TW202043617A - Reciprocating compressor monitoring system and method thereof - Google Patents
Reciprocating compressor monitoring system and method thereof Download PDFInfo
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本發明係關於一種監測系統及方法,尤指一種往復式壓縮機監測系統及其監測方法。The invention relates to a monitoring system and method, in particular to a reciprocating compressor monitoring system and a monitoring method.
往復式壓縮機是一種由曲柄軸帶動活塞驅動的壓縮機,當曲柄軸往復運動時,會先打開進氣閥,關閉排氣閥,進氣由進氣閥進入壓縮缸,然後進氣閥關閉,活塞運動使壓縮缸容積減小,壓縮氣體,之後排氣閥打開,排出高壓的氣體。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.
往複式壓縮機運行過程中,各運動部件會發出有節奏的與轉速一致的正常響聲,有經驗的診斷人員能從不同響聲中判斷出壓縮機運行是否正常。當響聲有刺耳的噪聲、撞擊聲和不規則的節奏時,他們可立即判定機器運轉不正常,甚至能判斷故障發生的大致部位。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.
但是由人工透過聲音方式判斷,其精準度不高,也容易發生判斷錯誤;所以為了改善人工判斷方式,而發展出以智慧系統判斷方式,例如:中國大陸第CN102797671號專利,揭示一種往復壓縮機的故障檢測方法及裝置,其需獲取往復壓縮機的震動信號參數特徵及汽缸進氣溫度、排氣溫度、進氣壓力及排氣壓力在內的熱力參數特徵,根據振動信號參數生成狀態特徵指標集,根據振動信號參數特徵和熱力參數特徵生成工況特徵指標集,依據狀態特徵指標集與工礦特徵指標集產生故障檢測結果。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.
然而,前述專利必須將振動信號參數結合製程資料(汽缸進氣溫度、排氣溫度、進氣壓力及排氣壓力在內的熱力參數特徵)等大量數據,才能夠斷往復壓縮機之機台狀態,所以若有其中一項參數特徵有異常,便無法取得準確之故障檢測結果。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.
再者,於前述專利之說明書揭示,需要將加速度傳感器裝設於往復壓縮機的曲軸軸承座、氣缸缸套外表面與氣閥閥座,以量測振動信號參數,且利用溫度傳感器與壓力傳感器,分別量測往復壓縮機的汽缸進氣溫度、排氣溫度、進氣壓力與排氣壓力,以取得製程資料(汽缸進氣溫度、排氣溫度、進氣壓力及排氣壓力在內的熱力參數特徵),也就是說,前述專利需要安裝至少5個以上之感測器才能夠取得判斷往復壓縮機之機況資訊,所以透過前述專利進行往復壓縮機的故障檢測時,架設成本過高,而且需要花費大量時間處理各感測器產生之數據,相對取得故障檢測結果之時間較長。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.
為解決上述課題,本發明提供一種往復式壓縮機監測系統及其監測方法,透過單一感測器取得往復式壓縮機運作時之作動訊號,即可進行往復式壓縮機之檢測判斷,以準確掌握往復式壓縮機之機台狀況。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.
本發明之一項實施例提供一種往復式壓縮機監測系統,其包含:一感測器,其用以擷取往復式壓縮機運行時所產生之一作動訊號;以及一分析控制器,其與感測器訊號連接且接收作動訊號,分析控制器具有一處理模組及一判斷模組,處理模組將作動訊號轉換為一角度訊號,且將作動訊號與角度訊號匹配形成一狀態資訊;判斷模組透過一運算程式將狀態資訊與一模板資訊相互比對,判斷狀態資訊是否符合模板資訊,以取得往復式壓縮機之機況。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.
於其中一項實施例中,感測器架設於往復式壓縮機之氣缸;感測器為加速規;作動訊號為往復式壓縮機運行時之加速度訊號;運算程式為監督式神經網路學習,判斷模組透過運算程式判斷狀態資訊是否符合模板資訊。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.
於其中一項實施例中,處理模組將作動訊號積分轉換為一作動速度訊號,處理模組將作動速度訊號轉換為角度訊號。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.
於其中一項實施例中,所述模板資訊具有往復式壓縮機之各元件所對應之角度及各元件所對應作動訊號;分析控制器具有一記憶模組,記憶模組儲存所述模板資訊。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.
於其中一項實施例中,模板資訊為擷取往復式壓縮機運行時之作動訊號所處理而成之狀態資訊,且將所述狀態資訊建立儲存於記憶模組。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.
於其中一項實施例中,運算程式判斷狀態資訊與模板資訊間之差異度,以產生一差異程度資訊。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.
本發明之另一項實施例提供一種往復式壓縮機監測方法,其包含下列步驟:量測步驟:透過一感測器產生往復式壓縮機運行時之一作動訊號;分析步驟:透過一分析控制器接收感測器產生之作動訊號,分析控制器將作動訊號轉換為一角度訊號,且將作動訊號與角度訊號匹配形成一狀態資訊;以及判斷步驟:分析控制器透過一運算程式將狀態資訊與一模板資訊相互比對,判斷狀態資訊是否符合模板資訊,以取得往復式壓縮機之機況。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.
