A motor health status monitor

Abstract

The invention discloses a motor health status monitor, comprising a data acquisition unit, a data processing unit, a storage unit, a display unit and a transmission unit; the data acquisition unit comprises an integrated vibration and temperature sensor for measuring the vibration and bearing temperature of the motor; the data processing unit samples and processes the data collected by the data acquisition unit; the storage unit stores the total vibration value, vibration spectrum, envelope total value, envelope spectrum and bearing temperature processed by the data processing unit; the display unit displays the total vibration value, envelope total value and bearing temperature collected and processed; the transmission unit transmits the stored data to the outside world in a wireless manner, adopting automatic timing transmission or manual transmission. The invention can simultaneously monitor the vibration of the motor, the bearing temperature and the damage status of the bearing components, and comprehensively express the health status of the motor with multiple parameters.

Description

Technical Field

[0001] The present invention relates to the field of electric motors, and in particular to an electric motor health status monitor which expresses the health status of the electric motor by monitoring the vibration, bearing temperature and bearing component damage status of the electric motor. Background Art

[0002] The operating state parameters of the motor can be divided into two categories, one is the electrical state parameters, such as resistance, capacitance, current, voltage, power, power factor, etc., and the other is the mechanical state parameters, such as motor vibration, bearing temperature, bearing component damage state and other mechanical states. The former represents the functional index of the motor, and the latter represents the health index of the motor. The present invention relates to the monitoring of the health index of the motor.

[0003] At present, the monitoring of motor health indicators in enterprises can only rely on manual regular monitoring with handheld instruments to obtain data such as motor vibration, bearing temperature, and bearing component damage. This method is affected by many factors such as human factors, technical level, and measurement conditions. It often fails to reflect the health status of the motor in a timely and accurate manner, resulting in motor failures and accidents, which bring unnecessary losses to the company and even affect the company's normal production. Summary of the invention

[0004] The purpose of the present invention is to provide a motor health status monitor that can simultaneously monitor motor vibration, bearing temperature, and bearing component damage status, and comprehensively express the health status of the motor with multiple parameters.

[0005] In order to solve the above technical problems, the technical solution adopted by the present invention is:

[0006] A motor health status monitor comprises a data acquisition unit, a data processing unit, a storage unit, a display unit and a transmission unit;

[0007] The data acquisition unit includes an integrated vibration and temperature sensor for measuring the vibration and bearing temperature of the motor;

[0008] The data processing unit samples and processes the data collected by the data collection unit;

[0009] The storage unit stores the total vibration value, vibration spectrum, envelope total value, envelope spectrum and bearing temperature obtained by the data processing unit;

[0010] The display unit displays the total vibration value, total envelope value, and bearing temperature obtained through collection and processing;

[0011] The transmission unit transmits the stored data to the outside world wirelessly, using automatic timed transmission or manual transmission.

[0012] Furthermore, the data processing unit includes an amplification / filtering circuit, an A / D converter and a central processing unit. The signal output end of the vibration-temperature integrated sensor is connected to the signal input end of the amplification / filtering circuit, the signal output end of the amplification / filtering circuit is connected to the signal input end of the A / D converter, the signal output end of the A / D converter is connected to the signal input end of the central processing unit, and the signal output end of the central processing unit is connected to the signal input end of the display unit and the storage unit.

[0013] Furthermore, the central processing unit adopts two sampling frequencies of 2.56kHz and 25.6kHz for the vibration signal and a sampling frequency of 10Hz for the bearing temperature.

[0014] Preferably, the amplifier / filter circuit is of 4th order or 8th order.

[0015] Preferably, the A / D converter is 16-bit or 24-bit.

[0016] Preferably, the display unit is a liquid crystal display screen or a touch screen display screen.

[0017] Furthermore, the storage interval of the storage unit is set to 5min, 10min, 30min, 60min, 1h, 2h, 4h, 8h, 24h and custom time intervals to store data for more than one year, and the storage capacity of the storage unit is 8GB and above.

[0018] Furthermore, the display unit uses green, yellow and red lights to indicate whether the vibration, bearing temperature and bearing component damage status exceed the standard. The green light indicates normal, the yellow light indicates warning, and the red light indicates alarm. The status of the motor parameters is displayed in numbers.

[0019] Preferably, the data processing unit is connected to two or four integrated vibration and temperature sensors, and the vibration of the integrated vibration and temperature sensors is uniaxial or biaxial.

