CN114088192B - Vibration monitoring protection system and method, storage medium - Google Patents
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Abstract
The invention provides a vibration monitoring protection system, a vibration monitoring protection method and a storage medium, wherein the system comprises an inertia measurement device, a processor, a wireless communication device and a wireless communication device, wherein the inertia measurement device is arranged on an object to be monitored and used for detecting axial vibration parameters of three dimensions of space of the object to be monitored, the processor is electrically connected with the inertia measurement device and used for receiving the axial vibration parameters, performing minimum noise filtering on the axial vibration parameters, calibrating the axial vibration parameters after filtering, expanding the axial vibration parameters after the calibration, acquiring different data of a set group from the expanded axial vibration parameters, performing standard value analysis, gaussian distribution establishment and corresponding logic control algorithm on at least the acquired data, creating a relevant threshold value based on the logic control algorithm, generating alarm or prompt information based on the relevant threshold value, and receiving and outputting the alarm or prompt information of the processor. The invention has more accurate data acquisition and alarm output, and reduces the occurrence probability of accidents.
Description
Technical Field
The present invention relates to system monitoring and protecting technologies, and in particular, to a vibration monitoring and protecting system, a vibration monitoring and protecting method, and a storage medium.
Background
At present, with the continuous development of industries related to steam, oil and heavy metals, related safety accidents are also increased gradually, and a plurality of explosion events of chemical plants occur in recent years. From the point of view of the survey data, the actual cause of these explosions is currently not determined. However, it is well known that explosion events tend to cause death of a large number of people and damage to the infrastructure. Studies have shown that most of these events occur in devices with many rotating or rotating reciprocating machines and legacy infrastructure that plumbing liquids. Thus, an explosion may be caused by a chemical plant leaking explosive gas during normal transportation of the explosive gas/liquid pipeline. Based on research on the cause of accidents, many industries have attempted to find a solution for detecting chemical leaks using explosive gas testers or test strips, or gas detection business cards or so-called artificial noses. These methods detect the percentage of explosive leakage liquid or gas so that maintenance personnel can trace the leakage area to find a leak point to avoid a possible explosion event. However, the above detection means requires leakage of gas to a certain concentration, and for an object to be monitored placed in an open environment, it is likely that an accident has occurred before the detection parameters do not reach the alarm condition.
Disclosure of Invention
The invention provides a vibration monitoring protection system, a vibration monitoring protection method and a storage medium, which are used for at least solving the technical problems in the prior art.
In one aspect, the present invention provides a vibration monitoring protection system comprising:
The inertial measurement device without natural drift is arranged on the object to be monitored and is used for detecting the axial vibration parameters of the three dimensions of the space of the object to be monitored;
the processor is electrically connected with the inertia measurement equipment and is used for receiving the axial vibration parameters, performing minimized noise filtration on the axial vibration parameters, calibrating the axial vibration parameters after filtration and expanding the axial vibration parameters after calibration; acquiring different data of a set group from the expanded axial vibration parameters, at least carrying out standard value analysis, gaussian distribution establishment and corresponding logic control algorithm on the acquired data, establishing a relevant threshold value based on the logic control algorithm, and generating alarm or prompt information based on the relevant threshold value;
The wireless communication device comprises at least one prompt information output unit, at least one light source and a wireless/network communication unit, wherein the wireless communication device is used for receiving alarm or prompt information of a processor and activating the at least one prompt information output unit and/or the at least one light source at least partially based on the alarm or prompt information, and providing a remote maintenance reference strategy for maintenance personnel.
Optionally, the inertial measurement device comprises three axial accelerometers and three axial gyroscopes, wherein the three axial accelerometers and the three axial gyroscopes are arranged on the object to be monitored and are used for measuring the axial acceleration, the angular velocity and the angle of the three dimensions;
The processor is also provided with a high-pass filter, a least square discrete optimization filter and a low-pass filter, which are used for carrying out high-pass and low-pass filtering on the axial vibration parameters and carrying out least square optimization.
Optionally, the axial vibration parameters comprise at least one of acceleration, angular velocity and angle;
The processor is further used for determining offset between two axes of other dimensions of the inertial measurement device and the set coordinate axis based on the set coordinate axis, automatically centralizing acceleration parameters measured by the inertial measurement device on a natural force line, and enabling acceleration values of X, Y axes in three axial directions to be close to 0, acceleration values of Z axes to be close to-9.8 and angular speed and angle to be close to 0 under the static condition of the inertial measurement device.
Optionally, the processor is further configured to:
Calculating at least one of three-dimensional axial stress, speed, momentum and kinetic energy based on acceleration parameters measured by the inertial measurement equipment after measurement parameter calibration, and determining an alarm threshold corresponding to the calculated parameters;
And comparing at least one of acceleration, accumulated speed, stress and accumulated energy with a corresponding alarm threshold value, and determining whether the vibration response of the object to be monitored in the operation time period needs to be alarmed or not, and carrying out remote alarm through the wireless communication equipment when the vibration response needs to be alarmed.
Optionally, the processor is further configured to:
And determining a normal distribution function for at least one of acceleration, stress, speed, momentum, kinetic energy and moment of a coordinate axis measured by the inertial measurement device after parameter calibration, determining a normal distribution coefficient of at least one of acceleration, stress, speed, momentum, kinetic energy and moment of the coordinate axis based on the normal distribution function, and determining whether vibration response of the object to be monitored in the operation time period needs to be alarmed or not based on the normal distribution coefficient, and remotely alarming through the wireless communication device when the vibration response needs to be alarmed.
