A fan current fault model, establishment method and fault analysis method

Abstract

The present invention discloses a fan current fault model, a establishing method and a fault analysis method, belonging to the technical field of fan fault monitoring, and is used for monitoring ventilation system faults; it is characterized by at least including: a fan type module for reading and writing the fan type and the reference current; a fault information analysis module that first receives the type and actual current of the fan to be tested, conducts data interaction with the fan type module, then obtains the reference current of the fan to be tested according to the fan type, and finally calculates the current change rate according to the actual current and the reference parameters; a fault information feedback module that determines ventilation system faults according to the current change rate. By tracking the change of the fan current, the present invention can quickly and timely judge whether there is a fault in the ventilation system, and at the same time play a role in monitoring the dust deposition state of the equipment filter screen. This application can maximize the service life of the dust-proof net and ensure the normal operation of the equipment.

Description

Technical Field

[0001] The present invention belongs to the technical field of fan fault monitoring, and particularly relates to a fan current fault model, a establishing method and a fault analysis method. Background Art

[0002] At present, due to the need for heat dissipation, various electrical cabinets or electronic chassis are designed with heat dissipation channels inside the body to meet the heat dissipation requirements of internal components or devices; similarly, in order to meet the dust-proof needs inside the device, various styles of filters are installed at the air inlet of the device to block floating dust, hair, etc. in the air, and a heat dissipation fan is installed at the air outlet to quickly extract the internal heat. However, at present, most of such devices cannot judge the true service life of the filter, resulting in insufficient effective utilization rate of the filter or the situation of using it beyond the service life, which not only causes material waste but also brings certain risks to the normal use of the device. There are mainly three categories on the market:

[0003] 1. For most dust-proof nets, there are no effective measures to provide dust accumulation degree alarms, and only regular replacement is required. The problems brought by such devices are that the degree of use of the filter cannot be measured under different environments and different usage frequencies, which may lead to waste of the service life of the filter or equipment failures caused by overuse;

[0004] 2. At present, on the market, some systems are equipped with air pressure difference sensors before and after the dust-proof net. By judging the change of the air pressure at the inlet and the air pressure in the channel, the dust accumulation degree of the filter of the device can be judged. The air pressure difference sensor needs to be used in combination with a control instrument. The cost of this method is relatively high, and it is mainly for systems with precise control requirements, so its universality of use is relatively low;

[0005] 3. Another method is to realize the filter replacement alarm according to the obvious increase in the fan temperature for a long time when the dust accumulation degree of the filter is serious. This method only provides an alarm message when the fan works in a situation of poor air intake for a long time and the temperature reaches the corresponding set value. However, this method is easily affected by the external temperature and cannot classify the abnormal situations of the device well. Summary of the Invention

[0006] Aiming at the above technical defects, the present invention provides a fan current fault model, a establishing method and a fault analysis method. By tracking the change of the fan current, it can quickly and timely judge whether there is a fault in the ventilation system, and at the same time play a role in monitoring the dust accumulation state of the device filter. This application can realize two modes of on-site alarm or off-site alarm, and send the device state to relevant management personnel quickly and timely. This application can maximize the service life of the dust-proof net and ensure the normal operation of the device.

[0007] To achieve the above technical objectives, the present invention is realized through the following technical solutions:

[0008] The first objective of the present invention is to provide a fan current fault model, including:

[0009] A fan type module for reading and writing the fan type and reference current;

[0010] A fault information analysis module that first receives the type and actual current of the fan to be tested, conducts data interaction with the fan type module, then obtains the reference current of the fan to be tested according to the fan type, and finally calculates the current change rate based on the actual current and reference parameters;

[0011] A fault information feedback module that determines the ventilation system fault according to the current change rate.

[0012] Preferably: The fan type module includes a human-computer interaction unit, a type database for storing the fan type, and a reference current database for storing the reference current; there is a one-to-one mapping relationship between the type database and the reference current database.

[0013] Preferably: The fault information analysis module includes:

[0014] A communication unit that conducts data interaction with the fan type module, the fault information feedback module, and a data acquisition module for obtaining the actual current;

[0015] A matching unit that matches the type of the fan to be tested with the type database to obtain the reference current of the fan to be tested;

[0016] An analysis unit that calculates the ratio of the actual current to the reference current.

