CN219299495U

CN219299495U - Diaphragm compressor fault detection device

Info

Publication number: CN219299495U
Application number: CN202320211011.9U
Authority: CN
Inventors: 黄景龙; 李通; 黄满满; 李坤峰
Original assignee: Zhengxing Hydrogen Electric Technology Zhengzhou Co ltd
Current assignee: Zhengxing Hydrogen Electric Technology Zhengzhou Co ltd
Priority date: 2023-02-14
Filing date: 2023-02-14
Publication date: 2023-07-04
Anticipated expiration: 2033-02-14

Abstract

The application discloses diaphragm compressor fault detection device, through pressure transmitter's self-diagnosis, solves the unable self-checking of pressure switch among the prior art and has the problem of potential safety hazard. The device comprises a control unit and a power supply module, wherein the control unit is respectively and correspondingly and electrically connected with a diaphragm detection unit, an air inlet valve detection unit and an air outlet valve detection unit; the diaphragm detection unit comprises a diaphragm head pressure transmitter arranged at a position corresponding to the diaphragm head of the compressor; the air inlet valve detection unit comprises an air inlet pressure transmitter arranged at a position corresponding to the air inlet end of the compressor; the exhaust valve detection unit comprises an exhaust pressure transmitter arranged at a position corresponding to the exhaust end of the compressor. The device has the advantages of strong reliability, various detection functions, accurate positioning of fault points and the like.

Description

Diaphragm compressor fault detection device

Technical Field

The application relates to the technical field of hydrogen energy filling equipment, in particular to a fault detection device for a diaphragm compressor.

Background

The hydrogen diaphragm compressor is an important device of a hydrogenation station, wherein a diaphragm, an air inlet valve, an air outlet valve, a pressure regulating valve of a hydraulic oil system and the like of the diaphragm compressor are vulnerable parts, a certain failure rate exists, and particularly when the diaphragm is broken, hydrogen is mixed with hydraulic oil of the compressor, so that great potential safety hazards exist.

In order to obtain the condition of the compressor diaphragm in time, a pressure switch is usually only arranged at the diaphragm head of the compressor to detect the perfect state of the three layers of diaphragms, so that safety interlocking stopping after the diaphragms are broken is realized, and safety accidents caused by mixing of hydrogen in the compressor diaphragm head and compressor hydraulic oil are prevented. The prior art known to the inventor discloses a diaphragm fault detection device (CN 204283837U) of a diaphragm compressor, which comprises a pressure switch, when the diaphragm breaks, leakage pressure enters the pressure switch, when the leakage pressure (air pressure or oil pressure) reaches a set value, the pressure switch is pushed to act, a closed loop is formed by a normally open contact of the pressure switch and a relay, the normally open contact of the relay is closed and self-locked, a control circuit closes a motor, and a buzzer alarms.

However, in the process of implementing the technical solution in the embodiment of the present application, the present inventors have found that at least the following technical problems exist in the above technology: the pressure switch can not realize self fault detection, and potential safety hazards exist.

The information disclosed in this background section is only for enhancement of understanding of the background of the disclosure and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art that is well known to a person skilled in the art.

Disclosure of Invention

In view of at least one of the above technical problems, the present disclosure provides a diaphragm compressor fault detection device, which solves the problem that a pressure switch cannot be self-inspected and has potential safety hazards in the prior art through self-diagnosis of a pressure transmitter.

According to one aspect of the present disclosure, there is provided a diaphragm compressor fault detection device, including a control unit, and further including a diaphragm detection unit, an intake valve detection unit, and an exhaust valve detection unit, which are respectively and correspondingly electrically connected to the control unit; the diaphragm detection unit comprises a diaphragm head pressure transmitter which is arranged at a position corresponding to the diaphragm head of the compressor; the air inlet valve detection unit comprises an air inlet pressure transmitter which is arranged at a position corresponding to the air inlet end of the compressor; the exhaust valve detection unit comprises an exhaust pressure transmitter which is arranged at a position corresponding to the exhaust end of the compressor.