Optionally, the measurement parameters further include a transverse inclination angle, a pitch angle, a roll angle of the object to be monitored in a three-dimensional coordinate system, and an angular velocity and an angle of the AHRS without natural drift based on the axial vibration parameters measured by the inertial measurement device;
The processor is further configured to determine whether an alarm is required for a vibration response in an operation time period of the object to be monitored, or not, based on at least one of the pitch angle and the roll angle, or at least one of the pitch angle and the roll angle, and at least one of acceleration, stress, speed, momentum, kinetic energy, and moment of a coordinate axis, and a corresponding alarm threshold, and remotely alarm through the wireless communication device when required.
Optionally, the object to be monitored includes at least one of a pump, a generator, a ship engine, a rotating machine;
The inertial measurement device is arranged at the top of an installation room of the object to be monitored, or the root area of the object to be monitored, or a pipeline of the object to be monitored, or a tank body connected with the object to be monitored.
In another aspect, the present invention provides a vibration monitoring protection method, including:
Acquiring axial vibration parameters of three dimensions of a space measured by an inertial measurement device arranged on an object to be monitored;
Acquiring different data of a set group from the expanded axial vibration parameters, at least carrying out standard value analysis, gaussian distribution establishment and corresponding logic control algorithm on the acquired data, establishing a relevant threshold value based on the logic control algorithm, and generating alarm or prompt information based on the relevant threshold value;
triggering the wireless communication equipment to output alarm or prompt information to the user equipment to remind the maintenance of the object to be monitored.
Optionally, the method further comprises:
Determining the offset between two axes of other dimensions of the inertial measurement device and the set coordinate axis based on the set coordinate axis, automatically focusing the acceleration parameters measured by the inertial measurement device onto a natural force line, wherein the acceleration value of X, Y axes in three axial directions is close to 0, the acceleration value of the Z axis is close to-9.8, the angular velocity and the angle are both close to 0 under the static condition of the inertial measurement device, and
Calculating at least one of three-dimensional axial stress, speed, momentum and kinetic energy based on acceleration parameters measured by the inertial measurement equipment after measurement parameter calibration, and determining an alarm threshold corresponding to the calculated parameters;
And comparing at least one of acceleration, accumulated speed, stress and accumulated energy with a corresponding alarm threshold value, determining whether the vibration response of the object to be monitored in the operation time period needs to be alarmed, and carrying out remote alarm through the wireless communication/network equipment when the vibration response needs to be alarmed.
In a further aspect the invention provides a computer readable storage medium having stored therein a computer program which when executed by a processor implements the steps of the vibration monitoring protection method.
The invention collects the vibration related parameters of the rotating object to be monitored, carries out noise filtration on the collected parameters, carries out calibration, expansion and the like based on the filtered related parameters, so that the detection parameters are more accurate and noiseless, and the judgment result generated by carrying out standard value analysis, gaussian distribution establishment and corresponding logic control algorithm processing on the processed data is more accurate and reliable, thereby providing accurate alarm information for the object to be monitored, carrying out related fault alarm in advance, further effectively avoiding the occurrence of explosion accidents in the industries of steam, oil and heavy metals and improving the operation safety of factories and mines.
Drawings
FIG. 1 is a schematic diagram showing the constitution of a vibration monitoring protection system according to an embodiment of the present invention;
FIG. 2 shows a data processing schematic of a processor according to an embodiment of the invention;
FIG. 3 shows a schematic diagram of a logic control algorithm of an embodiment of the present invention;
FIG. 4 shows a schematic representation of Gaussian standard values for an embodiment of the invention;
FIG. 5 is a schematic diagram of alarm information output logic according to an embodiment of the present invention;
Fig. 6 shows a flow chart of a vibration monitoring protection method according to an embodiment of the invention.
Detailed Description
In order to make the objects, features and advantages of the present invention more comprehensible, the technical solutions according to the embodiments of the present invention will be clearly described in the following with reference to the accompanying drawings, and it is obvious that the described embodiments are only some embodiments of the present invention, not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Fig. 1 is a schematic diagram showing a composition structure of a vibration monitoring protection system according to an embodiment of the present invention, and as shown in fig. 1, the vibration monitoring protection system according to an embodiment of the present invention includes:
the inertial measurement device is arranged on an object to be monitored and used for detecting axial vibration parameters of three dimensions of space of the object to be monitored, wherein the object to be monitored comprises at least one of a pump, a generator, a ship engine and a rotary machine. In the embodiment of the invention, the inertial measurement device comprises three axial accelerometers and three axial gyroscopes of a three-dimensional axial accelerometer or a navigation attitude reference system AHRS sensor which are arranged on an object to be monitored, and the three axial accelerometers and the three axial gyroscopes are used for measuring the three-dimensional axial acceleration and the related transverse inclination angle, pitch angle, side inclination angle, angular velocity and angle thereof so as to determine the parameters and the related influence of the parameters on the object to be monitored.
As shown in fig. 1, in the embodiment of the present invention, monitoring may be performed for a plurality of objects to be monitored, so long as corresponding inertial measurement devices are installed on the devices to be monitored, and each inertial measurement device is connected to each other through a processor. The inertial measurement device can report the detected relevant inertial parameters through the Internet of things mode, and the processor receives the relevant inertial parameters and analyzes the relevant inertial parameters to determine whether the object to be monitored needs to give an alarm to the background or not, so as to remind maintenance personnel of carrying out necessary maintenance on the object to be monitored.
In embodiments of the present invention, a machine vibration monitoring and active protection system (MVMPPS, machine Vibration Monitoring and Proactive Protection System) is used to monitor and protect a machine to be monitored, where the machine to be monitored and protected may be a pump, a generator, a reciprocator, any rotating machine and associated equipment such as a wind turbine, etc.