於其中一項實施例中,分析控制器將作動訊號積分轉換為一作動速度訊號,且將作動速度訊號轉換為角度訊號。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.
於其中一項實施例中,本發明更具有學習步驟:感應器於往復式壓縮機初始運行時或初次發生異常時所產生之作動訊號,透過分析控制器將所述作動訊號處理產生狀態資訊,且將所述狀態資訊建立為模板資訊,並且儲存於分析控制器。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.
於其中一項實施例中,分析控制器透過運算程式判斷狀態資訊與模板資訊間之差異度,以產生一差異程度資訊,以取得往復式壓縮機之機況異常程度。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.
藉由上述,本發明僅須透過單一感測器取得之作動訊號,即可進行檢測判斷,便能夠準確掌握往復式壓縮機之機況;藉以改善習知透過人工判斷方式之不準確性,或是需要裝設多種感測器,透過多種檢測參數信號才能夠判斷出往復式壓縮機之異常狀況。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.
為便於說明本發明於上述發明內容一欄中所表示的中心思想,茲以具體實施例表達。實施例中各種不同物件係按適於說明之比例、尺寸、變形量或位移量而描繪,而非按實際元件的比例予以繪製,合先敘明。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.
請參閱圖1至圖8所示,本發明提供一種往復式壓縮機監測系統100,其包含:Please refer to FIG. 1 to FIG. 8. The present invention provides a reciprocating
一感測器10,其用以擷取往復式壓縮機1運行時所產生之一作動訊號11;於本發明實施例中,感測器10架設於往復式壓縮機1之氣缸,而往復式壓縮機1為往復式活塞壓縮機(piston compressor),如圖5所示,但感測器10之架設位置不以此為限,感測器10只要能夠產生往復式壓縮機1運行時之作動訊號11即可;感測器10為加速規,作動訊號11為往復式壓縮機1運行時所產生之加速度訊號。A
一分析控制器20,其與感測器10訊號連接且接收作動訊號11,分析控制器20具有一處理模組21,處理模組21用以將作動訊號11轉換為一角度訊號211;其中,處理模組21能夠直接將作為加速度之作動訊號11處理成角度訊號211,或是由處理模組21將作動訊號11積分轉換為一作動速度訊號,且處理模組21將作動速度訊號轉換為角度訊號211’。An
進一步舉例說明,當作動訊號11為10Hz,表示1秒作動訊號11中有10次週期發生(一次表示轉360度),而週期一次時間為0.1秒,將0.1秒作動訊號11轉換成用360度表示,所以1秒作動訊號11表示轉動360度10次,如此就能夠將作動訊號11轉換成角度訊號211;再者,往復式壓縮機1之運作行程固定,以轉動360度來說,每個角度或角度區間代表往復式壓縮機1之各元件,也就是說,每個角度或角度區間所產生之作動訊號11能表示為各元件之狀態。For further example, when the
再者,處理模組21再將作動訊號11與角度訊號211匹配形成一狀態資訊,狀態資訊具有往復式壓縮機1之各元件所對應之角度及各元件所對應作動訊號11,也就是說,狀態資訊為往復式壓縮機1於每個角度下所產生作動訊號11所對應之資訊;如圖6所示,表示往復式壓縮機1之各元件呈現正常狀態之狀態資訊。Furthermore, the
分析控制器20更具有一判斷模組22,判斷模組22透過一運算程式將狀態資訊與一模板資訊23相互比對,以判斷狀態資訊是否符合模板資訊23,進而取得往復式壓縮機1之機況,如圖4所示;其中,運算程式為監督式神經網路學習。The
分析控制器20具有一記憶模組24,記憶模組24用以儲存模板資訊23,模板資訊23為往復式壓縮機1初次運行或初次發生異常時產生之作動訊號11處理而成之狀態資訊,分析控制器20之處理模組21會透過運算程式進行學習,並且將學習後之狀態資訊建立為模板資訊23,以儲存於記憶模組24,如圖1及圖3所示。The
模板資訊23具有往復式壓縮機1之各元件所對應之角度及各元件所對應作動訊號11及對應作動訊號11之角度訊號211;而作為加速度之作動訊號11處理成角度訊號211及匹配作動訊號11而形成之狀態資訊,用以判斷往復式壓縮機1之十字頭是否磨損、進排氣作動是否異常或汽缸是否發生碰撞;而由作動速度訊號轉換為角度訊號211’及匹配作動訊號11形成之狀態資訊,用以判斷往復式壓縮機1之曲軸是否平衡、曲軸是否偏心或活塞連桿是否異常;請參閱圖7所示,為十字頭磨損之模板資訊23;請參閱圖8所示,為活塞上下死點異常之模板資訊23。The
此外,判斷模組22會透過運算程式判斷狀態資訊與模板資訊23間之差異度,以產生一差異程度資訊,也就是說,判斷模組22能夠先判斷出狀態資訊是否符合模板資訊23,以確認往復式壓縮機1是否發生異常,而當往復式壓縮機1發生異常時,則判斷模組22能夠透過運算程式計算出往復式壓縮機1之異常嚴重程度,也就是異常程度資訊,例如:十字頭之磨損約10%。In addition, the
