An intelligent diagnosis system based on abnormal cooling water temperature in diesel engine

Abstract

The application discloses an intelligent diagnosis system based on abnormal intercooling water temperature of a diesel engine, comprising: a data acquisition module, which acquires information of an intercooling water inlet temperature, an intercooling water pressure, a high-temperature water pressure and a diesel engine rotating speed; an intelligent diagnosis module, which receives data information transmitted by the data acquisition module, carries out data analysis, adopts a parameter abnormality judgment method, a fault root diagnosis method and an operation and maintenance suggestion prompting method to check abnormal parameters of the diesel engine, automatically judges a fault root causing the abnormal intercooling water temperature by establishing a fault diagnosis process and issues a warning and an operation and maintenance suggestion; and a warning display module, which receives a warning signal of the intelligent diagnosis module and carries out alarm prompting; the system comprehensively realizes state monitoring, automatic alarm, abnormal intelligent diagnosis and operation and maintenance suggestion prompting of the intercooling water temperature of the diesel engine.

Description

Technical Field

[0001] This invention relates to the field of diesel engine technology, and in particular to an intelligent diagnostic system based on abnormal cooling water temperature in a diesel engine. Background Technology

[0002] Diesel engines, as complex power machines, have intricate mechanical principles. When a malfunction occurs, experienced technicians are required to be on-site to troubleshoot the root cause. This results in low maintenance efficiency, long repair times, and inconsistent uptime. Utilizing advanced sensor technology can improve the diesel engine's sensing capabilities and promptly reflect its operating status. Based on robust diesel engine condition monitoring technology, and combined with computer technology and intelligent diagnostic development technology, diesel engine fault mechanisms and multi-parameter fusion diagnostic techniques are integrated into advanced data analysis tools. This enables intelligent judgment of the status of the entire diesel engine and its system components, allowing for timely detection of faults and potential problems, effectively addressing the issue of low maintenance efficiency.

[0003] Diesel engines release a large amount of heat during combustion, and the cooling water system ensures that its heated components remain at a stable normal temperature through water circulation. During diesel engine operation, the cooling water system frequently malfunctions due to harsh environments, prolonged high-load use, product quality issues, and inadequate maintenance, impacting engine operation. Intercooler temperature is a crucial indicator of the health status of the diesel engine's cooling water system; abnormal intercooler temperature indicates a cooling water system failure. By combining this with other parameters, the specific causes of system failures can be diagnosed, providing an intelligent operation and maintenance method that is significant for improving the intelligence level of diesel engines.

[0004] Currently, diesel engines monitor intercooler temperature, intercooler pressure, and high-temperature water pressure, but only select one fixed threshold range for over-threshold alarms. After an alarm is triggered, only the parameter and the abnormality of the cooling water system are displayed; the specific cause of the fault within the cooling water system cannot be determined, nor can a solution be provided.

[0005] The existing diesel engine microcomputer system lacks multi-parameter integrated diagnostics. When the intercooler temperature alarm occurs, there is no intelligent diagnostic method to locate the root cause of the fault, and it cannot provide accurate diagnostic results. Troubleshooting can only be carried out on-site by experienced technicians, which places high demands on personnel and results in insufficient maintenance. Because the existing system cannot provide accurate fault diagnosis results, it lacks a maintenance suggestion push function. For inexperienced personnel, timely maintenance guidance cannot be provided, leading to low maintenance efficiency and long repair times. Summary of the Invention

[0006] In view of the problems existing in the prior art, the present invention discloses an intelligent diagnostic system based on abnormal intermediate cooling water temperature in a diesel engine, and a data acquisition module that collects information on intermediate cooling water inlet temperature, intermediate cooling water pressure, high-temperature water pressure and diesel engine speed.

[0007] The intelligent diagnostic module receives data information transmitted by the data acquisition module and performs data analysis. It uses parameter anomaly judgment method, fault root cause diagnosis method and operation and maintenance suggestion prompt method to investigate abnormal parameters of diesel engine. It automatically judges the fault root cause of abnormal intercooler temperature by establishing a fault diagnosis process and issues early warning and operation and maintenance suggestions.

