EP1477678A2 - Early detection of failures in pump valves - Google Patents
Early detection of failures in pump valves Download PDFInfo
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- EP1477678A2 EP1477678A2 EP04011109A EP04011109A EP1477678A2 EP 1477678 A2 EP1477678 A2 EP 1477678A2 EP 04011109 A EP04011109 A EP 04011109A EP 04011109 A EP04011109 A EP 04011109A EP 1477678 A2 EP1477678 A2 EP 1477678A2
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- pump
- valve
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- valves
- signal level
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- 238000001514 detection method Methods 0.000 title claims abstract description 15
- 238000000034 method Methods 0.000 claims abstract description 28
- 239000012530 fluid Substances 0.000 claims abstract description 15
- 238000012544 monitoring process Methods 0.000 claims abstract description 8
- 230000001960 triggered effect Effects 0.000 claims abstract description 3
- 230000005236 sound signal Effects 0.000 claims description 9
- 238000012935 Averaging Methods 0.000 claims description 7
- 238000006073 displacement reaction Methods 0.000 claims description 6
- 230000001133 acceleration Effects 0.000 claims description 5
- 239000012528 membrane Substances 0.000 claims description 3
- 239000002184 metal Substances 0.000 claims description 2
- 230000002950 deficient Effects 0.000 description 6
- 238000010586 diagram Methods 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 230000006870 function Effects 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 239000013589 supplement Substances 0.000 description 1
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B51/00—Testing machines, pumps, or pumping installations
Definitions
- the invention relates to a method for monitoring and automatic early fault detection the valves, in particular the suction and / or pressure valves, an oscillating positive displacement pump, in particular a diaphragm metering pump, according to the preamble of claim 1.
- the invention also relates to a device for carrying out this method Device according to the preamble of claim 14.
- suction and pressure valves are subject to constant wear and tear has a negative effect on the delivery rate of the pump and on its dosing accuracy.
- valves fail prematurely. This causes unwanted due to the then necessary immediate business interruption Consequential damages.
- the invention is therefore based on the object to eliminate the described Disadvantages of providing a method and a device by means of which it is possible to monitor the valves of a pump of the generic type in such a way that results in an automatic fault early detection of the valves, so that valve damage can be detected in time and an interruption of the Pump can be planned.
- the invention also provides one created for carrying out this method Device before whose features are listed in claim 14.
- the method according to the invention is based on the essential idea that from a leaking valve due to the backflow of the conveying fluid in the closed Valve condition generated increased operating noise as a measure of the Leakage of the valve to use.
- the generated effective signal level continuously monitored and with one of the operating noise the reference valve level formed with the valve intact valve, wherein at a predetermined level deviation due to an increase in level Operating noise a fault early detection indicator is triggered.
- the invention thus makes advantageous advantage of the effect that at intact pump a certain background noise can be seen. Join this at the same time some discrete typical single sounds. These have different Causes, such as the meshing in the reduction gear on the pump engine or the opening and closing noises of the valves.
- valves have become leaky due to the backflow of the delivery fluid in the closed valve state increased typical operating noise. This increased operating noise depends on the return flow the delivery fluid and are inventively as a measure of the leakage of the Valve used.
- the in the oscillating displacement pumps, especially in the speech standing diaphragm dosing pumps, used for applying suction and Pressure valves are usually either ball valves or plate valves or Cone valves that can be spring loaded or pressure controlled.
- These demands placed on these valves in that they are just at the right time open and close and that they are tight in the foreseeable time have to be.
- the damage that may occur to such valves is expressed either in a notch leakage generated by one or more notches on the valve seat, where a local damage occurs, or from a one-dimensional damage generating surface leakage.
- the sealing edge of the valve seat is not punctually by one or more notches, but over the entire circumference damaged. In both cases, increased flow noise occurs at the valve seat on what u.a. by the coincidence of the occurring cavitation bubbles explain.
- the operating noise generated by the pump and thus also that of the valves measured as structure-borne noise may be in the embodiment of Invention by means of a structure-borne sound sensor or a microphone, in particular but by means of a vibration acceleration sensor, preferably works on the piezoelectric compression principle and an integrated May have charge amplifier.
- the generated structure-borne noise at the pump head in particular at a central location thereof.
- the generated structure-borne sound at or near the valve in question measure up.
- This may be the suction and / or pressure valve, but in addition also the provided on the pump body further hydraulic valves, the leak supplement or the removal of excess hydraulic fluid serve.
- the invention provides various possibilities. So it is in Embodiment of the invention possible with the operating noise of the pump intact valves formed reference signal level over a predetermined period to mediate. Also, the increased operating noise of the pump with leaky valves formed RMS signal level over a predetermined Period to be averaged.
- a trigger signal for use which leads to a defined Time of the pump stroke cycle is generated. This can e.g. in the suction stroke end position of the piston.
- the trigger signal must advantageously no meet very high accuracy requirements. For example, an accuracy from +/- 5 ° crank angle. This is for monitoring the suction valve in a defined period of time, the generated structure-borne sound signal during the displacement phase (Pressure stroke) detected and compared. In contrast, for the Monitoring the pressure valve the corresponding period in the intake phase (Suction stroke).
- the defined period can only be used for monitoring purposes, for example of the pressure valve extend over a range of 90 - 160 ° of the crank angle, while for the monitoring of the suction valve such a defined Period sufficient, extending over a range of 270 - 340 ° of the crank angle extends.
- the generation of the trigger signal can according to the invention in various ways carried out, for example by means of a contactor mounted on the pump engine, by means of a corresponding scanning of the piston rod, by means of the detection a characteristic signal in the generated structure-borne sound signal, for example due to the game envelope in the engine, and also on the basis of other characteristic signals, e.g. the measured pressure in the airspace of the hydraulic storage room or in the engine.
- the reference signal level is expediently taken to be the reference value. which is associated with an intact valve.
- This reference value can be up be detected in different ways, for example, by measuring integrity Condition of the valve under operating conditions, by selecting from predefined values, e.g. from a matrix with defined values for different ones Valve designs and operating conditions, from a map determination, i.e. a computational determination from valve data and operating data, such as delivery pressure, Fluid, etc., and the like.