The processor is electrically connected with the inertial measurement equipment and is used for receiving the axial vibration parameters, carrying out minimized noise filtration on the axial vibration parameters, calibrating the axial vibration parameters after filtration, expanding the axial vibration parameters after calibration, acquiring different data of a set group from the axial vibration parameters after expansion, carrying out standard value analysis, gaussian distribution establishment and corresponding logic control algorithm on the acquired data at least, creating a relevant threshold value based on the logic control algorithm, and generating alarm or prompt information based on the relevant threshold value. In an embodiment of the invention, the processor may be constituted by at least one micro control unit (Micro Control Unit, MCU).
The wireless communication device comprises at least one prompt information output unit, at least one light source and a wireless communication unit, wherein the wireless communication unit is used for receiving alarm or prompt information of a processor and activating the at least one prompt information output unit and/or the at least one light source at least partially based on the alarm or prompt information, and providing a remote maintenance reference strategy for maintenance personnel. In the embodiment of the invention, the line communication equipment comprises 3G, 4G, 5G communication equipment, or Internet of things communication equipment and the like.
In an embodiment of the present invention, MVMPPS of inertial measurement units may be mounted on a centrifugal pump with a conduit. As an example, MVMPPS may also be mounted on the roof of the pump-mounted room for detecting object accelerometer responses on X, Y, Z axis in a coordinate system, such as forward/backward = ±x, left/right lateral = ±y, and up/down = ±z. Note that MVMPPS may also be installed on any part of the pump system, such as the root area, piping, and tanks of the pump system, as long as the assembly or device or subsystem is most sensitive to vibration response or is most safe. MVMPPS of embodiments of the present invention may be mounted to a sloped surface of a pump system. Since embodiments of the present invention can automatically recalibrate MVMPPS to zero all three-dimensional accelerometers, and other angles and angular rates are also zero, the force, energy, and momentum of the inertial measurement device can be initialized from a neutral point (zero). Therefore, the influence of the deviation of the uneven slope and temperature and the random noise can be minimized.
In embodiments of the present invention, the rotating machine may typically make the machine loud before failure, and in particular, the machine may cause cracking or fatigue of the connection area or fluid leakage before the rotating machine is damaged. Therefore, MVMPPS is not limited by the machine itself. Can be installed at joint parts such as pipelines and the like which generate vibration motion due to machine rotation.
Fig. 2 shows a data processing schematic diagram of a processor according to an embodiment of the present invention, and as shown in fig. 2, a processing unit (MCU) control sequence according to an embodiment of the present invention includes three operation steps, namely, a data operation, a logic control algorithm, and a switch logic arrangement. The MCU obtains three axial parameters measured by the inertial measurement device through the inertial measurement device, for example, three inertial measurement devices such as an accelerometer, an angle and an angular rate are respectively arranged in three axial directions, or an AHRS sensor is directly arranged to perform three axial acceleration measurements, the angle and the angular rate are respectively measured, so that three axial acceleration, angle and angular rate measurements are realized, and the inertial measurement device can also be called an (x, y, z) accelerometer, an angle and an angular rate.
In the embodiment of the invention, the AHRS or the three accelerometers are installed, and the directions are not required to be arranged according to the earth coordinates when the angles and the angular velocities are measured. Any direction associated with the coordinates of the rotating body may be set.
The measured microelectromechanical System (MEMS) data is very noisy and may change over time and temperature due to its natural characteristics from the MEMS materials and design before the accelerometer data measured by the inertial measurement device enters the MCU for operation and computation. These data are referred to as raw data with deviations and drifts on a single axis. If these data are incorrectly processed and manipulated, they are difficult to use to accurately predict machine vibration responses.
In addition, almost all acceleration sensors are pre-stressed in the MEMS mechanical design. The accelerometer sensor measurements do not return to zero even after all noise is removed and without any prestressing. The preset value of the accelerometer sensor will conduct from one sensor to the other, resulting in a serious deviation of the measurement results. The preset value of the accelerometer sensor is not fixed and may vary from + -0.1 m/s 2 or up to + -0.3 m/s 2. Since the variation of the preset values on all three axes is not small, this may be the root cause of failure in vibration monitoring using raw data. Currently, there is a method for building three axial acceleration motion models using a single axial accelerometer vibration monitoring function, which obviously does not eliminate the problem of mutually perpendicular coordinate axes. They simply move the vertical problem from the MEMS side to the processor side.
In practice, it is very difficult to manufacture a tri-axial MEMS sensor with each axis perfectly perpendicular to each other. Typically, the axial coupling value varies between 3% and 17%. These couplings will later lose accuracy in the final measurement. And the loss of accuracy may be random, without any pattern being found. Therefore, the embodiment of the invention considers all the factors and successfully eliminates the obstacles by using an MCU on-line control algorithm. Thus, as shown in FIG. 2, once the accelerometer data enters the MCU side, the MCU will perform a number of algorithms on the data to ensure the accuracy and usefulness of the data. The main algorithm comprises three parts, namely data operation, logic control algorithm and switching logic arrangement.
The data manipulation is a manipulation of the triaxial acceleration measurements so that various types of manipulation data can be converted and generated for the control logic to properly estimate the vibration threshold. The alarm threshold may then be a dynamic change with respect to mass, size, rotational frequency, associated connection items, etc. of the various machines. The data operation consists of three parts.
When raw data enters the MCU, it must be filtered to minimize noise and interference during normal operation of the sensor.
In the embodiment of the invention, the minimum noise filtering is firstly carried out on the acquired data, and the minimum noise filtering is realized by three basic filters, namely a high-pass filter, a least square discrete optimization filter and a low-pass filter. While a three-filter design is employed to achieve minimal noise cancellation, any filters may be added or removed as needed to achieve a filter design that is best suited for the filter design, thereby reducing accelerometer MEMS noise effects. The reason for using a discrete least squares filter design is to introduce its advanced time-varying calculations and newton's deepest search algorithm that has been demonstrated to remove up to 75% of the operating white random noise without losing the rapidity of the sensor response, which is primarily the least squares criterion value for optimizing noise error. The low pass filter is a combined design that can be used for various machine speed requirements. For example, if the operating system requires a low response speed, a low pass may be introduced to counteract more of the noise effects. In return, it will reduce the response bandwidth of the data output system.
