KR102659356B1 - Anomaly diagnosis system of industrial boiler blower using vibration sensor - Google Patents

Abstract

The present invention relates to an abnormality diagnosis system for an industrial boiler blower using a vibration sensor, and more specifically, (a) when the vibration value of the blower changes due to a change in boiler load during boiler test operation, the amplitude according to the fluctuating vibration value and the amplitude thereof. Setting the slope value to the variation amplitude or reference slope value of the blower 20 for the corresponding load; (b) measuring vibration according to a change in the operating amount of the blower when the load changes during actual operation of the boiler; (c) transmitting the measured value in step (b) to a server, and the server generating an amplitude for each load of the boiler based on the transmitted measured value; (d) determining whether the change in amplitude due to vibration of the blower exceeds the reference slope value set in step (a); and (e) If the amplitude change measured in step (d) exceeds the standard slope value, after stopping operation of the boiler, the manager is notified of the abnormal condition of the blower, and the measured amplitude change is below the standard slope value. and setting the measured amplitude to the amplitude for the load, wherein a vibration sensor is attached to the blower and is configured to detect vibration of the blower.
That is, the present invention detects the vibration of the blower for each boiler load using a vibration sensor when commissioning the boiler, sets the amplitude of the blower vibration for each boiler load, and the slope value for this amplitude as the reference slope value for each boiler load, , A vibration sensor that detects changes in the vibration of the blower due to load changes during actual operation of the boiler in real time through a vibration sensor and compares the amplitude or slope value of the changed vibration with the reference slope value to diagnose whether the blower is in an abnormal state. We would like to propose a fault diagnosis system for industrial boiler blowers using .

Description

Anomaly diagnosis system of industrial boiler blower using vibration sensor}

In the present invention, when commissioning a boiler, the vibration of the blower for each boiler load is detected using a vibration sensor, and the amplitude of the blower vibration for each boiler load and the slope value for this amplitude are set as the reference slope value for each boiler load, During actual operation of the boiler, vibration changes in the blower due to load changes are detected in real time by a vibration sensor, and the amplitude or slope value of the changed vibration is compared with the reference slope value to diagnose whether the blower is in an abnormal state. This relates to an abnormality diagnosis system for used industrial boiler blowers.

Typically, in the case of industrial boilers, vibration is an important theme in stable operation and operation. Such vibration may be caused by external factors such as earthquakes, or may be caused by internal vibration that occurs when the boiler itself is operating.

Among such vibrations, the factor that generates self-vibration is vibration caused by the operation of the blower. The boiler's blower is a key part of the industrial boiler, and when it breaks down, the boiler must stop operating immediately, and repairs also take a lot of time and money.

Therefore, stable management of the blower is more important than anything else. Since these blowers are driven by large-capacity motors in industrial boilers, normal operation of the motor ensures normal operation of the blower.

In this case, the operating amount of the blower motor is determined according to the load of the boiler. For example, if the maximum operating amount of the motor is 100%, and the boiler load is 100, it operates at a specific value between 90 and 100%, and this specific value can be set during boiler test operation to suit the situation. In other words, the operating amount of the blower motor set according to the load of the boiler has a unique vibration, and if this vibration is identified in real time, stable boiler operation can be confirmed.

Therefore, the present invention detects the vibration of the blower according to the operating amount of the motor to diagnose the operating state of the blower, thereby enabling stable operation of the boiler.

Republic of Korea Patent Publication No. 10-2022-0067734 (May 25, 2022)

The present invention was devised to solve the problems described above,

When commissioning a boiler, the vibration of the blower for each boiler load is detected using a vibration sensor, the amplitude of the blower vibration for each boiler load, and the slope value for this amplitude are set as the standard slope value for each boiler load, and the actual operation of the boiler is set. One purpose is to detect changes in the vibration of the blower due to changes in load in real time using a vibration sensor and compare the amplitude or slope value of the changed vibration with the reference slope value to diagnose whether the blower is in an abnormal state.

The present invention not only allows for prior knowledge of blower failures or abnormalities by immediately notifying the manager when diagnosing an abnormality in the blower, but also facilitates inspection and enables immediate response in the event of a sudden abnormal situation such as an earthquake. Another purpose is to do this.

Another purpose of the present invention is to convert the vibration data of the blower accumulated in real time even in the normal state of the blower into data and continuously analyze it, so that if different vibration values are found at the same load and persist, this can be used for failure prediction and diagnosis. do.

