CN117662510B - Fan fault diagnosis system and method thereof - Google Patents
Fan fault diagnosis system and method thereof Download PDFInfo
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- CN117662510B CN117662510B CN202410002301.1A CN202410002301A CN117662510B CN 117662510 B CN117662510 B CN 117662510B CN 202410002301 A CN202410002301 A CN 202410002301A CN 117662510 B CN117662510 B CN 117662510B
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- 238000003745 diagnosis Methods 0.000 title claims abstract description 72
- 238000000034 method Methods 0.000 title claims description 32
- 238000012423 maintenance Methods 0.000 claims description 161
- 238000011156 evaluation Methods 0.000 claims description 108
- 238000001514 detection method Methods 0.000 claims description 95
- 238000012544 monitoring process Methods 0.000 claims description 81
- 238000007405 data analysis Methods 0.000 claims description 38
- 238000012545 processing Methods 0.000 claims description 33
- 230000004907 flux Effects 0.000 claims description 32
- 238000004804 winding Methods 0.000 claims description 31
- 230000002159 abnormal effect Effects 0.000 claims description 29
- 238000004364 calculation method Methods 0.000 claims description 26
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- 230000008859 change Effects 0.000 claims description 18
- 238000007726 management method Methods 0.000 claims description 16
- 238000010606 normalization Methods 0.000 claims description 13
- 238000004458 analytical method Methods 0.000 claims description 7
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- 238000009776 industrial production Methods 0.000 abstract description 5
- 230000008439 repair process Effects 0.000 description 8
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D27/00—Control, e.g. regulation, of pumps, pumping installations or pumping systems specially adapted for elastic fluids
- F04D27/001—Testing thereof; Determination or simulation of flow characteristics; Stall or surge detection, e.g. condition monitoring
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2260/00—Function
- F05D2260/80—Diagnostics
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/70—Wind energy
- Y02E10/72—Wind turbines with rotation axis in wind direction
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Abstract
The invention relates to the technical field of fan fault diagnosis, which is used for solving the problems that the existing fan fault diagnosis system can only diagnose single fault of a fan, the diagnosis precision is not high, and the actual industrial production requirement cannot be met.
Description
Technical Field
The invention relates to the technical field of fan fault diagnosis, in particular to a fan fault diagnosis system and a method thereof.
Background
The fan is equipment widely applied to various industrial occasions, the running state of the fan directly affects the safety and efficiency of industrial production, however, due to the fact that the fan is complex in structure and bad in running environment, various faults, such as mechanical faults, dynamic balance faults, electric faults, overload of fan load, overtemperature and the like, can affect the running efficiency of the fan, and can cause serious potential safety hazards to industrial production, so that fault diagnosis and maintenance management of the fan are very important;
At present, the existing fan fault diagnosis system can only diagnose a single fault of a fan, the diagnosis precision is not high, the requirement of actual industrial production cannot be met, in addition, the existing system also lacks the function of maintenance management of the fan, analysis and management of maintenance records of the fan cannot be carried out, and the maintenance quality of the fan cannot be evaluated, so that the fan fault diagnosis system is urgently needed to be capable of comprehensively monitoring the running state of the fan, accurately diagnosing the fault of the fan and managing the maintenance of the fan;
In order to solve the above-mentioned defect, a technical scheme is provided.
Disclosure of Invention
The invention aims to solve the problems that the conventional fan fault diagnosis system can only diagnose single fault of a fan, has low diagnosis precision and cannot meet actual industrial production requirements, and provides a fan fault diagnosis system and a method thereof.
The aim of the invention can be achieved by the following technical scheme:
A fan fault diagnosis system, comprising:
and a data acquisition module: the system comprises a data analysis module, a maintenance management module, a server, a control module and a control module, wherein the control module is used for controlling the operation state parameters and the maintenance record state parameters of a target fan;
And a data analysis module: the system comprises a vibration data analysis unit, a magnetic field data analysis unit and a temperature data analysis unit, wherein the vibration data analysis unit is used for receiving the operation state parameters of the target fan, and the operation state parameters comprise a vibration data parameter, a magnetic field data parameter and a temperature data parameter;
the vibration data analysis unit is used for receiving magnetic field data parameters of the target fan, and analyzing and processing the first evaluation coefficient of the target fan according to the magnetic field data parameters to obtain the first evaluation coefficient of the target fan;
the magnetic field data analysis unit is used for receiving magnetic field data parameters of the target fan, and analyzing and processing the second evaluation coefficient of the target fan according to the magnetic field data parameters to obtain the second evaluation coefficient of the target fan;
the temperature data analysis unit is used for receiving temperature data parameters of the target fan, and analyzing and processing the third evaluation coefficient of the target fan according to the temperature data parameters to obtain the third evaluation coefficient of the target fan;
the first evaluation coefficient, the second evaluation coefficient and the third evaluation coefficient of the target fan are sent to a fault diagnosis module;
And a fault diagnosis module: the system comprises a first evaluation coefficient, a second evaluation coefficient and a third evaluation coefficient, wherein the first evaluation coefficient, the second evaluation coefficient and the third evaluation coefficient are used for receiving a target fan, and accordingly, diagnosis, analysis and processing are carried out on fault types of the target fan in operation to obtain fault type signals, wherein the fault type signals comprise a first class of fault signals, a second class of fault signals and three classes of fault signals;
The maintenance management module is used for detecting maintenance record state parameters of the target fan to obtain a maintenance quality judgment value of the target fan, and accordingly, the maintenance quality of the target fan is evaluated, judged and processed to obtain a maintenance quality grade signal, wherein the maintenance quality grade signal comprises a maintenance quality grade signal, a maintenance quality grade signal and a maintenance quality difference grade signal.
