CN117554043A - Air valve monitoring method, equipment and storage medium - Google Patents
Air valve monitoring method, equipment and storage medium Download PDFInfo
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Abstract
The application provides a gas valve monitoring method, equipment and a storage medium, and relates to the technical field of compressors, wherein the method is used for monitoring equipment for monitoring the fault of a gas valve of a reciprocating compressor, and the monitoring equipment comprises the following steps: a vibration sensor and a temperature sensor installed at a valve cover position of each gas valve of the reciprocating compressor; the method comprises the following steps: vibration data and temperature data synchronously acquired by monitoring equipment are acquired; performing phase compensation on the vibration waveform of the vibration data to obtain a single-circle or multi-circle vibration waveform; and determining the fault of the air valve according to the single-circle or multi-circle vibration waveform and the temperature data change trend of the temperature data. By means of vibration monitoring, the early crack of the valve plate of the air valve, the insensitive faults of temperature manifestations such as looseness of the jackscrew of the air valve and the like can be predicted in advance; the air valves are monitored in a mode of combining vibration and temperature, so that the accuracy of fault identification of the air valves is improved, and each air valve can be effectively monitored in a targeted mode and accurately positioned.
Description
Technical Field
The application relates to the technical field of compressors, in particular to a gas valve monitoring method, gas valve monitoring equipment and a storage medium.
Background
The reciprocating compressor is one kind of compressor with cylinder with piston inside the cylinder to change the cylinder volume periodically and realize the pressurization and transportation of gas, and belongs to the field of volumetric compressor. The reciprocating compressor drives the connecting rod through the crankshaft, the connecting rod drives the piston to move, and the working process of compressed gas can be divided into four processes of expansion, air suction, compression and air exhaust. The air valves are used as wearing parts of the reciprocating compressor, the number is large, the failure rate is high, and one cylinder of the reciprocating compressor is usually provided with 2 to 8 air valves which are divided into an air inlet valve and an air outlet valve. The air valve is composed of a valve seat, a valve cover, a valve plate, a spring, a nut and the like, and the opening and closing actions of the air valve are automatically realized through the pressure difference of the two sides of the valve plate of the air valve.
At present, the prior art generally relies on a mode of monitoring the temperature of the air valve and the dynamic pressure of the air valve to identify the fault of the air valve. The main disadvantage of the former is that the valve plate is insensitive to faults such as early cracks of the valve plate or loosening of fastening bolts, the main disadvantage of the latter is that an airtight test is required before access, construction safety risks are fully estimated, a certain construction risk exists, and the fault of which air valve can not be specifically positioned.
Disclosure of Invention
In view of the above, an object of an embodiment of the present application is to provide a method, an apparatus, and a storage medium for monitoring air valves, which are capable of more effectively monitoring the operation state of the air valve in real time by providing a vibration sensor and a temperature sensor at a valve cover position of each air valve, collecting vibration data and temperature data, comprehensively determining air valve faults according to the vibration data and the temperature data for performing phase compensation on the vibration waveforms, and directly collecting the vibration waveforms of the air valve during the operation of the reciprocating compressor; the temperature monitoring is effective for the air leakage faults of the air valve caused by the breakage of the air valve sheet or the failure of the spring, but is insensitive to the faults of early cracks of the air valve sheet or loosening of a fastening bolt and the like, the vibration signal can well capture the abnormal signals, the early prediction of the air valve faults is realized, the air valve vibration waveform data are combined, the temperature monitoring can be supplemented, and each air valve can be effectively monitored in a targeted manner, so that the technical problem is solved.
In a first aspect, embodiments of the present application provide a method for monitoring a valve failure of a reciprocating compressor, the method comprising: a vibration sensor and a temperature sensor installed at a valve cover position of each gas valve of the reciprocating compressor; the method comprises the following steps: vibration data and temperature data synchronously acquired by the monitoring equipment are acquired; performing phase compensation on the vibration waveform of the vibration data to obtain a single-circle or multi-circle vibration waveform; and determining the fault of the air valve according to the single-circle or multi-circle vibration waveform and the temperature data change trend of the temperature data.
In the implementation process, the temperature monitoring can be supplemented by combining the vibration waveform data of the air valves, so that each air valve can be effectively monitored in a targeted manner; by means of vibration monitoring, the early crack of the valve plate of the air valve, the insensitive faults of the temperature manifestation such as looseness of the jackscrew of the air valve and the like can be predicted in advance; the air valve is monitored in a mode of combining vibration and temperature, so that the accuracy of fault identification of the air valve is improved, and meanwhile, the air valve can be accurately positioned.
Optionally, the phase compensating the vibration waveform of the vibration data to obtain a single-circle or multi-circle vibration waveform includes:
selecting a reference cylinder, and taking an outer dead center of the reference cylinder as a key phase zero point;
determining a phase compensation angle value according to a crankshaft rotation direction and a crank angle between a cylinder and the reference cylinder;
and taking the phase-bonding zero point as a reference point, and intercepting a single-circle or multi-circle vibration waveform of the vibration waveform according to the phase compensation angle value.
