TW202043617A - Reciprocating compressor monitoring system and method thereof - Google Patents

Abstract

A reciprocating compressor monitoring system and method thereof are provided. The system includes a sensor, and an analysis controller. The sensor captures an operating signal when the reciprocating compressor is operated. The analysis controller receives the operating signal, converts the operating signal into an angle signal, and matches the operating signal and the angle signal to form a state information. The analysis controller compares the state information with a template information by a calculation program to determine if the state information agrees with the template information, thereby acquiring the condition of the reciprocating compressor. Thus, the condition of the reciprocating compressor is detected and accurately acquired without referring to the process data.

Description

Reciprocating compressor monitoring system and monitoring method

The invention relates to a monitoring system and method, in particular to a reciprocating compressor monitoring system and a monitoring method.

A reciprocating compressor is a compressor driven by a piston driven by a crankshaft. When the crankshaft reciprocates, it first opens the intake valve and closes the exhaust valve. The intake air enters the compression cylinder from the intake valve, and then the intake valve closes. , The movement of the piston reduces the volume of the compression cylinder, compresses the gas, and then the exhaust valve opens to discharge high-pressure gas.

During the operation of the reciprocating compressor, the moving parts will emit a rhythmic normal sound consistent with the speed. Experienced diagnostic personnel can judge whether the compressor is operating normally from the different sounds. When there are harsh noises, impacts, and irregular rhythms, they can immediately determine that the machine is not working properly, and even determine the general location of the failure.

However, the accuracy of manual judgment through voice method is not high, and judgment errors are prone to occur. Therefore, in order to improve the manual judgment method, a smart system judgment method has been developed. For example: Mainland China Patent No. CN102797671, which discloses a reciprocating compressor The fault detection method and device of the reciprocating compressor need to obtain the characteristics of the vibration signal parameters of the reciprocating compressor and the characteristics of the thermal parameters including the cylinder intake temperature, exhaust temperature, intake pressure and exhaust pressure, and generate state characteristic indicators based on the vibration signal parameters Set, according to the vibration signal parameter characteristics and thermal parameter characteristics to generate the working condition characteristic index set, and generate the fault detection result according to the state characteristic index set and the industrial and mining characteristic index set.

However, the aforementioned patents must combine vibration signal parameters with process data (thermodynamic parameter characteristics including cylinder intake temperature, exhaust temperature, intake pressure and exhaust pressure) and other large amounts of data to be able to break the machine status of the reciprocating compressor , So if one of the parameter features is abnormal, accurate fault detection results cannot be obtained.

Furthermore, the specification of the aforementioned patent discloses that it is necessary to install an acceleration sensor on the crankshaft bearing seat, the outer surface of the cylinder liner and the valve seat of the reciprocating compressor to measure the vibration signal parameters, and use temperature sensors and pressure sensors , Respectively measure the cylinder intake temperature, exhaust temperature, intake pressure and exhaust pressure of the reciprocating compressor to obtain process data (heat power including cylinder intake temperature, exhaust temperature, intake pressure and exhaust pressure) Parameter characteristics), that is to say, the aforementioned patent needs to install at least 5 sensors to obtain the information to determine the condition of the reciprocating compressor. Therefore, when the failure detection of the reciprocating compressor is performed through the aforementioned patent, the installation cost is too high. Moreover, it takes a lot of time to process the data generated by each sensor, which is relatively long to obtain the fault detection result.

In order to solve the above-mentioned problems, the present invention provides a reciprocating compressor monitoring system and a monitoring method thereof. Through a single sensor to obtain the operating signal of the reciprocating compressor during operation, the detection and judgment of the reciprocating compressor can be performed to accurately grasp Machine status of reciprocating compressors.

An embodiment of the present invention provides a reciprocating compressor monitoring system, which includes: a sensor for capturing an actuation signal generated during operation of the reciprocating compressor; and an analysis controller, which is connected with The sensor signal is connected and receives the actuation signal. The analysis controller has a processing module and a judgment module. The processing module converts the actuation signal into an angle signal, and matches the actuation signal and the angle signal to form a state information; The group compares the status information with a template information through a calculation program to determine whether the status information matches the template information to obtain the condition of the reciprocating compressor.

In one of the embodiments, the sensor is installed on the cylinder of the reciprocating compressor; the sensor is an accelerometer; the actuation signal is the acceleration signal when the reciprocating compressor is running; the calculation program is a supervised neural network learning, The judgment module judges whether the status information matches the template information through the calculation program.

In one of the embodiments, the processing module converts the actuation signal integral into an actuation speed signal, and the processing module converts the actuation speed signal into an angle signal.

