EP3019845A1 - Procédé et système de surveillance d'un équipement technique tel qu'une machine ou une installation - Google Patents

Procédé et système de surveillance d'un équipement technique tel qu'une machine ou une installation

Info

Publication number
EP3019845A1
EP3019845A1 EP13766918.0A EP13766918A EP3019845A1 EP 3019845 A1 EP3019845 A1 EP 3019845A1 EP 13766918 A EP13766918 A EP 13766918A EP 3019845 A1 EP3019845 A1 EP 3019845A1
Authority
EP
European Patent Office
Prior art keywords
frequency band
bearing
khz
characteristic value
process variable
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP13766918.0A
Other languages
German (de)
English (en)
Inventor
Hans-Henning Klos
Dirk Scheibner
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Siemens AG
Original Assignee
Siemens AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Siemens AG filed Critical Siemens AG
Publication of EP3019845A1 publication Critical patent/EP3019845A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/14—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object using acoustic emission techniques
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01H—MEASUREMENT OF MECHANICAL VIBRATIONS OR ULTRASONIC, SONIC OR INFRASONIC WAVES
    • G01H1/00—Measuring characteristics of vibrations in solids by using direct conduction to the detector
    • G01H1/003—Measuring characteristics of vibrations in solids by using direct conduction to the detector of rotating machines
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M13/00—Testing of machine parts
    • G01M13/04—Bearings
    • G01M13/045—Acoustic or vibration analysis

