CN112987613A - Distributed rotating machinery state online monitoring and fault analysis system - Google Patents
Distributed rotating machinery state online monitoring and fault analysis system Download PDFInfo
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Abstract
The invention relates to a distributed rotating machinery state on-line monitoring and fault analysis system, which comprises: the device comprises a data acquisition unit, a data storage and analysis unit and a data result display unit; the data acquisition unit is used for acquiring original data of the rotary mechanical equipment, analyzing and calculating the original data by adopting a full-period synchronous sampling algorithm to obtain online monitoring data of the rotary mechanical equipment, and processing the online monitoring data to obtain a data analysis result; the data storage and analysis unit is used for storing and analyzing the online monitoring data and the data analysis result; and the data result display unit is used for displaying the data analysis result. The invention can output dynamic vibration signals to carry out fault analysis, can carry out real-time monitoring at the present time, and can carry out remote monitoring, evaluation and fault diagnosis on the unit through a network.
Description
Technical Field
The invention relates to the technical field of monitoring of rotary power mechanical equipment in a nuclear power plant, in particular to a distributed on-line monitoring and fault analysis system for the state of rotary machinery.
Background
The primary and secondary loop host equipment of the nuclear power plant comprises a main pump, a primary loop pressure container, a steam Turbine and a generator, wherein the vibration safety of the steam Turbine and the generator is widely regarded, a steam Turbine safety monitoring system (TSI) is arranged in the engineering design and construction stage, the TSI can play a role in monitoring and protecting the vibration state of the unit operation, but the TSI is lack of deep analysis and excavation of unit vibration data, and when fault diagnosis and analysis are needed, the TSI system provides original vibration signals to be output for portable vibration measurement equipment or a steam Turbine generator unit vibration online state monitoring and analyzing system (Turbine diagnostic Management-TDM) to use. In contrast, even a primary circuit pressure vessel, a pipeline, a main pump and the like of a main system of the nuclear island are configured with a KIV system in a newly-built EPR (ethylene propylene diene monomer) power plant, and other large-scale rotating equipment (more than 30) of the nuclear island are configured with a KIM system, but remote monitoring and fault diagnosis software is not provided, so that expensive purchase cost is required. Therefore, the power plant pays more attention to the vibration safety of the rotary auxiliary machine, but the specific vibration device is insufficient in the mode selection and configuration, and a congenital defect is formed.
The vibration monitoring product of the current important auxiliary machine configuration has more defects: firstly, the cost for installing the TSI system is too high, which is not beneficial to large-scale use and popularization; secondly, the TSI system can only provide monitoring and safety protection, and lacks corresponding data analysis and fault diagnosis functions. Therefore, in order to reduce the cost of the auxiliary machine vibration monitoring products, nuclear power plants are beginning to deploy a series of simplified vibration monitoring products, which have two main functions: firstly, sending 4-20 MA steady-state vibration data to a DCS; second, the vibration amplitude is displayed in situ. The defects are that dynamic vibration signals cannot be output for fault analysis, the quality of products is uneven, and the measurement point arrangement and vibration amplitude display of a considerable part of products are wrong.
Disclosure of Invention
The present invention provides a distributed rotating machine state online monitoring and fault analysis system, which is directed to the above-mentioned defects in the prior art.
The technical scheme adopted by the invention for solving the technical problems is as follows: a distributed rotating machinery state online monitoring and fault analysis system is constructed, and the system comprises: the device comprises a data acquisition unit, a data storage and analysis unit and a data result display unit;
the data acquisition unit is used for acquiring original data of the rotary mechanical equipment, analyzing and calculating the original data by adopting a full-period synchronous sampling algorithm to obtain online monitoring data of the rotary mechanical equipment, and processing the online monitoring data to obtain a data analysis result;
the data storage and analysis unit is used for storing and analyzing the online monitoring data and the data analysis result;
and the data result display unit is used for displaying the data analysis result.
