A fault diagnosis and health management system and method

Abstract

The embodiment of the present application provides a kind of fault diagnosis and health management system, method, the system includes data acquisition module, data simulation module, data processing module and health degree evaluation module, data acquisition module is used to obtain the operating data of each subsystem of diesel engine under different operating conditions;Data simulation module is used to establish diesel engine simulation model, calibrates diesel engine simulation model according to the real-time operating data of diesel engine current time, to generate a variety of health simulation data under the condition by using the calibrated diesel engine simulation model after calibration, generates a variety of fault simulation data under the condition by injecting fault model simulation;Data processing module is used to develop data processing algorithm and obtain operating condition identification result and abnormal result information according to real-time operating data and a variety of health simulation data under the condition, fault simulation data;Health degree evaluation module is used to evaluate the overall health degree of diesel engine, to obtain health degree evaluation result.

Description

Technical Field

[0001] This invention relates to the field of fault detection technology, and more specifically, to a fault diagnosis and health management system and method. Background Technology

[0002] Diesel engines are engines that burn diesel fuel to release energy. Due to their high power and good economic performance, they are used in many power systems. As a core component of a power system, the diesel engine's operating efficiency, reliability, and safety performance play a crucial role in the entire power system. Therefore, it is necessary to monitor the diesel engine's operating status in real time during equipment operation or with minimal disassembly, analyze the abnormal parts and causes, and predict the future development trend of the diesel engine's condition. However, diesel engines are typical complex engineering machines involving multiple disciplines and systems. The occurrence of faults during operation is uncertain, faults are difficult to reproduce, and fault testing is costly. In addition, the data characteristic signals of various subsystems overlap and influence each other, making them difficult to separate, further increasing the difficulty of obtaining health and fault data during diesel engine operation.

[0003] In existing technologies, the main fault diagnosis methods for diesel engines include vibration detection, temperature detection, speed detection, and fluid level detection. These methods, to a certain extent, monitor the operating status of the diesel engine and diagnose subsystem faults. However, existing fault diagnosis methods can only monitor and display parameters based on the diesel engine's healthy state and diagnose subsystem faults. They lack an understanding of diesel engine fault data and cannot evaluate the overall operating status and comprehensive health of the diesel engine from a holistic perspective. They ignore the mutual influence between faults in different subsystems and lack a perspective on the overall state of the diesel engine. Furthermore, existing fault diagnosis methods are detached from the actual operating conditions of the diesel engine or only consider fault manifestations under certain specific operating conditions, failing to achieve monitoring and fault diagnosis of abnormal states under all operating conditions of the diesel engine. Summary of the Invention

[0004] This specification provides a fault diagnosis and health management system and method to overcome at least one technical problem existing in the prior art.

[0005] In a first aspect, according to embodiments of this specification, a fault diagnosis and health management system is provided, the system comprising:

[0006] The data acquisition module is used to acquire diesel engine data through the diesel engine's ECU and sensors to obtain operating data of each subsystem of the diesel engine under different operating conditions. The diesel engine data includes basic diesel engine information and diesel engine operating parameter information.

[0007] The data simulation module is used to establish a diesel engine simulation model and calibrate the diesel engine simulation model based on the real-time operating data of the diesel engine at the current moment. The calibrated diesel engine simulation model is used to generate health simulation data under various operating conditions. At the same time, by injecting fault models, fault simulation data under various operating conditions is generated.

[0008] The data processing module is used to acquire the real-time operating data of the diesel engine at the current moment, as well as the health simulation data and fault simulation data under various operating conditions. Based on the real-time operating data and the health simulation data and fault simulation data under various operating conditions, the module develops a data processing algorithm and obtains operating condition identification results and abnormal result information. The abnormal result information includes operating condition abnormality detection results and fault diagnosis results.

[0009] The health assessment module is used to evaluate the overall health of the diesel engine based on the abnormal result information obtained by the data processing module, so as to obtain the health assessment result.

[0010] Optionally, the data processing algorithm includes a working condition identification algorithm, a working condition anomaly detection algorithm, and a subsystem fault diagnosis algorithm.

[0011] The data processing module develops a data processing algorithm based on the real-time operating data and the health simulation data and fault simulation data under various operating conditions, and obtains operating condition identification results and abnormal result information, specifically used for:

[0012] Based on the real-time operating data and the health simulation data and fault simulation data under various operating conditions, the operating condition identification algorithm, the operating condition anomaly detection algorithm, and the subsystem fault diagnosis algorithm of the diesel engine are developed.

[0013] Based on the operating condition identification algorithm, the operating condition of the current state of the diesel engine is identified, and the operating condition identification result of the diesel engine is obtained;

[0014] Based on the working condition anomaly detection algorithm corresponding to the current working condition of the diesel engine, the algorithm identifies whether there is anomaly in the real-time operating data of the diesel engine at the current moment and the degree of anomaly when there is anomaly, and obtains the working condition anomaly detection result of the diesel engine.

[0015] Based on the subsystem fault diagnosis algorithm corresponding to the current operating condition of the diesel engine, the fault status of each subsystem of the diesel engine is diagnosed, and the fault diagnosis result of the diesel engine is obtained.