Definitions

  • Method and arrangement for monitoring a technical device such as e.g. a machine or a plant
  • the invention relates to a method and an arrangement for monitoring a technical device, such as e.g. a machine or a plant according to the preamble of claim 1 or claim 10.
  • condition monitoring with the aim of condition-based maintenance. For example, the bearing friction for condition monitoring is determined.
  • separate sensors are installed for each monitoring, in particular if they are relevant for different domains such as condition monitoring and process monitoring.
  • an oil circuit is monitored by measuring the power consumption of the pumps or by means of flow or pressure sensors.
  • the friction in the bearings is monitored by separate temperature sensors.
  • the oil circuit and its measurement technology are designed separately and are not at all metrologically or weakly coupled to the condition monitoring system of the bearing diagnosis (since usually different manufacturers).
  • the operation of the oil circuit has a direct influence on the running properties of oil-lubricated bearings and gearboxes.
  • the flow rate, viscosity, temperature, pressure, abrasion and foreign particles in the oil circuit are important factors influencing the service life of the bearings and gearboxes.
  • the problem is that the detection of bearing friction with temperature sensors is only greatly delayed and smoothed. Short frictional events due to particles in the bearing are not directly detectable. A significant increase in temperature often occurs shortly before the total failure of the camp.
  • Ultrasonic sonic acoustic sensors provide information about ultrasonic sound waves propagating in solids, and the acoustic emissions involved in a variety of processes, such as friction, electrical, and so on Discharge, leakage or corrosion, which measures material-specific frequencies that are excited by irreversible plastic deformation, thus determining "irreversible" material or shape changes (eg fractures, cracks, erosion, deformation) of the bearing itself.
  • a process variable is a variable that characterizes a process running in the device, such as a manufacturing process or a processing process for a product. As a rule, this is a "reversible" variable whose value can change depending on the operating state, but can (assuming the same operating states, for example) repeatedly assume previous values.
  • acoustic emissions of the device in a first frequency band in the ultrasonic range and in the first frequency band are produced during operation of the device detected a second frequency band in the ultrasonic range, wherein the first frequency band and the second frequency band is not overde- CKEN.
  • At least one characteristic value for the state of the bearing is determined from the acoustic emissions of the device in the first frequency band, and at least one characteristic value for a process variable of a process running in the device is determined from the acoustic emissions of the device in the second frequency band.
  • the invention is based on the idea that, in addition to monitoring the condition of the bearing with the aid of acoustic emissions, it is also possible to monitor a process variable on the basis of its acoustic emissions. As it turns out, many process variables in frequency bands that are different from the frequency bands used for condition monitoring produce acoustic emissions in the ultrasonic range. This takes place in a frequency range in which conventional acoustic sensors in the ultrasonic range are still sensitive to condition monitoring.
  • a broadband "noise-like" excitation through the oil circuit occurs.
  • This excitation is generated by the friction in the oil itself and the friction of the oil directly at the interfaces and spreads in the housing These vibrations are typically also measurable directly on the bearing and can thus be detected by a sensor mounted on the bearing.
  • the separation of the frequency ranges from a Transmission signal can be done by means of analog and / or digital filters.
  • each separate sensors for the two frequency bands are used, one of the sensors has its resonance frequency in the range of the first frequency band and the other sensor has its resonant frequency in the range of the second frequency band, and wherein both sensors, for example, together in a single sensor device such For example, a sensor head are housed.
  • the detection of the acoustic emissions in the two frequency bands is preferably carried out simultaneously, whereby a particularly accurate monitoring can be achieved.
  • the at least one characteristic value for the process variable may be, for example, an envelope of a sensor signal, a root mean square value or a maximum value.
  • the characteristic value can also be determined by a further frequency analysis on the basis of the time profile of the sensor signal and its envelope curve. As a result, it is also possible, for example, to filter out interfering signals by means of known storage frequencies or electrical interferences of a fixed frequency. Preferably, not only one but several characteristic values are determined.
  • a plurality of subprocesses each having a process variable assigned to this subprocess, are active in the device and are acoustically well coupled to the one sensor or to the two sensors, it is of course also possible to use the second frequency band or further frequency bands in the ultrasound range To determine characteristic values for further process variables. These can be compared with each other and thus conclusions about their operating condition can be concluded in a particularly simple manner. If the sub-processes are, for example, different lubricant For example, by comparing the characteristic values, it is possible, for example, to detect the failure of one or more of the circuits or to conclude on changes (for example with respect to flow, pressure, viscosity) in one or more of the circuits.
  • the first frequency band for status monitoring is preferably higher than the second frequency band for monitoring the process variable.
  • the second frequency band is preferably below 80 kHz (preferably at least in a subregion of the frequency band extending between 30 kHz and 80 kHz), since broadband "noise-like" excitations of process variables are particularly frequent there.
  • the at least one characteristic value for the process variable is taken into account in the determination of the at least one characteristic value for the state of the bearing.
  • the at least one characteristic value for the process variable is used to check the plausibility of the at least one characteristic value for the state of the bearing. This can improve the accuracy of condition monitoring or erroneous results can be detected and excluded or corrected.
  • a defect of the sensor in the first frequency band or a subsequent evaluation unit can be detected and the sensor or the evaluation unit can be replaced before it comes to errors in the condition-based maintenance.
  • a temperature of the bearing is additionally detected and determined at least one characteristic value for the temperature.
  • a sensor for the detection of the temperature can also be accommodated in a sensor device in which the one or the two sensors for the detection of the acoustic emissions are already accommodated.
  • the characteristic value for the temperature can be used, for example, to check the quality of the coupling of the sensor or sensors for the detection of the acoustic emissions.
  • the temperature coupling is typically also poor, i. the temperature values are then lower than expected.
  • the temperature is an important variable for declaring that the subprocess associated with the process variable is operating correctly.
  • the temperature can then be used to check the plausibility of the at least one parameter for the process variable.
  • the temperature gives, for example, a clue as to whether the oil circuit is operating at the desired temperature or viscosity.