In the distributed online monitoring and fault analysis system for the state of the rotating machine, the data acquisition unit comprises: the device comprises a signal conditioning module, an analog-to-digital conversion module, a first processing module, a second processing module and a communication module;
the signal conditioning module is used for acquiring original data of the rotary mechanical equipment and conditioning the original data;
the analog-to-digital conversion module is used for performing analog-to-digital conversion on the conditioned original data to obtain digital signal data;
the first processing module synchronously acquires the digital signal data to output a synchronous signal;
the second processing module adopts a full-period synchronous sampling algorithm to analyze and calculate the synchronous signals to obtain online monitoring data of the rotary mechanical equipment, and processes the online monitoring data to obtain a data analysis result;
and the communication module sends the data analysis result to the data storage and analysis unit.
In the distributed online monitoring and fault analysis system for the state of the rotating machine, the signal conditioning module comprises: a first conditioning module, a second conditioning module, and a third conditioning module; the raw data includes: a key phase signal, a vibration signal, and a current signal;
the first conditioning module is used for collecting the key phase signal and conditioning the key phase signal;
the second conditioning module is used for collecting the vibration signal and conditioning the vibration signal;
the third conditioning module is used for collecting the current signal and conditioning the current signal.
In the distributed online monitoring and fault analyzing system for a rotating machine according to the present invention, the first processing module includes: an FPGA module;
and the FPGA module synchronously acquires the vibration signal, the current signal and the key phase signal and outputs the synchronous signal.
In the system for online monitoring and fault analysis of a state of a distributed rotating machine according to the present invention, the second processing module includes: a DSP processor.
In the distributed online monitoring and fault analysis system for the state of the rotating machine, the DSP processor comprises: the device comprises an interpolation filtering module, a digital tracking filtering module, an interpolation resampling module and a waveform reconstruction module;
the interpolation filtering module interpolates the key phase signal to obtain a time sequence corresponding to the vibration signal with equal angle;
the digital tracking filtering module performs anti-aliasing digital filtering on the vibration signal to output a digital filtering signal;
the interpolation resampling module performs interpolation resampling on the digital filtering signal and the time sequence by adopting a preset interpolation resampling method to obtain an equiangular sampling signal;
and the waveform reconstruction module performs waveform reconstruction on the equal-angle sampling signals to obtain a rotating machinery vibration order spectrum and a harmonic waveform.
In the distributed online monitoring and fault analysis system for the state of the rotating machine, the digital tracking filtering module adopts an adaptive filter with an FIR structure to perform anti-aliasing digital filtering on the vibration signal.
In the distributed online monitoring and fault analysis system for the state of the rotating machine, the preset interpolation resampling method comprises the following steps: any one of a linear interpolation method, a spline interpolation method, a lagrange interpolation method, a sinc interpolation method, and a fuzzy control interpolation method.
In the system for online monitoring and fault analysis of the state of the distributed rotating machine, the waveform reconstruction module performs waveform reconstruction on the equal-angle sampling signal to obtain a rotating machine vibration order spectrum and a harmonic waveform, and the method comprises the following steps:
the waveform reconstruction module performs Fourier transform on the equal-angle sampling signals to obtain a rotating machinery vibration order spectrum and performs constant bandwidth filtering or Gabor transform on the equal-angle sampling signals to obtain the harmonic waveform.
In the online state monitoring and fault analyzing system for a distributed rotating machine according to the present invention, the data analysis result includes: an axis trace graph, a wave form graph, a polar coordinate graph, a Bode graph, a trend graph, a waterfall graph, a cascade graph and an axis static position graph.
The distributed rotating machinery state on-line monitoring and fault analysis system has the following beneficial effects: the method comprises the following steps: the device comprises a data acquisition unit, a data storage and analysis unit and a data result display unit; the data acquisition unit is used for acquiring original data of the rotary mechanical equipment, analyzing and calculating the original data by adopting a full-period synchronous sampling algorithm to obtain online monitoring data of the rotary mechanical equipment, and processing the online monitoring data to obtain a data analysis result; the data storage and analysis unit is used for storing and analyzing the online monitoring data and the data analysis result; and the data result display unit is used for displaying the data analysis result. The invention can output dynamic vibration signals to carry out fault analysis, can carry out real-time monitoring at the present time, and can carry out remote monitoring, evaluation and fault diagnosis on the unit through a network.