[0020] A method for processing motor health status parameters comprises the following steps:

[0021] Step 1: Sampling at 2.56kHz sampling frequency, obtaining the spectrum through FFT calculation, calculating the total vibration value of 10 to 1000H, and comparing it with the limit value of GB / T6075 to determine the running state of the motor; at the same time, the spectrum diagram of 10 to 1000Hz is given for manual analysis of mechanical faults such as imbalance, misalignment, and mechanical looseness;

[0022] Step 2: Sampling at a sampling frequency of 25.6kHz, the total envelope value obtained by envelope calculation is used to judge the bearing condition, and the envelope waveform is calculated by FFT to obtain the envelope spectrum of 10 to 1000Hz. The specific parts with damage are judged by comparing with the bearing library. The bearing library gives the characteristic frequencies of various parts of bearings of different models;

[0023] Step 3: Sample the bearing temperature at a sampling frequency of 10 Hz to determine whether the bearing is overheated. The bearing temperature limit is 75°C.

[0024] Step 4: Compare the total vibration value, envelope total value and bearing temperature obtained through the above processing with the set threshold value, and give an alarm signal if they exceed the standard.

[0025] The beneficial effects of the present invention are:

[0026] The present invention avoids the influence of human factors (including human inertia, emotions, measurement technology, etc.) on the accuracy of measurement data; solves the problem that the rear bearing of the motor cannot be measured manually in the fan cover, and that some dangerous positions and dangerous spaces that are inaccessible to personnel cannot be measured manually; and realizes high-frequency monitoring to avoid accidents caused by some rapidly developing faults that cannot be discovered in time.

[0027] The present invention monitors and comprehensively evaluates the vibration, bearing temperature, and bearing component damage status that express the motor's health parameters, which can accurately reflect the motor's health status and provide a scientific basis for the motor's operation, inspection, and maintenance, thus having significant advancement. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The present invention will be further described in detail below in conjunction with the accompanying drawings and specific embodiments.

[0029] Figure 1 This is a structural block diagram of a motor health status monitor provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0030] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. The components of the embodiments of the present invention generally described and shown in the drawings here can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the drawings is not intended to limit the scope of the claimed invention, but merely represents the selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without making creative work belong to the scope of protection of the present invention.

[0031] Example

[0032] In order to simultaneously monitor the vibration, bearing temperature, and damage status of bearing components of the motor and comprehensively express the health status of the motor with multiple parameters, an embodiment of the present invention provides a motor health status monitor, which comprehensively judges the health status of the motor by monitoring the vibration, bearing temperature, and damage status of bearing components of the motor. The results are accurate and reliable, and have significant advancedness.

[0033] like Figure 1 As shown, the motor health status monitor includes a vibration-temperature integrated sensor 101, an amplifier / filter circuit 102, an A / D converter 103, a central processing unit 104, a storage unit 106, a display unit 107 and a transmission unit 105; the signal output end of the vibration-temperature integrated sensor 101 is connected to the signal input end of the amplifier / filter circuit 102, and the vibration-temperature integrated sensor 101 is used to measure the vibration and bearing temperature of the motor; the signal output end of the amplifier / filter circuit is connected to the signal input end of the A / D converter, the signal output end of the A / D converter 103 is connected to the signal input end of the central processing unit 104, the signal output end of the central processing unit 104 is connected to the display unit 107 and the signal input end of the storage unit 106, and the transmission unit 105 is connected to the storage unit 106.

[0034] The data collected by the integrated vibration and temperature sensor 101 is transmitted to the central processor 104 through the amplification / filtering circuit 102 and the A / D converter 103. The central processor 104 samples and processes the data. The vibration of the integrated vibration and temperature sensor 101 is uniaxial.

[0035] In another embodiment, the amplification / filtering circuit 102 is connected to two or four integrated vibration-temperature sensors 101 , and the vibration of the integrated vibration-temperature sensor 101 is biaxial.

[0036] The method for processing motor health status parameters comprises the following steps:

[0037] Step 1: Sampling at 2.56kHz sampling frequency, obtaining the spectrum through FFT calculation, calculating the total vibration value of 10 to 1000H, and comparing it with the limit value of GB / T6075 to determine the running state of the motor; at the same time, the spectrum diagram of 10 to 1000Hz is given for manual analysis of mechanical faults such as imbalance, misalignment, and mechanical looseness;

[0038] Step 2: Sampling at a sampling frequency of 25.6kHz, the total envelope value obtained by envelope calculation is used to judge the bearing condition, and the envelope waveform is calculated by FFT to obtain the envelope spectrum of 10 to 1000Hz. The specific parts with damage are judged by comparing with the bearing library. The bearing library gives the characteristic frequencies of various parts of bearings of different models;

[0039] Step 3: Sample the bearing temperature at a sampling frequency of 10 Hz to determine whether the bearing is overheated. The bearing temperature limit is 75°C.

[0040] Step 4: Compare the total vibration value, envelope total value and bearing temperature obtained through the above processing with the set threshold value, and give an alarm signal if they exceed the standard.

[0041] After the above method is used, the data of the total vibration value, the vibration spectrum, the total envelope value, the envelope spectrum and the bearing temperature are obtained, and the storage unit 106 stores the above data for the next step of processing.

