CN206221222U - Submersible pump energy-saving and frequency-variable integrated test system - Google Patents
Submersible pump energy-saving and frequency-variable integrated test system Download PDFInfo
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Abstract
本实用新型属于水泵检测技术领域，特别涉及一种潜水电泵变频节能综合测试系统。本实用新型是由水源单元的输出端和水路单元的输入端相连接，水路单元的出水端和水泵的入水端相连接，水泵的电源输入端和变频试验电源的输出端相连接；水路单元的控制端和控制单元的输出端相连接；压力测试单元和流量测试单元的测量端均和水路单元相连接，压力测试单元和流量测试单元的信号输出端均和数据采集单元的信号输入端相连接。本实用新型采用变频试验电源通过改变速度进而实现流量的调节，在同样流量的试验情况下，原来消耗在阀门的功率就可以避免，能节省试验过程电能损耗，具有变频调速效果好、节能效果显著、安全可靠等优点。
The utility model belongs to the technical field of water pump detection, in particular to a frequency conversion and energy-saving comprehensive test system for submersible electric pumps. The utility model is connected by the output end of the water source unit and the input end of the waterway unit, the water outlet end of the waterway unit is connected with the water inlet end of the water pump, the power supply input end of the water pump is connected with the output end of the frequency conversion test power supply; the waterway unit The control terminal is connected to the output terminal of the control unit; the measurement terminals of the pressure test unit and the flow test unit are connected to the waterway unit, and the signal output terminals of the pressure test unit and the flow test unit are connected to the signal input terminal of the data acquisition unit . The utility model adopts the frequency conversion test power supply to realize the adjustment of the flow rate by changing the speed. Under the test condition of the same flow rate, the power consumed in the valve can be avoided, which can save the power loss in the test process, and has good effect of frequency conversion speed regulation and energy saving effect. Significant, safe and reliable advantages.
Description
技术领域technical field
本实用新型属于水泵检测技术领域，特别涉及一种潜水电泵变频节能综合测试系统。The utility model belongs to the technical field of water pump detection, in particular to a frequency conversion and energy-saving comprehensive test system for submersible electric pumps.
背景技术Background technique
潜水电泵是指泵体叶轮和驱动叶轮的电机都潜入水中工作的一种水泵，有深井用和作业面用两种。随着机电一体化技术的迅猛发展，新的测试技术和测试手段不断推陈出新，使得检测手段、检测方法和检测设备也发生了变革性的变化，形成了自动化、实时化和智能化的检测系统。微电子学、信息技术和现代控制理论在各个领域具有广泛的运用。潜水电泵的测试技术和测试手段不断进步，逐渐形成了以工业计算机和变频调速技术为核心智能化、实时化的检验系统。Submersible electric pump refers to a kind of water pump in which both the impeller of the pump body and the motor driving the impeller are submerged in water. There are two types for deep wells and working surfaces. With the rapid development of mechatronics technology, new testing technologies and testing methods are constantly being introduced, resulting in transformative changes in testing methods, testing methods and testing equipment, forming an automated, real-time and intelligent testing system. Microelectronics, information technology and modern control theory are widely used in various fields. The test technology and test methods of submersible pumps have been continuously improved, and an intelligent and real-time inspection system with industrial computers and frequency conversion technology as the core has gradually been formed.
实用新型内容Utility model content
针对上述现有技术中存在的不足之处，本实用新型提供一种潜水电泵变频节能综合测试系统。其目的是为了提供一种具有结构合理、变频调速效果好、节能效果显著、安全可靠的综合测试系统。实现水泵检验过程的自动化和智能化，同时避免能量的浪费。Aiming at the deficiencies in the above-mentioned prior art, the utility model provides a comprehensive test system for frequency conversion and energy saving of submersible electric pumps. Its purpose is to provide a comprehensive test system with reasonable structure, good effect of frequency conversion speed regulation, remarkable energy saving effect, safety and reliability. Realize the automation and intelligence of the pump inspection process while avoiding energy waste.