In the embodiment of the invention, after the data is filtered, the data is calibrated, centered and zeroed, so as to enhance the design and integration of the whole system.
The data alignment consists of two parts, as shown in fig. 2. The first is calibration, and the second is automatic centering/zeroing of data. During the design phase, data calibration values and centering values are preserved and added in real-time testing. Embodiments of the present invention preserve multiple sets of data for calibration and centering. The values of the calibration data are stored, which is known as a dynamic memory balancing method. Dynamic memory trim is to apply the c-code (pointer) method to various parameters and use the pointer to store in flash memory. If these trim values are undefined, then the default value for these values will be zero. The main purpose of data calibration is to output the output data to the required machine position area and to concentrate the output data to the required values in order to remove all the deviations and offsets of the MEMS data. By data calibration, the machine alarm system will not have any offset or deviation, and therefore inertial measurement without natural drift can improve MVMPPS accuracy.
Data calibration and centering/zeroing is by reading the sensor data to check its calibration offset. And controls and automatically enters the offset data, adjusts the gain parameters, and verifies the final trigger point of the alarm. After ensuring that the data is concentrated to the desired value, the data must be expanded to further reduce the offset and bias effects on the control logic. Instead of using a pure accelerometer to predict machine vibration levels.
In the embodiment of the invention, a three-dimensional calibration accelerometer is used for acquiring data. In order for the (X, Y, Z) accelerometer to be properly and reasonably applied to MVMPPS throughout the testing and monitoring process, the data must be corrected centrally using an autonomous matrix calculation method after the acceleration data of the AHRS or accelerometer sensor is filtered. One of the key targets of the autonomous matrix calculation method is to automatically concentrate the acceleration values of the accelerometer on its natural force lines. For example, under static conditions (accelerometer sensor not stressed), the three axial acceleration values should be close (A x～0,Ay～0,Az to-9.8), where A x is X axial acceleration, A y is Y axial acceleration, and A z is Z axial acceleration. The second key objective of the autonomous matrix calculation method is to find the offset of the sensor from each axis to the other two axes based on detecting whether the axes of the sensor are perpendicular to each other. The key objective of the autonomous matrix calculation method is to combine matrix calculation with the perpendicular deviation angles of the two axes, so as to calculate the offset of each angle. Once these angles off perpendicular are found, the three axial accelerometers (X, Y, Z) can be calibrated back to their natural force lines, i.e. the mass of the object is fixed (f=ma).
After the three automatic calibration and automatic centering methods are completed, the angles and the angular rates of the three axial directions deviating from the vertical angle can be found to be centered and zeroed. All of these calculations can be done automatically using a software matrix angular transformation matrix.
Thus, the three-dimensional accelerometer can be calibrated to approximate the formula magnitude
Where (abs) is defined as the absolute value of the subject item.
According to the embodiment of the invention, acceleration data acquired by the (X, Y, Z) axes of the accelerometer on the pump can be calibrated to the accuracy below the formula (1).
Furthermore, the angular rate and angle of the three vertical accelerometers are centered and zeroed.
Thus, to achieve this accuracy performance, first, the accelerometer must be automatically calibrated and centered.
In the embodiment of the invention, the three-dimensional calibration speed on the time T can be accumulated. In particular, in order for the accelerometer to be sufficiently accurate, the natural drift of the accelerometer must be less than 0.1m/s 2 per hour. After the correct three axial accelerometer calibration values are obtained, these values will be used to calculate the three axial speeds. The velocity will be obtained using the following formula, with a cycle time T:
where T may be the calculated time range (Δt), an operating time of a real-time operating system (RTOS) or one second, or any user-defined time.
It is assumed that the system does not have any yaw angle movement in the x-y plane. Only roll and pitch angles will affect the speed calculation. Thus, the angular change caused by these two angles can be formulated as follows:
Where (V x,Vy,Vz) is the speed calculated by the accelerometer and (V x M,Vy M,Vz M) is the new speed of the machine due to the change in ground level angle caused by the ground (roll angle phi, pitch angle theta) effect.
When roll and pitch angles are at or near zero, the matrix will be an identity matrix, with one on all matrix diagonal terms. Thus, if the AHRS angular velocity and angle without natural drift are used, the three axial velocities will not change. The non-diagonal terms of the matrix in equation (3) are all zero.
As the off-diagonal terms increase, the diagonal terms will decrease. This indicates that the ground has moved from (roll and pitch) directions. The larger the off-diagonal terms of the matrix in equation (3), the larger the angular displacement. However, the total matrix standard value will remain unchanged. This is a method of checking ground movement. The above summarizes the ground problems affecting the rotating machine.
Similarly, if the total standard value of (x, y, z) velocity increases from the accelerometer, the vibratory force affecting the level of the device to be monitored increases. Effects on these parallel displacement amplitudes.
In the embodiment of the invention, the three-dimensional force is also required to be determined based on the measurement parameters. Force is defined as the mass times the measurement of the accelerometer, as shown in the following equation:
the three-dimensional momentum refers to the momentum of three coordinate axes, which is:
three-dimensional kinetic energy refers to the kinetic energy of three coordinate axes, where energy is defined as the kinetic energy on a single axis, as follows:
In the present embodiment, the standard value is defined as the square root of all three axes. They are used to calculate the total accelerometer, force or velocity or kinematic energy as follows:
where x defines the forward/backward direction of MVMPPS, y is the right/left direction, and z is the down/up direction. Positive or negative values of these directions follow the right hand rule.
