CN117553126A - Mechanical seal with built-in acoustic emission sensor and state evaluation method - Google Patents
Mechanical seal with built-in acoustic emission sensor and state evaluation method Download PDFInfo
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Abstract
The invention belongs to the technical field of mechanical seal design and monitoring, and particularly relates to a mechanical seal with an acoustic emission sensor and a state evaluation method. The sound emission sensor is matched with the static ring arranged on the static ring seat. The invention has the beneficial effects that: aiming at the rub-impact and abrasion states of the dynamic and static friction pair of the mechanical seal, an effective monitoring means is lacking at present, the damage to the seal is usually recognized when the leakage quantity is abnormally increased, and the equipment is stopped, the stress wave signals generated by the contact of the dynamic and static friction pair are directly monitored through the built-in acoustic emission sensor, so that the accurate monitoring and judgment of the contact state and the abrasion state of the dynamic and static friction pair of the mechanical seal are realized, and the basis is provided for analysis of failure reasons of the mechanical seal, optimization of operation parameters and improvement of reliability.
Description
Technical Field
The invention belongs to the technical field of mechanical seal design and monitoring, and particularly relates to a mechanical seal with an acoustic emission sensor and a state evaluation method.
Background
The mechanical seal is used as a pressure-bearing boundary, so that the safety operation of large-scale pump equipment is concerned. The operation experience of nuclear power key pump equipment shows that the mechanical seal frequently has faults such as abnormal abrasion, increased leakage quantity, short service life and the like in the operation process, the contact state of a friction pair is known, and the operation state of the mechanical seal is judged to be urgently needed to be known in the operation process of the mechanical seal. When the mechanical seal operates, the liquid film between the dynamic ring and the static ring is used for cooling and lubricating, but the liquid film state is influenced by various factors, the existing monitoring means for the mechanical seal state is limited, and the abnormal friction state of friction cannot be directly monitored, so that on one hand, the reasons generated in the abnormal state of the mechanical seal cannot be analyzed in time, on the other hand, aiming at important mechanical seals, the operation parameters cannot be adjusted in time according to the sealing state, and the abnormal damage of the mechanical seal is protected.
Disclosure of Invention
Aiming at the problems that the contact state of a dynamic friction pair and a static friction pair of a mechanical seal of a key pump lacks an effective monitoring means, the abnormal operation state of the seal cannot be found in time, the cause of seal failure is unknown, the seal is damaged and the like, the invention aims to provide the mechanical seal with the built-in acoustic emission sensor and the state evaluation method, which can identify the abnormal contact state of the mechanical seal friction pair and realize the accurate monitoring and judgment of the abnormal rub and abrasion of the seal friction pair.
The technical scheme of the invention is as follows: a mechanical seal with an acoustic emission sensor comprises the acoustic emission sensor, a static ring seat, a static ring is arranged on the static ring seat, the acoustic emission sensor is arranged in the static ring seat, and the acoustic emission sensor is matched with the static ring arranged on the static ring seat.
The acoustic emission sensor and the sealing static ring adopt an interference fit mode, so that the close contact between the sensing end of the sensor and the mechanical sealing static ring is ensured.
The tail end of the acoustic emission sensor is provided with a cable protection sleeve, and a sensor wire of the acoustic emission sensor is arranged in the cable protection sleeve.
The protective sleeve is made of soft and wear-resistant materials.
The acoustic emission sensor is a small acoustic emission sensor with the diameter of 7-8 mm.
And the side end of the static ring seat is provided with an opening.
The acoustic emission sensor is screwed into the hole of the static ring seat through threads.