Further, the first evaluation coefficient of the target fan is analyzed and processed, and the specific operation process is as follows:
Detecting the sound intensity of each monitoring time point corresponding to each detection point of each component corresponding to the target fan in the set detection period through a sound sensor to obtain the sound intensity of each monitoring time point corresponding to each detection point of each component corresponding to the target fan in the set detection period, and carrying out mean value calculation to obtain the sound intensity value of each monitoring time point of each component corresponding to the target fan in the set detection period;
Detecting the rotation time of each monitoring time point of each component corresponding to the target fan in the set detection period through a rotation speed sensor to obtain the rotation time of each monitoring time point of each component corresponding to the target fan in the set detection period;
The rotating speed of each monitoring time point of each component corresponding to the target fan in the set detection period is detected by a rotating speed sensor, and the specific detection mode is as follows: acquiring the rotation number of each monitoring time point of each component corresponding to the target fan in a set detection period, dividing the rotation time length of each monitoring time point of each component corresponding to the target fan in the set detection period by the rotation number of each monitoring time point to obtain the rotation speed of each monitoring time point of each component corresponding to the target fan in the set detection period;
Extracting the values of the sound average intensity value, the rotation time length and the rotation speed of each component corresponding to each monitoring time point in the set detection period, respectively marking the values as yjq i j、zsci j and zsp i j, wherein i represents the number of each component of the target fan, i=1, 2,3 … … n1, n1 represents the total number of the number of each component of the target fan, j represents the number of each monitoring time point, j=1, 2,3 … … n2, n2 represents the total number of the number of each monitoring time point, and carrying out normalization processing on the extracted values according to the formula: obtaining a first evaluation coefficient delta 1 of the target fan, wherein lambda represents a natural constant,/> And/>The reference equal intensity value, the reference rotation time length and the reference rotation speed are respectively represented by yjq i j-1、zsci j-1 and zsp i j-1, the equal intensity value, the rotation time length and the rotation speed of the ith component corresponding to the set target fan at the j-1 th monitoring time point in the set detection period are respectively represented by yjq i 1、zsci 1 and zsp i 1, the equal intensity value, the rotation time length and the rotation speed of the ith component corresponding to the set target fan at the 1 st monitoring time point in the set detection period are respectively represented by alpha 1, alpha 2, alpha 3, alpha 4, alpha 5 and alpha 6, the set scale factors are respectively represented by eta 1, eta 2 and eta 3, and the weight coefficients of the equal intensity value change evaluation index, the rotation time length change evaluation index and the rotation speed change evaluation index are respectively represented by eta 1, alpha 2 and eta 3.
Further, the second evaluation coefficient of the target fan is analyzed and processed, and the specific operation process is as follows:
Detecting the magnetic flux density of each monitoring time point of the corresponding motor winding of the target fan in the set detection period through a moment magnetometer to obtain the magnetic flux density value of each monitoring time point of the corresponding motor winding of the target fan in the set detection period, carrying out difference value calculation on the magnetic flux density value of each adjacent monitoring time point of the corresponding motor winding of the target fan in the set detection period, and taking the absolute value of the difference value to obtain the magnetic flux density change value of the corresponding motor winding of the target fan in the set detection period; and extracting a maximum magnetic flux density variation value and a minimum magnetic flux density variation value therefrom;
Detecting the current of each monitoring time point of the corresponding motor winding of the target fan in the set detection period through an ammeter to obtain the current value of each monitoring time point of the corresponding motor winding of the target fan in the set detection period, carrying out average value calculation on the current value of each monitoring time point of the corresponding motor winding of the target fan in the set detection period to obtain the average current value of the corresponding motor winding of the target fan in the set detection period, and carrying out difference value calculation on the current value and the average current value of each monitoring time point of the corresponding motor winding of the target fan in the set detection period to obtain the current fluctuation value of the corresponding motor winding of the target fan in the set detection period; extracting a maximum current fluctuation value and a minimum current fluctuation value from the current fluctuation value;
Extracting the values of the maximum magnetic flux density change value CT max, the minimum magnetic flux density change value CT min, the maximum current fluctuation value DB max and the minimum current fluctuation value DB min for normalization processing, and carrying out normalization processing according to the formula: A second evaluation coefficient δ2 of the target blower fan is obtained, wherein γ1 and γ2 represent the scaling factors of the degree of variation of the magnetic flux density and the degree of fluctuation of the current, respectively.
Further, the third evaluation coefficient of the target fan is analyzed and processed, and the specific operation process is as follows:
Detecting the operation temperature value of each monitoring time point of the target fan in the set detection period by using a temperature sensor to obtain the operation temperature value of each monitoring time point of the target fan in the set detection period;
Setting the running temperature value of each monitoring time point in the detection period as an ordinate and the detection period as an abscissa, thereby establishing a two-dimensional running temperature dynamic coordinate system, drawing the running temperature value of each monitoring time point in the detection period on the two-dimensional running temperature dynamic coordinate system in a dot drawing mode, and obtaining a running temperature line graph,
Acquiring a slope value between an operating temperature value of each monitoring time point in a set detection period and an origin on a two-dimensional operating temperature dynamic coordinate system, obtaining an operating temperature slope value, setting an operating temperature reference slope threshold value, comparing and analyzing the operating temperature slope value with the set operating temperature reference slope threshold value, judging the operating temperature state of a target fan as abnormal operating temperature when the operating temperature slope value is larger than the set operating temperature reference slope threshold value, counting the number of the judged abnormal operating temperatures, and calculating the ratio of the operating temperature value to the total judging number of the operating temperature states of the target fan in the set detection period according to the formula: Obtaining an abnormal running temperature fluctuation value bdz of the target fan, wherein z1 and z2 are preset weight factors; setting an abnormal operating temperature fluctuation threshold of the target fan as bdy, calculating the difference between the abnormal operating temperature fluctuation value of the target fan and the abnormal operating temperature fluctuation threshold, and according to the formula: δ3= bdz-bdy, resulting in a third evaluation coefficient δ3 of the target fan.