In some embodiments of the present disclosure, the control unit includes a PLC, an analog input module correspondingly electrically connected to the PLC; and the membrane head pressure transmitter, the air inlet pressure transmitter and the air outlet pressure transmitter are respectively and correspondingly and electrically connected with the terminals of the analog input module.

In some embodiments of the present disclosure, the power module includes a UPS power source, a switching power source correspondingly electrically connected to an output of the UPS power source; the switching power supply is used for providing DC24V power supply.

In some embodiments of the present disclosure, the system further comprises current transformers arranged in phases of the three-phase power supply of the compressor, a multifunctional intelligent instrument correspondingly and electrically connected with the current transformers, and 485 communication between the multifunctional intelligent instrument and the control unit.

In some embodiments of the present disclosure, the corresponding I/O port of the control unit is electrically connected to a corresponding switching value output port of the compressor controller, for transmitting a compressor operation state feedback signal.

In some embodiments of the present disclosure, the corresponding I/O port of the control unit is electrically connected to a corresponding digital input channel of the compressor controller for transmitting an alarm interlock shutdown signal when a fault is implemented.

In some embodiments of the present disclosure, the system further includes a station control terminal, and the control unit is correspondingly communicatively connected to the station control terminal through an RJ45 port.

One or more technical solutions provided in the embodiments of the present application at least have any one of the following technical effects or advantages:

1. the membrane head pressure transmitter is arranged to detect the sound state of the compressor membrane, and the disconnection and short circuit self-diagnosis detection functions of the pressure transmitter can be realized through the output value judgment of the pressure transmitter, so that the technical problem that whether the pressure switch works reliably or not cannot be judged when the pressure switch is adopted in the prior art is effectively solved. The potential safety hazard caused by mixing hydrogen and hydraulic oil after the membrane is damaged is avoided, and the problem of membrane damage is ensured to be found in time.

2. Because the air inlet pressure transmitter is arranged at the air inlet end of the compressor, the fault state of the air inlet valve can be judged by utilizing pressure fluctuation, the rapid positioning of the air inlet valve fault can be realized, the fault removal time during maintenance is greatly saved, and the maintenance efficiency is greatly improved.

3. Because the exhaust pressure transmitter is arranged at the exhaust end of the compressor, the fault state of the exhaust valve can be judged by utilizing pressure fluctuation, the rapid positioning of the fault of the exhaust valve can be realized, the fault removal time of maintenance is greatly saved, and the maintenance efficiency is greatly improved.

4. The current transformer and the corresponding multifunctional intelligent instrument which are arranged corresponding to each phase in the three-phase power supply of the compressor can realize motor overload, phase-missing and three-phase unbalance monitoring, achieve the aim of monitoring the state of the motor of the compressor and prevent damage to the motor and equipment.

Drawings

FIG. 1 is a schematic diagram of the installation of pressure transmitters in an embodiment of the application.

FIG. 2 is a schematic diagram of a pressure transmitter arrangement according to an embodiment of the present application.

Fig. 3 is a block diagram of a PLC system according to an embodiment of the present application.

Fig. 4 is a schematic diagram of the connection of the analog input module according to an embodiment of the present application.

Fig. 5 is a schematic diagram of PLC wiring in an embodiment of the present application.

Fig. 6 is a schematic diagram of a power module connection in an embodiment of the present application.

In the above figures, 1 is a compressor, 10 is a compressor membrane head, 11 is a compressor crankcase, 2 is a compressor motor, 3 is a membrane head pressure transmitter, 4 is an air inlet pressure transmitter, 40 is an air inlet pipeline, 5 is an air outlet pressure transmitter, 50 is an air outlet pipeline, 6 is an analog input module, 7 is an alarm interlocking stop output, 80 is a UPS power supply, 81 is a switching power supply, 90, 91 and 92 are respectively a current transformer, and 93 is a multifunctional intelligent instrument.