[0008] The early warning display module receives parameter information from the data acquisition module and early warning signals from the intelligent diagnosis module, and provides alarm prompts and maintenance prompts. The early warning display module also downloads historical data and intelligent diagnosis results.

[0009] When the intelligent diagnostic module uses the parameter anomaly judgment method for fault diagnosis:

[0010] The received intermediate cooling water temperature, intermediate cooling water pressure, and high-temperature water pressure are compared with the set high and low thresholds, respectively. If the received data value is greater than the high threshold or lower than the low threshold, an alarm signal is issued and R1=1 is output. If the received data value is between the low and high thresholds, R1=0 is output. The received data value is then compared with the second high threshold and the second low threshold. If the received data value is greater than the second high threshold or lower than the second low threshold, R2=1 is output. If the received data value is between the second low threshold and the second high threshold, R2=0 is output.

[0011] When the intelligent diagnostic module uses the root cause diagnosis method for fault diagnosis: during the threshold determination process, if any output determination result R1 of the intermediate cooling water temperature information, intermediate cooling water pressure information, or high temperature water pressure is 1, the intelligent diagnostic module outputs the diagnosis result: the sensor of this parameter or its connecting harness is abnormal.

[0012] If the output judgment result shows that the cold water temperature R1 is 0 and R2 is 1, the intelligent diagnosis module will determine whether the intercooling water pressure R2 is 1. If the intercooling water pressure R2 is 1, the diagnosis result of poor locomotive cold water heat dissipation will be automatically output. If the intercooling water pressure R2 is 0, the diagnosis result of high temperature water pressure R2 will be determined. If it is, the diagnosis result of abnormal cooling water pipeline or abnormal low temperature water pump will be automatically output. If it is not, the diagnosis result of abnormal locomotive water level or abnormal cold water pipeline will be automatically output.

[0013] When the intelligent diagnostic module uses the maintenance suggestion prompt method for fault diagnosis: when the intelligent diagnostic module diagnoses an abnormality in a certain electrical component of the diesel engine, it outputs maintenance suggestions. When multiple diagnostic results are output, the multiple maintenance suggestions are checked for duplicates and duplicates are removed, and a comprehensive maintenance suggestion is output.

[0014] By employing the above technical solution, this invention provides an intelligent diagnostic system for abnormal coolant temperature in diesel engines. This system comprehensively monitors the coolant temperature status of diesel engines, automatically alarms, intelligently diagnoses anomalies, and provides maintenance suggestions. When the coolant temperature is abnormal, the system automatically locates the problematic component and provides maintenance recommendations, improving the timeliness of diesel engine operation and maintenance, and reducing operation and maintenance costs. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a schematic diagram of the intelligent diagnostic system for abnormal cooling water temperature in a diesel engine according to the present invention.

[0017] Figure 2 This is a flowchart for diagnosing abnormal parameters of intermediate cooling water temperature, intermediate cooling water pressure, and high-temperature water pressure in a diesel engine according to the present invention.

[0018] Figure 3 This is a flowchart of the method for diagnosing the root cause of cooling water temperature faults in diesel engines according to the present invention.

[0019] Figure 4 This is a flowchart of the maintenance suggestion method for diesel engines according to the present invention. Detailed Implementation

[0020] To make the technical solutions and advantages of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention:

[0021] like Figure 1 The system shown is an intelligent diagnostic system based on abnormal cooling water temperature in a diesel engine, including a data acquisition module, an intelligent diagnostic module, and an early warning display module.

[0022] The data acquisition module uses multiple sensors to collect information on the diesel engine's intercooler inlet temperature, intercooler pressure, high-temperature water pressure, and diesel engine speed. The specific implementation process is as follows: a speed sensor is used to collect the diesel engine's speed value; a PT100 platinum resistance temperature sensor is installed at the intercooler inlet measuring point; a pressure transmitter is connected to the intercooler inlet and high-temperature water inlet measuring points; and the other end of the sensor is connected to the data acquisition module. The data acquisition module is equipped with a PT100 input signal detection circuit, a 0-5V analog input signal detection circuit, and a frequency input signal detection circuit. The sensor signals collected by each signal detection circuit are converted and output to the intelligent diagnostic module.