The abnormality diagnosis system of an industrial boiler blower using a vibration sensor according to the present invention is (a) when the vibration value of the blower changes due to a change in boiler load during boiler test operation, the amplitude and slope value of the amplitude according to the fluctuating vibration value are distributed to the corresponding load. Setting the fluctuation amplitude or reference slope value of the blower 20 for each other; (b) measuring vibration according to a change in the operating amount of the blower when the load changes during actual operation of the boiler; (c) transmitting the measured value in step (b) to a server, and the server generating an amplitude for each load of the boiler based on the transmitted measured value; (d) determining whether the amplitude change due to vibration of the blower exceeds the reference slope value set in step (a); and (e) If the amplitude change measured in step (d) exceeds the standard slope value, after stopping operation of the boiler, the manager is notified of the abnormal condition of the blower, and the measured amplitude change is below the standard slope value. and setting the measured amplitude to the amplitude for the load, wherein a vibration sensor is attached to the blower and is configured to detect vibration of the blower.

In step (a) according to the present invention, the server stores the output value of the vibration sensor according to the load change of the boiler during test operation of the boiler, and determines the blower operation in the normal operating state based on the minimum and maximum values of the stored output value. It is characterized by setting the amplitude.

Through trial operation of the boiler according to the present invention, the amplitude according to the steady-state blower operation for all loads is set, and the slope value according to the average vibration change is set as the reference slope value based on the field vibration output value. do.

When setting the reference slope value according to the present invention, the vibration value measured by the vibration sensor in the load change section of the boiler is excluded.

During the actual operation of the boiler according to the present invention, the measured value of the vibration sensor is outside the set amplitude range, and the slope value of the corresponding amplitude outside the set amplitude range is calculated and the normal operation of the blower is diagnosed by comparing the reference slope value. It is characterized by:

The abnormality diagnosis system for industrial boiler blowers using a vibration sensor according to the present invention detects the vibration of the blower for each boiler load using a vibration sensor during test operation of the boiler, determines the amplitude of the blower vibration for each boiler load, and determines the amplitude of this amplitude. The slope value is set as the standard slope value for each boiler load, and the change in vibration of the blower due to load changes during actual operation of the boiler is detected in real time by a vibration sensor, and the amplitude or slope value of the changed vibration is compared with the standard slope value. You can diagnose whether the blower is in abnormal condition.

In addition, the present invention not only provides advance notice of blower failures or abnormalities by immediately notifying the manager when diagnosing an abnormality in the blower, but also facilitates inspection, and provides immediate and rapid response in the event of a sudden abnormal situation such as an earthquake. makes possible.

In addition, the present invention continuously analyzes the vibration data of the blower accumulated in real time even in the normal state of the blower, so that if different vibration values are found at the same load and persist, this can be used for failure prediction and diagnosis.

1 is a block diagram showing an abnormality diagnosis system for an industrial boiler blower using a vibration sensor according to the present invention;
Figure 2 is a conceptual diagram showing an abnormality diagnosis system for an industrial boiler blower according to the present invention;
Figure 3 is a photograph showing the mounting structure of the vibration sensor in the abnormality diagnosis system for the industrial boiler blower according to the present invention;
Figure 4 is a graph showing the setting of the reference slope value in the abnormality diagnosis system for the industrial boiler blower according to the present invention;
Figure 5 is a graph showing changes in the fluctuation amplitude and slope value of the pump at a specific load in the abnormality diagnosis system for the industrial boiler blower according to the present invention.

In order to explain the present invention, the operational advantages of the present invention, and the purpose achieved by practicing the present invention, preferred embodiments of the present invention will be exemplified and examined with reference to them.

First, the terms used in this application are only used to describe specific embodiments and are not intended to limit the present invention, and singular expressions may include plural expressions unless the context clearly indicates otherwise. In addition, in the present application, terms such as "comprise" or "have" are intended to designate the presence of features, numbers, steps, operations, components, parts, or combinations thereof described in the specification, but are not intended to indicate the presence of one or more other It should be understood that this does not exclude in advance the presence or addition of features, numbers, steps, operations, components, parts, or combinations thereof.

In describing the present invention, if it is determined that a detailed description of a related known configuration or function may obscure the gist of the present invention, the detailed description will be omitted.