Drawings
The invention will be further described with reference to the accompanying drawings and examples, in which:
FIG. 1 is a schematic diagram of a monitoring function of a distributed rotating machine state online monitoring and fault analysis system according to an embodiment of the present invention;
FIG. 2 is a schematic block diagram of a data acquisition unit provided by an embodiment of the present invention;
FIG. 3 is a flowchart of a DSP calculation order tracking algorithm provided by an embodiment of the present invention;
fig. 4 is a schematic structural diagram of a distributed rotating machine state online monitoring and fault analysis system according to an embodiment of the present invention.
Detailed Description
For a more clear understanding of the technical features, objects and effects of the present invention, embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
The system constructs the vibration online monitoring and fault analysis functions aiming at the states of the series of rotary mechanical equipment 101 (auxiliary machines), realizes the vibration online real-time monitoring and data remote analysis and diagnosis functions, can integrate the network or mobile network resources of the nuclear power plant, and releases data by combining a cloud server, thereby not only realizing real-time monitoring in the nuclear power plant, but also enabling a vibration expert to remotely monitor, evaluate and diagnose the machine set through the network in different places. In addition, the system has the advantages of simple wiring, firm and small collector, low installation cost and no server maintenance, and is suitable for a distributed remote state online monitoring system of the rotary machinery (auxiliary machinery) of the nuclear power plant.
Referring to fig. 1, fig. 1 is a schematic view of a monitoring function of a distributed rotating machine state online monitoring and fault analysis system according to an embodiment of the present invention.
Specifically, as shown in fig. 1, the distributed online monitoring and fault analysis system for the state of the rotating machine includes: a data acquisition unit 102, a data storage and analysis unit 103 and a data result display unit 104.
The data acquisition unit 102 is configured to acquire raw data of the rotating mechanical device 101, perform analysis and calculation on the raw data by using a full-period synchronous sampling algorithm, obtain online monitoring data of the rotating mechanical device 101, and process the online monitoring data to obtain a data analysis result.
In some embodiments, as shown in fig. 2, the data acquisition unit 102 includes: a signal conditioning module, an analog-to-digital conversion module 1024, a first processing module, a second processing module, and a communication module 1027.
The signal conditioning module is used for acquiring original data of the rotary mechanical equipment 101 and conditioning the original data; the analog-to-digital conversion module 1024 is configured to perform analog-to-digital conversion on the conditioned raw data to obtain digital signal data; the first processing module synchronously acquires digital signal data to output a synchronous signal; the second processing module adopts a full-period synchronous sampling algorithm to analyze and calculate the synchronous signals to obtain online monitoring data of the rotating mechanical equipment 101, and processes the online monitoring data to obtain a data analysis result; the communication module 1027 transmits the data analysis result to the data storage and analysis unit 103.
In some embodiments, the communication module includes, but is not limited to, a 4G/5G router, an Ethernet output interface, and a Modbus485 output interface.
In some embodiments, the signal conditioning module comprises: a first conditioning module 1021, a second conditioning module 1022, and a third conditioning module 1023. The raw data includes: a key phase signal, a vibration signal, and a current signal. Wherein, the key phase signal comprises one path (channel); the vibration signal includes multiple paths (channels), for example, 10 channels; the current signal comprises multiple paths (channels), which may be, for example, 5 channels.
The first conditioning module 1021 is used for collecting the key phase signal and conditioning the key phase signal; the second conditioning module 1022 is configured to collect the vibration signal and condition the vibration signal; the third conditioning module 1023 is used for collecting the current signal and conditioning the current signal.
Specifically, the collected key phase signal, vibration signal and current signal can be adjusted by the first conditioning module 1021, the second conditioning module 1022 and the third conditioning module 1023, respectively, to obtain data or signals that can satisfy the processing of the first processing module and/or the second processing module.
Optionally, the data acquisition unit 102 selects a DSP + FPGA dual-core mode to analyze and process the vibration signal on hardware. Wherein, the first processing module includes: an FPGA module 1025. The second processing module comprises: a DSP processor 1026. The FPGA module 1025 performs synchronous acquisition on the vibration signal, the current signal, and the key phase signal, and outputs a synchronous signal. Specifically, the FPGA module 1025 is responsible for synchronously acquiring the 10-channel vibration signal and the 1-channel rotation speed/key signal and transmitting the signals to the DSP processor 1026. The DSP processor 1026 is mainly responsible for vibration signal analysis and processing, specifically, for calculating the phase-to-phase rotation speed and calculating the order tracking calculation.