- the mean are formed from a number of pump strokes.
- This will be the automatic Early disturbance detection method according to the invention insensitive to short-term disturbances. This can e.g. be useful if contaminated fluids be metered by the pump in question. By fluid particles between Valve seat and valve closing body are inadvertently pinched, it comes at individual pump strokes to a fluid backflow, but because only temporarily and temporarily, not yet displayed as a fault should.
- a further embodiment of the method according to the invention may consist in that of a number of pump strokes before their further signal processing a certain number of pump strokes with extreme values or not plausible values.
- the signal values of 100 pump strokes can be detected, with three pump strokes with the highest as well with the lowest individual values sorted out.
- the average value is formed from the remaining 94 values.
- valve internals these are in particular fittings on the valve seat, the purpose of which is due to the leakage backflow to be excited to vibrate, to amplify the structure-borne sound signal to reach.
- the inventively provided device for carrying out the described Method is provided with a connected to a pump component Measuring device, which by a leaking valve due to the backflow the delivery fluid in the closed valve state generated increased operating noise monitored and measures as RMS signal level, and with a with the Measuring device connected comparison device, which the RMS signal level with an operating noise of the pump with intact valves formed Reference signal level compares and at a predetermined level deviation or change generates a fault message as early fault detection.
- the measuring device has at least one sensor for detection of the structure-borne noise generated by the operating noise of the pump.
- This structure-borne sound sensor can be a vibration acceleration sensor, preferably be piezoelectric.
- the measuring device either on the pump head, in particular at a central point thereof, be connected.
- the measuring device directly on or near the pump valves, i.e. the suction and pressure valve and the other hydraulic valves, provided.
- the structure-borne sound signal generated by suitable fittings are reinforced in the valve seat.
- a Vibration device provided, which is provided at or near the valve seat is.
- Such a vibrating device may consist of at least one obliquely in the Valve built-in wing or consist of a membrane sheet metal ring, the is installed in the valve seat.
- a measuring device 5 is provided, which at a central Place the pump cover 6 is connected and that of a leaking valve 3 or 4 due to the backflow of the conveying fluid in the closed valve state monitored increased operating noise as well as RMS signal level measures.
- the measuring device 5 is for measuring each generated by the operating noise Structure-borne sound and has a corresponding sensor. This is a piezoelectric working in the illustrated embodiment Vibration acceleration sensor.
- a comparison device 7 which of the measuring device 5 supplied via a signal line 8 RMS signal level with a from the operating noise of the pump with intact valves 3 and 4 formed Reference signal level compares and at a predetermined level deviation or change generates a fault message as early fault detection.
- FIGS. 2a-2e the various diagrams show the characteristics of the diaphragm metering pump 1 according to FIG Fig. 2a shows the piston travel over time.
- FIG. 2 b shows the pressure curve in the hydraulic chamber 9 of the pump 1, where clearly the characteristic course of the performed by the piston 10 Pressure stroke and the suction stroke of the membrane 11 (see Fig. 1) can be seen.
- Fig. 2c the course of the designed by a pump 1 with intact valves 3 and 4 generated operating noise, as a structure-borne noise signal is measured, typically, with the course shown in Fig. 2c represents the reference signal level. This reproduces typical noise peaks, during the pressure stroke and suction stroke performed by the pump piston 10 be generated.
- Fig. 2d shows the structure-borne sound profile of a pump 1 with defective Suction valve 3, which is typically performed during the piston 10 from Druckhubes appears in appearance, since in this case the suction valve 3 due to the occurred Leakage does not close exactly and thus an undesirable Leakage flow into the intake pipe permits.
- FIG. 2e shows the structure-borne sound signal in a pump 1 Defective pressure valve 4. This results, as shown, during the suction stroke of Piston 10, since here the leaking pressure valve 4 is no longer reliable closes and an undesirable backflow in the form of a leakage flow in the fluid space 12 of the pump 1 allows.
- FIGS. 3a and 3b show the level profile of the measured structure-borne sound signal in averaged form, wherein in Fig. 3a, the averaging period during several Pump strokes, i. so several times during the print stroke and the Suction stroke, is shown and the early fault detection due to a increased detected RMS signal level.
- Fig. 3b shows the Waveform at an averaging period that is only a fraction the pump stroke cycle, in the case shown, only a specific one Time of the suction stroke, extends.
Abstract
Description
Die Erfindung betrifft ein Verfahren zur Überwachung und automatischen Störungsfrüherkennung
der Ventile, insbesondere der Saug- und/oder Druckventile,
einer oszillierenden Verdrängerpumpe, insbesondere einer Membrandosierpumpe,
gemäß dem Oberbegriff des Anspruchs 1.The invention relates to a method for monitoring and automatic early fault detection
the valves, in particular the suction and / or pressure valves,
an oscillating positive displacement pump, in particular a diaphragm metering pump,
according to the preamble of
Die Erfindung betrifft außerdem eine zur Durchführung dieses Verfahrens geschaffene Vorrichtung gemäß dem Oberbegriff des Anspruchs 14.The invention also relates to a device for carrying out this method Device according to the preamble of claim 14.
Bei oszillierenden Verdrängerpumpen, vor allem aber bei Membrandosierpumpen, haben die Pumpenventile, insbesondere die Saug- und Druckventile, entscheidenden Einfluß auf die Pumpenfunktion.For oscillating positive displacement pumps, but especially for diaphragm metering pumps, have the pump valves, especially the suction and pressure valves, crucial Influence on the pump function.
Die Saug- und Druckventile sind einem ständigen Verschleiß unterworfen, der sich negativ auf die Förderleistung der Pumpe sowie auf deren Dosiergenauigkeit auswirkt. The suction and pressure valves are subject to constant wear and tear has a negative effect on the delivery rate of the pump and on its dosing accuracy.
In der Praxis wird bisher versucht, dieses Problem dadurch zu vermeiden, daß man aus der Erfahrung heraus die Ventile rechtzeitig austauscht.In practice, attempts have been made to avoid this problem by the fact that to change the valves in time from experience.