  • too high temperatures can be detected and thus the reliability can be further increased without a separate metrological device for the temperature measurement would be necessary.
  • the temperature can also be taken into account when determining the at least one characteristic value for the state of the bearing and can be used, for example, to check the plausibility or to correct the at least one characteristic for the state of the bearing, whereby the accuracy of the state-based maintenance can be improved.
  • the temperature in the bearing increases with a time delay after the occurrence of increased acoustic emissions in the ultrasonic range. The time constant for this depends on the thermal capacity and geometry of the bearing and is in the range of minutes. Before it is concluded that there is a mixed friction of detected increased acoustic emissions, it is thus possible, for example, to wait for the associated increase in temperature.
  • the detected temperature can also be used for an analysis of the temperature distribution. in case of a
  • the temperature detection can be used at very low temperatures to see how far a preheating of the lubricant has progressed in the vicinity of the bearing.
  • the temperature detection can even be used as a reference variable for controlling the preheating. If a clear temperature gradient is measured, the system is not in thermal equilibrium. For this condition, increased acoustic emissions in the ultrasonic range are to be expected, which arise only temporarily due to different expansions of components and do not allow a conclusion on permanent damage. Such periods of time can be hidden by additional evaluation of the temperature information in the determination of the at least one characteristic value for the state of the camp.
  • the at least one characteristic value for the process variable is used to check the plausibility of characteristic values from a condition monitoring system of the partial process assigned to the process variable.
  • a comparison with the data of a condition monitoring system for the lubricant circuit makes sense, for example a comparison with the flow rate determined by the condition monitoring system, the temperature of the lubricant, a pump pressure This results in an increase in the robustness of the statements of the condition monitoring system by an additional measurement method (redundancy) and thus the possibility of a plausibility cross-check.
  • the process variable is preferably a flow of a lubricant through the device, in particular through the bearing.
  • the technical device is controlled and / or regulated as a function of one or more of the characteristic values.
  • a parameter for the process variable for example, a flow of a lubricant, such as e.g. Considered oil, for example, the technical device is only started when the operating temperature is reached and resulting from an oil flow acoustic emissions and thus the characteristic value for this process variable has reached a predetermined range. Too low or high values of the acoustic emissions resulting from the flow of oil may put the machine in a different safe operating condition.
  • An inventive arrangement for monitoring a technical device such as a machine or a system, wherein the device comprises a rotating member and a bearing for this component, has a sensor device which is adapted to, preferably simultaneous, detection of acoustic emissions of the device in a first frequency band and a second frequency band in the ultra- sound area, wherein the first frequency band and the second frequency band do not overlap.
  • the arrangement according to the invention has an evaluation device with a first and a second evaluation unit, wherein the first evaluation unit is designed to determine a characteristic value for the state of the bearing from a sensor signal of the sensor device in the first frequency band, and wherein the second evaluation unit is designed for detection a parameter for a process variable of a running in the device process from a sensor signal of the sensor device in the second frequency band.
  • the first frequency band is higher than the second frequency band, wherein preferably the first frequency band is above 80 kHz, in particular extends over at least a portion of the frequency band between 90 kHz and 160 kHz, and wherein the second frequency band is preferably below 80 kHz, in particular extends over at least a portion of the frequency band between 30 kHz and 80 kHz.
  • reference values for different operating states for the at least one characteristic value for the process variable are stored in the second evaluation unit and the second evaluation unit is designed such that it compares the at least one determined characteristic value with these reference values, in order to conclude an operating state of a subprocess associated with the process variable.
  • the evaluation device is designed such that it takes into account the at least one characteristic value for the process variable in the determination of the at least one Kennwer- tes for the state of the camp, in particular checks the characteristic for plausibility.
  • the sensor device has a single sensor both for the detection of the acoustic emissions in the first frequency band and for the detection of the acoustic emissions in the second frequency band, preferably also a sensor for the detection of a temperature.
  • the process variable is the flow of a lubricant through the device, in particular through the bearing.
  • the arrangement advantageously has an interface for communication with a control and / or regulating device of the technical device, preferably also an interface for communication with a condition monitoring system for a sub-process of the technical device assigned to the process variable.
  • FIG. 3 shows an arrangement for monitoring a technical device with a sliding bearing and a lubricant system and an adjacent lubricant system and
  • FIG. 4 - FIG. 6 Measurement data of a sensor for acoustic emissions mounted on the gearbox bearing of a rock mill for three different operating cases.
  • the 1 shows a schematic representation of an arrangement 1 for monitoring a technical device 2 such as e.g. a machine or a plant.
  • the device 2 comprises a rotating component 3, e.g. a gear shaft, and a bearing 4 for this component 3.
  • the bearing 4 is formed in a conventional manner as a rolling bearing with an inner ring 5, an outer ring 6 and bearing balls 7 arranged therebetween.
  • a sensor device 10 is mounted with good acoustic coupling to the bearing 4 and is designed for (preferably simultaneous) detection of acoustic emissions of the device 1 in a first frequency band and a second frequency band in the ultrasonic range, wherein the first frequency band and the second frequency band do not overlap.
  • the sensor device 10 has a single structure-borne sound sensor 11 in the form of an "acoustic emission sensor" both for the detection of the acoustic emissions in the first frequency band and for the detection of the acoustic emissions in the second frequency band.
  • the sensor device 10 has a sensor 12 for detecting a temperature of the bearing 4.
  • An evaluation device 20 has a first evaluation unit 21, a second evaluation unit 22 and a third evaluation unit 23.
  • the first evaluation unit 21 is designed to determine a characteristic value for the state of the bearing 4 from a signal of the sensor 11 in the first frequency band.
  • the second evaluation unit 22 is designed to determine a characteristic value for a process variable of a process running in the device from a signal of the sensor 11 in the second frequency band.
  • the third evaluation unit 23 is designed to determine a characteristic value of the temperature of the bearing 4 from a signal of the temperature sensor 12.
  • the process variable is the flow of a lubricant of a lubricant system 30 through the bearing 4.
  • the lubricant is, for example, oil.
  • the lubricant equipment 30 comprises a lubricant circuit 31 with a supply line 32 for the lubricant to the bearing 4 and a discharge 33 for the lubricant from the bearing 4