Further, the fault type of the target fan in operation is diagnosed, analyzed and processed, and the specific operation process is as follows:
Extracting the values of a first evaluation coefficient delta 1, a second evaluation coefficient delta 2 and a third evaluation coefficient delta 3 of the target fan, and carrying out normalization processing according to the formula: zgp=δ1×r1+δ2×r2+δ3×r3, to obtain an operation state evaluation value ZGP of the target fan, where R1, R2, and R3 represent weight coefficients of the first evaluation coefficient, the second evaluation coefficient, and the third evaluation coefficient of the target fan, respectively;
Setting a comparison reference interval of the running state judgment value of the target fan, comparing and analyzing the running state judgment value of the target fan with a preset comparison reference interval, and judging the running state of the target fan as an abnormal state when the running state judgment value of the target fan is out of the preset comparison reference interval;
According to the running state of the target fan, judging the running state of the target fan as an abnormal state, calling the running state judgment value of the target fan, and carrying out difference value calculation on the running state judgment value of the target fan and a preset running state judgment threshold value, so as to obtain a fault judgment value;
Setting three diagnosis gradient comparison sections of the diagnosis value, namely a first gradient diagnosis section, a second gradient diagnosis section and a third gradient diagnosis section, generating one type of fault signal when the diagnosis value is in the preset first gradient diagnosis section, generating two types of fault signals when the diagnosis value is in the preset second gradient diagnosis section, and generating three types of fault signals when the diagnosis value is in the preset third gradient diagnosis section.
Further, the maintenance quality of the target fan is evaluated, judged and processed, and the specific operation process is as follows:
The oil filling times, the guard interval time and the repair rate of the event in the maintenance record state parameters of the target fan in a period of time are obtained, and are respectively marked as xpc, hgs and fxz, and meanwhile, the running state judgment value ZGP of the target fan is also called, and the following formula is adopted: Obtaining a maintenance quality judgment value WZL of the target fan, wherein θ represents a maintenance influence factor coefficient, and beta 1, beta 2 and beta 3 represent weight coefficients of oil filling times, guard period and repair rate respectively; setting a maintenance quality judgment threshold value of the target fan, comparing and analyzing the maintenance quality judgment value of the target fan with the maintenance quality judgment threshold value, generating a maintenance quality priority signal when the maintenance quality judgment value of the target fan is larger than the maintenance quality judgment threshold value, generating a maintenance quality signal when the maintenance quality judgment value of the target fan is equal to the maintenance quality judgment threshold value, and generating a maintenance quality difference signal when the maintenance quality judgment value of the target fan is smaller than the maintenance quality judgment threshold value;
And carrying out corresponding operation processing according to the generated maintenance quality grade signal.
Further, a fan fault diagnosis method comprises the following steps:
step one: and (3) data acquisition: collecting the running state parameters and maintenance record state parameters of the target fan;
Step two: data analysis: detecting and analyzing the running state parameters of the target fan to obtain a first evaluation coefficient, a second evaluation coefficient and a third evaluation coefficient of the target fan;
Step three: fault diagnosis: performing normalization calculation on the obtained first evaluation coefficient, second evaluation coefficient and third evaluation coefficient of the target fan to obtain an operation state judgment value of the target fan, comparing and analyzing the operation state judgment value with a preset comparison reference interval, judging the operation state of the target fan as an abnormal state when the operation state judgment value of the target fan is out of the preset comparison reference interval, and then calling the operation state judgment value of the target fan according to the operation state of the target fan to perform diagnosis analysis processing on the fault type of the target fan in operation to obtain a fault type signal;
Step four: maintenance management: detecting maintenance record state parameters of the target fan to obtain a maintenance quality judgment value of the target fan, evaluating and judging the maintenance quality of the target fan to obtain a maintenance quality grade signal, carrying out corresponding maintenance operation according to the maintenance quality grade signal, carrying out detailed record on the maintenance quality grade signal, generating a maintenance quality report every corresponding set time period for each maintenance operation process and result of the detailed record, and carrying out display notification on a display terminal.
Compared with the prior art, the invention has the beneficial effects that:
According to the invention, the running state parameters and the maintenance record state parameters are collected from the target fan in real time or periodically. The parameters are transmitted to the data analysis module and the maintenance management module through the server, so that real-time, accurate and efficient data acquisition is realized, and a foundation is provided for subsequent data analysis and maintenance management;
The state parameters from the data acquisition module are received and respectively sent to the corresponding data analysis units, so that the classification processing of the data is realized, and the efficiency and the accuracy of the data analysis are improved;
The vibration data parameter, the magnetic field data parameter and the temperature data parameter of the target fan are respectively analyzed and processed to obtain a first evaluation coefficient, a second evaluation coefficient and a third evaluation coefficient, the first evaluation coefficient, the second evaluation coefficient and the third evaluation coefficient respectively reflect the problems of mechanical failure, dynamic balance failure, electric failure, overload of fan load, overtemperature and the like of the fan, and the three evaluation coefficients are synthesized to perform fault diagnosis analysis, so that the working state of the fan can be more comprehensively known, the accuracy and the reliability of fault diagnosis are improved, the limitation of a single evaluation coefficient is avoided, the comprehensive evaluation mode is beneficial to timely finding and diagnosing the failure of the fan, so that maintenance measures are timely taken, the influence of the failure on the operation of the fan is avoided, the service life of the fan is prolonged, and the operation efficiency and the stability of the fan are improved;
The maintenance record state parameters of the target fan are detected and analyzed, so that the maintenance quality of the target fan is evaluated, a maintenance quality grade signal is given, and the maintenance quality is evaluated, so that the maintenance strategy can be timely adjusted, the stable operation of the fan is ensured, and the service life of the fan is prolonged.