In the implementation process, the air valve vibration measuring point is synchronous with other monitoring measuring points of the crankshaft cylinder, and the consistency of single-circle phases of each cylinder and the air valve can be ensured by combining key phases, so that the comparison analysis of air valve signals among different cylinders is facilitated, the accuracy of air valve fault identification is improved, and meanwhile, the accurate positioning can be realized.
Optionally, the determining the air valve fault according to the single-circle or multi-circle vibration waveform and the temperature data change trend of the temperature data includes:
comparing the vibration amplitude and trend change of the single-circle or multi-circle vibration waveform with those of the air valve of the same type of the same cylinder; and/or comparing the temperature data change trend of the temperature data with the temperature data change trend of the air valve of the same type of the same cylinder;
determining the air valve with the largest vibration amplitude and the largest trend change as the air valve fault; and/or determining the air valve with the largest temperature data change trend as the air valve fault.
In the implementation process, the vibration amplitude, the vibration trend change and the temperature data change trend of the single-circle or multi-circle waveform after phase compensation are compared with those of the same-level cylinder, and the air valve faults are determined by means of the comparison analysis of the vibration values and the temperature trends of the same-type air valves, so that a basis is provided for analysis of other measuring point data (such as piston rod displacement and cylinder pressure) of the associated reciprocating compressor, faults can be rapidly and intuitively positioned, and the fault determination efficiency is improved.
Optionally, the determining the air valve fault according to the single-circle or multi-circle vibration waveform and the temperature data change trend of the temperature data includes:
determining the vibration amplitude and the phase of the air valve at the opening moment according to the single-circle or multi-circle vibration waveform;
determining whether the temperature value of the air valve is in a normal allowable range or not in the working process of the air valve according to the temperature data change trend of the temperature data;
if the vibration amplitude is increased and the phase and the temperature value are unchanged within the normal allowable range, determining that the air valve fault is an air valve jackscrew bolt loosening fault.
In the implementation process, the position and impact form change of abnormal occurrence in the single-circle or multi-circle vibration waveform are identified according to the vibration amplitude, the phase and the temperature trend of the single-circle or multi-circle vibration waveform, so that the air valve fault type is deduced, data support is provided for researching the air valve fault type including the loosening fault of the air valve jackscrew bolt, a foundation is laid for intelligent diagnosis in the future, and the sensitivity of fault identification is improved.
Optionally, the determining the air valve fault according to the single-circle or multi-circle vibration waveform and the temperature data change trend of the temperature data includes:
according to the single-circle or multi-circle vibration waveform, determining the vibration amplitude and the phase of an impact peak at the moment of opening or closing the air valve;
determining whether the temperature value of the air valve is in a normal allowable range or not in the working process of the air valve according to the temperature data change trend of the temperature data;
if the vibration amplitude is lower, the phase is changed, and the temperature value is unchanged within a normal allowable range, the air valve fault is determined to be an early-stage crack fault of the air valve plate.
In the implementation process, the position and impact form change of abnormality occurrence in the single-circle or multi-circle vibration waveform are identified according to the vibration amplitude, the phase and the temperature trend of the single-circle or multi-circle vibration waveform, so that the air valve fault type is deduced, data support is provided for researching the air valve fault type including the early-stage crack fault of the air valve plate, a foundation is laid for the follow-up intelligent diagnosis, and the fault identification sensitivity is improved.
Optionally, the determining the air valve fault according to the single-circle or multi-circle vibration waveform and the temperature data change trend of the temperature data includes:
if the vibration amplitude and the phase change and the temperature value is increased within a normal allowable range, determining that the air valve fault is a later crack fault of the air valve plate.
In the implementation process, the position and impact form change of abnormal occurrence in the single-circle or multi-circle vibration waveform are identified according to the vibration amplitude, the phase and the temperature trend of the single-circle or multi-circle vibration waveform, so that the air valve fault type is deduced, data support is provided for researching the air valve fault type including the later crack fault of the air valve plate, a foundation is laid for the follow-up intelligent diagnosis, and the fault identification sensitivity is improved.
Optionally, the vibration sensor and the temperature sensor adopt a vibration and temperature integrated wireless sensor or a mode compatible with a wired sensor and a wireless sensor.
In the implementation process, the construction cost and the later operation and maintenance cost are reduced by adopting a low-cost sensor scheme integrating air valve vibration and temperature or a scheme compatible with a wired sensor and a wireless sensor.
In a second aspect, embodiments of the present application provide a valve monitoring apparatus for monitoring a reciprocating compressor valve fault, the valve monitoring apparatus comprising: a vibration sensor, a temperature sensor and a controller, the vibration sensor and the temperature sensor being installed at a valve cover position of each gas valve of the reciprocating compressor;
the controller is used for: vibration data and temperature data synchronously acquired by the monitoring equipment are acquired;
the controller is further configured to: performing phase compensation on the vibration waveform of the vibration data to obtain a single-circle or multi-circle vibration waveform;
the controller is further configured to: and determining the fault of the air valve according to the single-circle or multi-circle vibration waveform and the temperature data change trend of the temperature data.