  • Lubricating system 30 also comprises further components, not shown in further detail, such as e.g. a pump, a container, filters, sensors, a heater, valves etc.
  • the sensor 11 is a broadband structure-borne sound sensor, which is sensitive both in the frequency range below 80 kHz and in the frequency range above 80 kHz. In the frequency range above 80 kHz, preferably in a first frequency band between 90 kHz and 160 kHz, the friction in the bearing and mechanical damage in the bearing is detected directly by measuring material-specific frequencies that are excited in the event of irreversible plastic deformation of the material. In the frequency range below 80 kHz, this sensor 11 is also sensitive. Here, in a second frequency band between 30 kHz and 80 kHz, a broadband "noise-like" excitation occurs through the lubricant circuit 31. The friction in the
  • Lubricants themselves as well as the friction of the lubricant directly at the interfaces in this case generate an ultrasonic excitation, which in the technical device 2, e.g. a housing of a machine, spreads. These vibrations are typically also directly on the bearing 4 measurable and thus detected by the mounted on the bearing 4 sensor 11.
  • Separation of the frequency bands from a vibration signal of the sensor 11 may in the first evaluation unit 21 and / or second evaluation unit 22 by means of analog and / or digital filters.
  • the sensor device 10 has at least two structure-borne noise sensors, which are housed together in a sensor head of the sensor device 10.
  • the resonance frequency of a sensor is between 90 kHz and 160 kHz for monitoring the state of the bearing 4 and that of a further sensor between 30 kHz and 80 kHz for monitoring the lubricant circuit 31.
  • the envelope, RMS and maximum values are formed in the second evaluation unit 22 from the ultrasonic signal in the second frequency band between 30 kHz and 80 kHz. These characteristics directly characterize the friction in bearing 4 due to the lubricant flow. If this changes, these characteristics also change.
  • Reference values ("fingerprints”) for different operating states for the lubricant flow are stored in the second evaluation unit 22, and the second evaluation unit 22 is designed such that it compares the ascertained value for the lubricant flow with these reference values in order to determine an operating state of the lubricant circuit 31 and thus close the lubricant system 30.
  • frequency analyzes based on the signals of the sensor 11 and its envelope can also be carried out, for example to filter out interference signals by known storage frequencies or electrical interference of a fixed frequency.
  • the evaluation device 20 may be designed such that it determines the determined lubricant flow in the determination of the Characteristic value for the friction of the bearing 4 taken into account, in particular checked for plausibility.
  • the evaluation device 20 has an interface 8 to a network 40 for communication with a control and / or regulating device 41 of the technical device 2 and for communication with a separate state monitoring system 42 of the lubricant system 30.
  • a network 40 for communication with a control and / or regulating device 41 of the technical device 2 and for communication with a separate state monitoring system 42 of the lubricant system 30.
  • the connection directly to the network 40 preferably an industrial network based on, for example, Ethernet, Profinet, Profibus, OPC-UA, etc.
  • the temperature sensor 12 integrated into the sensor device 10 increases the informative value of the sensor 11.
  • the temperature coupling is typically also poor, ie the temperature values measured by the temperature sensor 12 are then normally lower than expected ,
  • the temperature also gives an indication as to whether the lubricant circuit 31 is operating at the desired temperature or viscosity. Too high temperatures can thus be detected. With mixed friction in bearing 4, the temperature also increases with a delay after the occurrence of increased acoustic emissions. The time constant for this depends on the thermal capacity and geometry of the bearing 4.
  • the temperature sensor 12 may additionally be used for analysis of the temperature distribution and used at very low temperatures to detect how far the preheating process of the lubricant has progressed in the vicinity of the bearing 4.
  • the sensor 12 can also be used as a reference variable for this control.
  • a clear temperature gradient is measured, then the lubricant system 30 is not in thermal equilibrium. For this condition, acoustic emissions are to be expected, which arise only temporarily from different expansions of components and do not allow any conclusion on permanent damage. Such periods of time can be hidden by additional evaluation of the temperature information.
  • the device 2 is for example only started when the operating temperature has been reached and the characteristic value of the acoustic emissions representing the lubricant flow has reached a necessary range. If the characteristic value is too low, the device 2 can be put into another, safe operating state. If the temperature values are too high, the device 2 can be put into another, safe operating state. An operation of the device 2 with a defined, controlled overload in a given time window by controlling the characteristic values of the acoustic emissions and the temperature, for example, to optimize yield is thereby possible. Overall, thus false states of the device 2 can be avoided or stopped.
  • the sensor characteristic values for checking the plausibility of characteristic values of the condition monitoring system 42 of the lubricant system 30.
  • the evaluation device 20 for the formation of the characteristic values can be coupled directly to the sensor device 10 as a separate electronic module, but it can also be integrated in the sensor device 10, as shown in FIG.
  • An arrangement 51 shown in a schematic representation for monitoring a technical device 52 such as a machine or a plant differs from the arrangement 1 shown in FIG 1 in that the device 52 has a sliding bearing 54 instead of a roller bearing 4 and that the Evaluation device 20 is integrated in the sensor device 10. Since the third evaluation unit 23 is thus integrated directly into the sensor device 10, the temperature sensor 12 may be, for example, a temperature sensor integrated into a microcontroller of the third evaluation unit 23.
  • FIG 3 shows a schematic representation of a monitoring of a lubricant circuit 61 of a lubricant system 60 of an adjacent aggregate 65 by the sensor device 10.
  • the lubricant is, for example, oil.
  • the monitoring of the lubricant circuit 61 in addition to the lubricant circuit 31 is possible with good acoustic coupling with the adjacent lubricant circuit
  • a steel or aluminum housing 64 through which the supply line 32 and the discharge line 33 of the lubricant circuit 31 and a feed line 62 and a discharge 63 of the adjacent lubricant circuit 61 are guided and to which the sensor device 10 is attached.
  • the activity of the two lubricant circuits 31, 61 can then be considered separately and compared. This can be used to detect a failure of one or more of the lubricant circuits 31, 61 or to change in the
  • FIG. 4 - FIG. 6 show, by way of example, measured data of a sensor mounted on the gearbox bearing of a rock mill for acoustic emissions, which in the indicated frequency band 71 um
  • FIG. 4 shows a first case of operation in which the shaft does not rotate (i.e., at a speed of 0 rpm).
  • a first lubricant circuit in the form of a high-pressure oil circuit is switched off, and a second lubricant circuit in the form of a low-pressure oil circuit is likewise switched off.
  • notable acoustic emissions can be detected in any of the two frequency bands 71, 72.
  • FIG. 6 shows a third operating case in which the shaft now rotates at a constant speed of 1000 rpm. Both the first lubricant circuit in the form of the high-pressure oil circuit and the second lubricant circuit in the form of the low-pressure oil circuit are switched on. As shown in FIG.