A mechanical sealing state evaluation method of a built-in acoustic emission sensor comprises the following steps:
step 1: installing a mechanical seal, setting a sampling rate Fs of acoustic emission signals, and obtaining an acoustic emission signal sequence X= [ X1, X2, X3, and X when the seal is in normal operation i ,...,x N ]The calculation formula of the effective value RMS is shown as (1) in order to obtain a waveform diagram of the acoustic emission signal, an effective value RMS of the acoustic emission signal and kurtosis value KUR of the acoustic emission signal in normal operation:
the calculation formula of kurtosis value KUR is shown as formula (2):
wherein, x= [ X1, X2, X3..x i ,...,x N ]To calculate the sequence of acoustic emission signals acquired within the window,
step 2: after the seal is installed, stably operating for 1 hour, sensing whether the leakage amount is normal, if the leakage amount is normal, acquiring acoustic emission data for 10 minutes, if the leakage amount is abnormal, representing that the seal operating state is abnormal, re-installing and adjusting the seal, then stably operating for 1 hour, observing the leakage amount to judge whether the seal is normal, and repeating the operation until acoustic emission signals during the seal operation are acquired;
step 3: acoustic emission signals x= [ X1, X2, X3, ·x were normally run at the acquired mechanical seal with a window of length W. i ,,.x. N Slide on, the length of slide is STEP, according to(1) And (2) calculating the effective value RMS and kurtosis value KUR of the signal in the sliding window to form an effective value list RMS_L= [ RMS ] in normal operation of the mechanical seal 1 ,RMS 2 ,…,RMS k ]Kurtosis value list kur_l= [ KUR ] 1 ,KUR 2 ,…,KUR k ]；
Step 4: calculating an effective value list RMS_L= [ RMS ] of normal operation of the mechanical seal 1 ,RMS 2 ,…,RMS k ]Calculating kurtosis value list kur_l= [ KUR ] when the mechanical seal is in normal operation 1 ,KUR 2 ,…,KUR k ]The effective value of the acoustic emission signal during normal operation of the mechanical seal is determined as [ RMS_AVE-3 x RMS_sigma, RMS_AVE+3 x RMS_sigma]Kurtosis value of acoustic emission signal during normal operation of mechanical seal is determined as [ KUR_AVE-3×KUR_sigma, KUR_AVE+3×KUR_sigma]；
Step 5: acquiring an acoustic emission signal x_new= [ X1, X2, X3, ], X, obtained by real-time monitoring i ,...,x N ]Calculating an effective value RMS_new and a kurtosis value KUR_new; judging whether the effective value RMS_new of the acoustic emission signal acquired in real time is in the range [ RMS_AVE-3 x RMS_sigma, RMS_AVE+3 x RMS_sigma ] of the acoustic emission effective value of the normal operation of the mechanical seal]An inner part;
step 6: if the effective value RMS_new exceeds the normal signal range, further comparing whether the kurtosis value KUR_new is in the range [ KUR_AVE-3 x KUR_sigma, KUR_AVE+3 x KUR_sigma ] of the acoustic emission kurtosis value of the mechanical seal, and if the effective value and the kurtosis value exceed the normal range, indicating that abnormal friction occurs in a friction pair of the mechanical seal; if only the effective value RMS_new of the acoustic emission signal exceeds the normal range and the kurtosis value KUR_new does not exceed the normal range, the abnormal increase of energy at other parts of the equipment can be judged, and some abnormality possibly exists, but is not caused by abnormal friction of the sealing friction pair.
W in the step 3 is Fs/10 data points.
The invention has the beneficial effects that: aiming at the rub-impact and abrasion states of the dynamic and static friction pair of the mechanical seal, an effective monitoring means is lacking at present, the damage to the seal is usually recognized when the leakage quantity is abnormally increased, and the equipment is stopped, the stress wave signals generated by the contact of the dynamic and static friction pair are directly monitored through the built-in acoustic emission sensor, so that the accurate monitoring and judgment of the contact state and the abrasion state of the dynamic and static friction pair of the mechanical seal are realized, and the basis is provided for analysis of failure reasons of the mechanical seal, optimization of operation parameters and improvement of reliability. The attenuation of weak friction signals is reduced, and the abnormal friction of the dynamic and static friction pair of the mechanical seal is captured more favorably; the friction state of the mechanical seal dynamic and static friction pair is monitored directly by an acoustic emission signal monitoring method; and judging the abnormal friction of the mechanical seal friction pair by comparing the effective value with the kurtosis value and combining with the waveform analysis of the acoustic emission signal.