利用前述本發明往復式壓縮機監測系統100,於實際應用時,能夠透過往復式壓縮機監測方法判斷往復式壓縮機1是否發生異常。Using the aforementioned reciprocating
本發明往復式壓縮機監測方法包含下列步驟:The monitoring method of the reciprocating compressor of the present invention includes the following steps:
量測步驟S1:將感測器10架設於往復式壓縮機1之氣缸,當往復式壓縮機1運行時,感測器10會產生往復式壓縮機1運行時之作動訊號11。Measurement step S1: Install the
分析步驟S2:感測器10會將作動訊號11傳送至分析控制器20,而分析控制器20會接收作動訊號11,且將作動訊號11轉換為角度訊號211,或是分析控制器20將作動訊號11積分轉換為作動速度訊號,且將作動速度訊號轉換為角度訊號211’;接著,分析控制器20會將作動訊號11與角度訊號211(角度訊號211’)匹配形成狀態資訊。Analysis step S2: The
判斷步驟S3:分析控制器20透過運算程式將狀態資訊與模板資訊23相互比對,判斷狀態資訊是否符合模板資訊23,以取得往復式壓縮機1之機況,如圖1及圖4所示;其中,當分析控制器20判斷往復式壓縮機1呈現異常時,分析控制器20會透過運算程式判斷狀態資訊與模板資訊23間之差異度,以產生差異程度資訊,以取得往復式壓縮機1之機況異常程度,使用者能夠透過機況異常程度,判斷是否得及時更換或維修元件。Judging step S3: The
學習步驟S4:當往復式壓縮機1初始運行時或初次發生異常時,能夠藉由量測步驟S1取得往復式壓縮機1初始運行時或初次發生異常時所產生作動訊號11;接著,透過分析步驟S2,計算取得角度訊號211,並且透過運算程式將所述狀態資訊經過學習建立為模板資訊23,並且儲存於分析控制器20中,如圖1及圖3所示。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
當往復式壓縮機1已建立用以判斷之模板資訊23後,而後每次往復式壓縮機1運作時,便能夠經由量測步驟S1及分析步驟S2取得狀態資訊,並且透過判斷步驟S3取得往復式壓縮機1之機況。After the reciprocating compressor 1 has established the
經由前述,本發明能夠達成之功效如下:Through the foregoing, the effects that the present invention can achieve are as follows:
一、本發明往復式壓縮機監測系統100僅須透過單一感測器10取得之作動訊號11,即可進行檢測判斷,便能夠準確掌握往復式壓縮機1之機況;藉以改善需要裝設多種感測器10,透過多種檢測參數信號才能夠判斷出往復式壓縮機1之異常狀況,進而達到簡單且快速取得檢測結果之功效。1. The reciprocating
二、本發明往復式壓縮機監測系統100之分析控制器20能夠透過運算程式取得往復式壓縮機1之機況異常程度,藉以提供使用者根據機況異常程度,判斷是否得及時更換或維修元件,以提供實際產業使用上之靈活調度性。2. The
以上所舉實施例僅用以說明本發明而已,非用以限制本發明之範圍。舉凡不違本發明精神所從事的種種修改或變化,俱屬本發明意欲保護之範疇。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:往復式壓縮機 100:往復式壓縮機監測系統 10:感測器 11:作動訊號 20:分析控制器 21:處理模組 211:角度訊號 211’:角度訊號 22:判斷模組 23:模板資訊 24:記憶模組 S1:量測步驟 S2:分析步驟 S3:判斷步驟 S4:學習步驟 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
圖1係本發明系統架構方塊示意圖。 圖2係本發明方法流程方塊示意圖。 圖3係本發明判斷模組透過運算程式將狀態資訊學習行程模板資訊演算式意圖。 圖4係本發明判斷模組透過運算程式將狀態資訊與模板資訊相互比對演算式意圖。 圖5係本發明架設實施例示意圖。 圖6係本發明模板資訊示意圖(一),表示往復式壓縮機正常狀態。 圖7係本發明模板資訊示意圖(二),表示往復式壓縮機之十字頭損傷。 圖8係本發明模板資訊示意圖(三),表示往復式壓縮機之活塞上下死點異常。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:往復式壓縮機監測系統 100: Reciprocating compressor monitoring system
10:感測器 10: Sensor
20:分析控制器 20: Analyze the controller
21:處理模組 21: Processing module
22:判斷模組 22: Judgment module
24:記憶模組 24: Memory module
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