particle spectrum result of the first detection, and retaining the abrasive particle spectrum result of the second detection; then, turning to step S6, and continuing to perform online detection on the next working oil;
if the second detection data is still abnormal, selecting a result of the detection data, which is close to a normal value, from the two detection results as a current detection result; and then, turning to step S6, continuously carrying out online detection of the next working oil, and carrying out early warning and investigation on equipment faults by combining the online detection results of the next or subsequent working oil.
After the abrasive particle spectrum is obtained, the characteristic data of the abrasive particles are obtained according to the analysis of the abrasive particle spectrum, if the abrasive particle data is abnormal, the abnormal examination of the abrasive particle is carried out if the abrasive particle data is calculated and judged, and the abnormal examination of the abrasive particle is carried out if the current detected spectrum possibly has the interference of bubbles and the like: by delaying the waiting time t 1 Then, grabbing the abrasive particle map again and performing a second detection analysis (the position of the air bubble is always changed if the air bubble exists, and the probability that the air bubble is shot by shooting the grabbed map twice is smaller), removing the result possibly having air bubble interference according to the detection calculation result of the two times, and recording the detection result of which the data are normal or more similar to the normal detection result in the two results; in general, the size of the residual bubbles after the oil sample is emptied is far greater than that of normal abrasive particles, so that in the two detection results, the smaller the data is, the closer the data is to the normal value, and the larger the data deviation from the normal value isThe spectrogram containing bubbles is needed to be removed. The probability of the abrasive particle map obtained by detection being interfered by bubbles can be further reduced by detecting and analyzing the bubble interference condition which can occur occasionally and with small probability again; meanwhile, a detection mode of drawing images twice is adopted only for the condition of abnormal abrasive particle data, so that the probability of bubble interference is greatly reduced and the real abnormal condition is avoided being ignored under the condition that the detection efficiency is basically not affected.
Meanwhile, when equipment fault early warning and investigation is carried out according to map anomaly investigation, twice drawing detection is adopted aiming at the condition that abrasive particle data are anomalous, if the second detection analysis result is still anomalous, next working oil detection is immediately carried out, equipment fault early warning and investigation is carried out by combining the next or subsequent multiple working oil online detection results, the equipment fault early warning state is comprehensively given through a working oil detection and analysis evaluation strategy, the influence of accidental factors on equipment state judgment accuracy is effectively avoided, and the high efficiency and reliability of the subsequent equipment fault diagnosis result are ensured.
Step S6: the exciting device in the detecting unit is powered off and abrasive particles are released; and simultaneously, closing the gas path pipeline, opening the oil inlet pipeline, continuously introducing working oil into the detection unit, and repeating the steps S1-S5 to perform the next working oil on-line detection.
Example 3
The present embodiment provides an online abrasion detection anti-bubble interference abrasive grain detector for implementing the method described in the above embodiment 1 or 2.
The abrasive particle detector comprises a shell, wherein a detection unit 4, an oil gas pipeline connected with the detection unit 4 and a peristaltic pump 5 are arranged in the shell.
As shown in fig. 3 to 4, the detection unit 4 includes an excitation device 404, an optical imaging device 405, a light source assembly, an oil passage 403, and a deposition observation window (not shown); an oil duct oil inlet port 401 is arranged on one side of the upper end of the oil duct 403, an oil duct oil outlet port 402 is arranged on one side of the lower end of the oil duct 403, two oppositely arranged glass sheets are vertically embedded in the oil duct 403, and working oil flowing into the oil duct 403 flows through a cavity between the two glass sheets from top to bottom, and the two glass sheets form the deposition observation window; the excitation device 404 and the optical imaging device 405 are respectively connected to two sides of the oil duct 403 and are arranged in parallel and opposite to a deposition observation window in the oil duct 403; the light source assembly includes a first light source assembly 406 (see fig. 4) and a second light source assembly (not shown); the first light source component 406 is integrally arranged on the optical imaging device 405; the second light source component is arranged on one side of the oil duct 403 near the excitation device 404, the excitation device 404 is arranged oppositely for the upper and lower two excitation components, and the second light source component can be arranged in the relative gap between the two excitation components or outside the relative gap according to the situation; the second light source assembly irradiates the optical imaging device 405 through a gap between the upper and lower excitation assemblies.