In one of the embodiments, the template information has the angle corresponding to each component of the reciprocating compressor and the operation signal corresponding to each component; the analysis controller has a memory module that stores the template information.

In one of the embodiments, the template information is the status information processed by capturing the operating signal of the reciprocating compressor during operation, and the status information is created and stored in the memory module.

In one of the embodiments, the calculation program determines the degree of difference between the state information and the template information to generate a degree of difference information.

Another embodiment of the present invention provides a reciprocating compressor monitoring method, which includes the following steps: measuring step: generating an actuation signal during operation of the reciprocating compressor through a sensor; analyzing step: controlling through an analysis The sensor receives the actuation signal generated by the sensor, the analysis controller converts the actuation signal into an angle signal, and matches the actuation signal with the angle signal to form a state information; and the determination step: the analysis controller combines the state information with the angle signal through a calculation program A template information is compared with each other to determine whether the status information matches the template information to obtain the condition of the reciprocating compressor.

In one of the embodiments, the analysis controller converts the actuation signal integral into an actuation speed signal, and converts the actuation speed signal into an angle signal.

In one of the embodiments, the present invention further has a learning step: the activation signal generated by the sensor during the initial operation of the reciprocating compressor or the first abnormality occurs, and the activation signal is processed to generate status information through the analysis controller, And the state information is created as template information and stored in the analysis controller.

In one of the embodiments, the analysis controller determines the degree of difference between the status information and the template information through a calculation program to generate a degree of difference information to obtain the degree of abnormality of the reciprocating compressor.

Through the above, the present invention can perform detection and judgment only through the actuation signal obtained by a single sensor, and can accurately grasp the condition of the reciprocating compressor; thereby improving the conventional inaccuracy of manual judgment, or It is necessary to install a variety of sensors to determine the abnormal condition of the reciprocating compressor through a variety of detection parameter signals.

In order to facilitate the description of the central idea of the present invention expressed in the column of the above-mentioned summary of the invention, specific embodiments are used to express it. The various objects in the embodiment are drawn according to the proportion, size, deformation or displacement suitable for explanation, rather than drawn according to the proportion of the actual element, which will be described first.

Please refer to FIG. 1 to FIG. 8. The present invention provides a reciprocating compressor monitoring system 100, which includes:

A sensor 10 is used to capture an actuation signal 11 generated when the reciprocating compressor 1 is running; in the embodiment of the present invention, the sensor 10 is installed on the cylinder of the reciprocating compressor 1, and the reciprocating compressor 1 The compressor 1 is a reciprocating piston compressor, as shown in FIG. 5, but the mounting position of the sensor 10 is not limited to this, as long as the sensor 10 can generate the action when the reciprocating compressor 1 is running The signal 11 is sufficient; the sensor 10 is an acceleration gauge, and the actuation signal 11 is an acceleration signal generated when the reciprocating compressor 1 is running.

An analysis controller 20 is connected to the sensor 10 and receives the actuation signal 11. The analysis controller 20 has a processing module 21 for converting the actuation signal 11 into an angle signal 211; The processing module 21 can directly process the actuation signal 11 as an acceleration into an angle signal 211, or the processing module 21 integrates the actuation signal 11 into an actuation speed signal, and the processing module 21 converts the actuation speed signal into an angle Signal 211'.

For further example, when the motion signal 11 is 10 Hz, it means that there are 10 cycles of the 1 second motion signal 11 (one time means 360 degrees), and the cycle time is 0.1 second, which converts the 0.1 second motion signal 11 into 360 degrees Therefore, the 1 second actuation signal 11 means rotating 360 degrees 10 times, so that the actuation signal 11 can be converted into an angle signal 211; furthermore, the reciprocating compressor 1 has a fixed operating stroke. In terms of rotating 360 degrees, each The angle or angle interval represents each element of the reciprocating compressor 1, that is, the action signal 11 generated by each angle or angle interval can be expressed as the state of each element.

Furthermore, the processing module 21 matches the actuation signal 11 with the angle signal 211 to form a state information. The state information has the angle corresponding to each component of the reciprocating compressor 1 and the actuation signal 11 corresponding to each component, that is, The status information is the information corresponding to the action signal 11 generated by the reciprocating compressor 1 at each angle; as shown in FIG. 6, the status information indicating that the components of the reciprocating compressor 1 are in a normal state.

The analysis controller 20 further has a judging module 22. The judging module 22 compares the status information with a template information 23 through an arithmetic program to determine whether the status information matches the template information 23, and then obtains the information of the reciprocating compressor 1. The situation is shown in Figure 4; among them, the algorithm is a supervised neural network learning.