As shown in Figures 1 to 3, the abnormality diagnosis system of the blower 20 of the industrial boiler 10 using the vibration sensor 30 according to the present invention detects changes in the vibration value of the blower 20 during test operation of the boiler 10. Based on the step (S100) of setting the reference slope value for the fluctuation amplitude of the blower 20 for each load of the boiler 10, and the vibration according to the change in the operation amount of the blower 20 when the load changes during actual operation of the boiler 10 (b) step (S200) to measure, (c) step (S300) to transmit the measured value to the server 60 and form the amplitude for each load of the boiler 10, and according to the vibration of the blower 20 It includes step (S400) to determine whether the amplitude change exceeds the reference slope value, and step (e) (S500) to take situational action according to the results of the judgment in step (d) (S400). .

First, in the case of the industrial boiler 10, vibration is an important theme in stable operation and operation. Such vibration may be caused by external factors such as earthquakes, and may also be caused by self-vibration that occurs when the boiler 10 itself is in operation.

Among such vibrations, the biggest factor causing self-vibration is the vibration caused by the blower 20. The blower 20 of the boiler 10 is a key part of the industrial boiler 10, and when it breaks down, the operation of the boiler 10 must be stopped immediately, and repairs also require a lot of time and money.

Therefore, stable management of the blower 20 is more important than anything else. Since this blower 20 is driven by a large capacity motor in the case of the industrial boiler 10, normal operation of the motor ensures normal operation of the blower 20.

In this case, the operating amount of the blower 20 motor is determined according to the load of the boiler 10. For example, if the maximum operating amount of the motor is 100%, if the load of the boiler (10) is 100, it is operated at a specific value between 90 and 100%, and this specific value can be set during test operation of the boiler (10) according to the situation. do. That is, the operating amount of the blower 20 motor set according to the load of the boiler 10 has a unique vibration, and when this vibration is detected in real time, stable operation of the boiler 10 can be confirmed.

Therefore, the present invention detects the vibration of the blower 20 according to the operating amount of the motor to diagnose the operating state of the blower 20, thereby enabling stable operation of the boiler 10.

The abnormality detection system for this purpose includes a boiler 10, a blower 20, and a vibration sensor 30 mounted on the blower 20. In addition, the vibration value detected by the vibration sensor 30 is transmitted to the server 60 through LAN or wireless communication 50 through the communication board 40 provided in the controller of the boiler 10. After the server 60 stores and analyzes the vibration data, it notifies the on-site manager 70 of the analysis results, and the on-site manager 70 takes on-site actions according to the notified analysis results.

Here, the server 60 not only stores the transmitted measurement value, that is, the vibration value, but also generates an amplitude corresponding to the vibration value using a data analysis program, which will be described in more detail below.

The abnormality diagnosis system configured in this way diagnoses the operating state of the blower 20 through a processor to be described later.

As shown in Figures 1 to 3, step (a) (S100) according to the present invention is a change in the vibration value of the blower 20 due to a change in the load of the boiler 10 during test operation of the boiler 10. This is a process of setting the amplitude and the slope value of the amplitude as the variation amplitude or reference slope value of the blower 20 for the corresponding load.

First, in order to detect the vibration of the blower 20, the present invention utilizes a vibration sensor 30. This vibration sensor 30 is mounted on the installation of the blower 20 to detect the vibration of the blower 20. It can be. For example, as shown in FIG. 3, whether the blower 20 is an attached type (see (a) of FIG. 3) or a free-standing type (see (b) of FIG. 3), the vibration of the blower 20 can be best detected according to the field situation. It is desirable to mount it in a location where it can be installed. For example, it is possible to mount it on an installation such as a support for the blower 20 motor.

The vibration sensor 30 installed in this way detects vibration occurring throughout the blower 20 as the motor of the blower 20 is driven when the boiler 10 is operated.

In particular, in step (a) (S100) according to the present invention, a reference slope value is set to diagnose the operating state of the blower 20, and this reference slope value can be set as follows.

First, during test operation of the boiler 10 before the actual operation of the boiler, the operation status of the boiler 10 is checked in advance by performing an operation for each load of the boiler 10. In the present invention, the vibration sensor 30 is used in this process. Thus, the vibration value of the blower 20 for all loads during boiler test operation is detected.

The vibration value of the blower 20 for each load detected in this way is transmitted to the server 60 through the communication board 40 and LAN or wireless communication 50. The server 60 stores the vibration value or output value of the blower 20, and simultaneously sets the reference slope value through a data analysis program.

That is, in the data analysis program, the amplitude for each load of the boiler 10 and the slope of the amplitude according to the change in the vibration value of the blower 20 are used to set the standard slope value for the fluctuation amplitude of the blower 20.

