EP2039939B2 - Verfahren zur Überwachung einer Energieumwandlungseinrichtung - Google Patents

Verfahren zur Überwachung einer Energieumwandlungseinrichtung Download PDF

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Publication number
EP2039939B2
EP2039939B2 EP07018530.1A EP07018530A EP2039939B2 EP 2039939 B2 EP2039939 B2 EP 2039939B2 EP 07018530 A EP07018530 A EP 07018530A EP 2039939 B2 EP2039939 B2 EP 2039939B2
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EP
European Patent Office
Prior art keywords
power
monitoring
pump
variables
assembly
Prior art date
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Active
Application number
EP07018530.1A
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German (de)
English (en)
French (fr)
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EP2039939B1 (de
EP2039939A1 (de
Inventor
Pierre Vadstrup
Carsten Skovmose Kallesøe
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Grundfos Management AS
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Grundfos Management AS
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Application filed by Grundfos Management AS filed Critical Grundfos Management AS
Priority to EP07018530.1A priority Critical patent/EP2039939B2/de
Priority to PCT/EP2008/007041 priority patent/WO2009039934A1/de
Priority to JP2010525224A priority patent/JP5439378B2/ja
Priority to US12/679,054 priority patent/US20100300220A1/en
Priority to CN200880108089.6A priority patent/CN101802413B/zh
Publication of EP2039939A1 publication Critical patent/EP2039939A1/de
Publication of EP2039939B1 publication Critical patent/EP2039939B1/de
Publication of EP2039939B2 publication Critical patent/EP2039939B2/de
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D27/00—Control, e.g. regulation, of pumps, pumping installations or pumping systems specially adapted for elastic fluids
    • F04D27/001—Testing thereof; Determination or simulation of flow characteristics; Stall or surge detection, e.g. condition monitoring
    • 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D15/00—Control, e.g. regulation, of pumps, pumping installations or systems
    • F04D15/0088—Testing machines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2260/00—Function
    • F05D2260/80—Diagnostics
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2270/00—Control
    • F05D2270/30—Control parameters, e.g. input parameters
    • F05D2270/335—Output power or torque