Drawings
For the convenience of those skilled in the art, the present invention will be further described with reference to the accompanying drawings;
FIG. 1 is a general block diagram of a system according to the present invention
Fig. 2 is a block diagram of the method of the present invention.
Detailed Description
The technical solutions of the present invention will be clearly and completely described in connection with the embodiments, and it is obvious that the described embodiments are only some embodiments of the present invention, 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.
As shown in fig. 1, a fan fault diagnosis system includes: the system comprises a data acquisition module, a server, a data analysis module, a fault diagnosis module, a maintenance management module and a display terminal, wherein the data analysis module comprises a vibration data analysis unit, a magnetic field data analysis unit and a temperature data analysis unit;
the data acquisition module is used for acquiring the running state parameters and the maintenance record state parameters of the target fan and respectively transmitting the running state parameters and the maintenance record state parameters to the data analysis module and the maintenance management module through the server;
The data analysis module is used for receiving the running state parameters of the target fan, wherein the running state parameters comprise vibration data parameters, magnetic field data parameters and temperature data parameters, and sending the vibration data parameters, the magnetic field data parameters and the temperature data parameters to the vibration data analysis unit, the magnetic field data analysis unit and the temperature data analysis unit respectively;
the vibration data analysis unit is used for receiving vibration data parameters of the target fan, and accordingly, the first evaluation coefficient of the target fan is analyzed and processed, and the specific operation process is as follows:
Detecting the sound intensity of each monitoring time point corresponding to each detection point of each component corresponding to the target fan in the set detection period through a sound sensor to obtain the sound intensity of each monitoring time point corresponding to each detection point of each component corresponding to the target fan in the set detection period, and carrying out mean value calculation to obtain the sound intensity value of each monitoring time point of each component corresponding to the target fan in the set detection period;
Detecting the rotation time of each monitoring time point of each component corresponding to the target fan in the set detection period through a rotation speed sensor to obtain the rotation time of each monitoring time point of each component corresponding to the target fan in the set detection period;
The rotating speed of each monitoring time point of each component corresponding to the target fan in the set detection period is detected by a rotating speed sensor, and the specific detection mode is as follows: acquiring the rotation number of each monitoring time point of each component corresponding to the target fan in a set detection period, dividing the rotation time length of each monitoring time point of each component corresponding to the target fan in the set detection period by the rotation number of each monitoring time point to obtain the rotation speed of each monitoring time point of each component corresponding to the target fan in the set detection period;
Extracting the values of the sound average intensity value, the rotation time length and the rotation speed of each component corresponding to each monitoring time point in the set detection period, respectively marking the values as yjq i j、zsci j and zsp i j, wherein i represents the number of each component of the target fan, i=1, 2,3 … … n1, n1 represents the total number of the number of each component of the target fan, j represents the number of each monitoring time point, j=1, 2,3 … … n2, n2 represents the total number of the number of each monitoring time point, and carrying out normalization processing on the extracted values according to the formula: obtaining a first evaluation coefficient delta 1 of the target fan, wherein lambda represents a natural constant,/> And/>The method comprises the steps of respectively representing a reference equal intensity value, a reference rotation time length and a reference rotation speed, wherein yjq i j-1、zsci j-1 and zsp i j-1 are respectively represented as a sound equal intensity value, a rotation time length and a rotation speed of a j-1 th monitoring time point of a set target fan corresponding to an i-th component in a set detection period, yjq i 1、zsci 1 and zsp i 1 are respectively represented as a sound equal intensity value, a rotation time length and a rotation speed of a1 st monitoring time point of a set target fan corresponding to the i-th component in the set detection period, alpha 1, alpha 2, alpha 3, alpha 4, alpha 5 and alpha 6 are respectively represented as set scale factors, eta 1, eta 2 and eta 3 are respectively represented as weight coefficients of a sound equal intensity value change evaluation index, a rotation time length change evaluation index and a rotation speed change evaluation index, eta 1 > eta 2 > eta 3, and the weight coefficients are used for balancing the duty ratio weight of each item of data in formula calculation so as to promote the accuracy of calculation results;
the magnetic field data analysis unit is used for receiving magnetic field data parameters of the target fan, analyzing and processing a second evaluation coefficient of the target fan according to the magnetic field data parameters, and the specific operation process is as follows:
Detecting the magnetic flux density of each monitoring time point of the corresponding motor winding of the target fan in the set detection period through a moment magnetometer to obtain the magnetic flux density value of each monitoring time point of the corresponding motor winding of the target fan in the set detection period, carrying out difference value calculation on the magnetic flux density value of each adjacent monitoring time point of the corresponding motor winding of the target fan in the set detection period, and taking the absolute value of the difference value to obtain the magnetic flux density change value of the corresponding motor winding of the target fan in the set detection period; and extracting a maximum magnetic flux density variation value and a minimum magnetic flux density variation value from the magnetic flux density variation values, and marking the maximum magnetic flux density variation value and the minimum magnetic flux density variation value as CT max and CT min respectively;
detecting the current of each monitoring time point of the corresponding motor winding of the target fan in the set detection period through an ammeter to obtain the current value of each monitoring time point of the corresponding motor winding of the target fan in the set detection period, carrying out average value calculation on the current value of each monitoring time point of the corresponding motor winding of the target fan in the set detection period to obtain the average current value of the corresponding motor winding of the target fan in the set detection period, and carrying out difference value calculation on the current value and the average current value of each monitoring time point of the corresponding motor winding of the target fan in the set detection period to obtain the current fluctuation value of the corresponding motor winding of the target fan in the set detection period; and extracting a maximum current fluctuation value and a minimum current fluctuation value therefrom, and marking them as DB max and DB min, respectively;