[0016] Further, optionally, the operating condition identification results include idling, low load, medium load, high load, deceleration, and acceleration.

[0017] The step of identifying the current operating condition of the diesel engine based on the operating condition identification algorithm and obtaining the operating condition identification result of the diesel engine specifically includes:

[0018] Determine the corresponding interval of the real-time operating data of the diesel engine on the diesel engine characteristic curve at the current moment, and obtain the operating condition identification result of the current state of the diesel engine based on the corresponding interval of the real-time operating data on the diesel engine characteristic curve.

[0019] Further optionally, the operating condition anomaly detection algorithm based on the current state of the diesel engine identifies whether there are any anomalies in the real-time operating data of the diesel engine at the current moment, and the degree of anomaly if any, to obtain the operating condition anomaly detection result of the diesel engine, specifically including:

[0020] The real-time operating data of the diesel engine at the current moment and the standard operating parameter value range of the diesel engine under the current operating condition are obtained. The real-time operating data is compared with the standard operating parameter value range to obtain the overall parameter deviation, and the overall parameter deviation is used as the abnormal detection result of the operating condition.

[0021] Optionally, the basic information of the diesel engine includes the diesel engine model and the diesel engine unique serial number, and the system further includes:

[0022] The data storage module is used to store the diesel engine operating parameter information, the operating condition identification result, the abnormal result information and the health assessment result, and to distinguish the diesel engine operating parameter information of different diesel engines according to the diesel engine number.

[0023] Optionally, the diesel engine simulation model includes an intake and exhaust system simulation model, a fuel system simulation model, a cooling system simulation model, and a lubrication system simulation model. The fault model can be implemented by direct parameter tuning and fault mechanism equivalent models.

[0024] Optionally, the health evaluation module assesses the overall health of the diesel engine based on the abnormal result information obtained by the data processing module to obtain a health evaluation result, specifically used for:

[0025] Based on the abnormal result information obtained by the data processing module, the subsystem health score of each subsystem of the diesel engine is obtained, wherein the subsystems of the diesel engine include the intake and exhaust system, the fuel system, the lubrication system, and the cooling system.

[0026] Based on the subsystem health scores of each subsystem of the diesel engine, the overall health score of the diesel engine is calculated to obtain the health assessment result.

[0027] Optionally, the subsystem health score includes a subsystem operating parameter score and a fault item diagnosis result score. The subsystem operating parameters of the intake and exhaust system include intake pressure, intake temperature, exhaust pressure, and exhaust temperature. The fault items of the intake and exhaust system include air filter blockage and reduced turbocharger efficiency.

[0028] The formula for calculating the health score of the subsystem is as follows:

[0029]

[0030] Among them, c i P is the subsystem health score for the i-th subsystem of the diesel engine. i For the parameter score of the i-th subsystem of the diesel engine, S i Score the fault item diagnosis results for the i-th subsystem of the diesel engine, p j To score the deviation of the operating parameters of the j-th subsystem of the i-th subsystem of the diesel engine, a j Let s be the weight of the operating parameter of the j-th subsystem of the i-th subsystem of the diesel engine during the operation of the i-th subsystem. k The diagnostic result of the k-th fault item in the i-th subsystem of the diesel engine is scored, b k This represents the weight of the k-th fault item in the i-th subsystem of the diesel engine in the subsystem health of the i-th subsystem;

[0031] If the subsystem health is a time-continuous parameter, then the subsystem health score at the current moment is:

[0032]

[0033] in, Let be the subsystem health score of the i-th subsystem at time t. Let P be the subsystem health score of the i-th subsystem at time t-1. i For the parameter score of the i-th subsystem of the diesel engine, S i Score the diagnostic results of the fault items in the i-th subsystem of the diesel engine, w i To update the weight values;

[0034] The formula for calculating the overall health score of the diesel engine is as follows:

[0035]

[0036] Among them, C t The overall health score of the diesel engine system at time t. Let η be the subsystem health score of the i-th subsystem at time t. iLet be the influence weight of the i-th subsystem in the diesel engine.

[0037] Secondly, according to the embodiments of this specification, a fault diagnosis and health management method is provided, including:

[0038] Diesel engine data is collected by the ECU and sensors of the diesel engine to obtain the operating data of each subsystem of the diesel engine under different operating conditions. The diesel engine data includes basic diesel engine information and diesel engine operating parameter information.

[0039] Obtain the real-time operating data of the diesel engine at the current moment;

[0040] A diesel engine simulation model is established, and the diesel engine simulation model is calibrated based on the real-time operating data of the diesel engine at the current moment. The calibrated diesel engine simulation model is used to generate health simulation data under various operating conditions. At the same time, by injecting a fault model, fault simulation data under various operating conditions is generated.

[0041] Based on the real-time operating data and the health simulation data and fault simulation data under various operating conditions, a data processing algorithm is developed to obtain operating condition identification results and abnormal result information, wherein the abnormal result information includes operating condition abnormality detection results and fault diagnosis results.

[0042] The overall health of the diesel engine is assessed based on the abnormal results information to obtain a health assessment result.

[0043] Optionally, the data processing algorithm includes a working condition identification algorithm, a working condition anomaly detection algorithm, and a subsystem fault diagnosis algorithm.