[0017] Preferably: The ventilation system faults include fan shutdown faults, fan locked-rotor faults, foreign object blockage faults, and dust deposition faults.

[0018] Preferably: The fault information feedback module includes:

[0019] A fan shutdown fault model. When the fan is working, if the current becomes 0, the fan has a fault; otherwise, the fan has no shutdown fault;

[0020] A fan locked-rotor fault model. The locked-rotor current change rate when each type of fan has a locked-rotor fault is pre-stored. When the fan is working, if the current change rate is consistent with the locked-rotor current change rate, the fan has a locked-rotor fault; otherwise, the fan has no locked-rotor fault;

[0021] A foreign object blockage fault model. The blockage current change rate when each type of fan has a blockage fault is pre-stored. When the fan is working, if the current change rate is consistent with the blockage current change rate, the fan has a blockage fault; otherwise, the fan has no blockage fault;

[0022] Dust-falling fault model, which pre-stores the dust-falling current change rate when dust-falling faults occur in various types of fans. When the fan is working, if the current change rate is consistent with the dust-falling current change rate, the fan has a dust-falling fault; otherwise, the fan has no dust-falling fault.

[0023] The second object of the present invention is to provide a method for establishing a fan current fault model, including the following steps:

[0024] S1. Collect different types of motors and obtain the reference current corresponding to each type of motor;

[0025] S2. Classify the ventilation system faults. For each type of fault, conduct repetitive fault simulation experiments to obtain the fault currents at different time periods, and calculate the fault current change rate by taking the ratio of the fault current to the reference current;

[0026] S3. Through a learning machine, establish a mapping relationship between the current change rate and the fault category; specifically:

[0027] Take the motor type, reference current, and current change rate as inputs, and the fault category as the output.

[0028] Preferably:

[0029] The fault simulation experiment of the fan locked-rotor fault model is: when the equipment is working normally, after artificially locking the fan, collect the fan current at this time, and calculate the fan current change rate within the instantaneous Δt time period;

[0030] The fault simulation experiment of the foreign object blockage fault model is: when the equipment is working normally, gradually block the air inlet with a sealing plate manually, test the fan current every 1 - 2 minutes, and record the fan current change rate curve from the start to the complete blockage;

[0031] The fault simulation experiment of the dust-falling fault model is: when the equipment is working normally, uniformly raise dust at the air inlet of the equipment to accumulate dust on the filter screen, test the fan current every 1 - 2 minutes, and record the fan current change rate curve from the start to the complete blockage.

[0032] Preferably: Divide the fan current change rate curve into segments.

[0033] The third object of the present invention is to provide a fan current fault analysis method, which is completed based on the above fan current fault model as follows:

[0034] Step 1. Analyze the fan shutdown fault. When the fan is working, if the current becomes 0, the fan has a fault and needs to be shut down for maintenance; otherwise, the fan has no shutdown fault, and proceed to Step 2;

[0035] Step 2: Analyze the fan locked-rotor fault. When the fan is working, if the current change rate is consistent with the locked-rotor current change rate, it indicates that the fan has a locked-rotor fault, and a locked-rotor alarm maintenance prompt is given; otherwise, the fan has no locked-rotor fault, and proceed to Step 3;

[0036] Step 3: Analyze the fan foreign object blockage fault. When the fan is working, if the current change rate is consistent with the blockage current change rate, it indicates that the fan has a blockage fault, and a blockage alarm maintenance prompt is given; otherwise, the fan has no blockage fault, and proceed to Step 4;

[0037] Step 4: Analyze the fan dust accumulation fault. When the fan is working, if the current change rate is consistent with the dust accumulation current change rate, it indicates that the fan has a dust accumulation fault, and a dust accumulation alarm maintenance prompt is given; otherwise, the fan has no dust accumulation fault.