As shown in fig. 3, the oil-gas pipeline comprises an oil inlet pipeline 6 and an air inlet pipeline, and the oil inlet pipeline 6 is sequentially provided with an oil way electromagnetic valve 1, a tee joint 2 and an air way electromagnetic valve 3; the tee joint 2 comprises two inlets and an outlet, wherein one inlet is connected with the oil circuit electromagnetic valve 1, and the other inlet is connected with the gas circuit electromagnetic valve 2 to form the gas circuit pipeline; the outlet of the tee joint 2 is connected with a first pipeline 7, the first pipeline 7 is connected with an oil duct oil inlet port 401 of the detection unit 4, an oil duct oil outlet port 402 of the detection unit 4 is connected with a peristaltic pump oil inlet port 501 of the peristaltic pump 5 through a second pipeline 8, and a peristaltic pump oil outlet port 502 of the peristaltic pump 5 is connected with an oil discharge pipeline 9.
When working oil flows between two glass sheets of the deposition observation window from top to bottom, the exciting device 404 adsorbs and deposits abrasive particles in the working oil on the glass sheets close to one side of the exciting device 404, and the working oil and bubbles in the working oil flow downwards to drain the oil duct 403 under the action of the pumping suction force and gravity of the peristaltic pump 5; after the working fluid and bubbles are completely discharged, the optical imaging device 405 performs imaging detection on the abrasive particles in the deposition observation window.
According to the abrasive particle detector, oil is fed from the upper end and discharged from the bottom of the oil duct of the detection unit, so that working oil flows through the vertically placed deposition observation window in the oil duct from top to bottom, abrasive particles in the oil are laterally adsorbed in the deposition observation window by the excitation device, bubbles in the oil and the oil flow downwards under the combined action of the pumping force and gravity to discharge the oil duct, the abrasive particles are better separated from the working oil and the bubbles, imaging detection is carried out in the air medium, and adverse effects on the imaging detection of the abrasive particles caused by the bubbles in the working oil are avoided when the abrasive particles are horizontally placed and directly detected in the working oil.
Meanwhile, the adopted equipment of the abrasive particle detector is simple and easy to obtain, and the installation and fixation mode of the detecting unit is simply adjusted on the basis of the original detector, namely the original detecting unit is horizontally installed and fixed and is adjusted to be vertically installed and fixed, and a tee joint and an air circuit electromagnetic valve are additionally arranged, so that the influence on the structural adjustment of the original online detecting instrument is small, the overall size change is small, the structure of the device is simple, the size is small, the device is easy to realize and the input cost is low; compared with devices such as vacuumizing or ultrasonic defoaming which are independently designed, the device provided by the invention has the advantages that the requirements on the overall size, input cost, design implementation difficulty and the like of a detection instrument are greatly reduced; and the flexibility is good, the universality is strong, can be widely applied to various oil media and working condition environments.
Example 4
The present embodiment provides a detection mechanism for detecting bubble interference resistance by online wear, which is used for implementing the method described in the above embodiment 1 or 2.
The detection mechanism comprises the abrasive particle detector of the embodiment 3, a pipeline mechanism and an industrial personal computer.
The industrial personal computer is used for controlling the operation process of the abrasive particle detector and the pipeline mechanism, and the pipeline mechanism is used for introducing working oil into the abrasive particle detector.
The industrial personal computer is internally integrated with an abrasive particle map analysis module and a map abnormality investigation module; the abrasive particle spectrum analysis module is respectively connected with the spectrum abnormality checking module and the detection unit of the abrasive particle detector.
The abrasive particle spectrum analysis module is used for analyzing the abrasive particle spectrum generated by the detection unit, and acquiring and storing detection data; when the detected data is abnormal, the abnormal detection data is marked and transmitted to the map abnormal investigation module.
The map abnormality investigation module is used for controlling the detection unit to carry out map abnormality investigation.