Optionally, the vibration sensor and the temperature sensor are integrated wireless sensors of vibration and temperature.
In a third aspect, embodiments of the present application further provide an electronic device, including: a processor, a memory storing machine-readable instructions executable by the processor, which when executed by the processor perform the steps of the method described above when the electronic device is run.
In a fourth aspect, embodiments of the present application provide a storage medium having a computer program stored thereon, which when executed by a processor performs the steps of the method described above.
In order to make the above objects, features and advantages of the present application more comprehensible, embodiments accompanied with figures are described in detail below.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings that are needed in the embodiments of the present application will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present application and should not be considered as limiting the scope, and other related drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a flowchart of a method for monitoring an air valve according to an embodiment of the present disclosure;
FIG. 2 is a schematic block diagram of an air valve monitoring device according to an embodiment of the present disclosure;
fig. 3 is a schematic block diagram of an electronic device according to an embodiment of the present application.
Icon: 210-a vibration sensor; 220-a temperature sensor; 230-a controller; 300-an electronic device; 311-memory; 312-a storage controller; 313-processor; 314-peripheral interface; 315-an input-output unit; 316-display unit.
Detailed Description
The following description of the embodiments of the present application will be made clearly and completely with reference to the drawings in the embodiments of the present application, and it is apparent that the described embodiments are only some embodiments of the present application, not all embodiments. The components of the embodiments of the present application, which are generally described and illustrated in the figures herein, may be arranged and designed in a wide variety of different configurations. Thus, the following detailed description of the embodiments of the present application, as provided in the accompanying drawings, is not intended to limit the scope of the application, as claimed, but is merely representative of selected embodiments of the application. All other embodiments, which can be made by those skilled in the art based on the embodiments of the present application without making any inventive effort, are intended to be within the scope of the present application.
It should be noted that: like reference numerals and letters denote like items in the following figures, and thus once an item is defined in one figure, no further definition or explanation thereof is necessary in the following figures. The terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one … …" does not exclude the presence of other like elements in a process, method, article, or apparatus that comprises the element. The terms "first," "second," and the like are used merely to distinguish between descriptions and are not to be construed as indicating or implying relative importance.
The inventors of the present application noted that the air valves are used as wearing parts of the reciprocating compressor, and the number and failure rate are high, and the reciprocating compressor generally has 2 to 8 air valves, which are divided into an air inlet valve and an air outlet valve. The air valve can bear larger impact load at the moment of opening and closing, the reciprocating compressor runs for one circle, and the air inlet valve and the air outlet valve are opened and closed once respectively. The failure types of the gas valve may include: (1) The valve plate is damaged, and has two forms of cracking and abrasion, mainly caused by impact stress and flutter stress; (2) spring failure or breakage; (3) The sealing surfaces of the valve seat and the valve plate are worn or foreign matters exist to cause the air valve to be closed incompletely so as to leak air; and (4) loose installation and manufacturing defects of the valve body. Once the air valve fails, the efficiency and gas yield of the compressor can be affected, and energy is wasted. Fragments after valve member breakage fall into the cylinder, which can cause the cylinder to be napped, and the piston ring are damaged, even more serious problems can be caused.
At present, the monitoring means of the air valve mainly comprise two types: the temperature of each air valve cover is monitored by means of temperature, a temperature sensor is additionally arranged on each air valve cover to monitor the temperature change of each air valve of the air cylinder, and when a certain air valve leaks due to failure, the temperature of the air valve can rise. However, the defects are that: the valve plate of the air valve breaks or the spring fails to cause air leakage in the air cylinder, so that the temperature of the air valve rises, but the air valve is insensitive to faults such as early cracks of the valve plate or loosening of a fastening bolt. Such fault field manual spot inspection can generally hear abnormal sounds, so that the field inspection maintenance action precedes the monitoring system, and the trust degree of field personnel on the compressor state monitoring system is affected. Meanwhile, abnormal impact generated by the air valve faults can transmit vibration waveforms of a cylinder cover of a compressor and measuring points of a cross head, but abnormal positioning is required to depend on perfect data type access and certain fault diagnosis capability.
Secondly, the fault of the air valve is judged by monitoring the dynamic pressure of the air cylinder, a dynamic pressure sensor is connected to the air cylinder, a P-V indicator diagram curve is made in the process of reciprocating the piston for one circle, and the fault of the air valve is judged from the change of the indicator diagram. However, the defects are that: (1) An indirect reaction to the air valve fault can be generated by means of a vibration measuring point arranged on the air cylinder, but the air valve fault is difficult to directly locate due to the influence of the air valve fault position and other vibration transmission of the equipment body. Meanwhile, the fault of the air valve can be judged by the change of the indicator diagram, and the fault of the air valve can not be specifically positioned only when the fault of the air valve is positioned. (2) The fault of the air valve is monitored by means of an external pressure sensor, so that a certain construction risk exists, on one hand, the compressor body is required to be provided with a pressure sensor access port, and an airtight test is required to be carried out before the access port, so that the construction safety risk is fully evaluated. The existing domestic technically improved compressor basically does not have the condition of directly accessing the dynamic pressure sensor. In view of this, embodiments of the present application provide a method, apparatus, and storage medium for monitoring a gas valve as described below.
