CN113646538A - Method for vibration avoidance in a pump - Google Patents

Method for vibration avoidance in a pump Download PDF

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Publication number
CN113646538A
CN113646538A CN202080029386.2A CN202080029386A CN113646538A CN 113646538 A CN113646538 A CN 113646538A CN 202080029386 A CN202080029386 A CN 202080029386A CN 113646538 A CN113646538 A CN 113646538A
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China
Prior art keywords
pump
frequency
rotational speed
order
signal
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CN202080029386.2A
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Chinese (zh)
Inventor
M·埃克尔
J·舒勒勒
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KSB SE and Co KGaA
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KSB SE and Co KGaA
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Publication of CN113646538A publication Critical patent/CN113646538A/en
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04DNON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00Details, component parts, or accessories
    • F04D29/66Combating cavitation, whirls, noise, vibration or the like; Balancing
    • F04D29/669Combating cavitation, whirls, noise, vibration or the like; Balancing especially adapted for liquid pumps
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04DNON-POSITIVE-DISPLACEMENT PUMPS
    • F04D15/00Control, e.g. regulation, of pumps, pumping installations or systems
    • F04D15/0066Control, e.g. regulation, of pumps, pumping installations or systems by changing the speed, e.g. of the driving engine
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04DNON-POSITIVE-DISPLACEMENT PUMPS
    • F04D15/00Control, e.g. regulation, of pumps, pumping installations or systems
    • F04D15/0088Testing machines

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Control Of Non-Positive-Displacement Pumps (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Control Of Positive-Displacement Pumps (AREA)

Abstract

The invention relates to a method for avoiding or reducing mechanical vibrations of a pump, in particular a centrifugal pump, during operation of the pump, wherein a frequency converter and a pump controller are provided and the pump controller detects at least one signal of a pump operating parameter and checks the signal oscillations in order to recognize occurring mechanical vibrations of the pump and, in order to reduce the recognized vibrations, changes the pump rotational speed by means of the frequency converter.