[0023] The intelligent diagnostic module employs a central processing unit with data processing and analysis capabilities and a memory with data storage function, and is equipped with Visual Studio development technology. Based on the data information transmitted by the data acquisition module, it performs data analysis, uses parameter anomaly judgment method, fault root cause diagnosis method, and operation and maintenance suggestion prompt method to investigate abnormal parameters of diesel engine, and automatically determines the root cause of the fault causing abnormal intercooler temperature by establishing a fault diagnosis process and issues early warning and operation and maintenance suggestions.

[0024] The early warning display module employs an LCD display module, a touchscreen, and a download port. Utilizing Visual Studio Code and QTCreator development technologies, a visual interface is designed to display the parameter signals received by the data acquisition module and the processing results generated by the intelligent diagnostic module, providing alarm prompts and maintenance suggestions. Data can be downloaded and stored as files via the download port, including historical data, alarm information, and maintenance suggestions.

[0025] Furthermore, when the intelligent diagnostic module uses the parameter anomaly judgment method for fault diagnosis: the first threshold range for the intercooler temperature is taken as the maximum range of the sensor, with the high threshold set as H1 and the low threshold as L1. (For example, the normal operating range of the PT100 sensor is -40℃ to 150℃, so H1 is 150℃ and L1 is -40℃.) The second threshold is taken according to the characteristics of the diesel engine, taking the range from zero speed to the maximum speed under normal operating conditions, with the high threshold set as H2 and the low threshold as L2. (For example, when the diesel engine is operating normally, the intercooler temperature is no lower than 0℃ and no higher than 65℃, so H2 is 65℃ and L2 is 0℃.)

[0026] The first threshold range for intercooled water pressure and high-temperature water pressure is taken from the maximum range of the pressure transmitter, with the high threshold set as H1 and the low threshold as L1. (For example, if the normal operating range of the pressure transmitter is 0 kPa to 1000 kPa, H1 is set to 1000 and L1 to 0.) However, unlike temperature, the normal constraint range for pressure parameters differs significantly between low and high speeds. Therefore, the high threshold H2 and low threshold L2 need to be defined according to the diesel engine speed. The high and low thresholds are set sequentially from low to high speeds to form a curve. (For example, if the intercooled water pressure is not less than 14 kPa at a diesel engine speed of 325 rpm, then L2 is set to 14 and H2 to 1000. If the intercooled water pressure is not less than 56 kPa at a diesel engine speed of 620 rpm, then L2 is set to 56 and H2 to 1000.)

[0027]

[0028] The real-time parameters received from the data acquisition module are first judged within the range of the first threshold H1 and L1. If the data is higher than L1 and lower than H1, the judgment result R1 = 0 is output; if the data is lower than L1 or higher than H1, the judgment result R1 = 1 is output. The judgment result is stored, and an alarm is triggered when the judgment result is 1. If the judgment result is 0, the second threshold H2 and L2 range are judged. If the data is higher than L2 and lower than H2, the judgment result R2 = 0 is output; if the data is lower than L2 but higher than L1, or higher than H2 but lower than H1, the judgment result R2 = 1 is output. The judgment result is stored, and an alarm is triggered when the judgment result is 1.

[0029] Furthermore, when the intelligent diagnostic module uses the root cause diagnosis method for fault diagnosis: when the received parameter R1 is 1, the system automatically outputs the diagnostic result "The sensor or its connection harness for this parameter is abnormal". When the received parameters R1 are all 0, and the received intercooler temperature R1 is 0 and R2 is 1, the system determines whether the intercooler pressure R2 is 1. If the intercooler pressure R2 is 1, the system automatically outputs the diagnostic result "Poor cooling water dissipation of the locomotive". If the intercooler pressure R2 is 0, the system determines whether the high-temperature water pressure R2 is 1. If yes, the system automatically outputs the diagnostic result "Abnormal cooling water pipeline" or "Abnormal low-temperature water pump". If not, the system automatically outputs the diagnostic result "Abnormal locomotive water level" or "Abnormal cooling water pipeline".