The foregoing description is only exemplary of the invention and is not intended to limit the invention. Any modification, equivalent replacement, improvement, etc. made within the scope of the present invention should be included in the protection scope of the present invention.
Claims (11)
1. The online abrasion detection anti-bubble interference method is used for detecting and analyzing working oil of equipment online through an abrasive particle detection mechanism, wherein the abrasive particle detection mechanism comprises an abrasive particle detector, a pipeline mechanism and an industrial personal computer; the industrial personal computer is used for controlling the operation of the abrasive particle detector and the pipeline mechanism, and the pipeline mechanism is used for introducing working oil into the abrasive particle detector; the abrasive grain detector is internally provided with a detection unit, the detection unit comprises an excitation device, and the excitation device is used for adsorbing and depositing abrasive grains in working oil liquid for detection by the detection unit; the method is characterized in that:
the method comprises the following steps:
step S1: introducing online working oil into the detection unit, so that the working oil flows through an oil duct of the detection unit from top to bottom;
step S2: and (3) abrasive particle deposition: energizing an excitation device in the detection unit to laterally adsorb and deposit abrasive particles in the working oil in the detection unit; meanwhile, working oil flows out from the bottom of an oil duct of the detection unit and enters an online working pipeline under the combined action of a pump suction and gravity;
step S3: closing an oil inlet pipeline, opening a gas circuit pipeline, stopping oil inlet and introducing air into the detection unit;
step S4: defoaming time delay: waiting time t 0 Detecting defoaming delay to ensure that working oil retained in the detection unit is continuously discharged out of an oil duct of the detection unit together with bubbles under the combined action of pumping suction force and gravity;
step S5: and (3) abrasive particle map acquisition and analysis: stopping pumping, and performing imaging detection on the deposited abrasive particles by a detection unit to obtain an abrasive particle map and transmitting the abrasive particle map to an industrial personal computer; the industrial personal computer analyzes the abrasive particle patterns to obtain abrasive particle characteristic data;
step S6: the exciting device in the detecting unit is powered off and abrasive particles are released; and simultaneously, closing the gas path pipeline, opening the oil inlet pipeline, continuously introducing working oil into the detection unit, and repeating the steps S1-S5 to perform the next working oil on-line detection.
2. The method according to claim 1, wherein the step S1 specifically comprises:
step S1: introducing online working oil into the abrasive particle detector to enable the working oil to flow through an oil duct of the detection unit from top to bottom; and (3) continuously introducing oil for a certain time, so that the oil duct of the detection unit is filled with the oil sample, and the original residual oil sample in the oil duct is replaced.
3. The method according to claim 1, wherein in step S2 the pump suction is provided by a peristaltic pump arranged on the detection unit oil drain line.
4. The method according to claim 1, wherein in the step S4, the defoaming delay time t is determined according to the oil flow characteristics and the oil viscosity for different oils 0 。
5. The method according to any one of claims 1 to 4, wherein the step S5 further comprises a profile anomaly investigation, in particular:
step S51: and (3) abrasive particle map acquisition: stopping pumping, and performing imaging detection on the deposited abrasive particles by a detection unit to obtain an abrasive particle map and transmitting the abrasive particle map to an industrial personal computer;
step S52: the industrial personal computer analyzes the abrasive particle patterns to obtain abrasive particle characteristic data;
if the characteristic data of the abrasive particles are normal, the step S6 is carried out, and the next online detection of the working oil is continued;
if the characteristic data of the abrasive particles are abnormal, marking the characteristic data of the abrasive particles, and turning to a step S53 for carrying out abnormal investigation of the map;
step S53: delay waiting time t 1 Then, a detection unit in the abrasive grain detector performs imaging detection again, grabs an abrasive grain map and transmits the abrasive grain map to the industrial personal computer, and the industrial personal computer performs secondary detection analysis;
if the analysis data of the second detection is normal, removing the abrasive particle spectrum result of the first detection, and retaining the abrasive particle spectrum result of the second detection; then, turning to step S6, and continuing to perform online detection on the next working oil;
if the second detection data is still abnormal, selecting a result of the detection data, which is close to a normal value, from the two detection results as a current detection result; and then, turning to step S6, continuously carrying out online detection of the next working oil, and carrying out early warning and investigation on equipment faults by combining the online detection results of the next or subsequent working oil.