[0044] The process of developing a data processing algorithm based on the real-time operating data and the health simulation data and fault simulation data under various operating conditions to obtain operating condition identification results and abnormal result information specifically includes:

[0045] Based on the real-time operating data and the health simulation data and fault simulation data under various operating conditions, the operating condition identification algorithm, the operating condition anomaly detection algorithm, and the subsystem fault diagnosis algorithm of the diesel engine are developed.

[0046] Based on the operating condition identification algorithm, the operating condition of the current state of the diesel engine is identified, and the operating condition identification result of the diesel engine is obtained;

[0047] Based on the working condition anomaly detection algorithm corresponding to the current working condition of the diesel engine, the algorithm identifies whether there is anomaly in the real-time operating data of the diesel engine at the current moment and the degree of anomaly when there is anomaly, and obtains the working condition anomaly detection result of the diesel engine.

[0048] Based on the subsystem fault diagnosis algorithm corresponding to the current operating condition of the diesel engine, the fault status of each subsystem of the diesel engine is diagnosed, and the fault diagnosis result of the diesel engine is obtained.

[0049] Thirdly, according to embodiments of this specification, a storage medium is provided, the storage medium storing a computer program, which, when run, executes the fault diagnosis and health management method described in the second aspect.

[0050] The beneficial effects of the embodiments in this specification are as follows:

[0051] This fault diagnosis and health management system solves the problems of incomplete and difficult-to-obtain diesel engine health and fault data in existing technologies, as well as the differences in operating data under different working conditions in existing fault diagnosis methods, and the lack of overall health evaluation in existing fault diagnosis systems. It can simulate data under the healthy and fault states of diesel engines, and can overcome the differences in operating data under different working conditions to accurately identify typical faults of diesel engine systems. It can also evaluate the current health status of diesel engines as a whole, improving the reliability and safety of the operation of power systems with diesel engines as the core, and has a wide range of applications. Attached Figure Description

[0052] To more clearly illustrate the technical solutions in the embodiments or prior art of this specification, the drawings used in the description of the embodiments or prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0053] Figure 1 This is a structural block diagram of the fault diagnosis and health management system provided in the embodiments of this specification;

[0054] Figure 2 This is a schematic diagram of the overall health of a diesel engine provided in the embodiments of this specification;

[0055] Figure 3 This is a flowchart illustrating the fault diagnosis and health management method provided in the embodiments of this specification. Detailed Implementation

[0056] The technical solutions in the embodiments of this specification will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0057] It should be noted that the terms "comprising" and "having," and any variations thereof, in the embodiments and drawings of this specification are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to the steps or units listed, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products, or devices.

[0058] This specification discloses a fault diagnosis and health management system. Based on model simulation of diesel engine health and fault data, it identifies and distinguishes different operating conditions of the diesel engine, performs fault diagnosis on the diesel engine subsystems under different operating conditions, and comprehensively evaluates the overall health of the diesel engine based on the diagnostic results of the subsystems. These are described in detail below.

[0059] Figure 1 This specification illustrates a fault diagnosis and health management system provided according to an embodiment. For example... Figure 1 As shown, the fault diagnosis and health management system mainly includes a data acquisition module 1, a data storage module 2, a data simulation module 3, a data processing module 4, and a health evaluation module 5. The output terminals of the data acquisition module 1, the data processing module 4, and the health evaluation module 5 are respectively connected to the input terminal of the data storage module 2. The output terminal of the data storage module 2 is respectively connected to the input terminals of the data simulation module 3 and the data processing module 4. The output terminal of the data simulation module 3 is connected to the input terminal of the data processing module 4, and the output terminal of the data processing module 4 is connected to the input terminal of the health evaluation module 5.

[0060] In this embodiment, the data acquisition module 1 is used to collect diesel engine data and transmit it to the data storage module 2. Specifically, the data acquisition module 1 collects diesel engine data through the diesel engine's ECU and sensors to obtain operating data of various subsystems of the diesel engine under different operating conditions, and stores it in the database within the data storage module 2 according to the diesel engine number. The aforementioned ECU and sensors are part of the diesel engine system. The diesel engine data includes basic diesel engine information and diesel engine operating parameter information. The basic diesel engine information includes, but is not limited to, the diesel engine model and unique diesel engine number. The diesel engine operating parameter information includes, but is not limited to, intake pressure, intake temperature, lubricating oil pressure, lubricating oil temperature, fuel pressure, output speed, output torque, exhaust pressure, and exhaust temperature.

[0061] In one specific embodiment, the data acquisition module 1 collects operating data of each subsystem under different operating conditions from the ECU and sensor signals of the diesel engine system via CAN communication, and transmits it to the data storage module 2 via the data transmission interface in the form of 4G wireless communication. According to the unique diesel engine number in the basic information of the diesel engine, the data storage module 2 stores the data in the database of the data storage module 2 according to the diesel engine number.

[0062] In this embodiment, the data storage module 2 is used to store data, including but not limited to the diesel engine operating parameter information obtained by the acquisition module 1, the operating condition identification results obtained by the data processing module 4, the abnormal result information, and the health assessment results obtained by the health assessment module 5. In the specific implementation process, the data storage module 2 distinguishes the diesel engine operating parameter information of different diesel engines according to the diesel engine number.