为了实现上述实用新型目的，本实用新型是通过以下技术方案来实现的：In order to realize above-mentioned utility model purpose, the utility model is realized through the following technical solutions:
潜水电泵变频节能综合测试系统，是由水源单元的输出端和水路单元的输入端相连接，水路单元的出水端和水泵的入水端相连接，水泵的电源输入端和变频试验电源的输出端相连接；The submersible pump frequency conversion energy-saving comprehensive test system is connected by the output end of the water source unit and the input end of the water circuit unit, the water outlet end of the water circuit unit is connected with the water inlet end of the water pump, the power input end of the water pump is connected with the output end of the frequency conversion test power supply connected;
水路单元的控制端和控制单元的输出端相连接；压力测试单元和流量测试单元的测量端均和水路单元相连接，压力测试单元和流量测试单元的信号输出端均和数据采集单元的信号输入端相连接；The control end of the waterway unit is connected to the output end of the control unit; the measurement ends of the pressure test unit and the flow test unit are connected to the waterway unit, and the signal output ends of the pressure test unit and the flow test unit are connected to the signal input of the data acquisition unit terminal connection;
转差测试单元、电压测试单元和电流测试单元的测试端均和水泵相连接，转差测试单元、电压测试单元和电流测试单元的信号输出端均和数据采集单元的信号输入端相连接，数据采集单元的信号输出端和控制单元的信号输入端相连接，工业计算机的通讯接口和控制单元的通讯接口通过串口相连接；变频试验电源的控制端和控制单元的信号输出端相连接。The test terminals of the slip test unit, the voltage test unit and the current test unit are all connected to the water pump, and the signal output terminals of the slip test unit, the voltage test unit and the current test unit are all connected to the signal input terminals of the data acquisition unit, and the data The signal output terminal of the acquisition unit is connected with the signal input terminal of the control unit, the communication interface of the industrial computer is connected with the communication interface of the control unit through the serial port; the control terminal of the frequency conversion test power supply is connected with the signal output terminal of the control unit.
所述水路单元的控制端为电磁阀。The control end of the waterway unit is a solenoid valve.
为了达到上述目的，本实用新型提出一种潜水电泵变频节能综合测试系统，该系统由水源单元、水路单元、压力测试单元、流量测试单元、转差测试单元、电压测试单元、电流测试单元、数据采集单元、工业计算机、控制单元、变频试验电源和水泵组成，其中水源单元的输出端和水路单元的输入端相连接，水路单元的控制端即电磁阀和控制单元的输出端相连接，压力测试单元和流量测试单元的测量端和水路单元相连接，压力测试单元和流量测试单元的信号输出端和数据采集单元的信号输入端相连接，转差测试单元、电压测试单元和电流测试单元的测试端和水泵相连接，转差测试单元、电压测试单元和电流测试单元的的信号输出端和数据采集单元的信号输入端相连接，数据采集单元的信号输出端和控制单元的信号输入端相连接，工业计算机的通讯接口和控制单元的通讯接口通过串口相连接，变频试验电源的控制端和控制单元的信号输出端相连接，变频试验电源的输出端和水泵的电源输入端相连接。In order to achieve the above purpose, the utility model proposes a comprehensive test system for frequency conversion and energy saving of submersible electric pumps. It is composed of data acquisition unit, industrial computer, control unit, frequency conversion test power supply and water pump. The output end of the water source unit is connected to the input end of the water circuit unit, and the control end of the water circuit unit is connected to the output end of the solenoid valve and the control unit. The measurement terminals of the test unit and the flow test unit are connected to the waterway unit, the signal output terminals of the pressure test unit and the flow test unit are connected to the signal input terminals of the data acquisition unit, the slip test unit, the voltage test unit and the current test unit are connected to each other. The test terminal is connected to the water pump, the signal output terminals of the slip test unit, the voltage test unit and the current test unit are connected to the signal input terminal of the data acquisition unit, and the signal output terminal of the data acquisition unit is connected to the signal input terminal of the control unit. Connection, the communication interface of the industrial computer and the communication interface of the control unit are connected through the serial port, the control terminal of the frequency conversion test power supply is connected with the signal output terminal of the control unit, and the output terminal of the frequency conversion test power supply is connected with the power input terminal of the water pump.
潜水电泵变频节能综合测试系统各个组成部分的功能描述如下：水源单元具有供试验用足够容量水和良好的水循环系统，可以为试验的顺利进行提供水源，同时具有水位调节功能；水路单元由六条不同直径的管道和电动阀门组成，实现试验过程的水循环和压力调节；压力测试单元、流量测试单元、转差测试单元、电压测试单元、电流测试单元采集矿用水泵的压力、流量、转差、电压和电流原始数据；数据采集单元将原始数据转换成控制单元可识别的信号，实现二次仪表采集数据和控制单元可接收信号之间的转换；控制单元和变频电源为整个系统的核心，实现整个试验系统控制指令输出、试验数据的处理及试验工况动态调节；工业计算机完成试验指令输入、试验数据分析处理、试验曲线的拟合及系统参数和试验结果的显示和存储。The functions of each component of the submersible pump frequency conversion energy saving comprehensive test system are described as follows: the water source unit has sufficient water capacity for the test and a good water circulation system, which can provide water for the smooth progress of the test, and has the function of water level adjustment; the water circuit unit consists of six It consists of pipes of different diameters and electric valves to realize water circulation and pressure regulation in the test process; the pressure test unit, flow test unit, slip test unit, voltage test unit, and current test unit collect the pressure, flow, slip, Raw data of voltage and current; the data acquisition unit converts the raw data into signals recognizable by the control unit, and realizes the conversion between the data collected by the secondary instrument and the signal that the control unit can receive; the control unit and the variable frequency power supply are the core of the whole system, realizing The entire test system controls command output, test data processing, and dynamic adjustment of test conditions; industrial computers complete test command input, test data analysis and processing, test curve fitting, and display and storage of system parameters and test results.