[0030] Furthermore, when the intelligent diagnostic module uses maintenance suggestion prompts to repair diesel engine faults: when the system diagnostic result includes "abnormal sensor or its connection harness," the system automatically outputs maintenance suggestions: check the sensor, harness and connection, and controller in sequence. When the system diagnostic result includes "poor locomotive cooling water dissipation," the system automatically outputs maintenance suggestions: check the locomotive cooling fan, louvers, and radiator section in sequence. When the system diagnostic result includes "abnormal cryogenic water pump," the system automatically outputs maintenance suggestions: check the cryogenic water pump and radiator in sequence. When the system diagnostic result includes "abnormal cooling water pipeline," the system automatically outputs maintenance suggestions: check the cooling water pipeline, cryogenic water pump, high-temperature water pump, and radiator in sequence. When the system diagnostic result includes "abnormal locomotive water level," the system automatically outputs maintenance suggestions: check the cooling water level. When multiple diagnostic results are output, the multiple maintenance suggestions are deduplicated, and duplicate items of the checked content are removed, outputting a comprehensive maintenance suggestion.

[0031] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An intelligent diagnostic system based on abnormality in cooling water temperature in a diesel engine, characterized by The application relates to a diesel engine intelligent fault diagnosis system, which comprises the following parts: a data acquisition module for acquiring information of the temperature of middle-cooling water, the pressure of middle-cooling water, the pressure of high-temperature water and the rotating speed of a diesel engine; an intelligent diagnosis module for receiving data information transmitted by the data acquisition module, performing data analysis, adopting a parameter abnormality judgment method, a fault root diagnosis method and an operation and maintenance suggestion prompting method to check abnormal parameters of the diesel engine, automatically judging the fault root causing the abnormality of the temperature of middle-cooling water and issuing a warning and operation and maintenance suggestions through the establishment of a fault diagnosis process; a warning display module for receiving parameter information of the data acquisition module and a warning signal of the intelligent diagnosis module and performing alarm and operation and maintenance suggestions, wherein the warning display module downloads historical data and intelligent diagnosis results; when the intelligent diagnosis module adopts the parameter abnormality judgment method to perform fault diagnosis, the received temperature information of middle-cooling water, the received pressure information of middle-cooling water and the received pressure information of high-temperature water are compared with set high and low threshold values respectively, if the received data value is greater than the high threshold value or lower than the low threshold value, a warning signal is issued and R1=1 is output, if the received data value is between the low threshold value and the high threshold value, R1=0 is output, and the received data value is compared with a second high threshold value and a second low threshold value, if the received data value is greater than the second high threshold value or lower than the second low threshold value, R2=1 is output, if the received data value is between the second low threshold value and the second high threshold value, R2=0 is output; when the intelligent diagnosis module adopts the fault root diagnosis method to perform fault diagnosis, if any one of the output judgment results of the temperature information of middle-cooling water, the pressure information of middle-cooling water or the pressure information of high-temperature water is 1 in the threshold value judgment process, the intelligent diagnosis module outputs a diagnosis result that a parameter sensor or a connecting wire harness thereof is abnormal; if the output judgment result of the temperature of middle-cooling water is 0 and R2 is 1, the intelligent diagnosis module judges whether the output judgment result of the pressure of middle-cooling water is 1, if the output judgment result of the pressure of middle-cooling water is 1, a diagnosis result that the cooling water of the locomotive is not well radiated is automatically output, if the output judgment result of the pressure of middle-cooling water is 0, whether the output judgment result of the pressure of high-temperature water is 1 is judged, if yes, a diagnosis result that a cooling water pipeline is abnormal or a low-temperature water pump is abnormal is automatically output, if not, a diagnosis result that a water level of the locomotive is abnormal or a cooling water pipeline is abnormal is automatically output. when the intelligent diagnosis module adopts the operation and maintenance suggestion prompting method to perform fault diagnosis, if the intelligent diagnosis module diagnoses that an abnormality occurs in a certain electric device of the diesel engine, an operation and maintenance suggestion is output, if multiple diagnosis results are output, multiple operation and maintenance suggestions are checked and repeated items are removed, and a comprehensive operation and maintenance suggestion is output.

2. The intelligent diagnostic system based on abnormality in intercooled water temperature in diesel engine as claimed in claim 1 wherein: ​

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