More specifically, the amplitude of the operation of the blower 20 in a normal operating state is set based on the minimum and maximum values of the output value of the blower 20 stored in the server 60.

Figure 4 shows an example of setting the amplitude range of the blower 20 with respect to the output value of the vibration sensor 30 when the load rate is 80% or 100%. That is, the interval between the red lines arranged up and down is the amplitude range of vibration according to the operation of the blower 20 in a normal state. The amplitude set in this way becomes a range between the maximum value (maximum amplitude) and the minimum value (minimum amplitude) among the output values of the vibration sensor 30. Here, the red line located at the top is the maximum amplitude, and the red line located at the bottom is the minimum amplitude.

In this way, when the amplitude of vibration according to the operation of the blower for each load is set, that is, the slope value according to the average vibration change is calculated based on the vibration output value in the field and set as the standard slope value.

The reference slope value set in this way is compared with the amplitude of vibration caused by the operation of the blower 20 and the slope value during actual operation of the boiler 10 to determine the operating state of the blower 20.

When setting the reference slope value according to the present invention, it is preferable that the vibration value measured by the vibration sensor 30 in the load change section of the boiler 10 is excluded. For example, in a section where the load factor changes from 80% to 100%, or conversely, in a section where the load rate changes from 100% to 80%, the measured vibration value may be unstable. In this case, the amplitude may also vary greatly, making it difficult to set an accurate reference value. Therefore, it is desirable to exclude the vibration value measured in the load variation section from setting the reference slope value.

Hereinafter, in step (a), that is, it is analyzed and determined whether the blower 20 operates normally during the actual operation of the boiler 10 based on the reference slope value set for all loads during the test operation of the boiler 10, and this analysis And the process of taking situational action according to the judgment result is carried out.

As shown in FIGS. 1 to 3, step (b) (S200) according to the present invention is a process of measuring vibration according to a change in the operating amount of the blower 20 when the load changes during actual operation of the boiler 10. .

That is, if the load of the boiler 10 changes during actual operation of the boiler 10, the operating amount of the blower 20 also changes, so the vibration sensor 30 detects vibration due to the change in the operating amount of the blower 20, The detected vibration value is transmitted to the server 60.

As shown in Figures 1 to 3, in step (c) (S300) according to the present invention, the measurement value in step (b) (S200) is transmitted to the server 60, and the server 60 transmits the transmitted measurement This is a process of generating amplitude for each load of the boiler 10 based on the value.

That is, in step (c) (S300), when the vibration value measured by the vibration sensor 30 is transmitted to the server 60 through the communication board 40 along with the operation data of the boiler 10, the server 60 Based on the transmitted measured values, that is, vibration data, the amplitude for each load is formed by a data analysis program. That is, as shown in FIG. 5, the amplitude for the corresponding load is formed during actual operation of the boiler 10.

In this way, the vibration sensor 30 measures the vibration value in real time according to the load change during the actual operation of the boiler 10, and the server 60 stores this value and calculates the amplitude for the corresponding load in real time by a data analysis program. is created.

As shown in Figures 1 to 3, step (d) (S400) according to the present invention determines whether the amplitude change due to vibration of the blower 20 exceeds the reference slope value set in step (a) (S100). It is a judgment process.

That is, step (d) (S400) determines whether the amplitude set for the corresponding load formed in step (c) (S300) is located within the set amplitude range during normal operation, that is, between the upper and lower red lines in FIG. 5. Here, if a specific amplitude is outside the amplitude range during normal operation, the slope value of that amplitude is calculated. If the slope value calculated in this way is higher than the standard slope value compared to the standard slope value, it is judged to be an abnormality of the blower 20, and if the calculated slope value is the same as or lower than the standard slope value, the blower 20 is operated normally. You will judge.

That is, Figure 5 is an example showing the amplitude of the blower 20 at a specific load. As shown in (a) of Figure 5, the amplitude range set for the load is outside the range, and the slope value of the amplitude outside this range is raised upward to the standard. If it is higher than the slope value, it is judged that the blower 20 is malfunctioning. Here, when the standard slope value is set to 0.5, the slope value of the amplitude outside the amplitude range exceeds 0.5.

In addition, as shown in (b) of FIG. 5, if the amplitude range set for the load is outside the range and the slope value of the amplitude outside this range is lowered and is lower than or equal to the reference slope value, the blower 20 is considered to be operating normally. You will judge. Here, when the reference slope value is set to 0.5, the slope value of the amplitude outside the amplitude range is equal to or smaller than 0.5.