extracting the numerical values of the maximum magnetic flux density change value, the minimum magnetic flux density change value, the maximum current fluctuation value and the minimum current fluctuation value, carrying out normalization processing, and according to the formula: Obtaining a second evaluation coefficient delta 2 of the target fan, wherein gamma 1 and gamma 2 respectively represent the proportional coefficients of the magnetic flux density change degree and the current fluctuation degree, gamma 1 is larger than gamma 2, and the proportional coefficients are used for balancing the duty ratio weight of each item of data in formula calculation, so that the accuracy of a calculation result is promoted;
The temperature data analysis unit is used for receiving temperature data parameters of the target fan, analyzing and processing a third evaluation coefficient of the target fan according to the temperature data parameters, and the specific operation process is as follows:
Detecting the operation temperature of each monitoring time point of the target fan in the set detection period by using a temperature sensor to obtain the operation temperature value of each monitoring time point of the target fan in the set detection period;
Setting the running temperature value of each monitoring time point in the detection period as an ordinate and setting the detection period as an abscissa, thereby establishing a two-dimensional running temperature dynamic coordinate system, and drawing the running temperature value of each monitoring time point in the detection period on the two-dimensional running temperature dynamic coordinate system in a dot drawing mode to obtain a running temperature line graph;
Acquiring a slope value between an operating temperature value of each monitoring time point in a set detection period and an origin on a two-dimensional operating temperature dynamic coordinate system, obtaining an operating temperature slope value, setting an operating temperature reference slope threshold value, comparing and analyzing the operating temperature slope value with the set operating temperature reference slope threshold value, judging the operating temperature state of a target fan as abnormal operating temperature when the operating temperature slope value is larger than the set operating temperature reference slope threshold value, counting the number of the judged abnormal operating temperatures, and calculating the ratio of the operating temperature value to the total judging number of the operating temperature states of the target fan in the set detection period according to the formula: Obtaining an abnormal running temperature fluctuation value bdz of the target fan, wherein z1 and z2 are preset weight factors, s Different species represents the number of abnormal running temperatures determined by the running temperature state of the target fan, and s Total (S) represents the total determination number of the running temperature states of the target fan in a set detection period; setting an abnormal operating temperature fluctuation threshold of the target fan as bdy, calculating the difference between the abnormal operating temperature fluctuation value of the target fan and the abnormal operating temperature fluctuation threshold, and according to the formula: δ3= bdz-bdy, obtaining a third evaluation coefficient δ3 of the target fan;
The first evaluation coefficient delta 1, the second evaluation coefficient delta 2 and the third evaluation coefficient delta 3 of the target fan are sent to a fault diagnosis module;
The fault diagnosis module is used for receiving the first evaluation coefficient delta 1, the second evaluation coefficient delta 2 and the third evaluation coefficient delta 3 of the target fan, and accordingly, diagnosing, analyzing and processing the fault type of the target fan in operation, wherein the specific operation process is as follows:
Extracting the values of a first evaluation coefficient delta 1, a second evaluation coefficient delta 2 and a third evaluation coefficient delta 3 of the target fan, and carrying out normalization processing according to the formula: zgp=δ1×r1+δ2×r2+δ3×r3, to obtain an operation state evaluation value ZGP of the target fan, where R1, R2, and R3 represent weight coefficients of the first evaluation coefficient, the second evaluation coefficient, and the third evaluation coefficient of the target fan, respectively, where the weight coefficients are used to equalize the duty weights of each item of data in the formula calculation, so as to promote accuracy of the calculation result;
Setting a comparison reference interval of the operation state judgment value of the target fan, comparing and analyzing the operation state judgment value of the target fan with a preset comparison reference interval, judging the operation state of the target fan as a normal state when the operation state judgment value of the target fan is within the preset comparison reference interval, and judging the operation state of the target fan as an abnormal state when the operation state judgment value of the target fan is outside the preset comparison reference interval;
According to the running state of the target fan judged to be an abnormal state, then the running state judgment value of the target fan is called, and the running state judgment value of the target fan and a preset running state judgment threshold value are subjected to difference value calculation, so that a fault judgment value is obtained;
Setting three diagnosis gradient comparison intervals of the diagnosis evaluation value, namely a first gradient diagnosis interval rong, a second gradient diagnosis interval rong and a third gradient diagnosis interval rong3 respectively, wherein rong1 = Arong 2=2 Arong3, rong1 > rong2 > rong, A represents the multiple of the gradient, and the setting of specific numerical values of A is specifically set in a specific fan example by a person skilled in the art;
Generating a first type of fault signal when the diagnosis value is in a preset first gradient diagnosis interval rong, generating a second type of fault signal when the diagnosis value is in a preset second gradient diagnosis interval rong, and generating three types of fault signals when the diagnosis value is in a preset third gradient diagnosis interval rong; the generated fault type signals are sent to a display terminal to be displayed and notified, wherein the fault type signals comprise one type of fault signals, two types of fault signals and three types of fault signals;
It should be noted that, a type of fault signal represents serious mechanical faults, the mechanical faults represent loosening or abrasion of components, the performance of the fan is easy to be reduced, even larger faults are caused, and the occurrence of the type of fault signal requires immediate investigation and repair, so that the fan is ensured to normally operate; the second-class fault signals represent electrical faults, the electrical faults represent problems in the aspects of motors, circuits or control systems, and maintenance needs to be carried out as soon as possible to avoid greater influence on the operation of the fan; the three types of fault signals represent faults of load overtemperature, the load overtemperature represents the conditions of the fan caused by long-time high-load operation, cooling system faults or poor ventilation and the like, the occurrence of the three types of fault signals reminds maintenance personnel to pay attention to the temperature condition of the fan, whether the cooling system works normally is checked, and corresponding measures are taken to prevent the fan from being further damaged by the overtemperature;