Trotzdem läßt es sich nicht vermeiden, daß Ventile vorzeitig ausfallen. Dies verursacht aufgrund der dann notwendigen sofortigen Betriebsunterbrechung unerwünschte Folgeschäden.Nevertheless, it can not be avoided that valves fail prematurely. This causes unwanted due to the then necessary immediate business interruption Consequential damages.
Der Erfindung liegt daher die Aufgabe zugrunde, zur Beseitigung der geschilderten Nachteile ein Verfahren sowie eine Vorrichtung zu schaffen, mittels denen es möglich ist, die Ventile einer Pumpe der gattungsgemäßen Art derart zu überwachen, daß sich eine automatische Störungsfrüherkennung der Ventile ergibt, so daß Ventilschäden rechtzeitig erkannt werden und eine Betriebsunterbrechung der Pumpe geplant werden kann.The invention is therefore based on the object to eliminate the described Disadvantages of providing a method and a device by means of which it it is possible to monitor the valves of a pump of the generic type in such a way that results in an automatic fault early detection of the valves, so that valve damage can be detected in time and an interruption of the Pump can be planned.
Die Merkmale des zur Lösung dieser Aufgabe geschaffenen Verfahrens gemäß
der Erfindung ergeben sich aus Anspruch 1.The features of the method created to solve this problem according to
The invention will become apparent from
Die Erfindung sieht außerdem eine zur Durchführung dieses Verfahrens geschaffene Vorrichtung vor, deren Merkmale in Anspruch 14 aufgeführt sind.The invention also provides one created for carrying out this method Device before whose features are listed in claim 14.
Vorteilhafte Ausgestaltungen des Verfahrens sowie der Vorrichtung gemäß der Erfindung sind in den jeweils abhängigen Ansprüchen aufgeführt.Advantageous embodiments of the method and the device according to the Invention are listed in the respective dependent claims.
Dem erfindungsgemäßen Verfahren liegt der wesentliche Gedanke zugrunde, das von einem undichten Ventil aufgrund der Rückströmung des Förderfluids im geschlossenen Ventilzustand erzeugte erhöhte Betriebsgeräusch als Maß für die Undichtigkeit des Ventils zu verwenden. Zu diesem Zweck wird der erzeugte Effektivsignalpegel kontinuierlich überwacht und mit einem vom Betriebsgeräusch der Pumpe mit intaktem Ventil gebildeten Referenzsignalpegel verglichen, wobei bei einer vorbestimmten Pegelabweichung bzw. -veränderung aufgrund eines erhöhten Betriebsgeräusches eine Störungsfrüherkennungsanzeige ausgelöst wird.The method according to the invention is based on the essential idea that from a leaking valve due to the backflow of the conveying fluid in the closed Valve condition generated increased operating noise as a measure of the Leakage of the valve to use. For this purpose, the generated effective signal level continuously monitored and with one of the operating noise the reference valve level formed with the valve intact valve, wherein at a predetermined level deviation due to an increase in level Operating noise a fault early detection indicator is triggered.
Die Erfindung macht sich damit in vorteilhafter Weise den Effekt zunutze, daß bei intakter Pumpe ein gewisses Grundrauschen zu erkennen ist. Hierbei treten gleichzeitig einige diskrete typische Einzelgeräusche auf. Diese haben verschiedene Ursachen, wie z.B. der Zahneingriff im Untersetzungsgetriebe am Pumpentriebwerk oder die Öffnungs- und Schließgeräusche der Ventile.The invention thus makes advantageous advantage of the effect that at intact pump a certain background noise can be seen. Join this at the same time some discrete typical single sounds. These have different Causes, such as the meshing in the reduction gear on the pump engine or the opening and closing noises of the valves.
Demgegenüber erzeugen undicht gewordene Ventile aufgrund der Rückströmung des Förderfluids im geschlossenen Ventilzustand erhöhte typische Betriebsgeräusche. Diese erhöhten Betriebsgeräusche sind abhängig von der Rückströmmenge des Förderfluids und werden erfindungsgemäß als Maß für die Undichtigkeit des Ventils verwendet.In contrast, valves have become leaky due to the backflow of the delivery fluid in the closed valve state increased typical operating noise. This increased operating noise depends on the return flow the delivery fluid and are inventively as a measure of the leakage of the Valve used.
So ist beispielsweise bei einem defekten Saugventil während der Verdrängungsphase, d.h. während des Druckhubs, ein erhöhter Geräuschpegel zu erkennen, während bei einem defekten Druckventil während der Ansaugphase, d.h. während des Saughubs, ein erhöhter Geräuschpegel auftritt.For example, with a defective suction valve during the displacement phase, i.e. during the print stroke to detect an increased noise level while at a defective pressure valve during the suction phase, i. while the suction stroke, an increased noise level occurs.
Die bei den oszillierenden Verdrängerpumpen, insbesondere bei den zur Rede stehenden Membrandosierpumpen, zur Anwendung gelangenden Saug- und Druckventile sind üblicherweise entweder Kugelventile oder Plattenventile oder Kegelventile, die befedert oder druckgesteuert sein können. Hierbei bestehen die an diese Ventile gestellten Forderungen darin, daß sie genau zum richtigen Zeitpunkt öffnen und schließen müssen und daß sie in der vorgesehenen Zeit dicht sein müssen.The in the oscillating displacement pumps, especially in the speech standing diaphragm dosing pumps, used for applying suction and Pressure valves are usually either ball valves or plate valves or Cone valves that can be spring loaded or pressure controlled. Here are the These demands placed on these valves in that they are just at the right time open and close and that they are tight in the foreseeable time have to be.
Die an solchen Ventilen möglicherweise auftretenden Schäden äußern sich entweder in einer durch eine oder mehrere Kerben am Ventilsitz erzeugten Kerbleckage, wobei ein lokaler Schaden auftritt, oder aus einer einen flächigen Schaden erzeugenden Flächenleckage. Hierbei ist die Dichtkante des Ventilsitzes nicht punktuell durch eine oder mehrere Kerben, sondern über den gesamten Umfang geschädigt. In beiden Fällen tritt ein erhöhtes Strömungsrauschen am Ventilsitz auf, was sich u.a. durch das Zusammenfallen der auftretenden Kavitationsblasen erklären läßt.The damage that may occur to such valves is expressed either in a notch leakage generated by one or more notches on the valve seat, where a local damage occurs, or from a one-dimensional damage generating surface leakage. Here, the sealing edge of the valve seat is not punctually by one or more notches, but over the entire circumference damaged. In both cases, increased flow noise occurs at the valve seat on what u.a. by the coincidence of the occurring cavitation bubbles explain.