Knowing all of the above-described operational data will provide more internal information from the raw measurements, so many alarm-triggering thresholds for machine vibration limits can be designed and understood, rather than one from the accelerometer.
When the three-dimensional acceleration is calibrated to be almost zero from the previous step (F z -9.8-0), the estimation of the force and energy for a single axis will be able to accumulate from zero to some value. Thus, the overall value (of the pure accelerometer, the accumulated speed, the force and the accumulated energy) and the alarm threshold value of the individual value may be used to correctly determine the vibrational response over the machine's operational period to determine at least one of whether the equipment (machine) to be monitored is in a maintenance required state, whether the machine is in an armed state, whether the machine has reached a failure time, etc.
In the embodiment of the invention, the processing of the logic control algorithm is also needed based on the well-calibrated and centered data. In particular, after the logic control algorithm obtains the aforementioned distinct data from the data operations, these will be used to generate relevant software logic flows for the control algorithm to create relevant thresholds so that the various maintenance/attention/warning alarms can be properly triggered. To achieve these goals, the logic control algorithm is built by standard value analysis, gaussian distribution building and control algorithm.
FIG. 3 illustrates a schematic diagram of a logic control algorithm of an embodiment of the present invention, as shown in FIG. 3, where the standard values of acceleration, speed, force, torque, and energy may be considered as the total values of dynamic motion of the rotary machine under powered operation. Assuming acceleration, velocity, force, moment and kinematic energy without any additional force, moment and energy resources, these values will be fixed to their individual constants, such as C A、CV、CF、CM and C KE, respectively, where C is defined as the constant and subscript is its physical motion parameter. Under standard operation, the respective axial physical movements should be orthogonal in the (x, y, z) direction. Therefore, they should be independent of each other. Initially, no coupling occurs between (x, y) or (y, z) or (z, x). These physical movements may be referred to as gaussian distributions because they are independently distributed.
In the embodiment of the invention, gaussian normal distribution calculation is also needed for three axial acquired data. In particular, when the rotary machine and the related devices are rigid, permanently fixed, and unable to perform any movements, the machine should be in a normal operating condition, which one should not fail or fail once installed. However, the machine and its associated equipment may not be sufficiently rugged for overall system integration. Thus, possible intrusion forces, momentum or energy may come from eccentric revolutions of the rotary machine, forces and momentum of the rotary mechanical system and the connected flexible structure, loosening of set screws on the rotary machine, external forces or momentum due to maintenance required functions, changes in the liquid transport in the rotary machine, and water hammer effects due to air bubbles or vacuum on the liquid transport due to temperature changes.
All of which change force, momentum and total energy. If the above factors are small and normally distributed in a short time, the rotary machine may remain centered in normal operation. But if the external force and momentum have been invaded to a certain percentage of the total force or energy, the multiaxial vibration amplitude of the rotating machine will increase to resist the invaded force and momentum. In general, if the force, momentum and energy increments on the device are normally distributed, the rotating mechanical system can still maintain its function smoothly. However, if the forces, momentum and energy are not normally distributed, vibration of the rotating machine may produce damaging movements which may cause damage to the machine, or break the connection, or cause leakage of the transfer line to relieve pressure, etc. In the embodiment of the invention, the connection robustness of the rotating machinery losing the performance of the rotating machinery is different according to the time length of the external force, the momentum and the energy applied to the vibration motion. For smaller forces, momentum and energy, the rotating machine takes longer to lose its robustness. But if the force, momentum and energy exceed the machine vibration threshold, the rotating machine may be immediately damaged. Thus, methods based on various rotating machines (RM, rotating Machine) predicting the vibrator threshold must provide a correct vibration estimate from an accurate sensor in order for the trigger points on which the judgment is based to be close enough to provide a timely alert to get attention. Thus, the calculation of the normal distribution is used as a first step in calculating the distributed energy required to reach the threshold. However, if it is checked that the external force, momentum and energy are not normally distributed, the setting of the corresponding threshold values is also different.
In the embodiment of the invention, in order to check the normal distribution function, it is necessary to verify whether the (x, y, z) axes are independent of each other, define the (x-axis force or moment) as α, define the (y-axis force or moment) as β, and if α and β are independent, α and β are independent and (α+β) and (α - β) are independent, then a and β must both obey the normal distribution, where a and β are acceleration, velocity, force, momentum or energy.
From the above, it follows that a single axis is independent of (x, y, z), and that the (x, y, z) accelerometer and the velocity or force should be independent. Thus, these calibration variables of the above formula are employed to estimate the normal distribution calculation. The accelerometer can be described by the following formula:
wherein the (i, j, k) axis represents the (x, y, z) direction. (A) The standard values of (2) will be:
This will satisfy the initial condition calculation. Rearranging equation (1) into a matrix of standard values may generate the following equation:
Applying the space transformation matrix to equation a above, a matrix format of the form:
Wherein (phi, theta, phi) are the roll angle, pitch angle and yaw angle of the object to be monitored, respectively. If the fuselage and its associated equipment are rigid, all angles will remain at zero degrees, and if an AHRS angular velocity and angle without natural drift is used, it will not move due to vibratory motion, meaning (phi = 0 deg., theta = 0 deg., phi = 0 deg.). Thus, the transformation matrix is:
the standard value of T R will be an identity matrix. Thus, if the system is operating normally and the relevant detection parameters conform to a gaussian distribution, the standard values of all the aforementioned matrices will remain at their standard values.
For small displacement angles on (phi, theta, phi), the off-diagonal terms of T R will have some values. If these values are above some range, e.g., θ >10 °, the off-diagonal terms will not be small any more, because the angular variation can be considered to be caused by machine vibration using AHRS angular velocities and angles that do not naturally drift. This indicates that (x, y, z) is no longer independent. For this reason, vibration of the machine may be considered to cause the machine to exceed a desired threshold, at which point an alarm is generated and sent to maintenance personnel for attention.