Drawings
FIG. 1 is a schematic diagram of a mechanical seal with an acoustic emission sensor built in according to the present invention;
FIG. 2 is a flow chart of a method for evaluating the mechanical sealing state of a built-in acoustic emission sensor provided by the invention;
FIG. 3 is a waveform diagram of acoustic emission signals in a normal friction state of a sealing friction pair;
fig. 4 is a diagram showing a friction pair contact state when the mechanical seal friction pair rubs abnormally.
FIG. 5 is a diagram of a mechanical seal condition monitoring device rack;
FIG. 6 is a graph showing the instability of the seal internal kurtosis value during steady operation;
FIG. 7 is a flow chart of the mechanical seal on-line monitoring data management and application.
In the figure: 1 acoustic emission sensor, 2 cable protective sheath, 3 screw threads, 4 quiet ring seat, 5 quiet rings.
Detailed Description
The invention will be described in further detail with reference to the accompanying drawings and specific examples.
When the mechanical seal normally operates, the dynamic and static friction pairs are lubricated and cooled by the liquid film, if the state of the liquid film changes, abnormal friction occurs to the dynamic and static friction pairs rotating at high speed, and weak signals of the abnormal friction are released. The invention provides a mechanical seal and state evaluation method of a built-in acoustic emission sensor based on the acoustic emission monitoring technology, which can effectively capture weak signals of abnormal friction release of a dynamic friction pair due to high sensitivity and high frequency response characteristics.
The mechanical seal with the built-in acoustic emission sensor has the advantages that the adopted acoustic emission sensor has high sensitivity, signals generated by abnormal friction of the mechanical seal friction pair can be detected, but because the abnormal friction signals are weak, the sensitivity of the acoustic emission sensor is high, the acoustic emission sensor is miniaturized and designed to be built-in the mechanical seal static ring seat, the interference of noise signals can be effectively reduced, and the effective abnormal friction signals of the mechanical seal friction pair are acquired.
As shown in fig. 1, a mechanical seal with an acoustic emission sensor is built in, including acoustic emission sensor 1, quiet ring seat 4, install quiet ring 5 on the quiet ring seat 4, open pore on the side of quiet ring seat 4, acoustic emission sensor 1 is screwed into the hole of quiet ring seat through the screw thread, acoustic emission sensor 1 and install quiet ring 5 on quiet ring seat are closely cooperated, acoustic emission sensor 1 adopts interference fit's mode with sealed quiet ring 5, guarantee sensor sensing end and mechanical seal quiet ring 5 in close contact, and for preventing producing inhomogeneous clearance between acoustic emission sensor 1 and quiet ring 5, when the sensor is installed, need scribble couplant, in order to fill the inhomogeneous clearance that sensor and quiet ring may exist, because quiet ring seat 4 can carry out displacement compensation along with sealed operation, quiet ring seat 4 and quiet ring 5's position can float, acoustic emission sensor 1 and the clearance between the quiet ring seat 4 mounting structure of left side can change, the condition that the signal cable exists the repeated vibration and the seal, for protecting acoustic emission signal cable, set up the acoustic emission sensor 1 and acoustic emission signal cable's the end, acoustic emission sensor 1 and acoustic emission sensor 2, the acoustic emission sensor 1 is arranged in the range of diameter of seal protection sleeve, the acoustic emission signal cable is selected in the range of the test range, the diameter protection sleeve is small-diameter protection sleeve is researched and the diameter is 7 mm, the diameter of the acoustic emission sensor 1 is used in the range is selected, the mechanical seal protection sleeve is used, the diameter is measured, and the diameter is measured.
When the mechanical seal dynamic and static friction pair rubs abnormally, the effective value of the acoustic emission signal is increased, meanwhile, the sampling rate of the acoustic emission signal is high, 1MHz is reached, the surface of the friction pair is not a complete plane, so that an instantaneous impact peak can be seen in a waveform during instantaneous friction, and the instantaneous impact peak is also increased in kurtosis value.