Erfindungsgemäß wird das erzeugte Betriebsgeräusch der Pumpe und damit auch dasjenige der Ventile als Körperschall gemessen. Dies kann in Ausgestaltung der Erfindung mittels eines Körperschallsensors oder eines Mikrophons, insbesondere aber mittels eines Schwingungsbeschleunigungssensors erfolgen, der vorzugsweise nach dem piezoelektrischen Kompressionsprinzip arbeitet und einen integrierten Ladungsverstärker besitzen kann.According to the invention, the operating noise generated by the pump and thus also that of the valves measured as structure-borne noise. This may be in the embodiment of Invention by means of a structure-borne sound sensor or a microphone, in particular but by means of a vibration acceleration sensor, preferably works on the piezoelectric compression principle and an integrated May have charge amplifier.
Erfindungsgemäß kann der erzeugte Körperschall am Pumpenkopf, insbesondere an einer zentralen Stelle hiervon, gemessen werden. Statt dessen ist es aber auch möglich, den erzeugten Körperschall an oder nahe dem betreffenden Ventil zu messen. Dies kann das Saug- und/oder Druckventil sein, zusätzlich aber auch die am Pumpenkörper vorgesehenen weiteren Hydraulikventile, die der Leckergänzung bzw. der Abfuhr von überschüssigem Hydraulikfluid dienen.According to the invention, the generated structure-borne noise at the pump head, in particular at a central location thereof. Instead, it is possible, the generated structure-borne sound at or near the valve in question measure up. This may be the suction and / or pressure valve, but in addition also the provided on the pump body further hydraulic valves, the leak supplement or the removal of excess hydraulic fluid serve.
Zur Durchführung der erfindungsgemäß vorgesehenen Vergleichsbildung zwischen Effektivsignalpegel und Referenzsignalpegel ist es wünschenswert, nicht den jeweils vom Körperschallsensor gemessenen Momentanwert heranzuziehen, sondern statt dessen einen solchen Wert, der über einen bestimmten Zeitraum gemittelt wurde.For carrying out the inventively provided comparison formation between Effective signal level and reference signal level, it is desirable not to use the instantaneous value measured by the structure-borne sound sensor, but instead such a value over a certain period of time was averaged.
Zu diesem Zweck sieht die Erfindung verschiedene Möglichkeiten vor. So ist es in Ausgestaltung der Erfindung möglich, den vom Betriebsgeräusch der Pumpe mit intakten Ventilen gebildeten Referenzsignalpegel über einen vorbestimmten Zeitraum zu mitteln. Auch kann der vom erhöhten Betriebsgeräusch der Pumpe mit undicht gewordenen Ventilen gebildete Effektivsignalpegel über einen vorbestimmten Zeitraum gemittelt werden.For this purpose, the invention provides various possibilities. So it is in Embodiment of the invention possible with the operating noise of the pump intact valves formed reference signal level over a predetermined period to mediate. Also, the increased operating noise of the pump with leaky valves formed RMS signal level over a predetermined Period to be averaged.
Als vorbestimmter Mittelungszeitraum kann beispielsweise derjenige während mehrerer Pumpenhübe oder auch derjenige während eines Bruchteils des Pumpenhubzyklus verwendet werden. Im letztgenannten Fall erfolgt die Auswertung der Signale innerhalb eines definierten Zeitfensters im Hubzyklus. Hierzu gelangt erfindungsgemäß ein Triggersignal zur Anwendung, das zu einem definierten Zeitpunkt des Pumpenhubzyklus erzeugt wird. Dies kann z.B. in der Saughubendstellung des Kolbens erfolgen. Das Triggersignal muß vorteilhafterweise keine sehr hohen Genauigkeitsanforderungen erfüllen. So reicht z.B. eine Genauigkeit von +/- 5° Kurbelwinkel aus. Hierbei wird für die Überwachung des Saugventils in einem definierten Zeitraum das erzeugte Körperschallsignal während der Verdrängungsphase (Druckhub) erfaßt und verglichen. Demgegenüber wird für die Überwachung des Druckventils der entsprechende Zeitraum in der Ansaugphase (Saughub) zugrunde gelegt.As a predetermined averaging period, for example, the one during several pump strokes or even that during a fraction of the pump stroke cycle be used. In the latter case, the evaluation takes place the signals within a defined time window in the stroke cycle. Get to this According to the invention, a trigger signal for use, which leads to a defined Time of the pump stroke cycle is generated. This can e.g. in the suction stroke end position of the piston. The trigger signal must advantageously no meet very high accuracy requirements. For example, an accuracy from +/- 5 ° crank angle. This is for monitoring the suction valve in a defined period of time, the generated structure-borne sound signal during the displacement phase (Pressure stroke) detected and compared. In contrast, for the Monitoring the pressure valve the corresponding period in the intake phase (Suction stroke).
Der definierte Zeitraum kann sich lediglich des Beispiels halber für die Überwachung des Druckventils über einen Bereich von 90 - 160° des Kurbelwinkels erstrecken, während für die Überwachung des Saugventils ein solcher definierter Zeitraum ausreicht, der sich über einen Bereich von 270 - 340° des Kurbelwinkels erstreckt.The defined period can only be used for monitoring purposes, for example of the pressure valve extend over a range of 90 - 160 ° of the crank angle, while for the monitoring of the suction valve such a defined Period sufficient, extending over a range of 270 - 340 ° of the crank angle extends.