The above case assumes that the standard values are at the same magnitude, but the increment of the off-diagonal term has exceeded the threshold. If external forces, moments, momentum, energy invade the rotating machine, the total standard value of the dynamic monitoring function will not be maintained. The reason for changing the entire standard value is that the diagonal terms are unchanged, the off-diagonal terms are changed, the off-diagonal terms are unchanged, or both the diagonal and off-diagonal terms are changed.
In the three possible cases described above, the total standard value will vary in the amplitude of its respective axis. Due to the influence of these external forces, the entire motion of a single axis will no longer be gaussian for the other axes. Thus, these features will be available for standard value analysis.
Standard value analysis it can be found from the gaussian distribution formula in the above-mentioned T R equation that due to the vibration effect of the rotating machine, the counter-propagation method of the aerodynamics motion can be used to track the maneuver of the rotating machine, i.e. the aerodynamics method is used to estimate the maneuver of the rotating machine. If the rotational maneuver exceeds a desired threshold, external disturbances to the RM may be considered to place the machine in a maintenance, caution or warning state.
In general, vibration effects can be attributed to faults or defects in certain parts of the rotary machine, changes in the pipeline conveying material characteristics of the rotary machine due to blockage or other reasons, loosening or loosening of a fixing screw caused by long service life of the rotary machine, overrun of fluctuation of rust parts of related devices of the rotary machine, loss of original position accuracy of the rotary machine due to structural flexibility influence, structure of the rotary fatigue machine, other influences such as environmental factors, temperature, humidity, loss of ground level, earthquake and the like.
In embodiments of the present invention, the rotating machine may utilize its vibration (force, momentum, and energy) changes beyond a limit to notify maintenance personnel. Vibration (force, momentum and energy) changes can be measured and compared from their original normal distribution of force, moment and energy from small changes or larger changes. Under the same operating conditions, this may indicate that the rotating machine has its associated hidden information, such as a condition requiring maintenance, attention to a condition that may require further inspection at a standstill, an alarm condition that must be handled immediately, or the machine may be damaged or an explosion event, depending on the change in vibration amplitude.
Thus, embodiments of the present invention employ all raw force, momentum and energy, and all calculated standard values of flight dynamics force and momentum spread to help determine the RM threshold. Fig. 4 shows a gaussian standard value diagram of an embodiment of the present invention, and as shown in fig. 4, since so many dynamic variables are used to perform vibration threshold calculation, the probability of erroneous judgment is small. The switch logic algorithm of the embodiment of the invention helps to correctly predict the trigger point.
The standard distribution of standard force, momentum and energy calculated from MVMPPS's AHRS sensor has been converted into six-dimensional aero-aerodynamic parameters. The reasons for transferring these (force, momentum and energy) are that the Rotating Machine (RM) works on a principle similar to an aircraft with more than 6 dimensions of dynamic motion, that all six angles of motion will be checked to help judge the vibration effect, that during steady state (static conditions on the ground) the RM should be 1mg (downward pressure) of ground support, and that if the rotating machine is firmly fixed on the ground and cannot move at all, the vibration forces and moments generated by the rotating machine initiating the rotating function can be regarded as white noise. With the greater vibration effect, small changes in lift/drag/lateral force and moment can be detected with the AHRS sensor. These minor changes are accumulated to see if they are growing/increasing. These variations may become uncontrollable, known as color noise. The effect of color noise on aerodynamic forces and moments of all three axes can then be monitored. These values may be very small, but they still continue to affect the fixed joint support of the RM. The six degrees of freedom of movement are monitored simultaneously for changes (acceleration, angular velocity and angle) rather than just three axial accelerometers. Thus, the rotary machine influenced by the parallel displacement, the angular force and the moment can be correctly calculated and accumulated. Furthermore, their incremental curves and changes can be obtained. Any parallel displacement force exceeding a certain value can be regarded as loosening of two or four joint supports. Any angular moment exceeding a certain value can be considered as loosening of one or three of the joint brackets. Once the translation, angular force and moment increment curves and changes reach the predefined and test values for the three levels, the alarm reporting system will trigger. These three ranking values of the alarm system are used to issue notifications (consultation, warning or warning messages) to the required crew members to devices using 3G/4G/5G/wifi/IoT. At the local rotary machine position, a buzzer alarm will be detected. The warning buzzer noise is not cancelled until either the crewmember is notified to press reset on the smartphone or MVMPPS on the rotating machine.
If the notified message is advisory, then maintenance records will be collected by cloud technology. IoT cloud technology will automatically dispatch maintenance teams to repair and maintain machines.
In the embodiment of the invention, for the analysis situation, the thresholds of the three possible triggering situations are discussed by utilizing the standard value of dynamic maneuver and the Gaussian distribution of five factors. More than three trigger conditions may occur in a system monitoring design, however, the desired approach is to estimate the possible conditions and classify them as best estimates of machine vibration thresholds using accelerometers and velocities. Thus, from the standard value analysis and gaussian distribution calculation, the following algorithm is generated for all variables to predict the active dynamic threshold.
In the embodiment of the invention, at least 11 trigger factors are used for alarming to determine whether a real trigger point exists. Since the threshold breakthrough operation will occur on the x, y, or z axes, and there are at least two variables per axis in 11 calculations. Due to the occurrence of a vibrating motor failure, it is estimated that at least two alarms of 11 factors will be triggered. This will be one of the key elements that helps determine whether or not a real vibration is occurring. Thus, in the default logic algorithm, 3 of 11 factors are triggered, and an alarm message will be used to determine whether an alarm is a maintenance requirement or a warning.