Referring to fig. 1, fig. 1 is a flowchart of a method for monitoring an air valve according to an embodiment of the present application. The embodiments of the present application are described in detail below. The method is used for monitoring the monitoring equipment for the fault of the air valve of the reciprocating compressor, and the monitoring equipment comprises the following steps: vibration sensor and temperature sensor, vibration sensor and temperature sensor install the valve gap position at each pneumatic valve of reciprocating compressor. The method comprises the following steps: step 100, step 120 and step 140.
Step 100: vibration data and temperature data synchronously acquired by monitoring equipment are acquired;
step 120: performing phase compensation on the vibration waveform of the vibration data to obtain a single-circle or multi-circle vibration waveform;
step 140: and determining the fault of the air valve according to the single-circle or multi-circle vibration waveform and the temperature data change trend of the temperature data.
Illustratively, the phase compensation may be: because a cylinder of the reciprocating compressor is usually provided with 2 to 8 air valves, a vibration sensor and a temperature sensor are arranged at the valve cover position of each air valve of the reciprocating compressor, the initial zero point of each cylinder can be set to be consistent with that of a reference cylinder through phase compensation, and the zero point of the reference cylinder is consistent with that of a key, so that the phase positions corresponding to the opening and closing moments of an air inlet valve and an air outlet valve can be accurately identified in single-circle or multi-circle waveforms of each cylinder, and when the air valves are in fault, the single-circle or multi-circle waveforms can intuitively reflect the phase positions corresponding to the abnormality and the phase changes.
Optionally, a low-cost vibration and temperature integrated wireless sensor can be installed on each air valve cover, and meanwhile, a key phase sensor is installed at the flywheel position at the shaft extension end of the motor, and the key phase zero point takes the outer dead point position of the selected reference air cylinder as the key phase zero point. After the installation of the measuring points is completed, each measuring point can be named and identified, and one-to-one correlation is carried out on a software interface, so that corresponding cylinder numbers and codes are carefully checked for the air valve measuring points, and the phenomenon that the alarm measuring points and the actual measuring points do not match is avoided. Meanwhile, according to the structure and basic parameters of the reciprocating compressor, relevant configuration is completed at a software interface, wherein the relevant configuration comprises the type of the reciprocating compressor, the air inlet and outlet pressure, the air inlet and outlet temperature, the phase compensation angle, the crank radius, the length and diameter of a piston rod, the stroke and other relevant parameters of each cylinder. After configuration is completed, the data acquisition process is carried out, and the acquisition station adopts a full sampling mode, so that the waveform data in all the wired channels can be ensured to be synchronously acquired; for air valve monitoring, the influence of the time of occurrence of actual air valve faults and the power consumption of a wireless battery is considered, the value of the air valve vibration data and the temperature data in a full sampling mode is low, the vibration waveform data and the temperature data can be acquired in an equidistant mode, and the upper computer software supports configuration of the acquisition period and the acquisition length. And synchronously collecting air valve temperature data and vibration data, and collecting temperature values according to a configuration period to form a temperature trend. And comprehensively determining the fault of the air valve according to the single-circle or multi-circle vibration waveform after the phase compensation and the change trend of the temperature data.
The vibration sensor and the temperature sensor are arranged at the valve cover position of each air valve, vibration data and temperature data are collected, air valve faults are comprehensively determined according to the vibration data and the temperature data for carrying out phase compensation on vibration waveforms, and the air valve operation state can be effectively monitored in real time based on directly collecting the vibration waveforms of the air valve in the operation process of the reciprocating compressor; the vibration signal can well make up for the defect of temperature monitoring, so that the air valve fault is predicted in advance, the temperature monitoring can be supplemented by combining the air valve vibration waveform data, and each air valve can be effectively monitored in a targeted manner; by means of vibration monitoring, the early crack of the valve plate of the air valve, the insensitive faults of the temperature manifestation such as looseness of the jackscrew of the air valve and the like can be predicted in advance; the air valve is monitored in a mode of combining vibration and temperature, so that the accuracy of fault identification of the air valve is improved, and meanwhile, the air valve can be accurately positioned.
In one embodiment, step 120 may include: step 121, step 122 and step 123.
Step 121: selecting a reference cylinder, and taking an outer dead center of the reference cylinder as a key phase zero point;
step 122: determining a phase compensation angle value according to the rotation direction of the crankshaft and the crank angle between the cylinder and the reference cylinder;
step 123: and taking the phase zero point of the key as a reference point, and intercepting single-circle or multi-circle vibration waveforms of the vibration waveforms according to the phase compensation angle value.