本实用新型相对现有技术具有如下优点和有益效果：Compared with the prior art, the utility model has the following advantages and beneficial effects:
传统水泵流量调节过程采用阀门控制的方式，这种控制方式控制时管道阻力变大，造成大量的能源浪费。潜水电泵变频节能综合测试系统采用变频试验电源通过改变速度进而实现流量的调节，在同样流量的试验情况下，原来消耗在阀门的功率就可以避免，能够节省试验过程电能损耗。The traditional water pump flow adjustment process adopts the valve control method. When this control method is controlled, the resistance of the pipeline becomes larger, resulting in a large amount of energy waste. The submersible pump frequency conversion energy saving comprehensive test system adopts the frequency conversion test power supply to adjust the flow rate by changing the speed. Under the test conditions of the same flow rate, the original power consumption in the valve can be avoided, which can save the power loss in the test process.
矿用水泵特性变频节能检验检测系统根据“GB/T 12785《潜水电泵试验方法》”和“GB/T 3216《回转动力泵水力性能验收试验1级和2级》”标准要求，完成不同规格的水泵扬程、流量、效率、功率等综合性能检测试验，具有结构合理、变频调速效果好、节能效果显著、安全可靠等优点。According to the standard requirements of "GB/T 12785 "Test Method for Submersible Electric Pump" and "GB/T 3216 "Grade 1 and 2 of Hydraulic Performance Acceptance Test of Rotary Power Pump", the mine water pump characteristic frequency conversion energy-saving inspection and detection system has completed different specifications It has the advantages of reasonable structure, good effect of frequency conversion speed regulation, remarkable energy saving effect, safety and reliability, etc.
下面结合附图和具体实施例，对本实用新型的技术方案进行详细的说明。The technical solutions of the present utility model will be described in detail below in conjunction with the accompanying drawings and specific embodiments.
附图说明Description of drawings
图1为矿用水泵特性变频节能检验检测系统结构图；Fig. 1 is a structural diagram of the mine water pump characteristic frequency conversion energy-saving inspection and detection system;
图2为控制单元与工业计算机通讯接口电路；Fig. 2 is the communication interface circuit between the control unit and the industrial computer;
图3试验系统调速过程中H-Q关系曲线。Fig. 3 H-Q relationship curve during speed regulation of the test system.
图中：水源单元1，水路单元2，水泵3，变频试验电源4，压力测试单元5，流量测试单元6，转差测试单元7，电压测试单元8，电流测试单元9，数据采集单元10，控制单元11，工业计算机12。In the figure: water source unit 1, waterway unit 2, water pump 3, frequency conversion test power supply 4, pressure test unit 5, flow test unit 6, slip test unit 7, voltage test unit 8, current test unit 9, data acquisition unit 10, Control unit 11, industrial computer 12.
具体实施方式detailed description
本实用新型是一种潜水电泵变频节能综合测试系统，其结构如图1所示，控制单元与工业计算机通讯接口电路如图2所示，试验系统调速过程中H-Q关系曲线如图3所示。The utility model is a comprehensive test system for frequency conversion and energy saving of submersible electric pumps. Its structure is shown in Figure 1. The communication interface circuit between the control unit and the industrial computer is shown in Figure 2. Show.
潜水电泵变频节能综合测试系统由水源单元1、水路单元2、压力测试单元5、流量测试单元6、转差测试单元7、电压测试单元8、电流测试单元9、数据采集单元10、工业计算机12、控制单元11、变频试验电源4和水泵3组成，其中水源单元1的输出端和水路单元2的输入端相连接，水路单元2的出水端和水泵3的入水端相连接，水泵3的电源输入端和变频试验电源4的输出端相连接。Submersible pump frequency conversion energy saving comprehensive test system consists of water source unit 1, waterway unit 2, pressure test unit 5, flow test unit 6, slip test unit 7, voltage test unit 8, current test unit 9, data acquisition unit 10, industrial computer 12. Control unit 11, frequency conversion test power supply 4 and water pump 3, wherein the output end of water source unit 1 is connected to the input end of water circuit unit 2, the water outlet end of water circuit unit 2 is connected to the water inlet end of water pump 3, and the water pump 3 The input terminal of the power supply is connected with the output terminal of the variable frequency test power supply 4 .