In an embodiment of the invention, when an alarm message is triggered, its associated value will be recorded and used to determine the importance level of the message based on machine vibration. Both the trigger value and the standard value added by the IC will be used as and gates to determine the importance level of the message. For any value that requires maintenance and is a warning message, the control algorithm determines it as requiring maintenance. For any message, one of which is an early warning message and the other of which is a warning message, the control algorithm will determine it as a warning message. In the embodiment of the invention, three out of 10 elements exceeding the limit are selected as trigger points, and the main reasons are that false alarm when a single message is used is avoided, trigger points are allowed to trigger when the trigger points are pressed, all 11 messages are avoided, calculation of standard values and initial IC values is used for ensuring that individual factors are indeed changed, and Gaussian normal distribution is used for ensuring that noise is not caused by the change of the characteristics of conveying materials.
Based on the logic, the fault false alarm condition can be avoided. Of course, 2, 4, 5, 6, etc. may be selected as points of the true decision logic, as shown in fig. 5, the sum of all alarm signal boolean values is added together and compared with (0,5,1.5,2.5,3.5,4.5,5.5, etc.). In the present case, the vibration alarm signal is true if the sum value is equal to or greater than 2.5. This means that the alarm will not be true unless more than three local signals are triggered. However, the more alert vibration elements selected for vibrating alert messages, the higher the GE trigger value is set, the more difficult it is to simultaneously initiate a true trigger condition. The conditions that trigger the vibration alarm will be very limited. The fewer factors selected, the easier the actual trigger condition can be detected. The logic of triggering the shock message is much easier. The trade-off may be determined from actual testing. But the following physical judgment is realized by using the reasons of three alarm elements, and when the two-axis vibration alarm element loses the Gaussian standard value distribution and is coupled, the system alarm is triggered. Typically, the vibration alert trigger points will pair, e.g., (x-force) and (x-momentum) typically trigger simultaneously due to their coupled behavior. (y force and y momentum) should be independent of the x-axis element. When coupled, triggered, and lost from normal distribution, the probability of a true trigger condition is much higher than in the traditional method of using only one element as the trigger point. Therefore, the current innovative design can avoid false triggering functions.
Once the true alert is determined, the vibration alert message will be processed in three levels, as shown in fig. 5. The RM software vibrates the alarm process to the point that the alarm system has been determined to be truly alarm. The alert messages sent to maintenance personnel and plant managers or higher level managers will depend on the basis that the remote control manager needs to know following the maintenance procedure. In the embodiment of the invention, the alarm message comprises three levels. Since the trigger value is offset from the original IC value and the standard value, the importance of the vibration alarm will depend on the offset of the trigger value from the original IC value and the standard value. For example, if the offset value is within ±10%, no message should be sent. But if the offset value is between 20% and 30% of its original value over several time ranges, a hint message will be sent. If the vibration alarm value reaches more than 250% of its original value, a warning message may appear. If the alarm value is between the alert and warning messages, an early warning message may occur. The reason for choosing 250% higher than its original value is to match the 2.5 times previously discussed in fig. 5. This value is arbitrary and can be modified according to the actual test results.
At MVMPPS, warning lights and buzzers are installed to notify the in-plant maintenance personnel locally when the RM vibration alarm is triggered. During normal operation (no alarm) the standard machine light will light up and the buzzer will be turned off. In the embodiment of the invention, the frequency and the amplitude of the sound of the lamp and the buzzer are different and can be used for vibrating the alarm logic switch. For example, if a message requiring maintenance (alert message) is triggered, the frequency will blink on/off least frequently, and the buzzer will sound and frequency least, which is called alert message.
In the embodiment of the invention, the remote message of the prompt message can be sent by using the Internet by using 4G/5G/Wi-Fi and/or Bluetooth so as to draw attention at a higher level. When the RM vibration alarm is switched to the pre-alarm information, the frequency will flash on/off more frequently for the attention of surrounding maintenance personnel. The network warning message will be sent to the coordinator. For a warning message, the buzzer and speaker will sound a sharp beep and flash at the fastest speed.
In the embodiment of the invention, the purpose of using 3G/4G/5G, wi-Fi or Bluetooth is to connect with the Internet, and the method can be used for sending an instant message to maintenance personnel or higher-level management personnel, sending data and resetting a trigger point with cloud computing communication, recording on-line trigger data for maintenance or insurance debate by using cloud storage, monitoring vibration conditions on line for remote control, automatically dispatching maintenance team to repair detected problems, recording reasons and repair of the problems and part change to automatically generate a maintenance record book;
The embodiment of the invention can be used for vibration monitoring/protection and alarm of new/old rotary machines, and the operation of the vibration monitoring/protection and alarm can use 3G/4G/5G or Wifi as a communication protocol using the Internet of things and cloud technology. Therefore, internet of things and cloud technology can help handle scheduling and recording events. The smart phone will alert the plant owner or maintenance manager or maintenance personnel to implement the autonomous function through smart phone remote control or local site notification. Embodiments of the present invention are capable of autonomous/seamless/intelligent monitoring/protection/alerting/reporting to a desired person or team. The process will also be recorded using cloud technology so that maintenance members can go directly to the desired event machine location for repair and/or maintenance. Furthermore, if all incident events can be designed to be automatically written into the cloud record with date and time and final processing status. Thus, an autonomous maintenance flow may be achieved.
Fig. 6 is a schematic flow chart of a vibration monitoring protection method according to an embodiment of the present invention, and as shown in fig. 6, the vibration monitoring protection method according to an embodiment of the present invention includes the following processing steps:
step 601, obtaining axial vibration parameters of three dimensions of a space measured by an inertial measurement device arranged on an object to be monitored.
In the embodiment of the invention, the inertial measurement device comprises three axial accelerometers and three axial gyroscopes, wherein the three axial accelerometers and the three axial gyroscopes are arranged on a three-dimensional axial accelerometer or a navigation attitude reference system AHRS sensor on an object to be monitored and are used for measuring the axial acceleration, the angular velocity and the angle of the three-dimensional axial accelerometer.