Description

Method for vibration avoidance in a pump
Technical Field
The invention relates to a method for avoiding or reducing mechanical vibrations during operation of a pump, in particular a centrifugal pump.
Background
Mechanical vibrations in centrifugal pumps result in increased wear and undesirable noise development in operation. The reasons for the vibrations may be varied. For example, externally excited vibrations due to the rotation of the pump impeller or free vibrations due to the natural frequency of the built-in pump may be the cause.
Free vibration occurs particularly in solid pumps. The solids pump is a centrifugal pump for conveying a pumping medium with a strongly abrasive solids fraction, such as a suspension of slag, coal or ore in the mining industry. Occasionally, the pumped medium may also contain stones or other rigid elements, which may cause impacts when hitting the pump structure during operation of the pump, which impacts result in excitation of free vibrations of the pump. This effect is also increasingly present in pumps used in the waste water sector.
A particularly disadvantageous situation exists when the rotational frequency of the impeller, i.e. the set pump rotational speed, falls on or corresponds to an integer multiple of the natural frequency of the internal pump. In this case, resonance occurs, i.e., the two vibration causes are amplified by each other. It is similarly problematic that the set rotational frequency of the impeller coincides with the pipe resonance of the conveying system.
This resonance situation is exemplarily shown in fig. 1. The figure shows the frequency response of a centrifugal pump built in ready to operate. The natural frequency of the free vibration of the system has a frequency value f1、f2、f3. Frequency response, i.e. natural frequency f1、f2、f3Depending on the particular pump configuration, the mounting location selected, the materials used, and the bearings mounted. If the rotational frequency of the pump wheel set by means of the frequency converter is equal to the illustrated natural frequency f1、f2、f3One of the same or alternatively a natural frequency f as shown1、f2、f3An integer multiple of one, the system is excited by the externally excited rotation of the impeller and amplified resonance of the pump occurs. If the rotational frequency of the impeller is instead at the anti-resonance af drawn here1、af2Within the range of one, the effect is minimal and no or only little vibration occurs.
Disclosure of Invention
The concept of the present application is based on the above knowledge and proposes a method which minimizes the risk of possible vibrations, in particular resonance, occurring by targeted measures during operation of the pump.
This object is achieved by a method according to the features of claim 1. Advantageous embodiments are the subject of the dependent claims.
For the implementation of the method, it is decisive to use a frequency converter to change the rotational speed of the pump. However, it does not matter here whether such a frequency converter is integrated into the pump, mounted on the pump housing, or mounted separately from the pump. The same applies to the pump control for the method implementation, which can be an integral part of the pump, but can also be installed as a separate unit with respect to the pump, if appropriate in combination with a separate frequency converter.
The solution according to the invention of the present application consists in that, in the case of a pump with a frequency converter, the rotational speed is varied by the pump controller during operation of the pump, so that the mechanical vibrations of the pump are reduced as optimally as possible. A further essential aspect of the invention is that the pump, during operation, independently identifies its existing natural frequency by means of a suitable signal evaluation in order to be able to optimally adapt the set pump rotational speed on the basis of this knowledge.
The pump therefore does not require information about its frequency response, which has been generated beforehand and stored in the pump, but can instead determine said information independently during operation. For this purpose, the pump records signals during the operation of the pump, which signals represent pump operating parameters that are influenced by the occurring mechanical vibrations. The recorded signals are then checked by the pump for the presence of possible vibrations, in particular resonances. This vibration is then reduced by a suitable change in the rotational speed.
In particular, signal fluctuations caused by mechanical vibrations of the pump can be detected in the recorded signals. The amplitude of the identified oscillation frequency of the signal is reduced by a suitable rotational speed change. Thus, according to an advantageous embodiment of the method, the frequency spectrum of the recorded signal is taken into account. Advantageously, the signal is first transformed into its frequency spectrum by means of a transformation, in particular by means of a fast fourier transformation, in order to identify the corresponding frequency values and the associated amplitudes of the occurring signal oscillations in this way.
One or more motor currents of the pump drive prove to be a suitable operating signal for detecting possible vibrations. The current value is always present in the frequency converter used, so that no further sensors are required. Since the mechanical vibrations of the pump system are also reflected in the motor windings of the pump drive and correspondingly in the current of the motor by magnetic induction, the motor functions as an effective and readily available sensor. The mechanical vibrations of the pump system can then be identified with sufficient accuracy by means of a corresponding current analysis. This possibility exists independently of the type of electric motor used for the electric pump drive.
As an alternative or in addition to the operating parameter for determining the frequency response of the pump, for example, the pump pressure, in particular the final pressure of the pump, is suitable. Here, the mechanical vibration is also reflected in the signal change process (Signalverlauf). The final pressure of the pump can be determined, for example, by means of an existing pressure sensor and can be transformed into its frequency spectrum by signal transformation, in particular by fast fourier transformation.