[0038] In Step 2: The locked-rotor current change rate includes multiple segments, each corresponding to a locked-rotor fault of a different degree; match the current change rate with each segment of the locked-rotor current change rate to obtain the specific locked-rotor degree, and execute alarm information of different levels according to the locked-rotor degree;

[0039] In Step 3: The blockage current change rate includes multiple segments, each corresponding to a blockage fault of a different degree; match the current change rate with each segment of the blockage current change rate to obtain the specific blockage degree, and execute alarm information of different levels according to the blockage degree;

[0040] In Step 4: The dust accumulation current change rate includes multiple segments, each corresponding to a dust accumulation fault of a different degree; match the current change rate with each segment of the dust accumulation current change rate to obtain the specific dust accumulation degree, and execute alarm information of different levels according to the dust accumulation degree.

[0041] Preferably: The alarm includes an on-site alarm or an off-site alarm.

[0042] The advantages and technical effects of the present invention are:

[0043] Through the quantitative analysis of the motor working current change rate, the present invention can quickly and accurately obtain the fault type and fault level, and then remind the staff to perform fault handling in a timely manner;

[0044] The present invention can timely remind the maintenance staff to replace the dust-proof filter according to the specific working conditions, rather than replacing it regularly. Due to the different environments where the equipment is located, for the equipment in some clean areas, regular replacement cannot effectively utilize the filter life. For places with serious dust accumulation, if the filter is replaced according to the original schedule, some faults such as downtime and reduced equipment service life may occur;

[0045] The present invention can effectively distinguish the current state of the device. For example, under normal use conditions, the dust accumulation degree, under abnormal conditions, such as the fan being blocked, or the air inlet of the device being suddenly blocked by a plastic bag, etc., can all well judge the problem in time according to the comparison of experimental data and send out an alarm signal in time.

[0046] Through the application of the wireless communication unit, the present invention can play a role in abnormal monitoring of the device without geographical restrictions, and notify the management personnel to handle the problems that occur in time. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Figure 1 It is a diagram for establishing a database of a preferred embodiment of the present invention;

[0048] Figure 2 It is a flowchart of the operation of a preferred embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0049] In order to make the above objects, the designed control system and advantages of the present invention clearer and more understandable, the following further details the present invention in conjunction with embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0050] Please refer to Figures 1 to 2 , a fan current fault model, including:

[0051] A fan type module for reading and writing the fan type and the reference current; since there are many types and models of fans, for the convenience of analysis, the fans are first classified in this application; among them: the fan type module includes a human-computer interaction unit (such as a touch screen), a type database for storing the fan type, and a reference current database for storing the reference current; there is a one-to-one mapping relationship between the type database and the reference current database.

[0052] A fault information analysis module, which first receives the type and actual current of the fan to be tested, and conducts data interaction with the fan type module, then obtains the reference current of the fan to be tested according to the fan type, and finally calculates the current change rate according to the actual current and the reference parameter; the fault information analysis module includes: a communication unit for conducting data interaction with the fan type module, a fault information feedback module, and a data acquisition module for obtaining the actual current; a matching unit for matching the type of the fan to be tested with the type database to obtain the reference current of the fan to be tested; an analysis unit for calculating the ratio of the actual current to the reference current.

[0053] A fault information feedback module for determining the ventilation system fault according to the current change rate.

[0054] In this preferred embodiment: the ventilation system faults specifically include fan shutdown faults, fan blockage faults, foreign object blockage faults, and dust accumulation faults.

[0055] Wherein, the fault information feedback module includes:

[0056] A fan shutdown fault model. When the fan is working, if the current becomes 0, the fan has a fault; otherwise, the fan has no shutdown fault.

[0057] A fan locked-rotor fault model. The locked-rotor current change rate when each type of fan has a locked-rotor fault is pre-stored. When the fan is working, if the current change rate is consistent with the locked-rotor current change rate, the fan has a locked-rotor fault; otherwise, the fan has no locked-rotor fault.

[0058] A foreign object blockage fault model. The blockage current change rate when each type of fan has a blockage fault is pre-stored. When the fan is working, if the current change rate is consistent with the blockage current change rate, the fan has a blockage fault; otherwise, the fan has no blockage fault.