For example, after the software interface configures the parameters of each cylinder, it may be ensured that the valve vibration waveform data of each cylinder stores one or more circles of waveform data according to the compensated phase. Specifically: selecting a reference cylinder, taking an outer dead center of the reference cylinder as a key phase zero point, and marking at a software interface; respectively marking phase compensation angle values of all the cylinders at a software interface according to the rotation direction of the crankshaft and the crank angle between each cylinder and a reference cylinder; in the actual acquisition process, the zero point of the key phase is used as a reference point, and each cylinder intercepts and displays a single-circle or multi-circle waveform according to the compensated phase. Therefore, after phase compensation, the single-circle waveform starting point of each cylinder can be ensured to reciprocate from the outer dead point to the inner dead point as the reference cylinder. The air valve vibration measuring points and other monitoring measuring points of the crankshaft cylinder are synchronously acquired, and the consistency of single-circle phases of each cylinder and the air valve can be ensured by combining key phases, so that the comparison analysis of air valve signals among different cylinders is facilitated, the accuracy of air valve fault identification is improved, and meanwhile, the accurate positioning can be realized.
In one embodiment, step 140 may include: step 141 and step 142.
Step 141: comparing the vibration amplitude and trend change of the single-circle or multi-circle vibration waveform with those of the air valve of the same type of the same cylinder; and/or comparing the temperature data change trend of the temperature data with the temperature data change trend of the air valve of the same type of the same cylinder;
step 142: determining the air valve with the largest vibration amplitude and the largest trend change as the air valve fault; and/or determining the air valve with the largest temperature data change trend as the air valve fault.
For example, the phase compensation in step 120 is performed to obtain single-circle or multi-circle vibration waveform data of the air valve, so that the vibration values of the air valves of the same type of the same cylinder can be compared, and the fault air valve can be positioned visually by means of vibration significance and vibration trend change. The single-circle waveform of the normal air valve is subjected to vibration transmission of other air valves or units besides the impact generated by opening and closing of the normal air valve, but the relative phase is basically fixed, and the overall vibration trend of the air valve is relatively stable. Once the air valve fails, the impact form and the impact energy change at the moment of opening or closing, and the abnormality can be judged and positioned by means of the vibration value and the waveform characteristic. In a software configuration interface, the compression stage number and the air valve type of each air cylinder can be configured, after the configuration is completed, the air valve synchronous analysis tool can carry out check comparison analysis on the air valves with the same compression stage number and the same type, compare the vibration amplitude and trend change of single-circle or multi-circle vibration waveforms with the vibration amplitude and trend change of the air valves with the same type of the same air cylinder, automatically identify the air valve with the largest vibration value and the air valve with the largest trend change difference or the air valve with the largest trend of temperature data change, determine that the air valve has the fault and push relevant alarm information. The vibration amplitude, the vibration trend change and the temperature data change trend of the waveform of the single circle or the waveform of the multiple circles after the phase compensation are compared with those of the same-level cylinder, and the air valve faults are determined by means of the comparison analysis of the vibration values and the temperature trends of the air valves of the same type, so that a foundation is provided for the analysis of other measuring point data (such as the displacement of a piston rod, the pressure of the cylinder and the like) of the associated reciprocating compressor, the faults can be rapidly and intuitively positioned, and the efficiency of fault determination is improved.
In one embodiment, step 140 may include: step 143, step 144 and step 145.
Step 143: determining the vibration amplitude and the phase of the air valve at the opening moment according to the single-circle or multi-circle vibration waveform;
step 144: determining whether the temperature value of the air valve is in a normal allowable range or not in the working process of the air valve according to the temperature data change trend of the temperature data;
step 145: if the vibration amplitude is increased and the phase and temperature values are unchanged within the normal allowable range, the air valve fault is determined to be the air valve jackscrew bolt loosening fault.
Illustratively, the normal permission range may be: the air valve is in a threshold range preset relative to normal operation. The phase compensation in step 120 is performed to obtain single-circle or multi-circle vibration waveform data of the air valve, and the vibration waveform and spectrum related characteristics of the air valve can be used for analyzing and extracting differences among different fault types, so that data support is provided for intelligent alarm and intelligent diagnosis of the follow-up air valve. The looseness of the valve jackscrew bolt can cause the gap between the valve seat and the valve cover to be enlarged, the spring force is reduced, larger impact load is generated at the moment of opening the valve plate of the valve, the vibration waveform is represented by the increase of the impact peak value at the moment of opening the valve, but the phase of the moment of opening the valve is unchanged relative to that of the normal running state. Because only the slight change of the air valve clearance does not obviously react to the air valve temperature, if the vibration amplitude of the single-circle or multi-circle vibration waveform of the air valve is increased, the phase is unchanged, and the temperature value is unchanged, the fault type of the air valve can be further determined to be the loosening fault of the air valve jackscrew bolt. The method realizes the identification of the abnormal position and the impact form change in the single-circle or multi-circle vibration waveform according to the vibration amplitude, the phase and the temperature trend of the single-circle or multi-circle vibration waveform, further deduces the air valve fault type, provides data support for researching the air valve fault type including the loosening fault of the air valve jackscrew bolt, lays a foundation for the follow-up intelligent diagnosis, and improves the fault identification sensitivity.