As shown in fig. 2, a method for evaluating a mechanical seal state of a built-in acoustic emission sensor includes the steps of:
step 1: a mechanical seal is installed, the sampling rate Fs of acoustic emission signals is set (the sampling rate Fs is usually 1 MHz), and an acoustic emission signal sequence X= [ X1, X2, X3 ] and X in normal operation of the seal are obtained i ,...,x N ]In order to obtain a waveform diagram (shown in fig. 3) of the acoustic emission signal in normal operation, an effective value RMS of the acoustic emission signal and a kurtosis value KUR of the acoustic emission signal, a calculation formula of the effective value RMS is shown as formula (1):
the calculation formula of kurtosis value KUR is shown as formula (2):
wherein, x= [ X1, X2, X3..x i ,...,x N ]For calculating the acoustic emission signal sequence collected in the window, wherein i represents the ith signal value in the primary signal collection list, and N represents the length of the signal list.
Step 2: according to the method shown in fig. 2, after the seal is installed, the seal is stably operated for 1 hour, whether parameters such as the leakage quantity are normal or not is sensed, if the leakage quantity is normal, acoustic emission data of 10 minutes are collected, if the leakage quantity is abnormal, the seal is represented as abnormal in operation state, the seal is reinstalled and adjusted, then the seal is stably operated for 1 hour again, the leakage quantity is observed to judge whether the seal is normal or not, and the operation is repeated until acoustic emission signals during the seal operation are collected;
step 3: acoustic emission signal x= [ X1, X2, X3, ], X was generated at the collected mechanical seal normal operation with a window of length W (W may take Fs/10 data points) i ,...,x N ]Upward feedingSliding, wherein the sliding length is STEP (STEP is preferably FS/40), and the effective value RMS and kurtosis value KUR of the signal in the sliding window are calculated according to (1) and (2), so that an effective value list RMS_L= [ RMS ] in normal operation of the mechanical seal is formed 1 ,RMS 2 ,…,RMS k ]Kurtosis value list kur_l= [ KUR ] 1 ,KUR 2 ,…,KUR k ]；
Step 4: calculating an effective value list RMS_L= [ RMS ] of normal operation of the mechanical seal 1 ,RMS 2 ,…,RMS k ]Calculating kurtosis value list kur_l= [ KUR ] when the mechanical seal is in normal operation 1 ,KUR 2 ,…,KUR k ]The effective value of the acoustic emission signal during normal operation of the mechanical seal is determined as [ RMS_AVE-3 x RMS_sigma, RMS_AVE+3 x RMS_sigma]Kurtosis value of acoustic emission signal during normal operation of mechanical seal is determined as [ KUR_AVE-3×KUR_sigma, KUR_AVE+3×KUR_sigma]；
Step 3: acquiring an acoustic emission signal x_new= [ X1, X2, X3, ], X, obtained by real-time monitoring i ,...,x N ]Calculating an effective value RMS_new and a kurtosis value KUR_new; judging whether the effective value RMS_new of the acoustic emission signal acquired in real time is in the range [ RMS_AVE-3 x RMS_sigma, RMS_AVE+3 x RMS_sigma ] of the acoustic emission effective value of the normal operation of the mechanical seal]An inner part;
step 3: if the effective value RMS_new exceeds the normal signal range, further comparing whether the kurtosis value KUR_new is in the range [ KUR_AVE-3 x KUR_sigma, KUR_AVE+3 x KUR_sigma ] of the acoustic emission kurtosis value of the mechanical seal, and if the effective value and the kurtosis value exceed the normal range, indicating that abnormal friction occurs in a friction pair of the mechanical seal; if only the effective value RMS_new of the acoustic emission signal exceeds the normal range and the kurtosis value KUR_new does not exceed the normal range, the abnormal increase of energy at other parts of the equipment can be judged, and some abnormality possibly exists, but is not caused by abnormal friction of the sealing friction pair.