Definitions

  • the invention relates to a method for monitoring an energy conversion device which consists of a plurality of functionally linked functional units.
  • energy conversion devices within the meaning of the invention can be, for example, centrifugal pump units driven by an electric motor, compressors driven by an electric motor, systems equipped with them, or the like. They consist of several functionally linked functional units, such as electric motor and centrifugal pump or electric motor and displacement pump or combustion engine and electric generator. Such energy conversion devices are used nowadays in almost all technical, but also domestic, areas.
  • EP-A-1 564 411 with all the features of the preamble of claim 1 counts a method comparable to the prior art with which the proper operation of the pump is monitored.
  • the invention is based on the object of improving a generic method for monitoring an energy conversion device that consists of several functionally linked functional units, in particular to the effect that not only a fault condition but also a deterioration in efficiency can be detected. Furthermore, corresponding energy conversion devices are to be designed for carrying out the method according to the invention.
  • the solution according to the invention provides a method for monitoring an energy conversion device with the features specified in claim 1.
  • an energy conversion device in particular an assembly, a machine or a system, can determine and display its individual performance characteristics, the resulting operating behavior, life expectancy and the like in a self-learning manner.
  • Performance-dependent variables in the context of the present invention are those which are in any way related to the performance characteristics of a functional unit.
  • the timing of the switching on and off processes can also be a performance-dependent variable in the sense of the present invention.
  • the inventive efficiency monitoring of the device or at least individual functional units of the device can be carried out comparatively easily if the functional units always run at the same operating point, since one measured value is then typically sufficient to determine the intended or decreased performance / efficiency of the respective unit.
  • an energy conversion device such as a heating circulation pump
  • Such units typically consist of the functional units motor and centrifugal pump, the centrifugal pump typically constantly changing its operating point, since the pipe network resistance of the heating system changes due to external influences.
  • the method according to the invention is advantageously carried out during normal operation of the device, that is to say in the case of a pump unit during the intended pumping operation, whereby the time interval for recording the quasi-simultaneous operating points for determining the surface profile can be in the range of minutes, for example, whereas the time interval after which a comparison measurement is carried out, can be in the daily, weekly or monthly range, depending on the device type.
  • Comparatively long intervals are z. B. result in heating circulation pumps, whereas short intervals can be useful for compressors, especially for cooling systems, since with such a monitoring method not only a deterioration in efficiency, but also a possible failure of the device can be detected.
  • the time interval at which the performance-dependent variables to be compared are determined depends on both the machine type and the intended use. However, the comparison is expediently carried out on the basis of the previously recorded variables or predetermined values, the latter method having the advantage that a bad function can already be detected when it is started up.
  • the method according to the invention can be carried out with significantly less effort in terms of measurement and computation if first an electrical variable of the motor that determines the power consumption of the motor and at least one variable that determines the hydraulic operating point of the pump are recorded and stored and the subsequent comparison measurement is waited for so long, until the previously recorded hydraulic operating point is reached again and the engine's power consumption parameters are then recorded and compared with those initially stored. A direct comparison can then be made without the need to determine operating point deviations and thus the aforementioned surface profiles.
  • the variables recorded later for comparison measurement can be recorded at any operating point of the system if the recorded variables are transferred on the basis of a mathematical, electrical motor model and / or a mathematical hydraulic pump model, i.e. are converted to variables that are independent of the operating point and then compared with the stored variables or vice versa, so that regardless of the operating point a comparison of the performance-determining parameters is possible.
  • the method is advantageously used only after a predetermined time has elapsed, this predetermined time corresponding at least to the running-in time of the unit, in particular the pump unit.
  • this predetermined time corresponding at least to the running-in time of the unit, in particular the pump unit.
  • At least one operating profile is automatically recorded after the predetermined time, typically the run-in time, and the expected energy consumption is determined taking into account the possibly determined change in efficiency and displayed by suitable means.
  • a comparison measurement it is not necessary for a comparison measurement to approach the same operating point. Rather, on the basis of several operating points, a multi-dimensional model character, which is dependent on the performance of a functional unit, is determined and stored, and such a surface profile is determined and stored again at time intervals and compared with the previously determined one, the distance between the surface profiles then being a predetermined one Operating point or operating range or the volume spanned between the surface courses can be used as a measure of the change in efficiency. Such an evaluation is particularly advantageous because it can take place during continuous operation without any intervention in the operating behavior of the machine. Such a method is particularly advantageous in the case of centrifugal pump assemblies, such as those used, for example, as heating circulation pumps, which usually run at constantly changing operating points.