Die Vorteile, die sich mit der Auswertung der Signale innerhalb eines definierten Zeitfensters im Pumpenhubzyklus ergeben, bestehen u.a. darin,
- daß Undichtigkeiten sowohl am Saugventil als auch am Druckventil genau unterschieden werden können,
- daß die Empfindlichkeit der Messung sehr hoch ist und
- daß störende Schallquellen, z.B. solche aus dem Antriebssystem, leicht ausgefiltert werden können, indem beispielsweise das Zeitfenster, innerhalb dessen die Messung erfolgte, entsprechend groß oder klein definiert wird.
- that leaks can be accurately distinguished both at the suction valve and at the pressure valve,
- that the sensitivity of the measurement is very high and
- that disturbing sound sources, for example those from the drive system, can be easily filtered out by, for example, defining the time window within which the measurement took place correspondingly large or small.
Die Erzeugung des Triggersignals kann erfindungsgemäß auf verschiedene Weise erfolgen, beispielsweise mittels eines am Pumpentriebwerks angebauten Kontaktgebers, mittels einer entsprechenden Abtastung der Kolbenstange, mittels der Erfassung eines charakteristischen Signals im erzeugten Körperschallsignal, beispielsweise aufgrund des Spielumschlags im Triebwerk, und auch anhand sonstiger charakteristischer Signale, z.B. des jeweils gemessenen Drucks im Luftraum des Hydraulikvorratsraums oder im Triebwerk.The generation of the trigger signal can according to the invention in various ways carried out, for example by means of a contactor mounted on the pump engine, by means of a corresponding scanning of the piston rod, by means of the detection a characteristic signal in the generated structure-borne sound signal, for example due to the game envelope in the engine, and also on the basis of other characteristic signals, e.g. the measured pressure in the airspace of the hydraulic storage room or in the engine.
Als Referenzsignalpegel wird zweckmäßigerweise derjenige Referenzwert genommen, der einem intakten Ventil zugeordnet ist. Dieser Referenzwert kann auf unterschiedliche Weise erfaßt werden, beispielsweise durch Messung im einwandfreien Zustand des Ventils unter Betriebsbedingungen, durch eine Auswahl aus vordefinierten Werten, z.B. aus einer Matrix mit definierten Werten für unterschiedliche Ventilausführungen und Betriebsbedingungen, aus einer Kennfeldermittlung, d.h. einer rechnerischen Ermittlung aus Ventildaten und Betriebsdaten, wie Förderdruck, Fluid usw., und dgl.The reference signal level is expediently taken to be the reference value. which is associated with an intact valve. This reference value can be up be detected in different ways, for example, by measuring impeccable Condition of the valve under operating conditions, by selecting from predefined values, e.g. from a matrix with defined values for different ones Valve designs and operating conditions, from a map determination, i.e. a computational determination from valve data and operating data, such as delivery pressure, Fluid, etc., and the like.
Bei dem vorerwähnten Verfahren, bei dem sowohl der Referenzsignalpegel als auch der Effektivsignalpegel über einen bestimmten Zeitraum während eines Bruchteils des Pumpenzyklus gemittelt wird, kann erfindungsgemäß der Mittelwert aus einer Anzahl von Pumpenhüben gebildet werden. Damit wird das automatische Störungsfrüherkennungsverfahren gemäß der Erfindung unempfindlich gegen kurzzeitige Störungen. Dies kann z.B. sinnvoll sein, wenn verschmutzte Fluide mittels der betreffenden Pumpe dosiert werden. Durch Fluidpartikel, die zwischen Ventilsitz und Ventilschließkörper unabsichtlich eingeklemmt werden, kommt es bei einzelnen Pumpenhüben zu einer Fluidrückströmung, die aber, weil lediglich kurzzeitig und vorübergehend auftretend, noch nicht als Störung angezeigt werden soll.In the aforementioned method, in which both the reference signal level and also the RMS signal level over a period of time during a A fraction of the pump cycle is averaged, according to the invention the mean are formed from a number of pump strokes. This will be the automatic Early disturbance detection method according to the invention insensitive to short-term disturbances. This can e.g. be useful if contaminated fluids be metered by the pump in question. By fluid particles between Valve seat and valve closing body are inadvertently pinched, it comes at individual pump strokes to a fluid backflow, but because only temporarily and temporarily, not yet displayed as a fault should.
Eine weitere Ausgestaltung des erfindungsgemäßen Verfahrens kann darin bestehen, daß von einer Anzahl von Pumpenhüben vor deren weiteren Signalverarbeitung eine bestimmte Anzahl von Pumpenhüben mit Extremwerten oder mit nicht plausiblen Werten aussortiert wird.A further embodiment of the method according to the invention may consist in that of a number of pump strokes before their further signal processing a certain number of pump strokes with extreme values or not plausible values.
So sei lediglich als Beispiel angegeben, daß die Signalwerte von 100 Pumpenhüben erfaßt werden können, wobei jeweils drei Pumpenhübe mit den höchsten sowie mit den niedrigsten Einzelwerten aussortiert werden. Für die weitere Signalverarbeitung wird dann aus den verbleibenden 94 Werten der Mittelwert gebildet.Thus, for example only, the signal values of 100 pump strokes can be detected, with three pump strokes with the highest as well with the lowest individual values sorted out. For further signal processing then the average value is formed from the remaining 94 values.
Damit nicht nur ein aktueller Ventilfehler angezeigt werden kann, liegt es im Rahmen der Erfindung, die auftretenden Fehler mit einer entsprechenden Zeitangabe in einem Speicher abzulegen oder diese Fehler an übergeordnete Leitsysteme zu melden. Dies ist besonders dann von Vorteil, wenn eine Ventilundichtigkeit nur zeitweise auftritt und die Undichtigkeit nicht durch Verschleiß, sondern z.B. durch zeitweise verunreinigtes Fluid verursacht wird. So that not only a current valve error can be displayed, it is within the scope of the invention, the errors occurring with a corresponding time in a memory store or these errors to higher-level control systems Report. This is particularly advantageous if a valve leaks only Occurs occasionally and the leakage is not due to wear, but e.g. by Occasionally contaminated fluid is caused.