水路单元2的控制端也就是电磁阀，和控制单元11的输出端相连接，压力测试单元5和流量测试单元6的测量端均和水路单元2相连接，压力测试单元5和流量测试单元6的信号输出端均和数据采集单元10的信号输入端相连接，转差测试单元7、电压测试单元8和电流测试单元9的测试端均和水泵3相连接，转差测试单元7、电压测试单元8和电流测试单元9的信号输出端均和数据采集单元10的信号输入端相连接，数据采集单元10的信号输出端和控制单元11的信号输入端相连接，工业计算机12的通讯接口和控制单元11的通讯接口通过串口相连接，变频试验电源4的控制端和控制单元11的信号输出端相连接，变频试验电源4的输出端和水泵3的电源输入端相连接。The control end of the waterway unit 2 is the solenoid valve, which is connected to the output end of the control unit 11, the measurement ends of the pressure test unit 5 and the flow test unit 6 are connected to the waterway unit 2, the pressure test unit 5 and the flow test unit 6 The signal output terminals of each are connected with the signal input terminals of the data acquisition unit 10, the test terminals of the slip test unit 7, the voltage test unit 8 and the current test unit 9 are all connected with the water pump 3, the slip test unit 7, the voltage test unit The signal output ends of unit 8 and current test unit 9 are all connected with the signal input end of data acquisition unit 10, the signal output end of data acquisition unit 10 is connected with the signal input end of control unit 11, the communication interface of industrial computer 12 and The communication interface of the control unit 11 is connected through a serial port, the control terminal of the variable frequency test power supply 4 is connected with the signal output terminal of the control unit 11 , and the output terminal of the variable frequency test power supply 4 is connected with the power input terminal of the water pump 3 .
潜水电泵变频节能综合测试系统各个组成部分的功能描述如下：水源单元1具有供试验用足够容量水和良好的水循环系统，可以为试验的顺利进行提供水源，同时具有水位调节功能；水路单元2由六条不同直径的管道和电动阀门组成，实现试验过程的水循环和压力调节；压力测试单元5、流量测试单元6、转差测试单元7、电压测试单元8、电流测试单元9采集矿用水泵3的压力、流量、转差、电压和电流原始数据；数据采集单元10将原始数据转换成控制单元11可识别的信号，实现二次仪表采集数据和控制单元11可接收信号之间的转换；控制单元11和变频试验电源4为整个系统的核心，实现整个试验系统控制指令输出、试验数据的处理及试验工况动态调节；工业计算机12完成试验指令输入、试验数据分析处理、试验曲线的拟合及系统参数和试验结果的显示和存储。The functional description of each component of the submersible pump frequency conversion energy saving comprehensive test system is as follows: water source unit 1 has sufficient water capacity for the test and a good water circulation system, which can provide water source for the smooth progress of the test, and has the function of water level adjustment; water circuit unit 2 It consists of six pipes of different diameters and electric valves to realize water circulation and pressure regulation during the test process; pressure test unit 5, flow test unit 6, slip test unit 7, voltage test unit 8, and current test unit 9 to collect mine water pump 3 The raw data of pressure, flow, slip, voltage and current; the data acquisition unit 10 converts the raw data into a signal recognizable by the control unit 11, and realizes the conversion between the data collected by the secondary instrument and the signal that the control unit 11 can receive; control The unit 11 and the frequency conversion test power supply 4 are the core of the whole system, which realize the output of control commands of the whole test system, the processing of test data and the dynamic adjustment of test working conditions; the industrial computer 12 completes the input of test commands, the analysis and processing of test data, and the fitting of test curves And the display and storage of system parameters and test results.
传统水泵流量调节过程采用阀门控制的方式，这种控制方式控制时管道阻力变大，造成大量的能源浪费。而本实用新型潜水电泵变频节能综合测试系统采用变频试验电源通过改变速度进而实现流量的调节，在同样流量的试验情况下，原来消耗在阀门的功率就可以避免，能够节省试验过程电能损耗。The traditional water pump flow adjustment process adopts the valve control method. When this control method is controlled, the resistance of the pipeline becomes larger, resulting in a large amount of energy waste. The utility model submersible pump frequency conversion energy-saving comprehensive test system adopts the frequency conversion test power supply to adjust the flow rate by changing the speed. Under the test conditions of the same flow rate, the original power consumption in the valve can be avoided, and the power loss in the test process can be saved.