The maintenance management module is used for detecting maintenance record state parameters of the target fan, so that the maintenance quality of the target fan is evaluated, judged and processed, and the specific operation process is as follows:
The oil filling times, the guard interval time and the repair rate of the event in the maintenance record state parameters of the target fan in a period of time are obtained, and are respectively marked as xpc, hgs and fxz, and meanwhile, the running state judgment value ZGP of the target fan is also called, and the following formula is adopted: Obtaining a maintenance quality judgment value WZL of the target fan, wherein θ represents a maintenance influence factor coefficient, beta 1, beta 2 and beta 3 represent weight coefficients of oil filling times, guard period and repair rate respectively, and beta 1 is more than beta 2 and more than beta 3, and the weight coefficients are used for balancing the duty ratio weight of each item of data in formula calculation, so that the accuracy of a calculation result is promoted;
It should be noted that the oil filling times refer to the times of filling oil into the fan lubrication system, and proper lubrication is critical to the normal operation of the fan, because friction and abrasion can be reduced, smooth operation of mechanical parts is ensured, and the degree of the oil filling times directly reflects the importance degree of maintenance personnel on the fan lubrication management; the guard period refers to the interval between regular maintenance or special protective measures for the fan, for example, certain critical components may need to be checked or replaced regularly, and the interval is the guard period, and this parameter can help to evaluate the rationality and effectiveness of maintenance planning; therefore, the repair rate refers to the frequency of maintenance after the fan fails, so that the reliability of the fan and the quality of maintenance work can be reflected by the repair rate, and if the repair rate is higher, the reliability of equipment and the maintenance work need to be further improved;
Setting a maintenance quality judgment threshold value of the target fan as WZY, comparing and analyzing the maintenance quality judgment value of the target fan with the maintenance quality judgment threshold value, generating a maintenance quality grade signal when the maintenance quality judgment value of the target fan is larger than the maintenance quality judgment threshold value, generating a maintenance quality grade signal when the maintenance quality judgment value of the target fan is equal to the maintenance quality judgment threshold value, and generating a maintenance quality grade signal when the maintenance quality judgment value of the target fan is smaller than the maintenance quality judgment threshold value, wherein the maintenance quality grade signal, the maintenance quality grade signal and the maintenance quality grade signal are collectively called as a maintenance quality grade signal;
According to the generated maintenance quality priority signal, the current maintenance strategy is indicated to be effective, the existing maintenance plan and maintenance operation are continuously maintained according to the current maintenance strategy and the maintenance operation are recorded in detail, and meanwhile, a maintenance quality report is generated and displayed on a display terminal every F1 time period according to each maintenance operation process and each maintenance result recorded in detail;
According to the generated maintenance quality signal, the maintenance plan can be moderately adjusted, for example, the inspection frequency is increased or the time interval for replacing vulnerable parts is increased, detailed records are carried out on the maintenance plan, meanwhile, each maintenance operation process and result recorded in detail are generated into a maintenance quality report every F2 time period, and display notification is carried out on a display terminal;
According to the generated maintenance quality poor-level signal, more strict maintenance measures are adopted, such as increasing maintenance frequency, improving maintenance process or replacing fault components, and recording the detailed maintenance process and the result, and meanwhile, each maintenance operation process and the result recorded in detail generate a maintenance quality report every F3 time period and display the report on a display terminal.
As shown in fig. 2, a fan fault diagnosis method includes the following steps:
step one: and (3) data acquisition: collecting the running state parameters and maintenance record state parameters of the target fan;
Step two: data analysis: detecting and analyzing the running state parameters of the target fan, wherein the running state parameters comprise vibration data parameters, magnetic field data parameters and temperature data parameters, and detecting and analyzing the sound intensity, the rotation time length and the rotation number of each monitoring time point of each component corresponding to the target fan in a set detection period to obtain a sound average intensity value, a rotation time length and a rotation speed, so that the first evaluation coefficient of the target fan is analyzed and processed to obtain the first evaluation coefficient of the target fan; detecting and analyzing the magnetic flux density and the current of the motor winding corresponding to the target fan at each monitoring time point in a set detection period to obtain a maximum magnetic flux density change value, a minimum magnetic flux density change value, a maximum current fluctuation value and a minimum current fluctuation value, and analyzing and processing a second evaluation coefficient of the target fan to obtain a second evaluation coefficient of the target fan; detecting and analyzing the operation temperature of the target fan at each monitoring time point in a set detection period to obtain an abnormal operation temperature fluctuation value, and analyzing and processing the third evaluation coefficient of the target fan to obtain the third evaluation coefficient of the target fan;
Step three: fault diagnosis: performing normalization calculation on the obtained first evaluation coefficient, second evaluation coefficient and third evaluation coefficient of the target fan to obtain an operation state judgment value of the target fan, comparing and analyzing the operation state judgment value with a preset comparison reference interval, judging the operation state of the target fan as an abnormal state when the operation state judgment value of the target fan is out of the preset comparison reference interval, and then calling the operation state judgment value of the target fan according to the operation state of the target fan to perform diagnosis analysis processing on the fault type of the target fan in operation to obtain a fault type signal;
Step four: maintenance management: detecting maintenance record state parameters of the target fan to obtain a maintenance quality judgment value of the target fan, evaluating and judging the maintenance quality of the target fan to obtain a maintenance quality grade signal, carrying out corresponding maintenance operation according to the maintenance quality grade signal, carrying out detailed record on the maintenance quality grade signal, generating a maintenance quality report every corresponding set time period for each maintenance operation process and result of the detailed record, and carrying out display notification on a display terminal.