[0059] A dust accumulation fault model. The dust accumulation current change rate when each type of fan has a dust accumulation fault is pre-stored. When the fan is working, if the current change rate is consistent with the dust accumulation current change rate, the fan has a dust accumulation fault; otherwise, the fan has no dust accumulation fault.

[0060] A method for establishing a fan current fault model includes the following steps:

[0061] S1. Collect different types of motors and obtain the reference current corresponding to each type of motor.

[0062] S2. Classify the ventilation system faults. For each type of fault, conduct repetitive fault simulation experiments to obtain the fault currents at different time periods, and calculate the fault current change rate by taking the ratio of the fault current to the reference current.

[0063] The fault simulation experiment for the fan locked-rotor fault model is as follows: When the equipment is working properly, artificially lock the fan and then collect the fan current at this time, and calculate the fan current change rate within the instantaneous Δt time period.

[0064] The fault simulation experiment for the foreign object blockage fault model is as follows: When the equipment is working properly, gradually block the air inlet with a sealing plate manually, test the fan current every 1 - 2 minutes, and record the fan current change rate curve from the start to the complete blockage.

[0065] The fault simulation experiment for the dust accumulation fault model is as follows: When the equipment is working properly, evenly dust the air inlet of the equipment to make the dust accumulate on the filter screen, test the fan current every 1 - 2 minutes, and record the fan current change rate curve from the start to the complete blockage.

[0066] In order to more quickly or specifically determine the severity of the fault: In this embodiment, the fan current change rate curve is segmented.

[0067] S3. Establish a mapping relationship between the current change rate and the fault category through a learning machine; specifically:

[0068] Take the motor type, reference current, and current change rate as inputs, and the fault category as the output.

[0069] A method for analyzing the current fault of a fan, based on the above fan current fault model, completes the following steps:

[0070] Step 1. Analyze the fan shutdown fault. When the fan is working, if the current becomes 0, the fan has a fault and needs to be shut down for maintenance; otherwise, the fan has no shutdown fault, and proceed to Step 2.

[0071] Step 2. Analyze the fan locked-rotor fault. When the fan is working, if the current change rate is consistent with the locked-rotor current change rate, the fan has a locked-rotor fault, and a locked-rotor alarm maintenance prompt is given; otherwise, the fan has no locked-rotor fault, and proceed to Step 3.

[0072] To achieve precise monitoring of the locked-rotor degree, the locked-rotor current change rate includes multiple segments, each corresponding to a different degree of locked-rotor fault; match the current change rate with each segment of the locked-rotor current change rate to obtain the specific locked-rotor degree, and execute different levels of alarm information according to the locked-rotor degree.

[0073] Step 3. Analyze the fan foreign object blockage fault. When the fan is working, if the current change rate is consistent with the blockage current change rate, the fan has a blockage fault, and a blockage alarm maintenance prompt is given; otherwise, the fan has no blockage fault, and proceed to Step 4.

[0074] To achieve precise monitoring of the blockage degree, the blockage current change rate includes multiple segments, each corresponding to a different degree of blockage fault; match the current change rate with each segment of the blockage current change rate to obtain the specific blockage degree, and execute different levels of alarm information according to the blockage degree.

[0075] Step 4. Analyze the fan dust accumulation fault. When the fan is working, if the current change rate is consistent with the dust accumulation current change rate, the fan has a dust accumulation fault, and a dust accumulation alarm maintenance prompt is given; otherwise, the fan has no dust accumulation fault.

[0076] To achieve precise monitoring of the dust accumulation degree, the dust accumulation current change rate includes multiple segments, each corresponding to a different degree of dust accumulation fault; match the current change rate with each segment of the dust accumulation current change rate to obtain the specific dust accumulation degree, and execute different levels of alarm information according to the dust accumulation degree.