  • a Kalman filter is advantageously used to determine the surface profile on the basis of the operating points. This iteration method makes it possible, with only a comparatively small number of measured operating points, to determine the surface profile with sufficient accuracy in order to be able to detect and quantitatively determine the deviations in question here.
  • the method according to the invention can in principle be used for monitoring with any energy conversion devices which consist of several functionally linked functional units. It is particularly advantageous to use centrifugal pump units, compressors, heating systems, refrigerators, freezers and the like, which are typically operated for years and decades without any deterioration in efficiency or failure.
  • the monitoring method according to the invention is suitable both for detecting and indicating a bad run, i.e. a deterioration in efficiency, which makes premature replacement of the unit or at least one functional unit of the unit appear economically sensible, as well as, for example, of particular advantage in the case of freezers or freezers to be able to display the expected failure of the unit so that a replacement can be provided in good time.
  • the method according to the invention can also be used effectively in the case of larger machines, the downtime of which has economic consequences, in order to indicate an impending failure in good time. It goes without saying that appropriate characteristic values are then expediently specified, which were previously determined in the laboratory test, so that the downtime can at least roughly be determined based on the change in efficiency or the change in performance of the machine.
  • the method according to the invention can advantageously be implemented in the form of a software program in the digital control and regulation electronics which are already present in modern units.
  • control and regulating electronics can be provided both in the unit itself and in the terminal or connection box of the unit.
  • the method according to the invention is advantageously used in a centrifugal pump unit with an electric motor and a centrifugal pump driven by it in a device provided there for monitoring the performance characteristics of at least one functional unit of the unit.
  • a device operating according to the method according to the invention can be provided for monitoring the performance characteristics, in particular for recording and monitoring efficiency.
  • a cooling unit can be provided with an electric motor, with a displacement pump driven by it, with an evaporator and with a condenser with a device for monitoring the performance characteristics that works according to the method according to the invention, the monitoring of the performance characteristics not only affecting the engine and Limited displacement pump, but advantageously includes evaporator and condenser.
  • a reduction in efficiency can be determined by monitoring the running time of the compressor after the installation of the device. This can be done, for example, in that the running time is determined within 24 hours and then later, for example after six months, is compared with the resulting running time within 24 hours. In its simplest form, it can be assumed that, due to constant environmental conditions and user behavior, an increasing number of Duty cycle is caused by a deterioration in the efficiency of the system. More precise conclusions can be drawn from an analysis of the compressor running time over time.
  • a device for monitoring the performance characteristics of the burner and at least one water circuit that can be heated by this can be provided in a heating system in order to be able to detect, for example, combustion residues on the primary heat exchanger and the associated deterioration in efficiency.
  • an indication of the required cleaning service can be given, which can thus be determined as required.
  • the device is expediently designed in such a way that it starts automatically after a predetermined time after commissioning the unit or the system with the acquisition and storage of the parameters relevant for monitoring the performance characteristics, in particular for determining and monitoring the efficiency, and at appropriate time intervals these parameters again recorded and compared with the pre-stored and / or the originally stored quantities and possibly indicates an impermissibly high deviation.
  • the device therefore advantageously has a measured value memory in which at least the variables recorded at the beginning of the measurement or variables derived therefrom are stored.
  • the machine is expediently monitored in its entirety if possible. However, it can also be sufficient to monitor only one functional unit of the machine. This will be particularly useful if the machine has a functional unit that typically fails significantly before all other functional units due to wear and tear or in some other way.
  • Fig. 1 an energy conversion device consisting of the functional units 1 and 2 is shown as an example for a large number of machines, systems and aggregates.
  • the functional units 1 and 2 are monitored independently of one another.
  • the power P 1 consumed by the functional unit 1 is a function of one or more variables x 1 recorded and saved as in Fig. 1 shown with 3.
  • the variables x 1 are through u 1 and y 1 , so that the area shown in FIG. 3 corresponds to the energy balance of the functional unit 1 at the input. Accordingly, a power P 2 is established at the output, which in turn depends on the variables x 1 is. This area is shown in FIG.
  • the functional units 1 and 2 are functional, e.g. B.
  • representation 4 corresponds to representation 5, which shows the power P 2 here as a function of x 2 defined according to the energy balance at the input of the functional unit 2, depending on the variables u 2 and y 2 .
  • a power P 3 occurs at the output of the functional unit 2, as shown in FIG. 6 and which is dependent on x 2 is.
  • the areas marked by hatching in Figures 3 to 6 are determined at the beginning of the method. This can be done in the factory or only after a certain time in operation. This can be done as an initialization process or during operation. In any case, it takes place at a point in time t 1 which, if several operating points are to be recorded, can also represent a time range. At a time t 2 becomes then in the same way an energy balance is created at the input of the functional unit 1, at the output of the functional unit 1, at the input of the functional unit 2 and at the output of the functional unit 2.