When the mechanical seal state monitoring is carried out, the sampling rate of the acoustic emission signal reaches 1MHz, so that huge monitoring data can be generated, and certain problems exist in data transmission, management and storage. And because the mechanical seal operation state is unstable and unpredictable, if the health state of the mechanical seal needs to be mastered in the whole operation life period, continuous online monitoring needs to be carried out. In order to manage and apply massive monitoring data, the invention provides a distributed deployment and edge node data processing mechanical seal on-line monitoring system architecture, wherein the monitoring data of each mechanical seal is placed in an edge computer to which the monitoring data belongs to perform characteristic calculation, the calculated characteristics are transmitted to a data server to be stored and managed, and a terminal accesses the data server through a wireless network to know the operation state of the seal.
The invention also relates to a mechanical seal state monitoring data acquisition and processing device and a distributed monitoring and processing system, wherein the device comprises acoustic emission sensors, data acquisition and edge calculation nodes, a data server and an access terminal, as shown in fig. 5, the acoustic emission sensors are arranged in the mechanical seals, each mechanical seal is internally provided with an acoustic emission sensor, the data acquisition and edge calculation nodes are arranged on site, the acoustic emission sensor signals acquired on a plurality of sites are directly subjected to characteristic value calculation, abnormality judgment and the like, and if the mechanical seal state is normal, only the characteristic value per second is stored and transmitted to the data server; and if the mechanical sealing state is abnormal, collecting the original waveform data at least 10 minutes before and after the sealing state is abnormal, and transmitting the original waveform data to a data server. The data server is arranged in the machine room and used for storing and managing the characteristic value of normal operation, storing and analyzing the original waveform data during abnormal alarming, applying a mechanical sealing state monitoring and evaluating method developed based on the data server and the like.
The usage flow of the mechanical seal state monitoring data acquisition and processing device is shown in fig. 7.
The edge computing node performs the following calculations and processes:
(1) Acquiring real-time acoustic emission data according to a sampling rate of 1MHz, dividing the second data according to a rotating speed N, and in order to reduce data quantity and accelerate data processing speed, reserving friction data of a dynamic friction pair and a static friction pair in relative motion for 4 circles, so that 2 seconds of data are cut into N/240 parts, one part of the N/240 parts is reserved, and the rest data are discarded;
(2) And calculating a valid value and a kurtosis value according to the reserved data fragments, and confirming whether one of the valid value and the kurtosis value exceeds a normal operation range. If not, transmitting the calculated effective value and kurtosis value to a data server, and simultaneously, caching the high-frequency original data fragments in an edge node
(3) If one of the effective value and the kurtosis value exceeds the normal range, the effective value and the kurtosis value are transmitted to the data management server, and the buffered first 10 minutes of original data fragments and the next 10 minutes of data fragments are transmitted to the data server so as to record the original data in an abnormal state.
The tasks performed by the data processing server are:
(1) Classifying, storing and managing the data transmitted from the edge for the user to review
(2) And judging and grading the friction state of the sealing friction pair according to the exceeding degree of the effective value and the kurtosis value, and counting the abnormal operation time of the sealing, so as to continuously monitor and judge the abrasion loss of the sealing on the basis.
Claims (9)
1. A mechanical seal with an acoustic emission sensor built in, characterized by: the sound emission sensor is matched with the static ring arranged on the static ring seat.
2. A mechanical seal incorporating an acoustic emission sensor as claimed in claim 1, wherein: the acoustic emission sensor and the sealing static ring adopt an interference fit mode, so that the close contact between the sensing end of the sensor and the mechanical sealing static ring is ensured.
3. A mechanical seal incorporating an acoustic emission sensor as claimed in claim 1, wherein: the tail end of the acoustic emission sensor is provided with a cable protection sleeve, and a sensor wire of the acoustic emission sensor is arranged in the cable protection sleeve.
4. A mechanical seal incorporating an acoustic emission sensor as claimed in claim 3, wherein: the protective sleeve is made of soft and wear-resistant materials.
5. A mechanical seal incorporating an acoustic emission sensor as claimed in claim 1, wherein: the acoustic emission sensor is a small acoustic emission sensor with the diameter of 7-8 mm.