However, for signal detection, a suitable sensor does not necessarily have to remain available. Alternatively, the current pump pressure can be determined computationally, for example, by means of an operating point estimate. A possible method for this is disclosed in DE102018200651, the content of which is hereby fully included.
According to one possible embodiment, the method can be carried out iteratively with varying pump rotational speeds, in order to identify, for example, a pump rotational speed at which the amplitude of the identified vibrations is minimized as much as possible. The pump therefore analyzes the frequency spectrum of the repeatedly recorded signal again after a change in the rotational speed has taken place and checks whether the change in the rotational speed has resulted in a corresponding reduction in amplitude.
The iterative implementation of the method steps can provide arbitrary or random or controlled rotational speed variations. The change in rotational speed that is made between two iterations is reversed if the amplitude is, for example, increased, and otherwise is maintained. It is also conceivable to drive completely through a defined speed range (abfahren) and then to set a speed with a minimum amplitude for the pump operation.
Instead, suitable methods and algorithms are used to identify local or global amplitude minima with associated rotational speed. It is conceivable to use an interval halving method and/or an optimization method, such as the active set method and/or newton method, in order to determine the appropriate rotational speed which leads to a minimum of the amplitude as quickly as possible. Genetic algorithms are also conceivable which, although comparatively slow, nevertheless enable the identification of a global minimum of the frequency response.
The setting of the rotational speed or its change during the method iteration also depends on which operating conditions are predefined, for example, by the pump operator. For example, it is conceivable for the pump operator to specify a constant pump speed or to specify only a small tolerance range for speed changes. During the method iteration, the rotational speed change is then only carried out within a previously defined tolerance range. In this case, an iterative method implementation in which all or at least a part of the permitted rotational speeds are operated in order to determine the corresponding amplitude minimum for the range is generally sufficient.
If, however, the operator does not specify an admissible speed range, i.e. the complete technically possible speed range of the pump can be used instead, it is expedient for the method to use one of the above-mentioned methods for determining the suitable speed.
However, according to a further advantageous embodiment of the invention, the method can be used not only for reducing occurring vibrations, but rather the determination according to the invention of the frequency response is likewise suitable for pump monitoring, in order for example to be able to detect wear or possible damage on the pump mechanism early. As already explained in detail above, a central aspect of the invention is to determine the frequency response of the pump. The frequency response depends primarily on the pump construction, its mounting location, the materials used, and the bearing components mounted. Changes in one of these factors, for example due to wear or material damage, result in changes in the frequency response of the pump. The pump therefore preferably stores the determined frequency response and monitors the frequency response by continuously repeating measurements of the frequency shift of the identified decisive frequency. If such a frequency deviation is recognized, this is an indication of a wear phenomenon or pump damage. The pump can then generate a corresponding warning message or take appropriate action.
Further detection of frequency changes can also distinguish between wear and damage. Typically wear results in slow changes in frequency response, while pump damage, such as bearing damage or impeller breakage, results in sudden changes in frequency response. The pump therefore takes into account the temporal component of the detected change in its evaluation in order to distinguish wear from damage. Varying degrees may also be included.
In addition to the method according to the invention, the invention furthermore relates to a pump, preferably a centrifugal pump, particularly preferably a waste water pump or a solids pump or a feed pump, having an internal or external frequency converter and an internal or external pump controller for carrying out the method according to the invention. Accordingly, such a pump is characterized by the same advantages and properties as have already been explained in detail above with the aid of the method according to the invention. For this reason, duplicate description is omitted.
Furthermore, the present application provides for the use of a pump, in particular a centrifugal pump, as a waste water pump, a solids pump or a supply pump. The minimization of the mechanical vibrations occurring according to the invention is particularly important in the case of wastewater pumps or solids pumps, so that the use of the method according to the invention in such pump types brings about far-reaching advantages.
Drawings
Further advantages and characteristics of the invention will be explained in more detail later on with the aid of embodiments shown in the figures.
FIG. 1: showing possible frequency responses of a centrifugal pump installed and ready to operate,
FIG. 2: showing a time diagram of a periodic signal, an
FIG. 3: the calculated spectrum of the time signal from figure 2 is shown.
Detailed Description
The invention according to the present application describes a method for specifically avoiding undesired vibration amplification in resonance conditions by means of a frequency converter during operation of a pump, in particular a solids pump, a waste water pump or another supply pump. The basis for specifically avoiding these resonances is that these resonances must first be detected by the pump controller, but as far as possible no special sensors, such as acceleration sensors, have to be added to the pump. However, nothing prevents the pump from being equipped with additional sensors, for example acceleration sensors, so that the accuracy of the method can be increased if necessary.