Detailed Description

The procedures involved or relied on in the following embodiments are conventional procedures or simple procedures in the technical field, and those skilled in the art can make routine selections or adaptation according to specific application scenarios.

Unless otherwise specified, the devices such as transmitters and electronic components in the following examples are commercially available products.

For better understanding of the technical solutions of the present application, the following detailed description will refer to the accompanying drawings and specific embodiments.

The embodiment discloses a diaphragm compressor fault detection device, which mainly comprises a control unit, a power module, a diaphragm detection unit, an air inlet valve detection unit and an air outlet valve detection unit, wherein the diaphragm detection unit, the air inlet valve detection unit and the air outlet valve detection unit are respectively and correspondingly and electrically connected with the control unit.

In order to solve the problem that the pressure switch cannot be diagnosed automatically, misinformation on the sound condition of the compressor diaphragm caused by failure of the pressure switch is avoided, in the embodiment, a pressure transmitter 3 with the model of DG2104-A-1-D is adopted as a diaphragm detection unit, see fig. 2, the pressure of the diaphragm head is led out to the side of the diaphragm head through a pressure guiding pipeline, and the pressure transmitter 3 of the diaphragm head is connected to the position corresponding to the end of the pressure guiding pipeline in a clamping sleeve connection mode, so that the pressure of the diaphragm head is monitored. The pressure transmitter can output the real-time pressure of the leakage of the compressor membrane head in the range of the measuring range in real time compared with the pressure switch, and can only judge whether the monitored pressure exceeds the limit or not compared with the pressure switch, and the continuous analog output of the pressure transmitter can provide more effective and reliable information for judging the state of the membrane head, so that the pressure transmitter is adopted to realize the self-diagnosis in the embodiment, the purpose of disconnection, short circuit or detection of the pressure transmitter is achieved, and the monitoring accuracy is prevented from being influenced by the working state of the pressure transmitter.

In this embodiment, the control unit adopts a PLC, and the data acquisition and judgment of the membrane head pressure transmitter are realized through the PLC. Considering that the output signal of the membrane head pressure transmitter is an analog signal of 4-20mA, see FIG. 3, the PLC in this example is additionally provided with an analog input module 6 with the model of EM-AI04, see FIG. 4, so that the membrane head pressure transmitter 3 is electrically connected with a port corresponding to the analog input module 6, and the transmission of pressure data to the PLC is realized. The digital value of the film head pressure transmitter, which is acquired by the PLC corresponding to the 4-20mA analog quantity signal, is 5530-27648, and the working state of the film head pressure transmitter is judged by the digital value of the film head pressure transmitter, which is acquired by the PLC corresponding to the analog quantity signal: the PLC acquires a digital value of 0, and indicates that the membrane head pressure transmitter is disconnected; and if the number acquired by the PLC is larger than 27648, the short circuit of the membrane head pressure transmitter is indicated. In addition, in this embodiment, the leakage pressure is set to be 0.1MPa, and when the membrane head pressure transmitter monitors that the membrane head pressure is greater than 0.1MPa, the PLC can determine that the hydrogen or the hydraulic oil is leaked, and then alarm and timely repair the membrane head.

In this example, in order to ensure the emergency stop of the compressor after the fault, referring to fig. 3 or fig. 5, an I/O port corresponding to the PLC outputs a switching value alarm interlocking stop signal, and the I/O port is correspondingly connected to a digital value input channel of the compressor controller, when the I/O port outputs the alarm interlocking stop signal, and the compressor controller receives the signal, the compressor controller controls the compressor to implement the emergency stop, so as to avoid the potential safety hazard caused by mixing of hydrogen and hydraulic oil of the compressor after the membrane is damaged.

In addition, because the device has different power utilization levels, and the stable and reliable power supply is considered, referring to fig. 6, a UPS power source 80 with the power supply voltage of AC220V is adopted to supply power, and a switching power source 81 with the model of PSU100D-24V/2.1A is connected in the UPS power supply line, so as to realize the conversion from 220V alternating current to 24V direct current, and meet the DC24V direct current power supply requirement of the pressure transmitter.