In one embodiment, step 140 may include: step 146, step 147 and step 148.
Step 146: according to the single-circle or multi-circle vibration waveform, determining the vibration amplitude and the phase of an impact peak at the moment of opening or closing the air valve;
step 147: determining whether the temperature value of the air valve is in a normal allowable range or not in the working process of the air valve according to the temperature data change trend of the temperature data;
step 148: if the vibration amplitude is lower, the phase is changed, and the temperature value is unchanged within the normal allowable range, the air valve fault is determined to be the early-stage crack fault of the air valve plate.
Illustratively, the phase compensation of step 120 results in single-turn or multi-turn vibration waveform data of the air valve, and the vibration waveform and spectrum related features of the air valve can be used to analyze and extract the differences between different fault types, so as to provide data support for intelligent alarm and intelligent diagnosis of the subsequent air valve. The crack fault of the valve plate of the air valve is expressed as abnormal sound change in early stage, and the valve plate at the breaking position has relative movement at the moment of opening or closing the air valve, so that a new impact peak can appear on the vibration waveform, the energy of the impact peak can be low, and the phase can also be changed. The influence of the early local cracks on the functional characteristics of the air valve is relatively small, and the valve plate can still be normally opened and closed, so that the temperature of the air valve is not obviously influenced. Therefore, if the vibration amplitude of the impact peak of the single-circle or multi-circle vibration waveform of the air valve at the opening or closing moment is low, the phase is changed, and the temperature value is unchanged, the fault type of the air valve can be further determined to be the early-stage crack fault of the valve plate of the air valve. The method realizes the identification of the abnormal position and the impact form change in the single-circle or multi-circle vibration waveform according to the vibration amplitude, the phase and the temperature trend of the single-circle or multi-circle vibration waveform, further deduces the air valve fault type, provides data support for researching the air valve fault type including the early-stage crack fault of the air valve plate, lays a foundation for the subsequent intelligent diagnosis, and improves the fault identification sensitivity.
In one embodiment, step 140 may include: step 149.
Step 149: if the vibration amplitude and the phase change and the temperature value is increased within the normal allowable range, the air valve fault is determined to be the later crack fault of the air valve plate.
Illustratively, early localized cracking has relatively little effect on the functional characteristics of the valve, and the valve plate can still open and close normally, thus not significantly affecting the valve temperature. The amplitude and the phase of the abnormal impact peak can be changed along with the gradual expansion of the valve plate crack, and when the valve plate is broken, the compressed gas in the cylinder can leak outwards, and the temperature of the air valve can be increased. Therefore, if the vibration amplitude and the phase of the impact peak of the single-circle or multi-circle vibration waveform of the air valve at the opening or closing moment change and the temperature value increases, the fault type of the air valve can be further determined to be the later crack fault of the valve plate of the air valve. The method realizes the identification of the abnormal position and the impact form change in the single-circle or multi-circle vibration waveform according to the vibration amplitude, the phase and the temperature trend of the single-circle or multi-circle vibration waveform, further deduces the air valve fault type, provides data support for researching the air valve fault type including the later crack fault of the air valve plate, lays a foundation for the subsequent intelligent diagnosis, and improves the fault identification sensitivity.
In one embodiment, the vibration sensor and the temperature sensor are integrated vibration and temperature wireless sensors or compatible wired and wireless sensors.
The acquisition hardware can comprise a multichannel acquisition station, and is formed by connecting a bottom plate and a plurality of A/D conversion plates in series, wherein each plate card maximally supports 8 channels of data acquisition, and the plate card supports various sensor types such as an acceleration sensor, an impact vibration sensor, a displacement sensor, a pressure sensor, a vibration temperature integrated wired sensor and the like; meanwhile, the types of hardware compatible key phase sensors, wireless vibration and wireless temperature sensors are collected. The wireless vibration sensor, the wireless temperature sensor and other acquisition hardware can be transmitted in a zigbee mode. The wired acquisition station is compatible with the acquisition modes of the wired sensor and the wireless sensor, so that the requirements of sudden fault high-density data capture such as cylinder collision and piston rod breakage of the reciprocating compressor are met, and the targeted effective monitoring can be realized aiming at the fault with low risk degree of the air valve. By adopting a low-cost sensor scheme integrating air valve vibration and temperature or a scheme compatible with a wired sensor and a wireless sensor, the construction cost and the later operation and maintenance cost are reduced.