[0063] The data simulation module 3 is used to establish a diesel engine simulation model. It uses operating data to calibrate the diesel engine simulation model and injects fault models to simulate health data and fault data, develop fault diagnosis algorithms, and update the key characteristic parameters of the diesel engine simulation model based on the continuous accumulation of operating data. This allows for continuous optimization of the model's simulation accuracy and improvement of the fault diagnosis algorithm performance.

[0064] In detail, the data simulation module 3 establishes a diesel engine simulation model and calibrates the diesel engine simulation model based on the real-time operating data of the diesel engine at the current moment. The calibrated diesel engine simulation model is then used to generate health simulation data under various operating conditions. At the same time, by injecting fault models, fault simulation data under various operating conditions is generated.

[0065] In a specific embodiment, the diesel engine simulation model includes, but is not limited to, an intake and exhaust system simulation model, a fuel system simulation model, a cooling system simulation model, and a lubrication system simulation model. The fault model is implemented by direct parameter tuning and fault mechanism equivalent model. Parameter tuning refers to modifying the parameter values ​​that are directly affected by the fault. The fault mechanism equivalent model is a model built based on an equivalent fault mechanism and injected into the original model.

[0066] In this embodiment, the data processing module 4 acquires real-time operating data of the diesel engine at the current moment, as well as health simulation data and fault simulation data under various operating conditions. Based on the real-time operating data and the health simulation data and fault simulation data under various operating conditions, it develops a data processing algorithm for the diesel engine's operating data. The developed data processing algorithm is then used to obtain operating condition identification results and abnormal result information. Simultaneously, the data processing module 4 transmits the operating condition identification results and abnormal result information to the database of the data storage module 2 in real time. The abnormal result information includes operating condition abnormality detection results and fault diagnosis results. The data processing algorithm includes an operating condition identification algorithm, an operating condition abnormality detection algorithm, and a subsystem fault diagnosis algorithm. Specifically, data processing module 4 develops operating condition identification algorithms, operating condition anomaly detection algorithms, and subsystem fault diagnosis algorithms for diesel engines based on real-time operating data and health simulation data and fault simulation data under various operating conditions. Based on the operating condition identification algorithm, data processing module 4 identifies the operating condition to which the diesel engine belongs in the current state and obtains the operating condition identification result. Based on the operating condition anomaly detection algorithm corresponding to the operating condition to which the diesel engine belongs in the current state, it identifies whether there are any anomalies in the real-time operating data of the diesel engine at the current moment and the degree of anomalies when they exist, and obtains the operating condition anomaly detection result. Based on the subsystem fault diagnosis algorithm corresponding to the operating condition to which the diesel engine belongs in the current state, it diagnoses the fault status of each subsystem of the diesel engine, that is, it calls the subsystem fault diagnosis algorithm corresponding to the current operating condition to diagnose the faults of each subsystem of the diesel engine and obtains the fault diagnosis result of the diesel engine.

[0067] It should be noted that the operating condition of the diesel engine in this article refers to the current working state of the diesel engine. In one embodiment, the operating conditions of the diesel engine mainly include six types: idling, low load, medium load, high load, deceleration, and acceleration. In other words, the operating condition identification results include idling, low load, medium load, high load, deceleration, and acceleration.

[0068] In one embodiment, the data processing module 4 mainly identifies the operating condition of the diesel engine through the diesel engine characteristic curve. Specifically, the data processing module 4 determines the corresponding interval of the real-time operating data of the diesel engine at the current moment on the diesel engine characteristic curve. Based on the corresponding interval of the real-time operating data on the diesel engine characteristic curve, the operating condition identification result of the current state of the diesel engine is obtained. That is, by determining which operating state the real-time operating data of the diesel engine at the current moment falls in the corresponding interval of the diesel engine characteristic curve, the operating condition to which the current state of the diesel engine belongs is identified.

[0069] In another embodiment, the data processing module 4 primarily identifies the abnormal operating conditions by comparing the current real-time operating parameters of the diesel engine with the standard operating parameter range under the current operating conditions, and provides the overall parameter deviation as the evaluation result of the abnormal operating conditions. Specifically, the data processing module 4 reads the real-time operating data of the specified diesel engine number from the database of the data storage module 2 based on the diesel engine's unique serial number, thereby obtaining the real-time operating data of the diesel engine at the current moment. It then compares the real-time operating data with the standard operating parameter range under the current operating conditions of the diesel engine to obtain the overall parameter deviation, and uses the overall parameter deviation as the result of the abnormal operating conditions detection.

[0070] The health assessment module 5 is used to evaluate the overall health of the diesel engine based on the abnormal result information obtained by the data processing module 4, to obtain a health assessment result, and transmits the health assessment result to the database of the data storage module 2 in real time. Specifically, based on the abnormal result information obtained by the data processing module 4, the health assessment module 5 obtains the subsystem health scores of each subsystem of the diesel engine, and calculates the overall health score of the diesel engine based on the subsystem health scores of each subsystem, thereby obtaining the health assessment result. In a specific embodiment, such as... Figure 2 As shown, the subsystems of a diesel engine include the intake and exhaust system, fuel system, lubrication system, and cooling system.