Further, in some embodiments, the DSP processor 1026 integrates a vibration signal full-period synchronous sampling algorithm for calculating the step ratio tracking in real time, so as to achieve accurate equal-angle sampling (i.e. the sampling point corresponds to the angular difference on the rotating shaft and is fixed in position on the rotating shaft every time the rotating shaft rotates, so as to achieve accurate full-period synchronous sampling).
In some embodiments, the DSP processor 1026 includes: the device comprises an interpolation filtering module, a digital tracking filtering module, an interpolation resampling module and a waveform reconstruction module.
The interpolation filtering module interpolates the key phase signal to obtain a time sequence corresponding to the vibration signal with equal angle; the digital tracking filtering module performs anti-aliasing digital filtering on the vibration signal to output a digital filtering signal; the interpolation resampling module performs interpolation resampling on the digital filtering signal and the time sequence by adopting a preset interpolation resampling method to obtain an equiangular sampling signal; and the waveform reconstruction module performs waveform reconstruction on the equal-angle sampling signals to obtain a rotating machinery vibration order spectrum and a harmonic waveform. Further, the DSP processor 1026 also includes a speed module that calculates the speed to obtain the instantaneous frequency. The specific step flow is shown in fig. 3.
As shown in fig. 3, signals of the rotation speed channel 1, the vibration channel 2, and the vibration channel n are synchronously acquired (at equal time intervals) by the FPGA module 1025 and transmitted to the DSP processor 1026, and after the DSP processor 1026 identifies the rotation speed pulse edge, the key phase signal (key phase pulse) is interpolated by the built-in interpolation filter module to obtain a time sequence corresponding to the equiangular vibration signal. The vibration signal output by the FPGA is subjected to anti-aliasing digital filtering by a digital tracking filtering module, a corresponding digital filtering signal is output, then, interpolation resampling is carried out on the digital filtering signal and a time sequence by an interpolation resampling module to obtain an equiangular sampling signal, and finally, waveform reconstruction is carried out on the equiangular sampling signal by a waveform reconstruction module to obtain a rotating machinery vibration order spectrum and a harmonic waveform (on-line monitoring data).
Optionally, the rotating mechanical vibration order ratio spectrum includes, but is not limited to, an order ratio power spectrum, an order ratio frequency spectrum, and the like.
In some embodiments, the DSP processor 1026 is embedded with an adaptive multistage interpolation filter algorithm program, so that the interpolation filter module can perform 2 × M interpolation on the key-phase pulses to obtain a time sequence corresponding to the equiangular vibration signal.
In some embodiments, the digital skip filter module prevents frequency aliasing by anti-aliasing digitally filtering the vibration signal by rotating the mechanical instantaneous frequency and time series. Optionally, the digital tracking filtering module performs anti-aliasing digital filtering on the vibration signal by using an adaptive filter with an FIR structure. The DSP processor 1026 may be pre-programmed with an adaptive filtering algorithm to process the input digital signal.
In some embodiments, the interpolation resampling module performs resampling to obtain an equiangular sampled signal.
In some embodiments, the default interpolation resampling method comprises: any one of a linear interpolation method, a spline interpolation method, a lagrange interpolation method, a sinc interpolation method, and a fuzzy control interpolation method. The linear interpolation method, the spline interpolation method, the Lagrange interpolation method and the sinc interpolation method all adopt the principle of an averaging method. The fuzzy control interpolation method adopts a fuzzy control principle, is high in speed and accuracy and precision, and therefore the fuzzy control interpolation method is preferred in the embodiment of the invention, so that more advantages in time domain and frequency domain are guaranteed.
In some embodiments, the waveform reconstructing module performs waveform reconstruction on the equal-angle sampling signal to obtain a rotating mechanical vibration order spectrum and a harmonic waveform includes: the waveform reconstruction module performs Fourier transform on the equal-angle sampling signals to obtain a rotating mechanical vibration order spectrum and performs constant bandwidth filtering or Gabor transform on the equal-angle sampling signals to obtain harmonic waveforms.