Since the mechanical vibrations are the result of the interaction of the structural structure with the motor forces, these mechanical vibrations can also be interpreted as a superposition of the drive currents of the pump drive. Since the strength of the individual superimposed vibrations is of interest here, the evaluation of the motor current is carried out by analyzing the frequency spectrum of the recorded motor signal, which is obtained by the pump controller by performing a Fast Fourier Transformation (FFT).
This way of processing can be briefly elucidated on the basis of the diagrams of fig. 2, 3. Fig. 2 shows a time diagram of a recorded signal, which is generated here for the sake of simplicity by the superposition of three sinusoidal signals with different frequencies. By applying an FFT, the time signal can now be decomposed into its harmonic components and the frequency magnitude spectrum shown in fig. 3 is derived, from which the individual frequencies of the sinusoidal signal can be read out as expected.
Due to the FFT of the motor current, the pump can thus recognize the mechanical vibrations reflected in the recorded motor current. In a subsequent step, the pump or the pump controller then attempts to set the pump rotational speed such that the resulting rotational frequency of the impeller does not fall on the natural frequency of the pump or a multiple of such a natural frequency. For this purpose, the rotational speed is first changed and, in a further step, a spectral analysis of the currently recorded motor current is carried out again with a change in rotational speed. If the amplitude of the occurring current oscillations has become smaller, this is an indication that the mechanical vibrations can be successfully reduced by the change in the rotational speed. The method is now performed iteratively in order to achieve as small an amplitude value as possible of the fluctuations occurring in the current signal. Finding the ideal rotational speed can in principle be performed according to two scenarios:
scene 1: the required rotational frequency is subject to fixed requirements.
According to scenario 1, the rotation frequency may have only a certain value. This may have energy-related reasons or the purpose of use requires a certain (fixed) rotational speed. In this case, the pump operator defines a tolerance value in the pump controller, which the rotational frequency can deviate from a nominal value by a maximum, for example ± 3 Hz. The pump controller then varies the rotational speed within the allowed tolerance range and iteratively finds the rotational speed at which the vibration amplitude is minimal. Often, a small change here is already sufficient to move away from the natural frequency of the system and thus to minimize the occurring mechanical vibrations.
Scene 2: no special requirements for rotation frequency
If there is no process requirement for the rotation frequency, the pump controller can arbitrarily change the pump speed. This makes it possible to search for the anti-resonance in a targeted manner and to set the final operating speed of the pump to this anti-resonance. The simplest approach (and thus the approach with the lowest memory and process requirements) for determining a suitable rotational speed (anti-resonance) from the available rotational speed range is based on the dichotomy. Mathematical optimization methods such as "active set method" or "newton method" are faster and more efficient. The global optimum can also be reliably determined by means of genetic algorithms.
Alternatively or additionally to the motor current, the signal of the final pressure of the pump can also be checked, wherein similarly to the motor current, here too, the frequency spectrum is analyzed by means of a fast fourier transformation and evaluated as a function of the corresponding resonance frequency. The final pressure can be calculated, for example, with a pressure sensor of the pump or by means of an operating point estimation.
In order to improve the signal quality, the two signals (final pressure and motor current) can also be combined by means of sensor data fusion. The current and pressure signals can also be evaluated separately if this is not possible. For sensor fusion, the individual signal values can be evaluated, for example, as indicated above, and then combined by means of weighting. It is likewise conceivable to define frequency ranges in which the individual results of the individually evaluated signals are weighted differently. For example, the results of the evaluation of the motor current in the frequency range between 10Hz and 200Hz are used, while taking into account the results of the final pressure evaluation at higher frequencies.
A particular advantage of the method presented here is that the pump itself can find its natural frequency and therefore does not require a mathematical process model which would have to be developed in a complex way. The main application of the method described herein is to avoid or reduce vibrations in order to reduce wear and noise during operation of the pump. Furthermore, the method may however also contribute to wear and damage monitoring and warn the user when damaged.
Wear monitoring
In the method described, the frequency response of the internal pump is permanently monitored. However, as mentioned above, the frequency response depends on the pump construction, mounting location, material, and bearings. Thus, a change in the frequency response is in any case an indication that one or more of these variables have changed, for example due to wear. This information can then be used for wear monitoring, for example also in combination with the solution from DE102018200651, which is explicitly referred to herein. The combination of these two approaches enables a more accurate assessment of wear conditions.
Warning of damage
Unlike wear, which results in very slow changes in frequency response, pump damage will change the frequency response abruptly and dramatically. The damage may be a bearing or impeller fracture, among many other damages. Due to the rapid change in frequency response, the pump controller can reliably separate wear and damage and can output a warning to the operator in the event of damage.