The analysis controller 20 has a memory module 24 for storing template information 23. The template information 23 is the state information processed by the actuation signal 11 generated when the reciprocating compressor 1 runs for the first time or when an abnormality occurs for the first time. The processing module 21 of the analysis controller 20 learns through arithmetic programs, and establishes the state information after learning as template information 23 to be stored in the memory module 24, as shown in FIGS. 1 and 3.

The template information 23 has the angle corresponding to each component of the reciprocating compressor 1, the corresponding actuation signal 11 of each component, and the angle signal 211 corresponding to the actuation signal 11; and the actuation signal 11 as acceleration is processed into an angle signal 211 and a matching actuation signal The status information formed by 11 is used to determine whether the crosshead of the reciprocating compressor 1 is worn, whether the intake and exhaust operation is abnormal, or whether the cylinder collides; and it is formed by converting the operating speed signal into an angle signal 211' and matching the operating signal 11 The status information is used to determine whether the crankshaft of the reciprocating compressor 1 is balanced, whether the crankshaft is eccentric or whether the piston connecting rod is abnormal; please refer to Figure 7, which is the template information 23 of crosshead wear; refer to Figure 8, Template information 23 for abnormal piston top and bottom dead center.

In addition, the judgment module 22 judges the degree of difference between the state information and the template information 23 through a calculation program to generate a degree of difference information, that is, the judgment module 22 can first determine whether the state information matches the template information 23, and then Confirm whether the reciprocating compressor 1 is abnormal, and when the reciprocating compressor 1 is abnormal, the judgment module 22 can calculate the abnormality severity of the reciprocating compressor 1 through a calculation program, that is, the abnormality information, for example: The wear of the cross head is about 10%.

Using the aforementioned reciprocating compressor monitoring system 100 of the present invention, in actual application, it is possible to determine whether the reciprocating compressor 1 is abnormal or not through the reciprocating compressor monitoring method.

The monitoring method of the reciprocating compressor of the present invention includes the following steps:

Measurement step S1: Install the sensor 10 on the cylinder of the reciprocating compressor 1. When the reciprocating compressor 1 is running, the sensor 10 will generate an actuation signal 11 when the reciprocating compressor 1 is running.

Analysis step S2: The sensor 10 transmits the actuation signal 11 to the analysis controller 20, and the analysis controller 20 receives the actuation signal 11 and converts the actuation signal 11 into an angle signal 211, or the analysis controller 20 will actuate The signal 11 is integrally converted into an actuation speed signal, and the actuation speed signal is converted into an angle signal 211'; then, the analysis controller 20 matches the actuation signal 11 with the angle signal 211 (angle signal 211') to form status information.

Judging step S3: The analysis controller 20 compares the status information with the template information 23 through the calculation program, and determines whether the status information matches the template information 23, so as to obtain the machine condition of the reciprocating compressor 1, as shown in FIGS. 1 and 4 ; Wherein, when the analysis controller 20 determines that the reciprocating compressor 1 is abnormal, the analysis controller 20 will determine the degree of difference between the state information and the template information 23 through a calculation program to generate difference degree information to obtain the reciprocating compressor 1 The abnormal degree of the machine condition, the user can judge whether the components should be replaced or repaired in time through the abnormal degree of the machine condition.

Learning step S4: When the reciprocating compressor 1 is initially operating or when an abnormality occurs for the first time, the measurement step S1 can be used to obtain the actuation signal 11 generated during the initial operation or the first abnormality of the reciprocating compressor 1; then, through analysis In step S2, the angle signal 211 is obtained by calculation, and the state information is established as template information 23 through learning through a calculation program and stored in the analysis controller 20, as shown in FIGS. 1 and 3.

After the reciprocating compressor 1 has established the template information 23 for judgment, and then every time the reciprocating compressor 1 operates, the state information can be obtained through the measurement step S1 and the analysis step S2, and the reciprocating compressor can be obtained through the judgment step S3. The machine condition of type compressor 1.

Through the foregoing, the effects that the present invention can achieve are as follows:

1. The reciprocating compressor monitoring system 100 of the present invention can perform detection and judgment only through the actuation signal 11 obtained by a single sensor 10, and can accurately grasp the condition of the reciprocating compressor 1; thereby improving the need for multiple installations The sensor 10 can judge the abnormal condition of the reciprocating compressor 1 through a variety of detection parameter signals, thereby achieving the effect of obtaining the detection result simply and quickly.