Specifically, Fast Fourier Transform (FFT) is performed on the equal angle sampling signal to obtain a continuous rotating mechanical vibration order spectrum. And carrying out constant bandwidth filtering or Gabor conversion on the equal-angle sampling signals to obtain continuous harmonic waveforms of each order.
Further, after the DSP processor 1026 implements the full-period synchronous sampling of the dynamic vibration signal through the integrated calculation order analysis algorithm, the vibration data (on-line monitoring data) is further processed to obtain a data analysis result. Wherein, the data analysis result includes but is not limited to: an axis trace graph, a wave form graph, a polar coordinate graph, a Bode graph, a trend graph, a waterfall graph, a cascade graph and an axis static position graph.
Compared with the traditional mode that continuous vibration waveforms are transmitted to an upper computer for signal analysis and processing, the method can directly transmit vibration signal waveform, frequency spectrum and vibration vector analysis results, greatly reduces the bandwidth and flow pressure of the mobile internet by data volume, and enables online monitoring of the vibration state of the unit to be possible based on the mobile internet (4G/5G) and a cloud platform. Moreover, the system of the invention has simple wiring, firm and small acquisition equipment, low installation cost and no server maintenance, is suitable for the distributed remote state online monitoring of the rotary machinery (auxiliary machinery) of the nuclear power plant, and is widely applied to: a water pump, a fan, a motor, a compressor, a steam turbine, a generator, a main pump, a blowout pump, a chemical capacitance pump and other rotating mechanical equipment 101.
The data storage and analysis unit 103 is used for storing and analyzing the online monitoring data and the data analysis result.
In some embodiments, the data storage and analysis unit 103 comprises: the server comprises a local server and a cloud server.
The data result display unit 104 is used for displaying the data analysis result.
In some embodiments, the data result display unit 104 includes, but is not limited to, a remote vibration monitoring and fault diagnosis center, a domain expert user terminal, an intelligent terminal, and the like.
As shown in fig. 4, the auxiliary device (the rotating mechanical device 101) in fig. 4 outputs a vibration signal, the data acquisition unit 102 (the acquisition device in fig. 4) may upload data to a cloud server in a cloud platform through mobile communication such as 4G/5G, and the cloud server stores, counts, analyzes real-time and historical vibration data and shutdown data, and provides a basis for unit maintenance and fault diagnosis; the cloud platform realizes remote monitoring and fault diagnosis of a B/S (browser/server) mode based on a JavaEE + MVC + MySQL programming technology.
The distributed online monitoring and fault diagnosis system for the state of the rotating machine realizes online remote monitoring and fault diagnosis of equipment, adopts JavaEE + MVC + MySQL technology in development based on 4G communication and cloud platform technology, integrates factory network and Internet resources, can monitor in real time in a factory, and can be used for a vibration expert to remotely monitor, evaluate and diagnose a unit in a remote place through an Internet. On the cloud platform, server software based on WEB and SQL technologies provides customized services for requirements of different clients, and the operation state of the unit can be monitored at any time through APP visit of the mobile client.
The embodiments in the present description are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other. The device disclosed by the embodiment corresponds to the method disclosed by the embodiment, so that the description is simple, and the relevant points can be referred to the method part for description.
Those of skill would further appreciate that the various illustrative elements and algorithm steps described in connection with the embodiments disclosed herein may be implemented as electronic hardware, computer software, or combinations of both, and that the various illustrative components and steps have been described above generally in terms of their functionality in order to clearly illustrate this interchangeability of hardware and software. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the implementation. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present invention.
The steps of a method or algorithm described in connection with the embodiments disclosed herein may be embodied directly in hardware, in a software module executed by a processor, or in a combination of the two. A software module may reside in Random Access Memory (RAM), memory, Read Only Memory (ROM), electrically programmable ROM, electrically erasable programmable ROM, registers, hard disk, a removable disk, a CD-ROM, or any other form of storage medium known in the art.
The above embodiments are merely illustrative of the technical ideas and features of the present invention, and are intended to enable those skilled in the art to understand the contents of the present invention and implement the present invention, and not to limit the scope of the present invention. All equivalent changes and modifications made within the scope of the claims of the present invention should be covered by the claims of the present invention.
