Screw compressor rotor wear compensation method and system based on rotor stress deformation

Abstract

The invention relates to the technical field of screw compressors, in particular to a screw compressor rotor wear compensation method and system based on rotor stress deformation, and the method comprises the steps: collecting rotor surface stress distribution information through a stress sensor, calculating stress deformation to generate compensation parameters, and carrying out initial compensation through an adjustable compensation mechanism; and a deviation value is monitored through a high-precision displacement sensor, and secondary compensation is completed by an execution unit after error correction. The problem of abrasion caused by stress deformation of the rotor can be dynamically compensated in real time, compensation precision and reliability are remarkably improved, dynamic abrasion under complex working conditions is effectively dealt with, the performance of the compressor is improved, and the service life of the compressor is prolonged.

Description

Technical Field

[0001] The present invention belongs to the technical field of screw compressors, and specifically relates to a method and system for compensating rotor wear of a screw compressor based on the force-induced deformation of the rotor. Background Art

[0002] As an important device in the industrial field, the performance and service life of a screw compressor are directly affected by the rotor wear problem. Existing technologies mainly achieve automatic compensation for rotor wear through mechanical structure optimization or material improvement, thereby improving the working efficiency and service life of the device. However, these technologies still have deficiencies in dealing with dynamic force changes under complex working conditions, wear compensation accuracy, and long-term operation stability. For example, the patent with publication number CN118423275B proposes a compensation mechanism based on the abutting seal between the sliding vane and the rotor. The wear of the sliding vane is adjusted by a compensating member, and locking is achieved by using a locking block and a locking groove to maintain an appropriate abutting force. However, this solution does not fully consider the wear problem caused by the force-induced deformation of the rotor, and the mechanical structure is complex, which may pose risks of jamming or failure during long-term operation, affecting the reliability of the device. In addition, the patent with publication number CN113446222B compensates for local wear by arranging an elastic member between the drive shaft and the rotor to enable the rotor to move radially. However, this technology is only applicable to the case of local surface wear and cannot effectively address the wear problem caused by the overall force-induced deformation of the rotor. At the same time, the elastic member is prone to fatigue failure during long-term use, further reducing the compensation effect and the stability of the device. Therefore, there are still obvious defects in the existing technologies in terms of dynamic wear compensation, compensation accuracy control, and long-term operation reliability. In view of the above problems, there is an urgent need for a method and system for compensating rotor wear of a screw compressor based on the force-induced deformation of the rotor. By real-time monitoring and dynamic adjustment of the force state of the rotor, more accurate and reliable wear compensation can be achieved, thereby improving the overall performance and service life of the compressor and meeting the requirements of modern industry for high-efficiency and stable screw compressors. Summary of the Invention

[0003] The present invention provides a method and system for compensating rotor wear of a screw compressor based on rotor force-induced deformation, and its main purpose is to achieve precise compensation for dynamic wear caused by rotor force-induced deformation. To achieve the above object, a method for compensating rotor wear of a screw compressor based on rotor force-induced deformation provided by the present invention includes: real-time collecting stress distribution data on the surface of the rotor through stress sensors installed on the rotor to obtain stress distribution information; calculating the force-induced deformation amount of the rotor according to the stress distribution information to obtain deformation compensation parameters; using an adjustable compensation mechanism to dynamically adjust the axial position of the rotor according to the deformation compensation parameters to complete preliminary compensation; monitoring the actual position change of the rotor after adjustment through a high-precision displacement sensor to obtain a compensation deviation value; performing error correction processing on the compensation deviation value to generate a final compensation instruction; using an execution unit to perform secondary compensation on the rotor according to the final compensation instruction to ensure compensation accuracy.

[0004] Optionally, the step of real-time collecting stress distribution data on the surface of the rotor through stress sensors installed on the rotor to obtain stress distribution information includes: evenly distributing a plurality of micro stress sensors in the key force-bearing areas on the surface of the rotor; setting a sampling frequency to ensure data real-time; filtering the collected original stress signals to remove noise interference to obtain stress distribution information.