The preferred embodiments of the invention disclosed above are intended only to assist in the explanation of the invention. The preferred embodiments are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and the practical application, to thereby enable others skilled in the art to best understand and utilize the invention. The invention is limited only by the claims and the full scope and equivalents thereof.
Claims (3)
1. A fan fault diagnosis system, comprising:
and a data acquisition module: the system comprises a data analysis module, a maintenance management module, a server, a control module and a control module, wherein the control module is used for controlling the operation state parameters and the maintenance record state parameters of a target fan;
And a data analysis module: the system comprises a vibration data analysis unit, a magnetic field data analysis unit and a temperature data analysis unit, wherein the vibration data analysis unit is used for receiving the operation state parameters of the target fan, and the operation state parameters comprise a vibration data parameter, a magnetic field data parameter and a temperature data parameter; the vibration data analysis unit is used for receiving magnetic field data parameters of the target fan, and analyzing and processing the first evaluation coefficient of the target fan according to the magnetic field data parameters to obtain the first evaluation coefficient of the target fan; the magnetic field data analysis unit is used for receiving magnetic field data parameters of the target fan, and analyzing and processing the second evaluation coefficient of the target fan according to the magnetic field data parameters to obtain the second evaluation coefficient of the target fan; the temperature data analysis unit is used for receiving temperature data parameters of the target fan, and analyzing and processing the third evaluation coefficient of the target fan according to the temperature data parameters to obtain the third evaluation coefficient of the target fan; the first evaluation coefficient, the second evaluation coefficient and the third evaluation coefficient of the target fan are sent to a fault diagnosis module;
And a fault diagnosis module: the system comprises a first evaluation coefficient, a second evaluation coefficient and a third evaluation coefficient, wherein the first evaluation coefficient, the second evaluation coefficient and the third evaluation coefficient are used for receiving a target fan, and accordingly, diagnosis, analysis and processing are carried out on fault types of the target fan in operation to obtain fault type signals, wherein the fault type signals comprise a first class of fault signals, a second class of fault signals and three classes of fault signals;
And a maintenance management module: the system comprises a maintenance quality judging device, a maintenance quality judging device and a maintenance quality judging device, wherein the maintenance quality judging device is used for detecting maintenance record state parameters of a target fan to obtain a maintenance quality judging value of the target fan, so that maintenance quality of the target fan is evaluated, judged and processed to obtain a maintenance quality grade signal, and the maintenance quality grade signal comprises a maintenance quality grade signal, a maintenance quality grade signal and a maintenance quality difference grade signal;
analyzing and processing a first evaluation coefficient of a target fan, wherein the specific operation process is as follows:
Detecting the sound intensity of each monitoring time point corresponding to each detection point of each component corresponding to the target fan in the set detection period to obtain the sound intensity of each monitoring time point corresponding to each detection point of each component corresponding to the target fan in the set detection period, and calculating the average value of the sound intensities to obtain the sound intensity value of each monitoring time point of each component corresponding to the target fan in the set detection period;
Detecting the rotation time length of each member corresponding to the target fan at each monitoring time point in the set detection period to obtain the rotation time length of each member corresponding to the target fan at each monitoring time point in the set detection period;
The rotating speed of each monitoring time point of each component corresponding to the target fan in the set detection period is detected, and the specific detection mode is as follows: acquiring the rotation number of each monitoring time point of each component corresponding to the target fan in a set detection period, dividing the rotation time length of each monitoring time point of each component corresponding to the target fan in the set detection period by the rotation number of each monitoring time point to obtain the rotation speed of each monitoring time point of each component corresponding to the target fan in the set detection period;
extracting the values of the sound average intensity value, the rotation duration and the rotation speed of each member corresponding to the target fan at each monitoring time point in the set detection period, and carrying out normalization processing to obtain a first evaluation coefficient of the target fan;
Analyzing and processing a second evaluation coefficient of the target fan, wherein the specific operation process is as follows:
Detecting the magnetic flux density of each monitoring time point of the corresponding motor winding of the target fan in a set detection period to obtain the magnetic flux density value of each monitoring time point of the corresponding motor winding of the target fan in the set detection period, calculating the difference value of the magnetic flux density values of each adjacent monitoring time point of the corresponding motor winding of the target fan in the set detection period, and taking the absolute value of the difference value to obtain the magnetic flux density change value of the corresponding motor winding of the target fan in the set detection period; and extracting a maximum magnetic flux density variation value and a minimum magnetic flux density variation value therefrom;
Detecting the current of each monitoring time point of the corresponding motor winding of the target fan in a set detection period to obtain the current value of each monitoring time point of the corresponding motor winding of the target fan in the set detection period, carrying out average value calculation on the current value of each monitoring time point of the corresponding motor winding of the target fan in the set detection period to obtain the average current value of the corresponding motor winding of the target fan in the set detection period, and carrying out difference value calculation on the current value and the average current value of each monitoring time point of the corresponding motor winding of the target fan in the set detection period to obtain the current fluctuation value of the corresponding motor winding of the target fan in the set detection period; extracting a maximum current fluctuation value and a minimum current fluctuation value from the current fluctuation value;