In weiterer Ausgestaltung der Erfindung ist vorgesehen, daß das vom jeweiligen Ventil erzeugte Körperschallsignal mittels Ventileinbauten verstärkt wird. Dies sind insbesondere Einbauten am Ventilsitz, deren Zweck es ist, aufgrund der Leckagerückströmung zum Schwingen angeregt zu werden, um eine Verstärkung des Körperschallsignals zu erreichen.In a further embodiment of the invention, it is provided that the respective of the respective Valve generated structure-borne sound signal is amplified by means of valve internals. these are in particular fittings on the valve seat, the purpose of which is due to the leakage backflow to be excited to vibrate, to amplify the structure-borne sound signal to reach.
In Weiterbildung der Erfindung kann es vorteilhaft sein, nur ein definiertes Frequenzband der gemessenen Signale auszuwerten, um den Abstand zum allgemeinen Rauschsignal zu erhöhen.In a further development of the invention, it may be advantageous to have only one defined frequency band evaluate the measured signals to the distance to the general To increase noise signal.
Es liegt schließlich im Rahmen der Erfindung, einzelne Meßdaten, wie z.B. ein Spielumschlag im Triebwerk, aus dem betrachteten Zeitfenster auszublenden. In diesem Fall ist dann die Existenz eines exakten Triggersignals von Vorteil.It is finally within the scope of the invention, individual measurement data, such. one Game envelope in the engine, hide from the considered time window. In In this case, the existence of an exact trigger signal is advantageous.
Die erfindungsgemäß vorgesehene Vorrichtung zur Durchführung des beschriebenen Verfahrens ist versehen mit einer an ein Pumpenbauteil angeschlossenen Meßeinrichtung, welche das von einem undichten Ventil aufgrund der Rückströmung des Förderfluids im geschlossenen Ventilzustand erzeugte erhöhte Betriebsgeräusch überwacht und als Effektivsignalpegel mißt, und mit einer mit der Meßeinrichtung verbundenen Vergleichseinrichtung, welche den Effektivsignalpegel mit einem vom Betriebsgeräusch der Pumpe mit intakten Ventilen gebildeten Referenzsignalpegel vergleicht und bei einer vorbestimmten Pegelabweichung bzw. -veränderung eine Störmeldung als Störungsfrüherkennung erzeugt.The inventively provided device for carrying out the described Method is provided with a connected to a pump component Measuring device, which by a leaking valve due to the backflow the delivery fluid in the closed valve state generated increased operating noise monitored and measures as RMS signal level, and with a with the Measuring device connected comparison device, which the RMS signal level with an operating noise of the pump with intact valves formed Reference signal level compares and at a predetermined level deviation or change generates a fault message as early fault detection.
Vorteilhafterweise weist die Meßeinrichtung wenigstens einen Sensor zur Erfassung des vom Betriebsgeräusch der Pumpe erzeugten Körperschalls auf. Hierbei kann dieser Körperschallsensor ein Schwingungsbeschleunigungssensor, vorzugsweise piezoelektrisch arbeitend, sein.Advantageously, the measuring device has at least one sensor for detection of the structure-borne noise generated by the operating noise of the pump. in this connection This structure-borne sound sensor can be a vibration acceleration sensor, preferably be piezoelectric.
In Ausgestaltung der Erfindung kann die Meßeinrichtung entweder am Pumpenkopf, insbesondere an einer zentralen Stelle hiervon, angeschlossen sein. Statt dessen ist es auch möglich, die Meßeinrichtung direkt an oder nahe den Pumpenventilen, d.h. dem Saug- und Druckventil sowie den weiteren Hydraulikventilen, vorzusehen. In an embodiment of the invention, the measuring device either on the pump head, in particular at a central point thereof, be connected. Instead of of which it is also possible to have the measuring device directly on or near the pump valves, i.e. the suction and pressure valve and the other hydraulic valves, provided.
Falls erwünscht, kann erfindungsgemäß das erzeugte Körperschallsignal durch geeignete Einbauten in den Ventilsitz verstärkt werden. Zu diesem Zweck ist eine Schwingungseinrichtung vorgesehen, die an oder nahe dem Ventilsitz vorgesehen ist.If desired, according to the invention, the structure-borne sound signal generated by suitable fittings are reinforced in the valve seat. For this purpose is a Vibration device provided, which is provided at or near the valve seat is.
Eine derartige Schwingungseinrichtung kann aus wenigstens einem schräg in das Ventil eingebauten Flügel oder aber aus einem Membranblechring bestehen, der in den Ventilsitz eingebaut ist.Such a vibrating device may consist of at least one obliquely in the Valve built-in wing or consist of a membrane sheet metal ring, the is installed in the valve seat.
Die Erfindung wird im folgenden anhand der Zeichnung näher erläutert. Hierbei zeigen:
- Fig. 1
- schematisch im Schnitt die Anwendung des Verfahrens sowie der Vorrichtung gemäß der Erfindung bei einer Membrandosierpumpe sowie bei einer Kolbenpumpe;
- Fig. 2a
- im Diagramm den Kolbenweg der Pumpe über der Zeit,
- Fig. 2b
- im Diagramm den zeitlichen Verlauf des Druckhubs sowie des Saughubs der Membrandosierpumpe;
- Fig. 2c
- den als Körperschallsignal gemessenen Referenzsignalpegel eines intakten Pumpenventils sowohl beim Druckhub als auch beim Saughub,
- Fig. 2d
- den Effektivsignalpegel bei einem defekten Saugventil und
- Fig. 2e
- bei einem defekten Druckventil;
- Fig. 3a
- den Referenzsignalpegel sowie den Effektivsignalpegel in zeitlicher Mittelung über mehrere Pumpenhübe und
- Fig. 3b
- in zeitlich begrenzter Mittelung, d.h. in einem definierten Zeitfenster innerhalb des Hubzyklus.
- Fig. 1
- schematically in section the application of the method and the device according to the invention in a diaphragm metering pump and in a piston pump;
- Fig. 2a
- in the diagram the piston stroke of the pump over time,
- Fig. 2b
- in the diagram, the time course of the pressure stroke and the suction stroke of the diaphragm metering pump;
- Fig. 2c
- the reference signal level of an intact pump valve measured as a structure-borne sound signal both during the pressure stroke and during the suction stroke,
- Fig. 2d
- the effective signal level at a defective suction valve and
- Fig. 2e
- at a defective pressure valve;
- Fig. 3a
- the reference signal level and the effective signal level in time averaging over several pump strokes and
- Fig. 3b
- in time-limited averaging, ie in a defined time window within the Hubzyklus.