The object to be monitored comprises at least one of a pump, a generator, a marine engine, and a rotating machine.
Step 602, performing minimized noise filtering on the axial vibration parameters, calibrating the filtered axial vibration parameters, expanding the calibrated axial vibration parameters, acquiring different data of a set from the expanded axial vibration parameters, performing standard value analysis, gaussian distribution establishment and corresponding logic control algorithm on at least the acquired data, creating a relevant threshold based on the logic control algorithm, and generating alarm or prompt information based on the relevant threshold.
In the embodiment of the invention, the axial vibration parameters are subjected to high-pass and low-pass filtering, and least square optimization is performed.
And step 603, triggering the wireless communication equipment to output an alarm or prompt message to the user equipment to remind the maintenance of the object to be monitored.
Determining the offset between two axes of other dimensions of the inertial measurement device and the set coordinate axis based on the set coordinate axis, automatically focusing the acceleration parameters measured by the inertial measurement device onto a natural force line, wherein the acceleration value of X, Y axes in three axial directions is close to 0, the acceleration value of the Z axis is close to-9.8, the angular velocity and the angle are both close to 0 under the static condition of the inertial measurement device, and
Calculating at least one of three-dimensional axial stress, speed, momentum and kinetic energy based on acceleration parameters measured by the inertial measurement equipment after measurement parameter calibration, and determining an alarm threshold corresponding to the calculated parameters;
And comparing at least one of acceleration, accumulated speed, stress and accumulated energy with a corresponding alarm threshold value, and determining whether the vibration response of the object to be monitored in the operation time period needs to be alarmed or not, and carrying out remote alarm through the wireless communication equipment when the vibration response needs to be alarmed.
As an implementation manner, a normal distribution function is determined for at least one of acceleration, stress, speed, momentum, kinetic energy and moment of a coordinate axis measured by the inertial measurement device after measurement parameter calibration, a normal distribution coefficient of at least one of acceleration, stress, speed, momentum, kinetic energy and moment of a coordinate axis is determined based on the normal distribution function, whether vibration response in the operation time period of the object to be monitored needs to be alarmed or not is determined based on the normal distribution coefficient, and remote alarm is performed through the wireless communication device when needed.
Correspondingly, the embodiment of the invention also determines whether vibration response of the object to be monitored in the operation time period needs to be alarmed or not by the wireless communication device when needed based on at least one of the pitch angle, the roll angle or at least one of the pitch angle, the roll angle and at least one of acceleration, stress, speed, momentum, kinetic energy and moment of a coordinate axis and a corresponding alarm threshold value.
The vibration monitoring protection method according to the embodiment of the present invention may be understood with reference to the foregoing description of the vibration monitoring protection system, and specific processing procedures thereof will not be described herein.
In addition to the methods and apparatus described above, embodiments of the application may also be a computer program product comprising computer program instructions which, when executed by a processor, cause the processor to perform steps in a method according to various embodiments of the application described in the "exemplary methods" section of this specification.
The computer program product may write program code for performing operations of embodiments of the present application in any combination of one or more programming languages, including an object oriented programming language such as Java, C++ or the like and conventional procedural programming languages, such as the "C" programming language or similar programming languages. The program code may execute entirely on the user's computing device, partly on the user's device, as a stand-alone software package, partly on the user's computing device, partly on a remote computing device, or entirely on the remote computing device or server.
Furthermore, embodiments of the application may also be a computer-readable storage medium, having stored thereon computer program instructions, which when executed by a processor, cause the processor to perform steps in a method according to various embodiments of the application described in the "exemplary method" section of the description above.
The computer readable storage medium may employ any combination of one or more readable media. The readable medium may be a readable signal medium or a readable storage medium. The readable storage medium may include, for example, but is not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or a combination of any of the foregoing. More specific examples (a non-exhaustive list) of a readable storage medium include an electrical connection having one or more wires, a portable disk, a hard disk, a Random Access Memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing.
The basic principles of the present application have been described above in connection with specific embodiments, but it should be noted that the advantages, benefits, effects, etc. mentioned in the present application are merely examples and not intended to be limiting, and these advantages, benefits, effects, etc. are not to be construed as necessarily possessed by the various embodiments of the application. Furthermore, the specific details disclosed herein are for purposes of illustration and understanding only, and are not intended to be limiting, as the application is not necessarily limited to practice with the above described specific details.
The block diagrams of the devices, apparatuses, devices, systems referred to in the present application are only illustrative examples and are not intended to require or imply that the connections, arrangements, configurations must be made in the manner shown in the block diagrams. As will be appreciated by one of skill in the art, the devices, apparatuses, devices, systems may be connected, arranged, configured in any manner. Words such as "including," "comprising," "having," and the like are words of openness and mean "including but not limited to," and are used interchangeably therewith. The terms "or" and "as used herein refer to and are used interchangeably with the term" and/or "unless the context clearly indicates otherwise. The term "such as" as used herein refers to, and is used interchangeably with, the phrase "such as, but not limited to.
It is also noted that in the apparatus, devices and methods of the present application, the components or steps may be disassembled and/or assembled. Such decomposition and/or recombination should be considered as equivalent aspects of the present application.
The previous description of the disclosed aspects is provided to enable any person skilled in the art to make or use the present application. Various modifications to these aspects will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other aspects without departing from the scope of the application. Thus, the present application is not intended to be limited to the aspects shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
The foregoing description has been presented for purposes of illustration and description. Furthermore, this description is not intended to limit embodiments of the application to the form disclosed herein. Although a number of example aspects and embodiments have been discussed above, a person of ordinary skill in the art will recognize certain variations, modifications, alterations, additions, and subcombinations thereof.
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