  • the corresponding representations are marked 3 ', 4', 5 'and 6'.
  • Different signals can be generated here by grading the values, for example a first warning signal which indicates a reduced efficiency above a certain value and a second warning signal which indicates such a reduction in efficiency that requires replacement or repair. Since the functional units 1 and 2 are monitored separately from one another, it can also be determined which of the functional units is wholly or partially responsible for the reduction in efficiency.
  • the constants are a p2 , a p1 , a p0, and p offset .
  • the figures 8, 9 and 10 in Fig. 2a The three-dimensional surfaces shown, which each describe the performance at the interfaces in front of, between and behind the functional units 1 a and 2a, are recorded and stored at a point in time t 1 .
  • the detection is typically made during normal operation a short period of time which is negligibly small in relation to the monitoring interval (time from T 1 to t 2 ), after which this process is repeated after a longer period of time, namely at time t 2 , so that the areas according to the representations 8 ', 9 'and 10' result.
  • the surfaces 8 and 8 'as well as 9 and 9' and finally 10 and 10 ' are compared with one another at time t 1 and t 2 . If the surfaces match, the unit works unchanged.
  • a performance monitoring takes place before and after each functional unit 1 a, 2a. However, this may be unnecessary depending on the application. It is also not absolutely necessary to determine the multi-dimensional and model-like surface courses representing the input or output power, as defined by equations 8, 9 and 10, but can, as in the exemplary embodiment according to FIG Figure 2b clarified, e.g. instead of the power P 3 according to illustration 10 in Fig. 2a alternatively, the hydraulic power characteristic can be determined, i.e. the differential pressure applied by the pump 2a as a function of the drive speed ⁇ r and the flow rate q. Which is recorded and stored at time t 1 .
  • the efficiency of the motor ⁇ m is the quotient of P 2 and P 1 and is dependent on ⁇ e (the supply frequency ) and s , the slip of the motor.
  • the motor efficiency is in Figure 2c in the illustration 11a represented by the area in the diagram at each operating point.
  • the power P 2 is shown as a function of ⁇ p and ⁇ r .
  • the power P 1 of the motor 1 a is also shown in the form of an area as a function of the supply frequency and the flow rate of the pump.
  • the engine power P 1 can be monitored in a manner analogous to that indicated above by equation (8).
  • Fig. 4 Based on Fig. 4 the inventive method for a refrigerator is shown consisting of a Motor 1c, a displacement pump 2c, the output of which acts on an evaporator 3c, which is connected via a throttle 4c to a capacitor 5c, the output of which is line-connected to the input of the pump 2c.
  • the cold room is marked with 7c.
  • Equation 15 describes the power P 2 at the input of the compressor
  • equation 17 describes the power at the output of the compressor.
  • the areas to be determined here to determine the power at the interfaces of the functional units can be two-dimensional or multidimensional.
  • the area according to illustration 17 is two-dimensional, that is, a line.
  • the other areas shown here are all three-dimensional. It goes without saying that these surfaces can possibly also be more than three-dimensional, depending on the type of machine to be monitored and the underlying mathematical-physical relationships.
  • the monitoring takes place in an analogous manner, in that the areas indicating the power at the interfaces of the functional units are determined according to representations 14, 15 and 17 at time t 1 and after a time interval at time t 2 (the areas then result according to Representations 14 '15' and 17 '), in order to then determine by determining the distance between the surfaces or the volume spanned between them which of the functional units 1c, 2c have decreased in their degree of efficiency.
  • P 2 ⁇ w qC pw T w , out - T w , in in which p w is the density of the water and C pw is the specific heat capacity of the water.
  • the method according to the invention can be used with a wide variety of devices such as units, machines and systems, with the multidimensional areas being advantageously always determined, which define the performance at the interfaces of the functional units to each other at any operating point and thus a reliable one Measure for the performance characteristics of the functional units as well as with a corresponding evaluation of the entire device result when these are compared with one another at different times (for example t 1 and t 2 ).
  • the times t 1 and t 2 are to be understood here only as examples; the values determined at the time t 1 are expediently always stored in order to be able to compare them with later ones, but this does not rule out that intermediate values are also saved possibly also to record the speed of the change. This can also be evaluated in a corresponding evaluation device.
  • EP 1 564 411 A1 referenced where comparable evaluations are described in detail.
  • two- or multi-dimensional surfaces have always been used to determine the power balance at the interfaces of the functional units, since this enables an evaluation to be practically independent of the respective operating point.
  • the two-dimensional or multi-dimensional surfaces in question are advantageously determined during operation, with attempts being made by means of suitable iteration methods to achieve a high level of accuracy of the surfaces on the basis of as few different operating points as possible. This can be achieved in particular using the Kámán filter, as has already been described above. However, other suitable iteration methods can also be used.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Control Of Positive-Displacement Pumps (AREA)
  • Control Of Non-Positive-Displacement Pumps (AREA)
  • Domestic Hot-Water Supply Systems And Details Of Heating Systems (AREA)
EP07018530.1A 2007-09-20 2007-09-20 Verfahren zur Überwachung einer Energieumwandlungseinrichtung Active EP2039939B2 (de)