2. The analysis controller 20 of the reciprocating compressor monitoring system 100 of the present invention can obtain the abnormality degree of the reciprocating compressor 1 through arithmetic program, so as to provide the user with the ability to determine whether components should be replaced or repaired in time according to the abnormality degree , In order to provide flexible scheduling in actual industrial use.

The above-mentioned embodiments are only used to illustrate the present invention, and are not used to limit the scope of the present invention. All modifications or changes made without violating the spirit of the present invention belong to the scope of the present invention.

1: Reciprocating compressor 100: Reciprocating compressor monitoring system 10: Sensor 11: Actuation signal 20: Analyze the controller 21: Processing module 211: Angle signal 211’: Angle signal 22: Judgment module 23: Template Information 24: Memory module S1: Measurement steps S2: Analysis step S3: Judgment steps S4: learning steps

Figure 1 is a block diagram of the system architecture of the present invention. Fig. 2 is a block diagram of the method of the present invention. Fig. 3 shows the intention of the judgment module of the present invention to learn the state information from the travel template information calculation formula through the calculation program. Fig. 4 shows the intention of the calculation formula comparing the state information and the template information by the judgment module of the present invention through the calculation program. Figure 5 is a schematic diagram of an erection embodiment of the present invention. Fig. 6 is a schematic diagram (1) of template information of the present invention, showing the normal state of the reciprocating compressor. Fig. 7 is a schematic diagram (2) of the template information of the present invention, showing the crosshead damage of the reciprocating compressor. Fig. 8 is a schematic diagram (3) of template information of the present invention, showing the abnormal top and bottom dead center of the piston of the reciprocating compressor.

100: Reciprocating compressor monitoring system

10: Sensor

20: Analyze the controller

21: Processing module

22: Judgment module

24: Memory module

Claims (10)

A reciprocating compressor monitoring system, which includes: A sensor for capturing an actuation signal generated when the reciprocating compressor is running; and An analysis controller is connected to the sensor signal and receives the actuation signal. The analysis controller has a processing module and a judgment module. The processing module converts the actuation signal into an angle signal, and the The actuation signal matches the angle signal to form a state information; the judging module compares the state information with a template information through an arithmetic program to determine whether the state information matches the template information to obtain the machine of the reciprocating compressor condition. The reciprocating compressor monitoring system according to claim 1, wherein the sensor is installed on the cylinder of the reciprocating compressor; the sensor is an accelerometer; the actuation signal is an acceleration signal when the reciprocating compressor is running ; The calculation program is a supervised neural network learning, and the judgment module uses the calculation program to determine whether the state information matches the template information. The reciprocating compressor monitoring system according to claim 2, wherein the processing module converts the actuation signal integral into an actuation speed signal, and the processing module converts the actuation speed signal into the angle signal. The reciprocating compressor monitoring system according to claim 1, wherein the state information has the angle corresponding to each component of the reciprocating compressor and the action signal corresponding to each component; the template information has reciprocating compression The angle corresponding to each component of the machine and the corresponding actuation signal of each component; the analysis controller has a memory module that stores the template information. The reciprocating compressor monitoring system according to claim 4, wherein the template information is the state information obtained by processing the operating signal when the reciprocating compressor is running or the first abnormality occurs, and the state information is established Stored in the memory module. The reciprocating compressor monitoring system according to claim 1 or 2, wherein the calculation program determines the degree of difference between the state information and the template information to generate a degree of difference information. A monitoring method for a reciprocating compressor includes the following steps: Measurement step: generate an actuation signal when the reciprocating compressor is running through a sensor; Analysis step: receiving the actuation signal generated by the sensor through an analysis controller, the analysis controller converts the actuation signal into an angle signal, and matches the actuation signal with the angle signal to form a state information; and Judging step: the analysis controller compares the status information with a template information through a calculation program, determines whether the status information matches the template information, and obtains the condition of the reciprocating compressor. The reciprocating compressor monitoring method according to claim 7, wherein the analysis controller converts the actuation signal integral into an actuation speed signal, and converts the actuation speed signal into the angle signal. The reciprocating compressor monitoring method described in claim 7 further has a learning step: the activation signal generated by the sensor during the initial operation of the reciprocating compressor or when an abnormality occurs for the first time, through the analysis controller The actuation signal processing generates the state information, and the state information is established as the template information and stored in the analysis controller. The reciprocating compressor monitoring method according to claim 7, wherein the analysis controller determines the degree of difference between the state information and the template information through the calculation program to generate a degree of difference information to obtain the reciprocating compressor The degree of abnormality of the machine.

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