Because the air inlet valve and the air outlet valve of the diaphragm compressor are vulnerable parts, a certain failure rate exists, and the working efficiency and the reliability of the compressor are possibly affected. Therefore, the device is provided with the air inlet valve detection unit and the air outlet valve detection unit to realize the monitoring of the working states of the air inlet valve and the air outlet valve, and can timely locate the position of the component with specific fault through monitoring information when the compressor fails, thereby greatly shortening the fault searching time and further improving the maintenance efficiency. In which, referring to fig. 1-2, an intake pressure transmitter 4 with a model DG2104-a-35-D is installed in the intake pipeline 40, the working state of the intake valve is monitored by the intake pressure transmitter 4 at any time, referring to fig. 3-4, and the intake pressure transmitter 4 is connected with an input port corresponding to the analog input module 6 of the PLC, so as to realize the transmission of intake pressure data to the PLC.

In this embodiment, the PLC records the maximum value and the minimum value of the intake pressure transmitter 4 in a unit time according to the intake pressure data, calculates the difference between the maximum value and the minimum value as the intake pressure fluctuation value, and according to the pressure fluctuation value of the intake valve normally intake and the pressure fluctuation value when the reverse direction cannot be sealed, which are measured according to the early test operation data, selects a value between the two fluctuation values as a set value, and then the PLC judges whether the intake pressure fluctuation value in actual operation is greater than the set value, in this case, selects the set value as the median between the pressure fluctuation value of the intake valve normally intake and the pressure fluctuation value when the reverse direction cannot be sealed, and when the intake pressure fluctuation value is set to be greater than the set value for 4 consecutive times for error elimination, determines that the hydrogen intake valve of the compressor cannot be sealed in the reverse direction, has a fault, and outputs an alarm interlock shutdown signal from the corresponding port of the PLC. In other embodiments, the number of times the intake pressure fluctuation value is continuously greater than the set value is selected to be at least two other times.

Also, referring to fig. 1-2, an exhaust pressure transmitter 5 of model DG2104-a-70-D is installed in the exhaust line 50, and referring to fig. 3-4, the operating state of the compressor exhaust valve is monitored in real time by the exhaust pressure transmitter 5 connected to a corresponding port of the PLC analog input module 6. The PLC records the maximum value and the minimum value of the exhaust pressure transmitter 5 in unit time according to the exhaust pressure data measured by the exhaust pressure transmitter 5, calculates the difference value between the maximum value and the minimum value as an exhaust pressure fluctuation value, determines a set value according to the same earlier test data, and then judges whether the exhaust pressure fluctuation value in actual operation is larger than the set value or not by the PLC.

In addition, in this embodiment, when the PLC determines that the fluctuation value of the intake pressure transmitter is continuously smaller than the set value (according to the early test operation data, the intake pressure fluctuation value when the hydraulic oil system fails and the intake pressure fluctuation value when the hydraulic oil system is normal are measured, and the median of the two fluctuation values is selected as the set value) and the fluctuation value of the exhaust pressure transmitter is continuously smaller than the set value (according to the early test operation data, the exhaust pressure fluctuation value when the hydraulic oil system fails and the exhaust pressure fluctuation value when the hydraulic oil system is normal are measured, and the median of the two fluctuation values is selected as the set value), the malfunction of the hydraulic oil system of the compressor is determined, the hydrogen compression cannot be performed, and the malfunction alarm interlock shutdown signal is output by the corresponding port of the PLC.