6. A mechanical seal incorporating an acoustic emission sensor as claimed in claim 1, wherein: and the side end of the static ring seat is provided with an opening.
7. A mechanical seal incorporating an acoustic emission sensor as claimed in claim 6, wherein: the acoustic emission sensor is screwed into the hole of the static ring seat through threads.
8. The mechanical sealing state evaluation method of the built-in acoustic emission sensor is characterized by comprising the following steps of:
step 1: installing a mechanical seal, setting a sampling rate Fs of acoustic emission signals, and obtaining an acoustic emission signal sequence X= [ X1, X2, X3, and X when the seal is in normal operation i ,...,x N ]The calculation formula of the effective value RMS is shown as (1) in order to obtain a waveform diagram of the acoustic emission signal, an effective value RMS of the acoustic emission signal and kurtosis value KUR of the acoustic emission signal in normal operation:
the calculation formula of kurtosis value KUR is shown as formula (2):
wherein, x= [ X1, X2, X3..x i ,...,x N ]To calculate the sequence of acoustic emission signals acquired within the window,
step 2: after the seal is installed, stably operating for 1 hour, sensing whether the leakage amount is normal, if the leakage amount is normal, acquiring acoustic emission data for 10 minutes, if the leakage amount is abnormal, representing that the seal operating state is abnormal, re-installing and adjusting the seal, then stably operating for 1 hour, observing the leakage amount to judge whether the seal is normal, and repeating the operation until acoustic emission signals during the seal operation are acquired;
step 3: normal operation of acoustic emission signals x= [ X1, X2, X3, ], X, on an acquired mechanical seal with a window of length W i ,...,x N ]Sliding the sliding window, wherein the sliding length is STEP, and calculating the effective value RMS and kurtosis value KUR of the signal in the sliding window according to (1) and (2) to form an effective value list RMS_L= [ RMS ] in normal operation of the mechanical seal 1 ,RMS 2 ,…,RMS k ]Kurtosis value list kur_l= [ KUR ] 1 ,KUR 2 ,…,KUR k ]；
Step 4: calculating an effective value list RMS_L= [ RMS ] of normal operation of the mechanical seal 1 ,RMS 2 ,…,RMS k ]Calculating kurtosis value list kur_l= [ KUR ] when the mechanical seal is in normal operation 1 ,KUR 2 ,…,KUR k ]The effective value of the acoustic emission signal during normal operation of the mechanical seal is determined as [ RMS_AVE-3 x RMS_sigma, RMS_AVE+3 x RMS_sigma]Kurtosis value of acoustic emission signal during normal operation of mechanical seal is determined as [ KUR_AVE-3×KUR_sigma, KUR_AVE+3×KUR_sigma]；
Step 5: acquiring an acoustic emission signal x_new= [ X1, X2, X3, ], X, obtained by real-time monitoring i ,...,x N ]Calculating an effective value RMS_new and a kurtosis value KUR_new; judging whether the effective value RMS_new of the acoustic emission signal acquired in real time is in the range [ RMS_AVE-3 x RMS_sigma, RMS_AVE+3 x RMS_sigma ] of the acoustic emission effective value of the normal operation of the mechanical seal]An inner part;
step 6: if the effective value RMS_new exceeds the normal signal range, further comparing whether the kurtosis value KUR_new is in the range [ KUR_AVE-3 x KUR_sigma, KUR_AVE+3 x KUR_sigma ] of the acoustic emission kurtosis value of the mechanical seal, and if the effective value and the kurtosis value exceed the normal range, indicating that abnormal friction occurs in a friction pair of the mechanical seal; if only the effective value RMS_new of the acoustic emission signal exceeds the normal range and the kurtosis value KUR_new does not exceed the normal range, the abnormal increase of energy at other parts of the equipment can be judged, and some abnormality possibly exists, but is not caused by abnormal friction of the sealing friction pair.
9. The method for evaluating the mechanical sealing state of a built-in acoustic emission sensor according to claim 8, wherein: w in the step 3 is Fs/10 data points.
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