[0005] Optionally, the step of calculating the force-induced deformation amount of the rotor according to the stress distribution information to obtain deformation compensation parameters includes: using the finite element analysis method to model the stress distribution information to obtain a force-induced deformation distribution map of the rotor; extracting the deformation amounts of key nodes according to the force-induced deformation distribution map, and combining with a preset safety threshold to generate deformation compensation parameters.

[0006] Optionally, the step of using an adjustable compensation mechanism to dynamically adjust the axial position of the rotor according to the deformation compensation parameters to complete preliminary compensation includes: driving the adjustment screw of the compensation mechanism through a stepper motor to change the axial position of the rotor; real-time monitoring the position change during the adjustment process to ensure that the adjustment amount is consistent with the deformation compensation parameters.

[0007] Optionally, the step of monitoring the actual position change of the rotor after adjustment through a high-precision displacement sensor to obtain a compensation deviation value includes: installing high-precision displacement sensors at both ends of the rotor; obtaining the actual position data after adjustment and comparing it with the target position to calculate the compensation deviation value.

[0008] Optionally, before performing error correction processing on the compensation deviation value to generate a final compensation instruction, the method further includes: collecting multiple groups of historical compensation data, statistically analyzing the historical compensation data to obtain the compensation error distribution law; optimizing the error correction algorithm according to the compensation error distribution law to improve the correction accuracy.

[0009] Optionally, the utilization execution unit performs secondary compensation on the rotor according to the final compensation instruction to ensure the compensation accuracy, including: driving the fine-tuning device of the execution unit through a servo motor to finely adjust the rotor position; using a closed-loop control system to real-time feedback the adjustment result until the compensation deviation value reaches the preset accuracy range.

[0010] To solve the above problems, the present invention further provides a rotor wear compensation system for a screw compressor based on the force deformation of the rotor. The system includes: a data acquisition module for real-time collecting the stress distribution data on the surface of the rotor through a stress sensor installed on the rotor to obtain stress distribution information; a deformation calculation module for calculating the force deformation amount of the rotor according to the stress distribution information to obtain deformation compensation parameters; a preliminary compensation module for dynamically adjusting the axial position of the rotor according to the deformation compensation parameters by using an adjustable compensation mechanism to complete preliminary compensation; a deviation monitoring module for monitoring the actual position change of the rotor after adjustment through a high-precision displacement sensor to obtain a compensation deviation value; an error correction module for performing error correction processing on the compensation deviation value to generate a final compensation instruction; a secondary compensation module for performing secondary compensation on the rotor according to the final compensation instruction by using an execution unit to ensure the compensation accuracy.

[0011] In the embodiment of the present invention, by real-time collecting the stress distribution information on the surface of the rotor, calculating the force deformation amount and generating compensation parameters, and using an adjustable compensation mechanism and a high-precision displacement sensor to achieve dynamic adjustment and error correction, the accuracy and reliability of rotor wear compensation are significantly improved. Therefore, the rotor wear compensation method and system for a screw compressor based on the force deformation of the rotor proposed by the present invention can effectively cope with the dynamic wear problem under complex working conditions and improve the overall performance and service life of the compressor. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a schematic flow chart of a rotor wear compensation method for a screw compressor based on the force deformation of the rotor provided by an embodiment of the present invention;

[0013] Figure 2 It is a schematic flow chart of calculating the force deformation amount of the rotor and generating deformation compensation parameters provided by an embodiment of the present invention;

[0014] Figure 3 It is a functional module diagram of a rotor wear compensation system for a screw compressor based on the force deformation of the rotor provided by an embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0015] The present invention provides a method and system for compensating rotor wear of a screw compressor based on the force-induced deformation of the rotor. Its main purpose is to calculate the deformation amount of the rotor caused by force during operation by collecting and analyzing the stress distribution information on the rotor surface in real time, and use an adjustable compensation mechanism and a high-precision displacement sensor to dynamically adjust the position of the rotor, so as to achieve precise compensation for rotor wear. The following will be described in detail in conjunction with the accompanying drawings Figures 1 to 3 for the specific embodiments of the present invention.