[0071] In one embodiment, the overall health score of the diesel engine is a combination of the subsystem health scores of each subsystem. Specifically, the overall health score of the diesel engine is the sum of the products of the subsystem health scores of each subsystem and the influence weight of each subsystem in the diesel engine. The calculation formula is as follows:

[0072]

[0073] In the above formula, C t The overall health score of the diesel engine system at time t. Let η be the subsystem health score of the i-th subsystem at time t. i Let be the influence weight of the i-th subsystem in the diesel engine.

[0074] The subsystem health score comprises two parts: subsystem operating parameter score and fault item diagnosis result score. The subsystem operating parameter score is the sum of the products of the deviation scores of all relevant subsystem operating parameters and the weights of each subsystem operating parameter during subsystem operation. The fault item score is the sum of the products of the diagnosis result scores of all relevant fault items and the weights of each fault item in the subsystem health score. In a specific embodiment, such as... Figure 2As shown, taking the intake and exhaust system as an example, the intake and exhaust system includes major components such as air filter, compressor, intercooler, turbine, cylinder, intake and exhaust pipes. The subsystem operating parameters involved in the subsystem operating parameter scoring are intake pressure, intake temperature, exhaust pressure, and exhaust temperature. The fault items involved in the fault item diagnosis result scoring are air filter blockage and turbocharger efficiency reduction.

[0075] The detailed formula for calculating the health score of this subsystem is as follows:

[0076]

[0077] In the above formula, c i P is the subsystem health score for the i-th subsystem of the diesel engine. i For the parameter score of the i-th subsystem of the diesel engine, S i Score the fault item diagnosis results for the i-th subsystem of the diesel engine, p j To score the deviation of the operating parameters of the j-th subsystem of the i-th subsystem of the diesel engine, a j Let s be the weight of the operating parameter of the j-th subsystem of the i-th subsystem of the diesel engine during the operation of the i-th subsystem. k The diagnostic result of the k-th fault item in the i-th subsystem of the diesel engine is scored, b k This represents the weight of the k-th fault item in the i-th subsystem of the diesel engine in the subsystem health of the i-th subsystem.

[0078] In this embodiment of the application, the subsystem health status is a time-continuous parameter, and the subsystem health status score of the current subsystem is:

[0079]

[0080] In the above formula, Let be the subsystem health score of the i-th subsystem at time t. Let P be the subsystem health score of the i-th subsystem at time t-1. i For the parameter score of the i-th subsystem of the diesel engine, S i Score the diagnostic results of the fault items in the i-th subsystem of the diesel engine, w i To update the weight values, i.e. the weight of the current state's influence on the historical health status, the values ​​are determined by combining historical data analysis and expert experience.

[0081] It should be noted that the division of specific subsystems and corresponding fault items are determined by the diesel engine model and the current operating condition of the diesel engine. In addition, the health evaluation module 5 and related parameters in this embodiment of the invention can be adjusted according to the abnormal operating condition detection and fault diagnosis items in the data processing module 4 to adapt to different diesel engine models and fault item combinations.

[0082] In addition, such as Figure 1 As shown, the fault diagnosis and health management system also includes a data display module 6. This module 6 is used to display diesel engine operating parameters, operating condition identification results, abnormal result information, and health assessment results in real time, and to enable human-machine interaction. For example, in a specific embodiment, the data display module 6 reads relevant data summarized by the data storage module 2 and displays in real time the diesel engine's operating parameters such as intake pressure, intake temperature, lubricating oil pressure, lubricating oil temperature, fuel pressure, output speed, output torque, exhaust pressure, and exhaust temperature, as well as operating condition identification results, abnormal operating condition detection results, fault diagnosis results, and health assessment results. It also enables human-machine interaction functions such as maintenance plan formulation, maintenance work order push, maintenance result feedback, query, and management.

[0083] In summary, this specification discloses a fault diagnosis and health management system. By establishing a diesel engine simulation model and injecting fault models, it simulates and acquires operational data of the diesel engine under multiple operating conditions, including normal and fault states, thus sustainably supporting the development of data processing algorithms. In real-time diesel engine condition monitoring, the system categorizes the engine's operating conditions, enabling it to establish corresponding anomaly detection algorithms and subsystem fault diagnosis algorithms based on different conditions. This achieves full-condition coverage of diesel engine condition detection and fault diagnosis. By decomposing the diesel engine's health status and comprehensively detecting anomalies in operating parameters and identifying fault diagnosis items, the system achieves an overall health evaluation of the diesel engine, improving the operational reliability of the diesel engine system. Furthermore, by flexibly adjusting the health evaluation framework and evaluation weights, the system can be adapted to different diesel engine systems and combinations of fault diagnosis items, significantly expanding its applicability.

[0084] This fault diagnosis and health management system solves problems related to diesel engine data acquisition and storage, operating condition identification, abnormal operating condition detection, fault diagnosis, and overall health evaluation. It can simulate data under healthy and faulty conditions of diesel engines and can accurately identify typical faults of diesel engine systems across differences in operating data under different operating conditions. It can also evaluate the current health status of diesel engines as a whole, improving the reliability and safety of the operation of power systems with diesel engines as the core, and has a wide range of applications.