[0077] The implementation principle of the present application is as follows: by time-sharing processing of the fan current sampled by the current acquisition unit, the fan current change rate is calculated after processing the fan current change within a period of time, and then compared with the laboratory data of the ventilation system stored in the database (the current change rate in the stalled rotor state, the current change rate in the case of large foreign body blockage, the fan current change rate in the free dust fall state, etc.), and then the state of the fan at this time (stall, large foreign body blockage or free dust fall degree, etc.) is judged, and then the corresponding instructions are sent to the alarm unit to remind the inspection management personnel to pay attention; at the same time, the relevant instructions are sent to the background monitoring server system through the wireless transmission unit, and the monitoring system sends the relevant information to the relevant non-resident management personnel to remind the management personnel to deal with the abnormalities in time to prevent the equipment from shutting down or overheating due to untimely filter replacement or abnormal air inlet, thereby reducing the service life or even burning.

[0078] Status judgment description: Due to different types of fans, their current change rates are different under different dust levels and faults. Taking axial flow fans as an example, when the air inlet is blocked, negative pressure will be formed, causing load overload, so the current will increase instead. According to the actual relevant situations and the size of the current change rate ΔI / Δt, the dust level or fault is divided into three states: stalled rotor, large foreign body air inlet blockage, and free dust fall; the different states are shown below.

[0079] 1. When the fan is in a blocked state, the fan rotor is braked due to the invasion of foreign matter. At this time, the fan current becomes very large instantaneously, generally 5-7 times the normal current, which is basically equal to the instantaneous starting current, that is, the current change rate ΔI / Δt will become larger. The size of the change rate varies according to different types of fans. The specific data shall be based on the actual measured data of the fan in actual application;

[0080] 2. When the air inlet is blocked by a large foreign object, such as a plastic sheet, the fan current will increase in a short period of time. At this time, the current change rate ΔI / Δt is related to the size of the blocked area S of the air inlet. The larger the blocked area S, the larger the current change rate ΔI / Δt, and the smaller S, the smaller the current change rate ΔI / Δt. However, compared with a shorter time period Δt, the current change rate ΔI / Δt changes more dramatically, and the specific change parameters can be obtained based on actual measurements of different types of fans;

[0081] 3. When the device is in the free dust accumulation state, the current change rate ΔI / Δt changes basically linearly with time. By taking values within different time periods Δt, the value of the current change ΔI is obtained. When it is detected that the working current of the fan reaches the set threshold within a certain period of time (the average value within 1 day, 3 days or other periods) (this threshold is obtained through different experimental data for different fans), it indicates that the dust accumulation on the dust filter reaches a certain level. When it reaches the replacement level, the device will send a filter replacement instruction through the control unit to remind the management staff to perform the replacement operation; it should be noted that the total duration of free dust accumulation is related to the cleanliness of the environment where the device is located. The higher the environmental cleanliness, the longer the free dust accumulation duration and the longer the filter is used; vice versa.

[0082] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, and improvements made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A fan current fault model; used to monitor ventilation system faults; characterized in that, It includes: A fan type module for reading and writing the fan type and reference current; The fault information analysis module first receives the type and actual current of the fan to be tested, conducts data interaction with the fan type module, then obtains the reference current of the fan to be tested according to the fan type, and finally calculates the current change rate based on the actual current and the reference parameters; ; A fault information feedback module for determining ventilation system faults based on the current change rate, where: The ventilation system faults include fan shutdown faults, fan locked-rotor faults, foreign object blockage faults, and dust accumulation faults; The fault information feedback module includes: A fan shutdown fault model. When the fan is working, if the current becomes 0, the fan has a fault; otherwise, the fan has no shutdown fault; A fan locked-rotor fault model. The locked-rotor current change rate when each type of fan has a locked-rotor fault is pre-stored. When the fan is working, if the current change rate is consistent with the locked-rotor current change rate, the fan has a locked-rotor fault; otherwise, the fan has no locked-rotor fault; A foreign object blockage fault model. The blockage current change rate when each type of fan has a blockage fault is pre-stored. When the fan is working, if the current change rate is consistent with the blockage current change rate, the fan has a blockage fault; otherwise, the fan has no blockage fault; A dust accumulation fault model. The dust accumulation current change rate when each type of fan has a dust accumulation fault is pre-stored. When the fan is working, if the current change rate is consistent with the dust accumulation current change rate, the fan has a dust accumulation fault; otherwise, the fan has no dust accumulation fault.