6. The anti-bubble-interference abrasive particle detector for online abrasion detection is characterized by comprising an oil gas pipeline, a detection unit and a peristaltic pump;
the detection unit comprises an excitation device, an optical imaging device, an oil duct and a deposition observation window; an oil inlet port of the oil duct is arranged on one side of the upper end of the oil duct, an oil outlet port of the oil duct is arranged on one side of the lower end of the oil duct, two oppositely arranged glass sheets are vertically embedded in the oil duct, working oil flowing into the oil duct flows through a cavity between the two glass sheets from top to bottom, and the two glass sheets form the deposition observation window; the excitation device and the optical imaging device are respectively connected to two sides of the oil duct and are arranged in parallel and opposite to the deposition observation window in the oil duct;
the oil gas pipeline comprises an oil inlet pipeline and an air inlet pipeline, the oil inlet pipeline and the air inlet pipeline are connected in parallel and summarized to a first pipeline, the first pipeline is connected with an oil inlet port of an oil duct, the oil outlet port of the oil duct is connected with a peristaltic pump through a second pipeline, and the peristaltic pump is connected with an oil discharge pipeline.
7. The abrasive grain detector according to claim 6, wherein the oil inlet pipeline is provided with an oil way electromagnetic valve, a tee joint and an air way electromagnetic valve in sequence;
the tee joint comprises two inlets and an outlet, wherein one inlet is connected with the oil circuit electromagnetic valve, and the other inlet is connected with the gas circuit electromagnetic valve to form a gas circuit pipeline; and an outlet of the tee joint is connected with a first pipeline.
8. The abrasive grain detector according to claim 6 or 7, wherein:
when working oil flows between two glass sheets of a deposition observation window from top to bottom, the exciting device adsorbs and deposits abrasive particles in the working oil on the glass sheets close to one side of the exciting device, and the working oil and bubbles in the working oil flow downwards to drain an oil duct under the action of a pump suction and gravity of a peristaltic pump; after the working oil liquid and the bubbles are completely discharged, the optical imaging device carries out imaging detection on the abrasive particles in the deposition observation window.
9. The abrasive grain detector of claim 8, wherein the detection unit further comprises a light source assembly comprising a first light source assembly and a second light source assembly;
the first light source component is integrally arranged on the optical imaging device;
the second light source assembly is arranged on one side of the oil duct close to the excitation device, the excitation device is arranged oppositely for the upper excitation assembly and the lower excitation assembly, and the second light source assembly irradiates the optical imaging device through a gap between the upper excitation assembly and the lower excitation assembly.
10. The abrasive particle detector of claim 9, wherein the abrasive particle detector further comprises a housing;
the oil gas pipeline, the detection unit and the peristaltic pump are all arranged in the shell.
11. An online abrasion detection anti-bubble interference abrasive grain detection mechanism comprises an abrasive grain detector, a pipeline mechanism and an industrial personal computer; the industrial personal computer is used for controlling the operation process of the abrasive particle detector and the pipeline mechanism, and the pipeline mechanism is used for introducing working oil into the abrasive particle detector; the method is characterized in that:
the abrasive grain detector is the abrasive grain detector according to any one of claims 6 to 10;
the industrial personal computer is internally integrated with an abrasive particle map analysis module and a map abnormality investigation module; the abrasive particle pattern analysis module is respectively connected with the pattern abnormality checking module and the detection unit of the abrasive particle detector;
the abrasive particle spectrum analysis module is used for analyzing the abrasive particle spectrum generated by the detection unit, and acquiring and storing detection data; when the detected data is abnormal, marking the abnormal detected data and transmitting the abnormal detected data to a map abnormal investigation module;
the map abnormality investigation module is used for controlling the detection unit to carry out map abnormality investigation.
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