Referring to fig. 2, fig. 2 is a schematic block diagram of an air valve monitoring device according to an embodiment of the present application. The valve monitoring apparatus is used for monitoring a valve failure of a reciprocating compressor, and comprises: a vibration sensor 210, a temperature sensor 220, and a controller 230, the vibration sensor 210 and the temperature sensor 220 being installed at a valve cover position of each gas valve of the reciprocating compressor;
the controller 230 is configured to: vibration data and temperature data synchronously acquired by the monitoring equipment are acquired;
the controller 230 is further configured to: performing phase compensation on the vibration waveform of the vibration data to obtain a single-circle or multi-circle vibration waveform;
the controller 230 is further configured to: and determining the fault of the air valve according to the single-circle or multi-circle vibration waveform and the temperature data change trend of the temperature data.
Alternatively, the vibration sensor 210 and the temperature sensor 220 are integrated vibration and temperature wireless sensors.
Referring to fig. 3, fig. 3 is a block schematic diagram of an electronic device. The electronic device 300 may include a memory 311, a memory controller 312, a processor 313, a peripheral interface 314, an input output unit 315, a display unit 316. It will be appreciated by those of ordinary skill in the art that the configuration shown in fig. 3 is merely illustrative and is not intended to limit the configuration of the electronic device 300. For example, electronic device 300 may also include more or fewer components than shown in FIG. 3, or have a different configuration than shown in FIG. 3.
The above-mentioned memory 311, memory controller 312, processor 313, peripheral interface 314, input/output unit 315, and display unit 316 are electrically connected directly or indirectly to each other to realize data transmission or interaction. For example, the components may be electrically connected to each other via one or more communication buses or signal lines. The processor 313 is used to execute executable modules stored in the memory.
The Memory 311 may be, but is not limited to, a random access Memory (Random Access Memory, RAM), a Read Only Memory (ROM), a programmable Read Only Memory (Programmable Read-Only Memory, PROM), an erasable Read Only Memory (Erasable Programmable Read-Only Memory, EPROM), an electrically erasable Read Only Memory (Electric Erasable Programmable Read-Only Memory, EEPROM), etc. The memory 311 is configured to store a program, and the processor 313 executes the program after receiving an execution instruction, and a method executed by the electronic device 300 defined by the process disclosed in any embodiment of the present application may be applied to the processor 313 or implemented by the processor 313.
The processor 313 may be an integrated circuit chip having signal processing capabilities. The processor 313 may be a general-purpose processor, including a central processing unit (Central Processing Unit, CPU), a network processor (Network Processor, NP), etc.; but also digital signal processors (digital signal processor, DSP for short), application specific integrated circuits (Application Specific Integrated Circuit, ASIC for short), field Programmable Gate Arrays (FPGA) or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components. The disclosed methods, steps, and logic blocks in the embodiments of the present application may be implemented or performed. A general purpose processor may be a microprocessor or the processor may be any conventional processor or the like.
The peripheral interface 314 couples various input/output devices to the processor 313 and the memory 311. In some embodiments, the peripheral interface 314, the processor 313, and the memory controller 312 may be implemented in a single chip. In other examples, they may be implemented by separate chips.
The input/output unit 315 is used for providing input data to a user. The input/output unit 315 may be, but is not limited to, a mouse, a keyboard, and the like.
The display unit 316 provides an interactive interface (e.g., a user interface) between the electronic device 300 and a user for reference. In this embodiment, the display unit 316 may be a liquid crystal display or a touch display. The liquid crystal display or the touch display may display a process of executing the program by the processor.
The electronic device 300 in the present embodiment may be used to perform each step in each method provided in the embodiments of the present application.
Furthermore, the embodiment of the present application also provides a storage medium, on which a computer program is stored, which when being executed by a processor, performs the steps in the above-mentioned method embodiments.
The computer program product of the above method provided in the embodiments of the present application includes a storage medium storing program codes, where instructions included in the program codes may be used to execute steps in the above method embodiments, and specifically, reference may be made to the above method embodiments, which are not repeated herein.
In the embodiments provided in the present application, it should be understood that the disclosed apparatus and method may be implemented in other manners. The above-described apparatus embodiments are merely illustrative, and the division of the modules is merely a logical function division, and there may be additional divisions when actually implemented, and for example, multiple units or components may be combined or integrated into another system, or some features may be omitted or not performed. Alternatively, the coupling or direct coupling or communication connection shown or discussed with each other may be through some communication interface, device or unit indirect coupling or communication connection, which may be in electrical, mechanical or other form. The functional modules in the embodiments of the present application may be integrated together to form a single part, or each module may exist alone, or two or more modules may be integrated to form a single part.
It should be noted that the functions, if implemented in the form of software functional modules and sold or used as a stand-alone product, may be stored in a computer-readable storage medium. Based on such understanding, the technical solution of the present application may be embodied essentially or in a part contributing to the prior art or in a part of the technical solution, in the form of a software product stored in a storage medium, including several instructions for causing a computer device (which may be a personal computer, a server, or a network device, etc.) to perform all or part of the steps of the methods described in the embodiments of the present application. And the aforementioned storage medium includes: a U-disk, a removable hard disk, a Read-Only Memory (ROM) random access Memory (Random Access Memory, RAM), a magnetic disk, or an optical disk, or other various media capable of storing program codes.