下面结合图3进行说明：传统阀门控制试验过程中,当流量需要从Q1减小到Q2时,必须关小阀门，此时阀门磨擦阻力将变大,阻力曲线从R1移到R2，扬程则从H1上升到H2,运行工况点从M点移到N点。采用变频试验电源进行流量调节过程中,当流量需要从Q1减小到Q2，将速度从Nl降到N2,运行工况点则从M点移到O点,扬程从H1下降到H3，由于阻力曲线R1不变,试验系统消耗的能量不变。The following will be explained in conjunction with Figure 3: In the traditional valve control test process, when the flow rate needs to be reduced from Q1 to Q2, the valve must be closed. H1 rises to H2, and the operating point moves from M point to N point. In the flow adjustment process using the frequency conversion test power supply, when the flow needs to be reduced from Q1 to Q2, the speed is reduced from N1 to N2, the operating point is moved from M point to O point, and the lift is reduced from H1 to H3. Due to the resistance The curve R1 remains unchanged, and the energy consumed by the test system remains unchanged.
根据离心泵的特性曲线公式:According to the characteristic curve formula of centrifugal pump:
P＝Q1Hr/102η (l)P=Q 1 H r /102η (l)
式中:p—水泵使用工况轴功率(kW)；In the formula: p—shaft power of the water pump under operating conditions (kW);
Q—使用工况点的水压或流量(m3/s)；Q—water pressure or flow rate (m3/s) at the point of use;
H—使用工况点的扬程(m)；H—head (m) of working condition point;
r—输出介质单位体积重量(kg/m3)；r—unit volume weight of output medium (kg/m3);
η—使用工况点的泵效率(％)。η—pump efficiency (%) at the operating point.
可求出运行在N点泵的轴功率和O点泵的轴功率分别为:The shaft power of the pump running at point N and the shaft power of the pump at point O can be calculated as:
PN＝Q2H1r/102η (2)P N ＝Q 2 H 1r /102η (2)
PO＝Q2H2r/102η (3)P O ＝Q 2 H 2r /102η (3)
两者之差为:The difference between the two is:
Δρ＝PN-PO＝Q2(H1-H2)r/102η (4)Δρ=P N -P O =Q 2 (H 1 -H 2 ) r /102η (4)
也就是说,用传统阀门控制方式进行流量时,有△P功率被阀门阻力损耗浪费掉了,且随着流量的变小，阀门不断关小,这个损耗还要增加。而用变频电源进行流量控制时,根据流量Q、扬程H、功率P和转速N之间的关系,有:That is to say, when using the traditional valve control method to control the flow rate, the △P power is wasted by the valve resistance loss, and as the flow rate becomes smaller, the valve keeps closing down, and this loss will increase. When using variable frequency power supply for flow control, according to the relationship between flow Q, head H, power P and speed N, there are:
根据公式(5)可知，流量Q与转速N的一次方成正比；扬程H与转速N的平方成正比；功率P与转速N的立方成正比，即功率与转速成3次方的关系下降。如果不是用关小阀门的方法，而采用变频电源进行流量调节时，那么在同样流量的试验情况下，原来消耗在阀门的功率就可以避免，从而获得图3中MNO区域大小的节能效果，这就是水泵调速节能原理。According to the formula (5), it can be seen that the flow Q is proportional to the first power of the rotational speed N; the head H is proportional to the square of the rotational speed N; the power P is proportional to the cube of the rotational speed N, that is, the relationship between the power and the rotational speed decreases to the third power. If the variable frequency power supply is used for flow regulation instead of closing the small valve, then under the same flow test conditions, the original power consumed in the valve can be avoided, thereby obtaining the energy-saving effect of the MNO area in Figure 3, which is It is the principle of water pump speed regulation and energy saving.
潜水电泵变频节能综合测试系统根据“GB/T 12785《潜水电泵试验方法》”和“GB/T3216《回转动力泵水力性能验收试验1级和2级》”标准要求，完成不同规格的水泵扬程、流量、效率、功率等综合性能检测试验，具有变频调速效果好、节能效果显著、安全可靠等优点。Submersible pump frequency conversion energy-saving comprehensive test system according to the "GB/T 12785 "submersible pump test method" and "GB/T3216 "rotary power pump hydraulic performance acceptance test level 1 and level 2"" standard requirements, complete different specifications of pumps Head, flow, efficiency, power and other comprehensive performance testing tests have the advantages of good frequency conversion speed regulation effect, remarkable energy saving effect, safety and reliability, etc.
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