In this way, when it is determined whether the blower 20 is in a normal state at the corresponding load, a situational action according to the determination result is taken in the process of step (e) (S500).

1 to 3, in step (e) (S500) according to the present invention, when the slope value of the amplitude change measured in step (d) (S400) exceeds the reference slope value, the boiler 10 After stopping operation, the abnormal state of the blower 20 is notified to the manager 70, and if the slope value of the measured amplitude change is less than the standard slope value, the measured amplitude is set as the amplitude for the load.

That is, in step (e) (S500), as shown in (a) of FIG. 5, when the slope value of the amplitude change at the corresponding load exceeds the reference slope value, the operation of the boiler 10 is stopped, and then the blower 20 The server notifies the manager 70 of the abnormal condition. When such a failure diagnosis is notified, the manager 70 inspects the blower 20 and takes corresponding measures according to the inspection results.

On the other hand, as shown in (b) of FIG. 5, when the slope value of the amplitude change at the corresponding load is equal to or lower than the reference slope value, the blower 20 is in normal operation and the boiler 10 continues to operate. In addition, the measured amplitude is set as the amplitude for the corresponding load. In this way, when the amplitude set for each load is databased, it becomes possible to continuously analyze the stored vibration data in real time and use the analysis results as data to determine whether the blower 20 is operating normally. In other words, if different vibration values are found and persist at the same load, it can be used to diagnose and predict failure of the blower 20 based on the analysis results as described above.

As such, the present invention has been described with reference to an embodiment shown in the drawings, but this is merely illustrative, and various modifications and other equivalent embodiments can be made by those skilled in the art. You will understand.

Therefore, the true technical protection scope of the present invention should be determined by the technical spirit of the attached claims.

10: Boiler
20: blower
30: Vibration sensor
40: Communication board
50: wireless communication
60: server
70: Administrator

Claims (5)

(a) During the test operation of the boiler 10, when the vibration value of the blower 20 changes due to a change in the load of the boiler 10, the amplitude and the slope value of the amplitude according to the fluctuating vibration value are changed to those of the blower 20 for the corresponding load. Setting the variation amplitude or reference slope value (S100);
(b) measuring vibration according to a change in the operating amount of the blower 20 when the load changes during actual operation of the boiler 10 (S200);
(c) transmitting the measured value in step (b) (S200) to the server 60, and the server 60 generates an amplitude for each load of the boiler 10 based on the transmitted measured value (S300) );
(d) determining whether the slope value of the amplitude change due to vibration of the blower 20 exceeds the reference slope value set in step (a) (S100) (S400); and
(e) If the slope value of the amplitude change measured in step (d) (S400) exceeds the reference slope value, after stopping operation of the boiler 10, the abnormal state of the blower 20 is reported to the manager 70. Notifying to and, if the slope value of the measured amplitude change is less than or equal to the reference slope value, setting the measured amplitude as the amplitude for the corresponding load (S500);
An abnormality diagnosis system for an industrial boiler blower using a vibration sensor, characterized in that a vibration sensor 30 is attached to the blower 20 and is configured to detect vibration of the blower 20.
According to claim 1,
In step (a) (S100), the server 60 stores the output value of the vibration sensor 30 according to the load change of the boiler 10 during test operation of the boiler 10, and stores the minimum and maximum values of the stored output values. An abnormality diagnosis system for an industrial boiler blower using a vibration sensor, which sets the amplitude of the operation of the blower (20) in a normal operating state based on the value.
According to claim 2,
Through trial operation of the boiler 10, the amplitude according to the operation of the blower 20 in a steady state for all loads is set, and the slope value according to the average vibration change is set as the reference slope value based on the field vibration output value. An abnormality diagnosis system for industrial boiler blowers using a characteristic vibration sensor.
According to claim 3,
When setting the reference slope value, the vibration value measured by the vibration sensor 30 in the load change section of the boiler 10 is excluded. An abnormality diagnosis system for an industrial boiler blower using a vibration sensor.
According to claim 4,
During the actual operation of the boiler 10, the measured value of the vibration sensor 30 is outside the set amplitude range, and the slope value of the corresponding amplitude outside the set amplitude range is calculated and compared with the reference slope value to control the blower 20. An abnormality diagnosis system for industrial boiler blowers using a vibration sensor, which is characterized by diagnosing normal operation.