Wie in Fig. 1 schematisch dargestellt, können das Verfahren und die Vorrichtung
gemäß der Erfindung sowohl bei einer Membrandosierpumpe 1 als auch bei einer
Kolbenpumpe 2 zur Anwendung gelangen. Hierbei dreht es sich darum, bei den
jeweils vorgesehenen Saugventilen 3 sowie Druckventilen 4, die beim dargestellten
Ausführungsbeispiel jeweils als druckgesteuerte Kugelventile ausgestaltet
sind, eine Störungsfrüherkennung durchzuführen.As shown schematically in Fig. 1, the method and the device
According to the invention both in a
Zu diesem Zweck ist eine Meßeinrichtung 5 vorgesehen, die an einer zentralen
Stelle des Pumpendeckels 6 angeschlossen ist und das von einem undichten Ventil
3 bzw. 4 aufgrund der Rückströmung des Förderfluids im geschlossenen Ventilzustand
erzeugte erhöhte Betriebsgeräusch überwacht sowie als Effektivsignalpegel
mißt.For this purpose, a measuring device 5 is provided, which at a central
Place the
Die Meßeinrichtung 5 ist zur Messung des jeweils vom Betriebsgeräusch erzeugten Körperschalls ausgebildet und weist einen entsprechenden Sensor auf. Dieser ist beim dargestellten Ausführungsbeispiel ein piezoelektrisch arbeitender Schwingungsbeschleunigungssensor.The measuring device 5 is for measuring each generated by the operating noise Structure-borne sound and has a corresponding sensor. This is a piezoelectric working in the illustrated embodiment Vibration acceleration sensor.
Es ist weiterhin eine Vergleichseinrichtung 7 vorgesehen, welche den von der Meßeinrichtung
5 über eine Signalleitung 8 angelieferten Effektivsignalpegel mit einem
vom Betriebsgeräusch der Pumpe mit intakten Ventilen 3 bzw. 4 gebildeten
Referenzsignalpegel vergleicht und bei einer vorbestimmten Pegelabweichung
bzw. -veränderung eine Störmeldung als Störungsfrüherkennung erzeugt.It is further provided a
Wie im einzelnen aus Fig. 2a - 2e ersichtlich, zeigen die verschiedenen Diagramme
die Charakteristika der Membrandosierpumpe 1 gemäß Fig. 1. Hierbei ist in
Fig. 2a der Kolbenweg über der Zeit dargestellt.As can be seen in detail from FIGS. 2a-2e, the various diagrams show
the characteristics of the
Fig. 2b zeigt demgegenüber den Druckverlauf im Hydraulikraum 9 der Pumpe 1,
wobei deutlich der charakteristische Verlauf des vom Kolben 10 durchgeführten
Druckhubs sowie des Saughubs der Membran 11 (s. Fig. 1) erkennbar ist. 2 b shows the pressure curve in the
Wie aus Fig. 2c zu ersehen, gestaltet sich der Verlauf des von einer Pumpe 1 mit
intakten Ventilen 3 bzw. 4 erzeugten Betriebsgeräuschs, das als Körperschallsignal
gemessen wird, in typischer Weise, wobei der in Fig. 2c dargestellte Verlauf
den Referenzsignalpegel darstellt. Dieser gibt typische Geräuschspitzen wieder,
die während des vom Pumpenkolben 10 durchgeführten Druckhubes und Saughubes
erzeugt werden.As can be seen from Fig. 2c, the course of the designed by a
Im Gegensatz hierzu zeigt Fig. 2d den Körperschallverlauf einer Pumpe 1 mit defektem
Saugventil 3, der typischerweise während des vom Kolben 10 durchgeführten
Druckhubes in Erscheinung tritt, da hierbei das Saugventil 3 aufgrund der aufgetretenen
Undichtigkeit nicht mehr exakt schließt und somit eine unerwünschte
Leckageströmung in die Ansaugleitung zuläßt.In contrast, Fig. 2d shows the structure-borne sound profile of a
Im Gegensatz hierzu zeigt Fig. 2e das Körperschallsignal bei einer Pumpe 1 mit
defektem Druckventil 4. Dieses ergibt sich, wie dargestellt, beim Saughub des
Kolbens 10, da hier das undicht gewordene Druckventil 4 nicht mehr zuverlässig
schließt und eine unerwünschte Rückströmung in Form einer Leckageströmung in
den Fluidraum 12 der Pumpe 1 zuläßt.In contrast, FIG. 2e shows the structure-borne sound signal in a
Fig. 3a und 3b zeigen schließlich den Pegelverlauf des gemessenen Körperschallsignals in gemittelter Form, wobei in Fig. 3a der Mittelungszeitraum während mehrerer Pumpenhübe, d.h. also mehrmals während des Druckhubes sowie des Saughubes, dargestellt ist und sich die Störungsfrüherkennung aufgrund eines erhöhten Effektivsignalpegels erkennen läßt. Demgegenüber zeigt Fig. 3b den Signalverlauf bei einem Mittelungszeitraum, der sich lediglich über einen Bruchteil des Pumpenhubzyklus, im dargestellten Fall während lediglich einer bestimmten Zeit des Saughubes, erstreckt.Finally, FIGS. 3a and 3b show the level profile of the measured structure-borne sound signal in averaged form, wherein in Fig. 3a, the averaging period during several Pump strokes, i. so several times during the print stroke and the Suction stroke, is shown and the early fault detection due to a increased detected RMS signal level. In contrast, Fig. 3b shows the Waveform at an averaging period that is only a fraction the pump stroke cycle, in the case shown, only a specific one Time of the suction stroke, extends.
Hinsichtlich vorstehend im einzelnen nicht näher erläuterter Merkmale der Erfindung wird im übrigen ausdrücklich auf die Zeichnung sowie die Ansprüche verwiesen.With regard to the above in detail not further explained features of the invention is otherwise expressly made to the drawings and the claims.