[0085] Corresponding to the above-described fault diagnosis and health management system embodiments, this invention also provides a fault diagnosis and health management method, which includes the following steps:

[0086] Step 100: Collect diesel engine data through the diesel engine's ECU and sensors to obtain operating data of each subsystem of the diesel engine under different operating conditions.

[0087] The diesel engine data includes basic diesel engine information and diesel engine operating parameters. The basic diesel engine information includes, but is not limited to, the diesel engine model and the diesel engine unique serial number. The diesel engine operating parameters include, but are not limited to, intake pressure, intake temperature, lubricating oil pressure, lubricating oil temperature, fuel pressure, output speed, output torque, exhaust pressure, and exhaust temperature.

[0088] In one specific embodiment, the data acquisition module collects operating data of each subsystem under different operating conditions from the ECU and sensor signals of the diesel engine system via CAN communication, and transmits it to the data storage module via the data transmission interface in the form of 4G wireless communication. According to the unique diesel engine number in the basic information of the diesel engine, the data storage module stores it in the database of the data storage module according to the diesel engine number.

[0089] Step 200: Obtain the real-time operating data of the diesel engine at the current moment.

[0090] Based on the diesel engine's unique serial number, the data processing module reads the real-time operating data of the specified diesel engine from the database of the data storage module, thereby obtaining the real-time operating data of the diesel engine at the current moment.

[0091] Step 300: Establish a diesel engine simulation model and calibrate the diesel engine simulation model based on the real-time operating data of the diesel engine at the current moment. Use the calibrated diesel engine simulation model to generate health simulation data under various operating conditions. At the same time, by injecting fault models, generate fault simulation data under various operating conditions.

[0092] The data simulation module establishes a diesel engine simulation model and calibrates the model based on the real-time operating data of the diesel engine. The calibrated model is then used to generate health simulation data under various operating conditions. Simultaneously, by injecting a fault model, fault simulation data under various operating conditions is generated.

[0093] Step 400: Based on real-time operating data and health simulation data and fault simulation data under various operating conditions, develop data processing algorithms and obtain operating condition identification results and abnormal result information.

[0094] The data processing algorithms include operating condition identification algorithms, operating condition anomaly detection algorithms, and subsystem fault diagnosis algorithms. These algorithms are developed by combining real-time operating data collected from actual data with health simulation data and fault simulation data under various operating conditions generated by the data simulation module.

[0095] In one embodiment, based on real-time operating data and health simulation data and fault simulation data under various operating conditions, a diesel engine operating condition identification algorithm, an abnormal operating condition detection algorithm, and a subsystem fault diagnosis algorithm are developed. Based on the operating condition identification algorithm, the operating condition to which the diesel engine currently belongs is identified, yielding the operating condition identification result. The abnormal operating condition detection algorithm corresponding to the current operating condition is invoked to identify whether the real-time operating data is in an abnormal range; that is, based on the abnormal operating condition corresponding to the current operating condition of the diesel engine, the algorithm identifies whether there are any anomalies in the real-time operating data of the diesel engine at the current moment and the degree of anomaly if they exist, yielding the abnormal operating condition detection result. Based on the subsystem fault diagnosis algorithm corresponding to the current operating condition of the diesel engine, the fault status of each subsystem of the diesel engine is diagnosed; that is, the subsystem fault diagnosis algorithm corresponding to the current operating condition is invoked to diagnose the faults of each subsystem of the diesel engine, yielding the fault diagnosis result. The operating condition identification result, the abnormal operating condition detection result, and the fault diagnosis result are then transmitted and written into the database of the data storage module in real time.

[0096] Step 500: Evaluate the overall health of the diesel engine based on the abnormal result information to obtain the health assessment result.

[0097] Combining the results of abnormal operating condition detection and fault diagnosis, the overall health of the current diesel engine is assessed through the health evaluation module to obtain the health evaluation result, which is then transmitted to the database of the data storage module in real time.

[0098] In addition, this fault diagnosis and health management method can also display the diesel engine's operating parameters, operating condition identification results, abnormal operating condition detection results, fault diagnosis results, and health assessment results in real time through the data display module, and realize human-computer interaction functions such as maintenance plan formulation, maintenance work order push, maintenance result feedback, query, and management.

[0099] It should be noted that the fault diagnosis and health management method provided in this embodiment of the invention is based on the same concept as the fault diagnosis and health management system of this invention, and the technical effects it brings are the same as those in the embodiment of the fault diagnosis and health management system of this invention. For any parts not mentioned in this embodiment, please refer to the description in the embodiment of the fault diagnosis and health management system of this invention, which will not be repeated here.

[0100] In addition, embodiments of the present invention also provide a storage medium storing a computer program, which, when run, executes the fault diagnosis and health management method described in the above embodiments.

[0101] Those skilled in the art will understand that the accompanying drawings are merely schematic diagrams of one embodiment, and the modules or processes shown in the drawings are not necessarily essential for implementing the present invention.

[0102] Those skilled in the art will understand that the modules in the apparatus of the embodiments can be distributed in the apparatus of the embodiments as described in the embodiments, or they can be located in one or more devices different from this embodiment with corresponding changes. The modules of the above embodiments can be combined into one module, or they can be further divided into multiple sub-modules.