Priority Applications (5)

Application Number Priority Date Filing Date Title
EP07018530.1A EP2039939B2 (de) 2007-09-20 2007-09-20 Verfahren zur Überwachung einer Energieumwandlungseinrichtung
CN200880108089.6A CN101802413B (zh) 2007-09-20 2008-08-28 用于监测能量转换装置的方法
JP2010525224A JP5439378B2 (ja) 2007-09-20 2008-08-28 エネルギー変換装置を監視する方法
US12/679,054 US20100300220A1 (en) 2007-09-20 2008-08-28 Method for monitoring an energy conversion device
PCT/EP2008/007041 WO2009039934A1 (de) 2007-09-20 2008-08-28 Verfahren zur überwachung einer energieumwandlungseinrichtung

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP07018530.1A EP2039939B2 (de) 2007-09-20 2007-09-20 Verfahren zur Überwachung einer Energieumwandlungseinrichtung

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EP2039939A1 EP2039939A1 (de) 2009-03-25
EP2039939B1 EP2039939B1 (de) 2017-08-09
EP2039939B2 true EP2039939B2 (de) 2020-11-18

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US (1) US20100300220A1 (ja)
EP (1) EP2039939B2 (ja)
JP (1) JP5439378B2 (ja)
CN (1) CN101802413B (ja)
WO (1) WO2009039934A1 (ja)

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US20130204546A1 (en) * 2012-02-02 2013-08-08 Ghd Pty Ltd. On-line pump efficiency determining system and related method for determining pump efficiency
JP2014202144A (ja) * 2013-04-05 2014-10-27 新日本造機株式会社 遠心ポンプの診断方法
EP3242033B1 (de) * 2016-12-30 2024-05-01 Grundfos Holding A/S Verfahren zum betreiben eines elektronisch gesteuerten pumpenaggregates
DE102018200651A1 (de) * 2018-01-16 2019-07-18 KSB SE & Co. KGaA Verfahren zur Eigendiagnose des mechanischen und/oder hydraulischen Zustandes einer Kreiselpumpe
EP3567256A1 (en) * 2018-05-11 2019-11-13 Grundfos Holding A/S A monitoring module and method for identifying an operating scenario in a wastewater pumping station
FR3094421A1 (fr) * 2019-03-29 2020-10-02 Wilo Intec Procede de maintenance predictive d’une pompe de circulation d’un fluide
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CN101802413A (zh) 2010-08-11
EP2039939B1 (de) 2017-08-09
US20100300220A1 (en) 2010-12-02
JP2010539380A (ja) 2010-12-16
JP5439378B2 (ja) 2014-03-12
EP2039939A1 (de) 2009-03-25
CN101802413B (zh) 2014-07-30
WO2009039934A1 (de) 2009-04-02

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