[0042] The display unit 107 of the present invention displays the total vibration value, the total envelope value, and the bearing temperature obtained through collection and processing.

[0043] The display unit 107 in the embodiment of the present invention has multiple display modes. To make the working principle of the embodiment of the present invention clearer, the embodiment of the present invention provides one of the implementation schemes:

[0044] The display unit 107 uses green, yellow, and red lights to indicate whether the vibration, bearing temperature, and bearing component damage status exceed the standard. The green light indicates normal, the yellow light indicates warning, and the red light indicates alarm. The display unit 107 of the present invention uses a dual display mode of the motor parameter status, that is, a combination of digital and light display, which facilitates the operator to monitor the health status of the motor.

[0045] For better display, the display unit 107 of the present invention is a liquid crystal display screen. When touch operation is required, the display unit 107 can adopt a touch display screen.

[0046] In addition, to facilitate data transmission, the transmission unit 105 transmits the stored data to the outside world wirelessly, either by automatic timed transmission or manual transmission.

[0047] In order to better process the collected signal, the amplifier / filter circuit 102 of this embodiment is of 4th order or 8th order. The A / D converter 103 is of 16 bits or 24 bits.

[0048] The storage unit 106 stores the total vibration value, vibration spectrum, envelope total value, envelope spectrum and bearing temperature obtained by the data processing unit. The storage interval of the storage unit 106 is set to 5min, 10min, 30min, 60min, 1h, 2h, 4h, 8h, 24h and custom time intervals. It stores data for more than one year. The storage capacity of the storage unit is 8GB and above.

[0049] The present invention monitors and comprehensively evaluates the vibration, bearing temperature, and bearing component damage status that express the motor's health parameters, which can accurately reflect the motor's health status and provide a scientific basis for the motor's operation, inspection, and maintenance, thus having significant advancement.

[0050] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A motor health status monitor, It is characterized in that It includes a data acquisition unit, a data processing unit, a storage unit, a display unit and a transmission unit; The data acquisition unit includes an integrated vibration and temperature sensor for measuring the vibration and bearing temperature of the motor; The data processing unit samples and processes the data collected by the data collection unit; The storage unit stores the total vibration value, vibration spectrum, envelope total value, envelope spectrum and bearing temperature obtained by the data processing unit; The display unit displays the total vibration value, total envelope value, and bearing temperature obtained through collection and processing; The transmission unit transmits the stored data to the outside world wirelessly, using automatic timed transmission or manual transmission. The data processing unit includes an amplifying / filtering circuit, an A / D converter and a central processing unit. The signal output end of the vibration-temperature integrated sensor is connected to the signal input end of the amplifying / filtering circuit, the signal output end of the amplifying / filtering circuit is connected to the signal input end of the A / D converter, the signal output end of the A / D converter is connected to the signal input end of the central processing unit, and the signal output end of the central processing unit is connected to the signal input end of the display unit and the storage unit. The CPU uses two sampling frequencies, 2.56kHz and 25.6kHz, for vibration signals and 10Hz for bearing temperature. The amplifier / filter circuit is 4th or 8th order. The A / D converter is 16-bit or 24-bit. The display unit is a liquid crystal display or a touch screen. The storage unit storage interval can be set to 5min, 10min, 30min, 60min, 1h, 2h, 4h, 8h, 24h and custom time intervals. The data can be stored for more than one year. The storage unit storage capacity is 8GB and above. The display unit uses green, yellow and red lights to indicate whether the vibration, bearing temperature and bearing component damage status are out of standard. The green light indicates normal, the yellow light indicates warning, and the red light indicates alarm. It also uses digital display to display the status of motor parameters. The data processing unit is connected to two or four integrated vibration and temperature sensors. The vibration of the integrated vibration and temperature sensor is uniaxial or biaxial. And the processing method of the motor health status parameters adopted by the motor health status monitor is: Step 1: Sampling at 2.56kHz sampling frequency, obtaining the spectrum through FFT calculation, calculating the total vibration value of 10 to 1000H, and comparing it with the limit value of GB / T6075 to determine the running state of the motor; at the same time, the spectrum diagram of 10 to 1000Hz is given for manual analysis of mechanical faults such as imbalance, misalignment, and mechanical looseness; Step 2: Sampling at a sampling frequency of 25.6kHz, the total envelope value obtained by envelope calculation is used to judge the bearing condition, and the envelope waveform is calculated by FFT to obtain the envelope spectrum of 10 to 1000Hz. The specific parts with damage are judged by comparing with the bearing library. The bearing library gives the characteristic frequencies of various parts of bearings of different models; Step 3: Sample the bearing temperature at a sampling frequency of 10 Hz to determine whether the bearing is overheated. The bearing temperature limit is 75°C. Step 4: Compare the total vibration value, envelope total value and bearing temperature obtained through the above processing with the set threshold value, and give an alarm signal if they exceed the standard.

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