[0103] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A fault diagnosis and health management system, characterized in that, The system includes: The data acquisition module is used to acquire diesel engine data through the diesel engine's ECU and sensors to obtain operating data of each subsystem of the diesel engine under different operating conditions. The diesel engine data includes basic diesel engine information and diesel engine operating parameter information. The data simulation module is used to establish a diesel engine simulation model and calibrate the diesel engine simulation model based on the real-time operating data of the diesel engine at the current moment. The calibrated diesel engine simulation model is used to generate health simulation data under various operating conditions. At the same time, by injecting fault models, fault simulation data under various operating conditions is generated. The data processing module is used to acquire the real-time operating data of the diesel engine at the current moment, as well as the health simulation data and fault simulation data under various operating conditions. Based on the real-time operating data and the health simulation data and fault simulation data under various operating conditions, it develops a data processing algorithm to obtain operating condition identification results and abnormal result information. The abnormal result information includes operating condition abnormality detection results and fault diagnosis results. The data processing algorithm includes an operating condition identification algorithm, an operating condition abnormality detection algorithm, and a subsystem fault diagnosis algorithm. Specifically, the data processing module develops the data processing algorithm based on the real-time operating data and the health simulation data and fault simulation data under various operating conditions to obtain operating condition identification results and abnormal result information. Based on real-time operating data and health simulation data and fault simulation data under various operating conditions, an operating condition identification algorithm, an abnormal operating condition detection algorithm, and a subsystem fault diagnosis algorithm for the diesel engine are developed. Based on the operating condition identification algorithm, the operating condition to which the diesel engine belongs in its current state is identified, yielding the operating condition identification result. Based on the abnormal operating condition detection algorithm corresponding to the operating condition to which the diesel engine belongs in its current state, the abnormal operating data of the diesel engine at the current moment is identified to determine whether there are any abnormalities and the degree of abnormality if they exist, yielding the abnormal operating condition detection result. Based on the subsystem fault diagnosis algorithm corresponding to the operating condition to which the diesel engine belongs in its current state, the fault states of each subsystem of the diesel engine are diagnosed, yielding the fault diagnosis result. The health assessment module is used to evaluate the overall health of the diesel engine based on the abnormal result information obtained by the data processing module, so as to obtain the health assessment result; The health evaluation module assesses the overall health of the diesel engine based on the abnormal result information obtained by the data processing module to obtain a health evaluation result. Specifically, it is used to: obtain subsystem health scores for each subsystem of the diesel engine based on the abnormal result information obtained by the data processing module. The subsystems of the diesel engine include the intake and exhaust system, fuel system, lubrication system, and cooling system. The subsystem health score includes subsystem operating parameter scores and fault item diagnosis result scores. The subsystem operating parameters of the intake and exhaust system include intake pressure, intake temperature, exhaust pressure, and exhaust temperature. The fault items of the intake and exhaust system include air filter blockage and turbocharger efficiency reduction. Based on the subsystem health scores of each subsystem of the diesel engine, the overall health score of the diesel engine is calculated to obtain a health evaluation result. The formula for calculating the health score of the subsystem is as follows: Among them, c i P is the subsystem health score for the i-th subsystem of the diesel engine. i For the parameter score of the i-th subsystem of the diesel engine, S i Score the fault item diagnosis results for the i-th subsystem of the diesel engine, p j To score the deviation of the operating parameters of the j-th subsystem of the i-th subsystem of the diesel engine, a j Let s be the weight of the operating parameter of the j-th subsystem of the i-th subsystem of the diesel engine during the operation of the i-th subsystem. k The diagnostic result of the k-th fault item in the i-th subsystem of the diesel engine is scored, b k This represents the weight of the k-th fault item in the i-th subsystem of the diesel engine in the subsystem health of the i-th subsystem; If the subsystem health is a time-continuous parameter, then the subsystem health score at the current moment is: in, Let be the subsystem health score of the i-th subsystem at time t. Let P be the subsystem health score of the i-th subsystem at time t-1. i For the parameter score of the i-th subsystem of the diesel engine, S i Score the diagnostic results of the fault items in the i-th subsystem of the diesel engine, w i To update the weight values; The formula for calculating the overall health score of the diesel engine is as follows: Among them, C t The overall health score of the diesel engine system at time t. Let η be the subsystem health score of the i-th subsystem at time t. i Let be the influence weight of the i-th subsystem in the diesel engine.

2. The fault diagnosis and health management system according to claim 1, characterized in that, The operating condition identification results include idling, low load, medium load, high load, deceleration, and acceleration. The step of identifying the current operating condition of the diesel engine based on the operating condition identification algorithm and obtaining the operating condition identification result of the diesel engine specifically includes: Determine the corresponding interval of the real-time operating data of the diesel engine on the diesel engine characteristic curve at the current moment, and obtain the operating condition identification result of the current state of the diesel engine based on the corresponding interval of the real-time operating data on the diesel engine characteristic curve.