Claims (10)
1. A distributed rotating machinery state on-line monitoring and fault analysis system is characterized by comprising: the device comprises a data acquisition unit, a data storage and analysis unit and a data result display unit;
the data acquisition unit is used for acquiring original data of the rotary mechanical equipment, analyzing and calculating the original data by adopting a full-period synchronous sampling algorithm to obtain online monitoring data of the rotary mechanical equipment, and processing the online monitoring data to obtain a data analysis result;
the data storage and analysis unit is used for storing and analyzing the online monitoring data and the data analysis result;
and the data result display unit is used for displaying the data analysis result.
2. The distributed rotary machine condition online monitoring and fault analysis system of claim 1, wherein the data acquisition unit comprises: the device comprises a signal conditioning module, an analog-to-digital conversion module, a first processing module, a second processing module and a communication module;
the signal conditioning module is used for acquiring original data of the rotary mechanical equipment and conditioning the original data;
the analog-to-digital conversion module is used for performing analog-to-digital conversion on the conditioned original data to obtain digital signal data;
the first processing module synchronously acquires the digital signal data to output a synchronous signal;
the second processing module adopts a full-period synchronous sampling algorithm to analyze and calculate the synchronous signals to obtain online monitoring data of the rotary mechanical equipment, and processes the online monitoring data to obtain a data analysis result;
and the communication module sends the data analysis result to the data storage and analysis unit.
3. The distributed rotary machine condition online monitoring and fault analysis system of claim 2, wherein the signal conditioning module comprises: a first conditioning module, a second conditioning module, and a third conditioning module; the raw data includes: a key phase signal, a vibration signal, and a current signal;
the first conditioning module is used for collecting the key phase signal and conditioning the key phase signal;
the second conditioning module is used for collecting the vibration signal and conditioning the vibration signal;
the third conditioning module is used for collecting the current signal and conditioning the current signal.
4. The distributed rotary machine condition online monitoring and fault analysis system of claim 3, wherein the first processing module comprises: an FPGA module;
and the FPGA module synchronously acquires the vibration signal, the current signal and the key phase signal and outputs the synchronous signal.
5. The distributed rotary machine condition online monitoring and fault analysis system of claim 4, wherein the second processing module comprises: a DSP processor.
6. The distributed rotary machine condition online monitoring and fault analysis system of claim 5, wherein the DSP processor comprises: the device comprises an interpolation filtering module, a digital tracking filtering module, an interpolation resampling module and a waveform reconstruction module;
the interpolation filtering module interpolates the key phase signal to obtain a time sequence corresponding to the vibration signal with equal angle;
the digital tracking filtering module performs anti-aliasing digital filtering on the vibration signal to output a digital filtering signal;
the interpolation resampling module performs interpolation resampling on the digital filtering signal and the time sequence by adopting a preset interpolation resampling method to obtain an equiangular sampling signal;
and the waveform reconstruction module performs waveform reconstruction on the equal-angle sampling signals to obtain a rotating machinery vibration order spectrum and a harmonic waveform.
7. The distributed online state monitoring and fault analysis system for rotary machines according to claim 6, wherein the digital tracking filter module performs anti-aliasing digital filtering on the vibration signal by using an adaptive filter with an FIR structure.
8. The distributed rotating machine condition online monitoring and fault analysis system of claim 6, wherein the pre-interpolation resampling method comprises: any one of a linear interpolation method, a spline interpolation method, a lagrange interpolation method, a sinc interpolation method, and a fuzzy control interpolation method.
9. The system for online monitoring and fault analysis of state of distributed rotating machinery according to claim 6, wherein the waveform reconstruction module performs waveform reconstruction on the equal-angle sampling signal to obtain a rotating machinery vibration order spectrum and a harmonic waveform comprises:
the waveform reconstruction module performs Fourier transform on the equal-angle sampling signals to obtain a rotating machinery vibration order spectrum and performs constant bandwidth filtering or Gabor transform on the equal-angle sampling signals to obtain the harmonic waveform.
10. A distributed rotating machine condition on-line monitoring and fault analysis system according to any of claims 1-9, wherein the data analysis results comprise: an axis trace graph, a wave form graph, a polar coordinate graph, a Bode graph, a trend graph, a waterfall graph, a cascade graph and an axis static position graph.
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