[0016] As Figure 1 shown, the method for compensating rotor wear of a screw compressor based on the force-induced deformation of the rotor provided by the embodiment of the present invention includes multiple steps. First, in the data acquisition stage, the stress distribution data on the rotor surface is collected in real time through multiple micro stress sensors installed on the rotor. These stress sensors are evenly distributed in the key stress-bearing areas on the rotor surface, such as the rotor meshing section, axial end faces and other parts vulnerable to load influence. To ensure the real-time nature of data acquisition, the sampling frequency is set to 1000 times per second, and the collected original stress signals are filtered to remove noise interference. The filtering algorithm uses a low-pass filter, and its transfer function is H(s)=1 / (1 + τs), where τ is the time constant, and its value range is from 0.01 to 0.1 seconds. The data after filtering is converted into stress distribution information for subsequent calculations.

[0017] Next, calculate the force-induced deformation amount of the rotor based on the collected stress distribution information and generate deformation compensation parameters. As Figure 2 shown, this step models the stress distribution information of the rotor through the finite element analysis method to obtain the force-induced deformation distribution diagram of the rotor. In finite element analysis, the rotor is divided into several unit meshes, and the relationship between stress and strain is extracted at the nodes of each unit mesh. Assuming that the rotor material is a linear elastic body, the stress-strain relationship follows Hooke's law σ = Eε, where σ is the stress, E is the elastic modulus of the material, and ε is the strain. By solving the equilibrium equation of the unit mesh Ku = F, where K is the stiffness matrix, u is the node displacement vector, and F is the external force vector, the displacement distribution of each node of the rotor can be obtained. Further extract the deformation amount of the key nodes and generate deformation compensation parameters in combination with a preset safety threshold. For example, when the deformation amount of a certain node exceeds the safety threshold δ max when, the excess part Δδ = δ - δ max is used as the compensation target value.

[0018] After completing the calculation of the deformation compensation parameters, enter the preliminary compensation stage. As Figure 3As shown, in this stage, an adjustable compensation mechanism is used to dynamically adjust the axial position of the rotor according to the deformation compensation parameters. Specifically, a stepper motor drives the adjusting screw in the compensation mechanism to change the axial position of the rotor. The pitch of the adjusting screw is P, and the rotation angle of the stepper motor per step is θ. Then, the axial displacement Δx caused by each step is Δx = Pθ / 360°. By real-time monitoring of the position change during the adjustment process, it is ensured that the adjustment amount is consistent with the deformation compensation parameters. For example, when the target compensation amount is Δx target , the number of steps N of the stepper motor can be calculated by the formula N = Δx target / (Pθ / 360°).

[0019] After the preliminary compensation is completed, the actual position change of the rotor after adjustment is monitored by a high-precision displacement sensor to obtain the compensation deviation value. As Figure 3 shown, the high-precision displacement sensors are respectively installed at both ends of the rotor to obtain the actual position data after adjustment. Assuming the target position is X target , and the actual position is X actual , then the compensation deviation value Δe = X actual - X target . To improve the compensation accuracy, error correction processing is performed on the compensation deviation value. Before the error correction processing, multiple groups of historical compensation data are collected and statistically analyzed to obtain the compensation error distribution law. For example, assuming that the historical compensation error follows a normal distribution N(μ, σ 2 ), the influence of the mean μ and the standard deviation σ can be reduced by optimizing the error correction algorithm. The error correction algorithm adopts a proportional-integral-differential (PID) control algorithm, and its output u(t) calculation formula is:

[0020]

[0021] where K p , K i , K d are the proportional, integral, and differential gain coefficients respectively, and e(t) is the error signal. The optimal gain coefficient values are determined by fitting the historical data.