In this document, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions.
The foregoing is merely exemplary embodiments of the present application and is not intended to limit the scope of the present application, and various modifications and variations may be suggested to one skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application should be included in the protection scope of the present application.
Claims (10)
1. A method of valve monitoring for a monitoring device for monitoring a reciprocating compressor valve for failure, the monitoring device comprising: a vibration sensor and a temperature sensor installed at a valve cover position of each gas valve of the reciprocating compressor; the method comprises the following steps:
vibration data and temperature data synchronously acquired by the monitoring equipment are acquired;
performing phase compensation on the vibration waveform of the vibration data to obtain a single-circle or multi-circle vibration waveform;
and determining the fault of the air valve according to the single-circle or multi-circle vibration waveform and the temperature data change trend of the temperature data.
2. The method of claim 1, wherein the phase compensating the vibration waveform of the vibration data to obtain a single or multiple turn vibration waveform comprises:
selecting a reference cylinder, and taking an outer dead center of the reference cylinder as a key phase zero point;
determining a phase compensation angle value according to a crankshaft rotation direction and a crank angle between a cylinder and the reference cylinder;
and taking the phase-bonding zero point as a reference point, and intercepting a single-circle or multi-circle vibration waveform of the vibration waveform according to the phase compensation angle value.
3. The method of claim 1, wherein said determining a valve failure based on a trend of temperature data of said single or multiple turn vibration waveform and said temperature data comprises:
comparing the vibration amplitude and trend change of the single-circle or multi-circle vibration waveform with those of the air valve of the same type of the same cylinder; and/or comparing the temperature data change trend of the temperature data with the temperature data change trend of the air valve of the same type of the same cylinder;
determining the air valve with the largest vibration amplitude and the largest trend change as the air valve fault; and/or determining the air valve with the largest temperature data change trend as the air valve fault.
4. The method of claim 1, wherein said determining a valve failure based on a trend of temperature data of said single or multiple turn vibration waveform and said temperature data comprises:
determining the vibration amplitude and the phase of the air valve at the opening moment according to the single-circle or multi-circle vibration waveform;
determining whether the temperature value of the air valve is in a normal allowable range or not in the working process of the air valve according to the temperature data change trend of the temperature data;
if the vibration amplitude is increased and the phase and the temperature value are unchanged within the normal allowable range, determining that the air valve fault is an air valve jackscrew bolt loosening fault.
5. The method of claim 1, wherein said determining a valve failure based on a trend of temperature data of said single or multiple turn vibration waveform and said temperature data comprises:
according to the single-circle or multi-circle vibration waveform, determining the vibration amplitude and the phase of an impact peak at the moment of opening or closing the air valve;
determining whether the temperature value of the air valve is in a normal allowable range or not in the working process of the air valve according to the temperature data change trend of the temperature data;
if the vibration amplitude is lower, the phase is changed, and the temperature value is unchanged within a normal allowable range, the air valve fault is determined to be an early-stage crack fault of the air valve plate.
6. The method of claim 5, wherein said determining a valve failure based on a trend of temperature data of said single or multiple turn vibration waveform and said temperature data comprises:
if the vibration amplitude and the phase change and the temperature value is increased within a normal allowable range, determining that the air valve fault is a later crack fault of the air valve plate.
7. The method according to any one of claims 1-6, wherein the vibration sensor and the temperature sensor are integrated with each other by vibration and temperature wireless sensors or compatible with wired and wireless sensors.
8. A valve monitoring apparatus for monitoring a reciprocating compressor valve for failure, the valve monitoring apparatus comprising: a vibration sensor, a temperature sensor and a controller, the vibration sensor and the temperature sensor being installed at a valve cover position of each gas valve of the reciprocating compressor;
the controller is used for: vibration data and temperature data synchronously acquired by the monitoring equipment are acquired;
the controller is further configured to: performing phase compensation on the vibration waveform of the vibration data to obtain a single-circle or multi-circle vibration waveform;
the controller is further configured to: and determining the fault of the air valve according to the single-circle or multi-circle vibration waveform and the temperature data change trend of the temperature data.
9. The device of claim 8, wherein the vibration sensor and the temperature sensor are integrated with a vibration and temperature wireless sensor or are compatible with a wired sensor and a wireless sensor.
10. A storage medium having stored thereon a computer program which, when executed by a processor, performs the steps of the method according to any of claims 1 to 7.
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| CN202311506711.1A CN117554043A (en) | 2023-11-09 | 2023-11-09 | Air valve monitoring method, equipment and storage medium |
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| CN202311506711.1A CN117554043A (en) | 2023-11-09 | 2023-11-09 | Air valve monitoring method, equipment and storage medium |
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