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Analytical Chemistry (AREA)
  • Biochemistry (AREA)
  • General Health & Medical Sciences (AREA)
  • Immunology (AREA)
  • Pathology (AREA)
  • Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)

Abstract

L'invention concerne la surveillance d'un équipement technique (2), par exemple d'une machine ou d'une installation, qui comprend un composant (3) rotatif et un palier (4) pour ce composant. Pendant le fonctionnement de l'équipement (2), on détecte les émissions acoustiques de l'équipement (2) dans une première bande de fréquence (71) dans le domaine ultrasonore ainsi que les émissions acoustiques de l'équipement (2) dans une deuxième bande de fréquence (72) dans le domaine ultrasonore, la première bande de fréquence (71) et la deuxième bande de fréquence (72) ne se chevauchant pas. Selon l'invention, on détermine au moins un paramètre d'état du palier (4) à partir des émissions acoustiques de l'équipement (2) dans la première bande de fréquence (71) et au moins un paramètre d'une grandeur d'un processus en cours d'exécution dans l'équipement (2) à partir des émissions acoustiques de l'équipement (2) dans la deuxième bande de fréquence (72). Avec une dépense technique inchangée, voire réduite en termes de mesure, ceci permet d'améliorer encore plus la surveillance d'un équipement technique tel qu'une machine ou une installation.
EP13766918.0A 2013-09-12 2013-09-12 Procédé et système de surveillance d'un équipement technique tel qu'une machine ou une installation Withdrawn EP3019845A1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/EP2013/068873 WO2015036021A1 (fr) 2013-09-12 2013-09-12 Procédé et système de surveillance d'un équipement technique tel qu'une machine ou une installation

Publications (1)

Publication Number Publication Date
EP3019845A1 true EP3019845A1 (fr) 2016-05-18

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EP13766918.0A Withdrawn EP3019845A1 (fr) 2013-09-12 2013-09-12 Procédé et système de surveillance d'un équipement technique tel qu'une machine ou une installation

Country Status (4)

Country Link
US (1) US20160223496A1 (fr)
EP (1) EP3019845A1 (fr)
CN (1) CN105531576A (fr)
WO (1) WO2015036021A1 (fr)

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US20160223496A1 (en) 2016-08-04
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