Extracting the numerical values of the maximum magnetic flux density change value, the minimum magnetic flux density change value, the maximum current fluctuation value and the minimum current fluctuation value, and carrying out normalization processing to obtain a second evaluation coefficient of the target fan;
analyzing and processing a third evaluation coefficient of the target fan, wherein the specific operation process is as follows:
detecting the operation temperature value of each monitoring time point of the target fan in the set detection period to obtain the operation temperature value of each monitoring time point of the target fan in the set detection period;
Setting the running temperature value of each monitoring time point in the detection period as an ordinate and setting the detection period as an abscissa, thereby establishing a two-dimensional running temperature dynamic coordinate system, and drawing the running temperature value of each monitoring time point in the detection period on the two-dimensional running temperature dynamic coordinate system in a dot drawing mode to obtain a running temperature line graph;
Acquiring a slope value between an operating temperature value of each monitoring time point in a set detection period and an original point on a two-dimensional operating temperature dynamic coordinate system, obtaining an operating temperature slope value, setting an operating temperature reference slope threshold value, comparing and analyzing the operating temperature slope value with the set operating temperature reference slope threshold value, judging the operating temperature state of a target fan as abnormal operating temperature when the operating temperature slope value is larger than the set operating temperature reference slope threshold value, counting the number of the judged abnormal operating temperatures, and performing duty ratio calculation with the total judging number of the operating temperature states of the target fan in the set detection period to obtain an operating temperature abnormal fluctuation value of the target fan; setting an abnormal operating temperature fluctuation threshold of the target fan, and calculating the difference between the abnormal operating temperature fluctuation value of the target fan and the abnormal operating temperature fluctuation threshold to obtain a third evaluation coefficient of the target fan;
The fault type of the target fan in operation is diagnosed, analyzed and processed, and the specific operation process is as follows:
Extracting the values of the first evaluation coefficient, the second evaluation coefficient and the third evaluation coefficient of the target fan, and carrying out normalization calculation processing to obtain an operation state judgment value of the target fan;
Setting a comparison reference interval of the running state judgment value of the target fan, comparing and analyzing the running state judgment value of the target fan with a preset comparison reference interval, and judging the running state of the target fan as an abnormal state when the running state judgment value of the target fan is out of the preset comparison reference interval;
According to the running state of the target fan judged to be an abnormal state, then the running state judgment value of the target fan is called, and the running state judgment value of the target fan and a preset running state judgment threshold value are subjected to difference value calculation, so that a fault judgment value is obtained;
Setting three diagnosis gradient comparison sections of the diagnosis value, namely a first gradient diagnosis section, a second gradient diagnosis section and a third gradient diagnosis section, generating one type of fault signal when the diagnosis value is in the preset first gradient diagnosis section, generating two types of fault signals when the diagnosis value is in the preset second gradient diagnosis section, and generating three types of fault signals when the diagnosis value is in the preset third gradient diagnosis section.
2. The fan fault diagnosis system according to claim 1, wherein the maintenance quality of the target fan is evaluated, judged and processed, and the specific operation process is as follows:
Acquiring the oil filling times, the guard period and the event repairing rate in maintenance record state parameters of the target fan within a period of time, and simultaneously, acquiring an operation state judgment value of the target fan, and processing according to a formula to obtain a maintenance quality judgment value of the target fan; setting a maintenance quality judgment threshold value of the target fan, comparing and analyzing the maintenance quality judgment value of the target fan with the maintenance quality judgment threshold value, generating a maintenance quality priority signal when the maintenance quality judgment value of the target fan is larger than the maintenance quality judgment threshold value, generating a maintenance quality signal when the maintenance quality judgment value of the target fan is equal to the maintenance quality judgment threshold value, and generating a maintenance quality difference signal when the maintenance quality judgment value of the target fan is smaller than the maintenance quality judgment threshold value;
And carrying out corresponding operation processing according to the generated maintenance quality grade signal.
3. The fan fault diagnosis system according to claim 1, wherein the fault diagnosis method of the system comprises the steps of:
step one: and (3) data acquisition: collecting the running state parameters and maintenance record state parameters of the target fan;
Step two: data analysis: detecting and analyzing the running state parameters of the target fan to obtain a first evaluation coefficient, a second evaluation coefficient and a third evaluation coefficient of the target fan;
Step three: fault diagnosis: performing normalization calculation on the obtained first evaluation coefficient, second evaluation coefficient and third evaluation coefficient of the target fan to obtain an operation state judgment value of the target fan, comparing and analyzing the operation state judgment value with a preset comparison reference interval, judging the operation state of the target fan as an abnormal state when the operation state judgment value of the target fan is out of the preset comparison reference interval, and then calling the operation state judgment value of the target fan according to the operation state of the target fan to perform diagnosis analysis processing on the fault type of the target fan in operation to obtain a fault type signal;
Step four: maintenance management: detecting maintenance record state parameters of the target fan to obtain a maintenance quality judgment value of the target fan, evaluating and judging the maintenance quality of the target fan to obtain a maintenance quality grade signal, carrying out corresponding maintenance operation according to the maintenance quality grade signal, carrying out detailed record on the maintenance quality grade signal, generating a maintenance quality report every corresponding set time period for each maintenance operation process and result of the detailed record, and carrying out display notification on a display terminal.
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