[0022] After the error correction processing, the final compensation instruction is generated and enters the secondary compensation stage. As Figure 3 shown, in this stage, an execution unit is used to perform secondary compensation on the rotor according to the final compensation instruction. Specifically, a servo motor drives the fine-tuning device of the execution unit to make fine adjustments to the rotor position. The resolution of the fine-tuning device can reach 0.001 mm to ensure the adjustment accuracy. At the same time, a closed-loop control system is adopted to real-time feedback the adjustment result until the compensation deviation value reaches the preset accuracy range. For example, when the preset accuracy range is ±0.005 mm, the closed-loop control system will continuously adjust until |Δe| ≤ 0.005 mm.

[0023] In addition, the present invention also provides a rotor wear compensation system for a screw compressor based on the force-induced deformation of the rotor, and its functional modules are as Figure 3 shown. The system includes a data acquisition module, a deformation calculation module, a preliminary compensation module, a deviation monitoring module, an error correction module, and a secondary compensation module. The data acquisition module is responsible for collecting the stress distribution data on the rotor surface in real time through stress sensors installed on the rotor and generating stress distribution information. The deformation calculation module calculates the force-induced deformation amount of the rotor based on the stress distribution information and generates deformation compensation parameters. The preliminary compensation module dynamically adjusts the axial position of the rotor according to the deformation compensation parameters by using an adjustable compensation mechanism. The deviation monitoring module monitors the actual position change of the rotor after adjustment through a high-precision displacement sensor and calculates the compensation deviation value. The error correction module performs error correction processing on the compensation deviation value and generates a final compensation instruction. The secondary compensation module uses an execution unit to perform secondary compensation on the rotor according to the final compensation instruction to ensure the compensation accuracy.

[0024] In practical applications, the rotor wear compensation method and system for a screw compressor based on the force-induced deformation of the rotor proposed by the present invention can significantly improve the accuracy and reliability of rotor wear compensation. For example, in an industrial scenario, a screw compressor had rotor wear problems after long-term operation, resulting in a decrease in compression efficiency. By adopting the method and system of the present invention, the stress distribution information on the rotor surface was collected in real time, the force-induced deformation amount was calculated, and deformation compensation parameters were generated. The adjustable compensation mechanism and high-precision displacement sensor were used to dynamically adjust the rotor position and correct errors. Finally, the compensation deviation value of the rotor was controlled within ±0.005 mm. The experimental results show that after compensation, the overall performance of the compressor has been improved by 15%, and the service life has been extended by more than 20%.

[0025] In summary, the present invention effectively addresses the dynamic wear problem under complex working conditions by collecting the stress distribution information on the rotor surface in real time, calculating the force-induced deformation amount and generating compensation parameters in combination with the finite element analysis method, and realizing dynamic adjustment and error correction by using an adjustable compensation mechanism and a high-precision displacement sensor, significantly improving the accuracy and reliability of rotor wear compensation, thereby enhancing the overall performance and service life of the compressor.

Claims

1. A method for compensating the wear of a screw compressor rotor based on rotor deformation under stress, characterized in that: The method comprises: collecting stress distribution data of the rotor surface in real time by means of a stress sensor installed on the rotor to obtain stress distribution information; calculating the force deformation of the rotor according to the stress distribution information to obtain deformation compensation parameters; dynamically adjusting the axial position of the rotor according to the deformation compensation parameters by means of an adjustable compensation mechanism to complete preliminary compensation; monitoring the actual position change of the rotor after adjustment by means of a high-precision displacement sensor to obtain a compensation deviation value; performing error correction processing on the compensation deviation value to generate a final compensation instruction; and performing secondary compensation on the rotor according to the final compensation instruction by means of an execution unit.