Claims (21)
dadurch gekennzeichnet, daß das von einem undichten Ventil aufgrund der Rückströmung des Förderfluids im geschlossenen Ventilzustand erzeugte erhöhte Betriebsgeräusch als Maß für die Undichtigkeit des Ventils verwendet wird, indem der erzeugte Effektivsignalpegel kontinuierlich überwacht und mit einem vom Betriebsgeräusch der Pumpe mit intakten Ventilen gebildeten Referenzsignalpegel verglichen wird, wobei bei einer vorbestimmten Pegelabweichung bzw. -veränderung aufgrund eines erhöhten Betriebsgeräusches eine Störungsfrüherkennungsanzeige ausgelöst wird.Method for monitoring and automatic early fault detection of the valves, in particular the suction and / or pressure valves, an oscillating positive displacement pump, in particular a diaphragm metering pump,
characterized in that the increased operating noise generated by a leaking valve due to the backflow of the delivery fluid in the valve closed state is used as a measure of the leakage of the valve by continuously monitoring the generated effective signal level and comparing it with a reference signal level formed by the operating sound of the intact valve pump wherein at a predetermined level deviation or change due to an increased operating noise, a fault early detection indicator is triggered.
gekennzeichnet durch
eine an ein Pumpenbauteil angeschlossene Meßeinrichtung (5), welche das von einem undichten Ventil (3 bzw. 4) aufgrund der Rückströmung des Förderfluids im geschlossenen Ventilzustand erzeugte erhöhte Betriebsgeräusch überwacht und als Effektivsignalpegel mißt, und
eine mit der Meßeinrichtung (5) verbundene Vergleichseinrichtung (7), welche den Effektivsignalpegel mit einem vom Betriebsgeräusch der Pumpe mit intaktem Ventil (3 bzw. 4) gebildeten Referenzsignalpegel vergleicht und bei einer vorbestimmten Pegelabweichung bzw. -veränderung eine Störmeldung als Störungsfrüherkennung erzeugt.Device for carrying out the method according to one of the preceding claims,
marked by
a measuring device (5) connected to a pump component, which monitors the increased operating noise generated by a leaking valve (3 or 4) due to the backflow of the conveying fluid in the closed valve state and measures it as an effective signal level, and
a comparison device (7) connected to the measuring device (5), which compares the RMS signal level with a reference signal level formed by the operating sound of the pump with intact valve (3 or 4) and generates a fault message as a fault early detection at a predetermined level deviation or change.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE10322220A DE10322220C5 (en) | 2003-05-16 | 2003-05-16 | Early fault detection on pump valves |
| DE10322220 | 2003-05-16 |
Publications (4)
| Publication Number | Publication Date |
|---|---|
| EP1477678A2 true EP1477678A2 (en) | 2004-11-17 |
| EP1477678A3 EP1477678A3 (en) | 2005-06-29 |
| EP1477678B1 EP1477678B1 (en) | 2007-02-21 |
| EP1477678B2 EP1477678B2 (en) | 2017-04-19 |
Family
ID=32946466
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP04011109.8A Active EP1477678B2 (en) | 2003-05-16 | 2004-05-10 | Early detection of failures in pump valves |
Country Status (4)
| Country | Link |
|---|---|
| US (1) | US7069183B2 (en) |
| EP (1) | EP1477678B2 (en) |
| AT (1) | ATE354730T1 (en) |
| DE (2) | DE10322220C5 (en) |
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| WO2007099057A2 (en) * | 2006-02-28 | 2007-09-07 | Auma Riester Gmbh+Co. Kg | Method and device for the monitoring, diagnosis or adjustment of an actuator for actuating a fitting |
| WO2007099057A3 (en) * | 2006-02-28 | 2007-11-15 | Auma Riester Gmbh & Co Kg | Method and device for the monitoring, diagnosis or adjustment of an actuator for actuating a fitting |
| DE102006055747A1 (en) * | 2006-11-25 | 2008-05-29 | Abb Ag | Method and arrangement for the diagnosis of an actuator |
| US8122905B2 (en) | 2006-11-25 | 2012-02-28 | Abb Ag | Method and arrangement for diagnosis of a final control element |
| DE102006055747B4 (en) | 2006-11-25 | 2021-08-26 | Abb Ag | Method and arrangement for diagnosing an actuator |
| DE102010034798A1 (en) | 2009-09-02 | 2011-03-03 | Schaeffler Technologies Gmbh & Co. Kg | Method for monitoring valves i.e. one-way non-return valves, of displacement pump, for use in oil-or gas supply system to pump drilling fluid, involves determining whether valve comprises defect based on characteristic values of signals |
| DE102010034800A1 (en) | 2009-09-02 | 2011-03-24 | Schaeffler Technologies Gmbh & Co. Kg | Method for monitoring valve in e.g. scavenging pump, utilized in oil or gas conveyor system, involves determining valve defects based on characteristic value of acoustic signal within evaluation interval and reference characteristic value |
| CN104895714A (en) * | 2015-03-12 | 2015-09-09 | 肖光生 | Gasoline direct injection |
| CN105822537A (en) * | 2016-04-12 | 2016-08-03 | 齐轩 | Fatigue test device for rubber diaphragms of diaphragm pump |
| CN108661891A (en) * | 2018-05-09 | 2018-10-16 | 浙江工业大学 | A kind of low cost metering diaphragm pump diaphragm breakage leakage detection method |
| CN108661891B (en) * | 2018-05-09 | 2019-07-30 | 浙江工业大学 | A kind of low cost metering diaphragm pump diaphragm breakage leakage detection method |
Also Published As
| Publication number | Publication date |
|---|---|
| US20040226346A1 (en) | 2004-11-18 |
| EP1477678B2 (en) | 2017-04-19 |
| US7069183B2 (en) | 2006-06-27 |
| ATE354730T1 (en) | 2007-03-15 |
| DE502004002932D1 (en) | 2007-04-05 |
| DE10322220B3 (en) | 2004-10-07 |
| EP1477678B1 (en) | 2007-02-21 |
| EP1477678A3 (en) | 2005-06-29 |
| DE10322220C5 (en) | 2010-10-14 |
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