Claims (12)

1. Method for avoiding or reducing mechanical vibrations of a pump, in particular a centrifugal pump, during operation of the pump, wherein a frequency converter and a pump controller are provided and the pump controller detects at least one signal of a pump operating parameter and checks the signal oscillations in order to recognize occurring mechanical vibrations of the pump and, in order to reduce the recognized vibrations, changes the pump rotational speed by means of the frequency converter.
2. The method of claim 1, wherein the spectrum of the detected signal is calculated by a fast fourier transform.
3. Method according to any of the preceding claims, characterized in that at least one of the examined signals corresponds to the motor current of the pump drive.
4. Method according to any one of the preceding claims, characterized in that at least one of the checked signals corresponds to a hydraulic final pressure of the pump, wherein the final pressure is preferably determined in a sensor manner by means of a pressure sensor and/or by estimating an operating point of the pump.
5. Method according to any of the preceding claims, characterized in that the method is iteratively carried out with a varying pump rotational speed in order to identify the pump rotational speed at which the amplitude of the mechanical vibrations recognized in the frequency-amplitude spectrum is minimal.
6. The method of claim 5, wherein the pump speed is varied within a definable tolerance range.
7. Method according to any of the preceding claims 1 to 5, characterized in that the method is performed iteratively at an arbitrarily varying rotational speed in order to identify at least one anti-resonance of a pump and to operate the pump in the anti-resonance.
8. Method according to one of claims 5 to 7, characterized in that the rotational speed is changed by an interval halving method and/or an optimization method, in particular by an active set method and/or a Newton method and/or by means of a genetic algorithm.
9. Method according to any of the preceding claims, characterized in that the frequency of the identified resonance is stored and the method is repeatedly carried out in order to recognize the frequency change of the identified resonance.
10. Method according to claim 9, characterized in that the pump is able to determine material wear of the pump and/or possible damage on the pump structure by means of the detected frequency change.
11. A pump device, preferably in the form of a centrifugal pump construction, particularly preferably a waste water pump or a solids pump or a supply pump, having a frequency converter and a pump controller which is configured to carry out the method according to any one of the preceding claims.
12. Use of a pump device according to claim 11 as a waste water pump or a solids pump or a supply pump.
CN202080029386.2A 2019-04-18 2020-04-14 Method for vibration avoidance in a pump Pending CN113646538A (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102019002826.0A DE102019002826A1 (en) 2019-04-18 2019-04-18 Process for avoiding vibrations in pumps
DE102019002826.0 2019-04-18
PCT/EP2020/060432 WO2020212330A1 (en) 2019-04-18 2020-04-14 Method for preventing vibration in pumps

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CN113646538A true CN113646538A (en) 2021-11-12

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US (1) US20220186749A1 (en)
EP (1) EP3956567A1 (en)
JP (1) JP2022529976A (en)
CN (1) CN113646538A (en)
BR (1) BR112021019522A2 (en)
DE (1) DE102019002826A1 (en)
WO (1) WO2020212330A1 (en)

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DE102021206777A1 (en) 2021-06-29 2022-12-29 Rolls-Royce Solutions GmbH Control device for controlling the operation of a turbomachine, turbomachine arrangement with such a control device, internal combustion engine with such a turbomachine arrangement, and method for operating a turbomachine

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JP2022529976A (en) 2022-06-27
EP3956567A1 (en) 2022-02-23
DE102019002826A1 (en) 2020-10-22
US20220186749A1 (en) 2022-06-16
WO2020212330A1 (en) 2020-10-22
BR112021019522A2 (en) 2021-12-07

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