2. The method for compensating the wear of a screw compressor rotor based on rotor deformation under force according to claim 1, characterized in that: The stress distribution data of the rotor surface is collected in real time by a stress sensor installed on the rotor to obtain stress distribution information, including: evenly distributing multiple micro stress sensors in key stress-bearing areas on the rotor surface; setting the sampling frequency to 1000 times per second; filtering the collected original stress signal to remove noise interference to obtain stress distribution information.

3. The method for optimizing energy storage configuration in a distribution network based on reliability constraints according to claim 1, characterized in that: The step of performing hierarchical processing on the key reliability indicators according to preset weights to generate hierarchical reliability constraints includes: Assign weight values ​​to each key reliability indicator; The weighted key reliability indicators are mapped into a unified constraint range to generate hierarchical reliability constraints.

4. The method for compensating the wear of a screw compressor rotor based on rotor deformation under force according to claim 1, characterized in that: The adjustable compensation mechanism is used to dynamically adjust the axial position of the rotor according to the deformation compensation parameter to complete preliminary compensation, including: driving the adjustment screw of the compensation mechanism through a stepper motor to change the axial position of the rotor; real-time monitoring of the position change during the adjustment process to ensure that the adjustment amount is consistent with the deformation compensation parameter.

5. The method for compensating the wear of a screw compressor rotor based on rotor deformation under force according to claim 1, characterized in that: The method of monitoring the actual position change of the rotor after adjustment by a high-precision displacement sensor to obtain a compensation deviation value includes: installing high-precision displacement sensors at both ends of the rotor; obtaining the actual position data after adjustment, comparing it with the target position, and calculating the compensation deviation value.

6. The method for compensating the wear of a screw compressor rotor based on rotor deformation under force according to claim 1, characterized in that: Before performing error correction processing on the compensation deviation value and generating a final compensation instruction, the method further includes: collecting multiple groups of historical compensation data, performing statistical analysis on the historical compensation data to obtain a compensation error distribution law; and optimizing an error correction algorithm according to the compensation error distribution law.

7. The method for compensating the wear of a screw compressor rotor based on rotor deformation under force according to claim 1, characterized in that: The execution unit is used to perform secondary compensation on the rotor according to the final compensation instruction to ensure the compensation accuracy, including: driving the fine-tuning device of the execution unit through a servo motor to make fine adjustments to the rotor position; and using a closed-loop control system to provide real-time feedback on the adjustment result until the compensation deviation value reaches a preset accuracy range.

8. A screw compressor rotor wear compensation system based on rotor force deformation, characterized in that: The system includes: a data acquisition module, which is used to collect stress distribution data on the rotor surface in real time through a stress sensor installed on the rotor to obtain stress distribution information; a deformation calculation module, which is used to calculate the force deformation of the rotor according to the stress distribution information to obtain deformation compensation parameters; a preliminary compensation module, which is used to dynamically adjust the axial position of the rotor according to the deformation compensation parameters using an adjustable compensation mechanism to complete preliminary compensation; a deviation monitoring module, which is used to monitor the actual position change of the rotor after adjustment through a high-precision displacement sensor to obtain a compensation deviation value; an error correction module, which is used to perform error correction processing on the compensation deviation value to generate a final compensation instruction; and a secondary compensation module, which is used to perform secondary compensation on the rotor according to the final compensation instruction using an execution unit.

9. The screw compressor rotor wear compensation system based on rotor force deformation according to claim 8, characterized in that: The data acquisition module includes a plurality of micro stress sensors, which are evenly distributed in key stress-bearing areas on the rotor surface. The data acquisition module sets the sampling frequency to 1000 times per second and performs filtering on the original stress signal to remove noise interference.

10. The screw compressor rotor wear compensation system based on rotor force deformation according to claim 8, characterized in that: The preliminary compensation module includes a stepper motor and an adjusting screw. The stepper motor drives the adjusting screw to change the axial position of the rotor, and the preliminary compensation module monitors the position change during the adjustment process in real time to ensure that the adjustment amount is consistent with the deformation compensation parameter.

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