3. The fault diagnosis and health management system according to claim 1, characterized in that, The operating condition anomaly detection algorithm based on the current state of the diesel engine identifies whether there are any anomalies in the real-time operating data of the diesel engine at the current moment, and the degree of anomaly if any, to obtain the operating condition anomaly detection result of the diesel engine, specifically including: The real-time operating data of the diesel engine at the current moment and the standard operating parameter value range of the diesel engine under the current operating condition are obtained. The real-time operating data is compared with the standard operating parameter value range to obtain the overall parameter deviation, and the overall parameter deviation is used as the abnormal detection result of the operating condition.

4. The fault diagnosis and health management system according to claim 1, characterized in that, The basic information of the diesel engine includes the diesel engine model and the diesel engine unique serial number. The system also includes: The data storage module is used to store the diesel engine operating parameter information, the operating condition identification result, the abnormal result information and the health assessment result, and to distinguish the diesel engine operating parameter information of different diesel engines according to the diesel engine number.

5. The fault diagnosis and health management system according to claim 1, characterized in that, The diesel engine simulation model includes an intake and exhaust system simulation model, a fuel system simulation model, a cooling system simulation model, and a lubrication system simulation model. The fault model is implemented by direct parameter tuning and fault mechanism equivalent models.

6. A fault diagnosis and health management method, characterized in that, include: Diesel engine data is collected by the ECU and sensors of the diesel engine to obtain the operating data of each subsystem of the diesel engine under different operating conditions. The diesel engine data includes basic diesel engine information and diesel engine operating parameter information. Obtain the real-time operating data of the diesel engine at the current moment; A diesel engine simulation model is established, and the diesel engine simulation model is calibrated based on the real-time operating data of the diesel engine at the current moment. The calibrated diesel engine simulation model is used to generate health simulation data under various operating conditions. At the same time, by injecting a fault model, fault simulation data under various operating conditions is generated. Based on the real-time operating data and the health simulation data and fault simulation data under various operating conditions, a data processing algorithm is developed to obtain operating condition identification results and abnormal result information. The abnormal result information includes operating condition abnormality detection results and fault diagnosis results. The data processing algorithm includes an operating condition identification algorithm, an operating condition abnormality detection algorithm, and a subsystem fault diagnosis algorithm. Specifically, developing the data processing algorithm based on the real-time operating data and the health simulation data and fault simulation data under various operating conditions to obtain operating condition identification results and abnormal result information includes: developing... The present invention provides an operating condition identification algorithm, an operating condition anomaly detection algorithm, and a subsystem fault diagnosis algorithm for the diesel engine. Based on the operating condition identification algorithm, the operating condition to which the current state of the diesel engine belongs is identified, and the operating condition identification result of the diesel engine is obtained. Based on the operating condition anomaly detection algorithm corresponding to the operating condition to which the current state of the diesel engine belongs, the present invention identifies whether there are any anomalies in the real-time operating data of the diesel engine at the current moment and the degree of anomaly when they exist, and obtains the operating condition anomaly detection result of the diesel engine. Based on the subsystem fault diagnosis algorithm corresponding to the operating condition to which the current state of the diesel engine belongs, the present invention diagnoses the fault state of each subsystem of the diesel engine, and obtains the fault diagnosis result of the diesel engine. The overall health of the diesel engine is assessed based on the abnormal result information to obtain a health assessment result. Specifically, this assessment includes: obtaining subsystem health scores for each subsystem of the diesel engine based on the abnormal result information. The subsystems of the diesel engine include the intake and exhaust system, fuel system, lubrication system, and cooling system. Each subsystem health score includes subsystem operating parameter scores and fault diagnosis result scores. The subsystem operating parameters of the intake and exhaust system include intake pressure, intake temperature, exhaust pressure, and exhaust temperature. Faults in the intake and exhaust system include air filter blockage and reduced turbocharger efficiency. Based on the subsystem health scores of each subsystem, the overall health score of the diesel engine is calculated to obtain the health assessment result. The formula for calculating the health score of the subsystem is as follows: Among them, c i P is the subsystem health score for the i-th subsystem of the diesel engine. i For the parameter score of the i-th subsystem of the diesel engine, S i Score the fault item diagnosis results for the i-th subsystem of the diesel engine, p j To score the deviation of the operating parameters of the j-th subsystem of the i-th subsystem of the diesel engine, a j Let s be the weight of the operating parameter of the j-th subsystem of the i-th subsystem of the diesel engine during the operation of the i-th subsystem. k The diagnostic result of the k-th fault item in the i-th subsystem of the diesel engine is scored, b k This represents the weight of the k-th fault item in the i-th subsystem of the diesel engine in the subsystem health of the i-th subsystem; If the subsystem health is a time-continuous parameter, then the subsystem health score at the current moment is: in, Let be the subsystem health score of the i-th subsystem at time t. Let P be the subsystem health score of the i-th subsystem at time t-1. i For the parameter score of the i-th subsystem of the diesel engine, S i Score the diagnostic results of the fault items in the i-th subsystem of the diesel engine, w i To update the weight values; The formula for calculating the overall health score of the diesel engine is as follows: Among them, C t The overall health score of the diesel engine system at time t. Let η be the subsystem health score of the i-th subsystem at time t. i Let be the influence weight of the i-th subsystem in the diesel engine.

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