2. The fan current fault model according to claim 1, wherein: The fan type module includes a human-computer interaction unit, a type database for storing the fan type, and a reference current database for storing the reference current; There is a one-to-one mapping relationship between the type database and the reference current database.

3. The fan current fault model according to claim 2, characterized in that: The fault information analysis module includes: A communication unit for data interaction with the fan type module, the fault information feedback module, and a data acquisition module for obtaining the actual current; A matching unit for matching the type of the fan to be tested with the type database to obtain the reference current of the fan to be tested; An analysis unit for calculating the ratio of the actual current to the reference current.

4. A method for establishing a fan current fault model according to any one of claims 1-3, characterized in that, It includes the following steps: S1. Collect different types of motors and obtain the reference current corresponding to each type of motor; S2. Classify the ventilation system faults. For each type of fault, conduct repetitive fault simulation experiments to obtain the fault currents at different time periods, and obtain the fault current change rate by taking the ratio of the fault current to the reference current; S3. Through a learning machine, establish a mapping relationship between the current change rate and the fault category; specifically: Taking the motor type, reference current, and current change rate as inputs and the fault category as the output.

5. The method for establishing a fan current fault model according to claim 4, wherein: The fault simulation experiment of the fan locked-rotor fault model is: when the equipment is working normally, artificially block the fan and then collect the fan current at this time, and calculate the fan current change rate within the instantaneous ∆t time period; The fault simulation experiment of the foreign object blockage fault model is: when the equipment is working normally, artificially block the air inlet with a sealing plate step by step, test the fan current every 1 - 2 minutes, and record the fan current change rate curve from the start to the complete blockage; The fault simulation experiment of the dust accumulation fault model is: when the equipment is working normally, evenly dust the air inlet of the equipment to accumulate dust on the filter screen, test the fan current every 1 - 2 minutes, and record the fan current change rate curve from the start to the complete blockage.

6. The method for establishing a fan current fault model according to claim 5, characterized in that: Divide the fan current change rate curve into segments.

7. A method for analyzing fan current faults, characterized in that, Based on the fan current fault model described in any one of claims 1-3, complete the following steps: Step 1: Analyze the fan shutdown fault. When the fan is working, if the current becomes 0, the fan has a fault and needs to be shut down for maintenance; otherwise, if the fan has no shutdown fault, proceed to Step 2. Step 2: Analyze the fan locked-rotor fault. When the fan is working, if the current change rate is consistent with the locked-rotor current change rate, the fan has a locked-rotor fault and a locked-rotor alarm maintenance prompt is given; otherwise, if the fan has no locked-rotor fault, proceed to Step 3. Step 3: Analyze the fan foreign object blockage fault. When the fan is working, if the current change rate is consistent with the blockage current change rate, the fan has a blockage fault and a blockage alarm maintenance prompt is given; otherwise, if the fan has no blockage fault, proceed to Step 4. Step 4: Analyze the fan dust accumulation fault. When the fan is working, if the current change rate is consistent with the dust accumulation current change rate, the fan has a dust accumulation fault and a dust accumulation alarm maintenance prompt is given; otherwise, the fan has no dust accumulation fault.

8. The fan current fault analysis method according to claim 7, wherein: In Step 2: The locked-rotor current change rate includes multiple segments, each corresponding to a locked-rotor fault of a different degree; match the current change rate with each segment of the locked-rotor current change rate to obtain the specific locked-rotor degree, and execute different levels of alarm information according to the locked-rotor degree.

9. The fan current fault analysis method according to claim 7, wherein: In Step 3: The blockage current change rate includes multiple segments, each corresponding to a blockage fault of a different degree; match the current change rate with each segment of the blockage current change rate to obtain the specific blockage degree, and execute different levels of alarm information according to the blockage degree.

10. The fan current fault analysis method according to claim 7, wherein: In Step 4: The dust accumulation current change rate includes multiple segments, each corresponding to a dust accumulation fault of a different degree; match the current change rate with each segment of the dust accumulation current change rate to obtain the specific dust accumulation degree, and execute different levels of alarm information according to the dust accumulation degree; The alarm includes an on-site alarm or an off-site alarm.

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