The detection device can also monitor the running state of the compressor motor, and avoid the occurrence of the conditions of motor overload, phase loss, three-phase imbalance and other damage motors. In this embodiment, referring to fig. 6,

current transformers

90, 91, 92 with the model number of SHT-0.66-30IS-200/5-0.5S are respectively arranged in each phase circuit of the three-phase power supply of the compressor motor 2, and each current transformer IS respectively connected with an input end of a multifunctional intelligent instrument 93, in this example, the multifunctional intelligent instrument 93 with the model number of PD194Z-9HY IS adopted to realize analysis of three-phase power, the multifunctional intelligent instrument 93 adopts UPS power supply to directly supply power, a communication output port of the multifunctional intelligent instrument 93 IS correspondingly connected to an RS485 port of the PLC, 485 communication connection IS established between the two, and electric quantity collection data of the compressor motor IS transmitted to the PLC. When the three-phase current transformer of the motor of the compressor detects that the current of any one phase is larger than the rated current of the motor, the motor overload can be judged; when the current of a certain phase is zero, the motor phase failure can be judged; when the difference value of any two-phase currents is more than 5%, the three-phase unbalance of the motor is judged; when any fault occurs, the port corresponding to the PLC outputs an alarm interlocking stop signal to prompt maintenance, so that potential safety hazards caused by continuous operation are avoided.

In this embodiment, referring to fig. 5, the operation state signal of the compressor is connected to the DI input channel of the PLC as a start signal of the fault detection. In addition, in this example, the RJ45 port of the PLC is correspondingly connected to the station control terminal, and uploading and displaying of the monitoring data are implemented through the TCP/IP protocol.

While certain preferred embodiments of the present application have been described, additional variations and modifications in those embodiments may occur to those skilled in the art once they learn of the basic inventive concepts. It is therefore intended that the following claims be interpreted as including the preferred embodiments and all such alterations and modifications as fall within the scope of the application.

It will be apparent to those skilled in the art that various modifications and variations can be made in the present application without departing from the spirit and scope of the utility model of the present application. Thus, if such modifications and variations of the present application fall within the scope of the claims and the equivalents thereof, the present application is intended to cover such modifications and variations.

Claims

1. The fault detection device of the diaphragm compressor comprises a control unit and a power supply module, and is characterized by further comprising a diaphragm detection unit, an air inlet valve detection unit and an air outlet valve detection unit which are respectively and correspondingly and electrically connected with the control unit; the diaphragm detection unit comprises a diaphragm head pressure transmitter which is arranged at a position corresponding to the diaphragm head of the compressor; the air inlet valve detection unit comprises an air inlet pressure transmitter which is arranged at a position corresponding to the air inlet end of the compressor; the exhaust valve detection unit comprises an exhaust pressure transmitter which is arranged at a position corresponding to the exhaust end of the compressor.

2. The diaphragm compressor failure detection apparatus according to claim 1, wherein the control unit includes a PLC, an analog input module correspondingly electrically connected to the PLC; and the membrane head pressure transmitter, the air inlet pressure transmitter and the air outlet pressure transmitter are respectively and correspondingly and electrically connected with the terminals of the analog input module.

3. The diaphragm compressor fault detection device of claim 1, wherein the power module comprises a UPS power source, a switching power source correspondingly electrically connected to an output of the UPS power source; the switching power supply is used for providing DC24V power supply.

4. The diaphragm compressor fault detection device of claim 1, further comprising current transformers for each phase of a three-phase power supply of the compressor, a multifunctional intelligent instrument electrically connected to the current transformers, and 485 communication between the multifunctional intelligent instrument and the control unit.

5. The diaphragm compressor fault detection device of claim 1, wherein the I/O port corresponding to the control unit is electrically connected to the corresponding switching value output port of the compressor controller for transmitting a compressor operation state feedback signal.

6. The diaphragm compressor fault detection device of claim 1, wherein the corresponding I/O port of the control unit is electrically connected to a corresponding digital input channel of the compressor controller for transmitting an alarm interlock shutdown signal upon implementation of a fault.

7. The diaphragm compressor fault detection device of claim 1, further comprising a station control terminal, wherein the control unit is in corresponding communication connection with the station control terminal through an RJ45 port.