A water pump or water turbine unit performance testing device and analysis method

Abstract

The present application belongs to the field of fluid machinery performance test and on-line monitoring, and discloses a water pump or water turbine unit operation performance test device and method. The test device comprises a collection module and a test module. The collection module comprises a sensor group and a portable interface box encapsulated power supply unit, signal conditioning circuit and data acquisition card. The interface box and the sensor group are connected by phoenix terminals, so that each sensor forms an independent signal channel. The test module comprises a rating module, a test module, a sorting module and a signal analysis module arranged from top to bottom. The rating module is used to determine the correspondence between the sensor and the signal channel. The test module is used for on-line monitoring, test and wave recording during the unit operation process, and obtains the wave recording data. The sorting module is used to obtain effective data by cutting the wave recording data. The signal analysis module is used for analyzing and processing the effective data. The present application simplifies the unit test process and greatly reduces the error probability.

Description

Technical Field

[0001] This invention belongs to the field of fluid machinery performance testing and online monitoring, and specifically relates to a device and method for testing the performance of a water pump or hydropower unit. Background Technology

[0002] The increasing size and integration of water pumps and hydropower units place more stringent demands on their stable operation. Therefore, testing water pumps and hydropower units is crucial for understanding their operational performance, determining their working status, predicting deterioration trends, diagnosing faults, optimizing operation, and developing maintenance plans. It also provides on-site measured data for improving the design of water pumps and hydropower units.

[0003] There are three main methods for testing the operational performance of water pumps or hydropower units: handheld testing instruments, portable multi-channel testing devices, and online monitoring systems. Early on, the operational performance of water pumps or hydropower units was mostly tested by personnel using handheld testing instruments at different measuring points. This involved significant manpower, complex procedures, and poor concurrency and real-time performance of signal readings, resulting in low accuracy in subsequent signal correlation analysis and difficulty in accurately assessing unit performance. With the development of sensor technology, data acquisition technology, communication technology, and computer technology, portable multi-channel testing devices and online monitoring systems have gradually been applied to the field of water pump or hydropower unit operational performance testing. However, online monitoring systems are costly, difficult to promote in some pumping stations or hydropower plants, and the fixed wiring patterns of pre-installed field measuring points and acquisition units make it difficult to add sensor measuring points and connect them, hindering the implementation of tests requiring additional measuring points. Existing portable multi-channel testing devices have the following shortcomings: on-site manual recording of test conditions and test time is required, the operation process is complex and prone to errors; the wiring terminals of the acquisition interface box are set separately for voltage or current signals, the function is relatively simple and the expandability is not strong; there is a lack of online monitoring function for unit operation status; for a specific portable multi-channel testing device, it is difficult to combine the performance testing and analysis functions of water pump units and hydropower units.

[0004] Currently, there is no portable multi-channel testing device developed specifically for water pumps or hydropower units that can combine online monitoring and testing functions for both water pumps and hydropower units, especially in the process of recording test waveforms without manual intervention to record test conditions and test time, while also being equipped with professional comprehensive testing and analysis software. Summary of the Invention

[0005] The purpose of this invention is to provide a performance testing device and analysis method for water pumps or hydropower units, overcoming the shortcomings of existing technologies such as complex wiring, the need for manual intervention to record test conditions and time during test waveform recording, cumbersome and error-prone testing procedures, inability to simultaneously perform performance testing functions for both water pumps and hydropower units, inability to integrate online monitoring and performance testing functions, and limited specialized comprehensive analysis capabilities. This invention enables multi-channel continuous parallel real-time sampling of measurement points on water pumps and hydropower units, realizing online monitoring and testing functions for the operating performance of these two types of units. In particular, it features continuous waveform recording during the test process, eliminating the need for manual intervention to record test time and conditions, simplifying the test operation process. The device has a simple wiring method, is easy to carry, and is equipped with specialized comprehensive testing and analysis software.

[0006] To achieve the above objectives, this invention proposes a performance testing device for a water pump or hydroelectric generator, comprising a data acquisition module and a testing module, which are electrically connected. The data acquisition module includes a sensor group, a power supply unit, a signal conditioning circuit, and a data acquisition card. The power supply unit, the signal conditioning circuit, and the data acquisition card are packaged in a portable interface box. The interface box and the sensor group are connected using Phoenix terminal blocks. Each sensor in the sensor group is connected to a Phoenix terminal block on the interface box to form an independent signal channel.

[0007] The testing module includes, from top to bottom, a calibration module, a testing module, a sorting module, and a signal analysis module;

[0008] The calibration module is used to name each signal channel, determine the correspondence between each sensor and each signal channel in the sensor group, and establish the correspondence between the physical quantities of the water pump or hydropower unit measured by each signal channel and the output current or voltage values ​​of the sensor.

[0009] The test module is used for online monitoring, testing, and waveform recording during the operation of water pumps or hydropower units, and to obtain waveform data.

[0010] The sorting module is used to trim the waveform recording data of the test module to obtain the valid data corresponding to the test conditions;

[0011] The signal analysis module is used to analyze and process the valid data.

[0012] According to one embodiment of the present invention, the sensor group is used to capture current signals or voltage signals corresponding to physical quantities of a water pump or hydroelectric generator, and transmits the current signals or voltage signals to a signal conditioning circuit. The signal conditioning circuit is used to condition the current signals or voltage signals into electrical signals within the input range of a data acquisition card. The data acquisition card is used to convert the electrical signals into digital signals and upload them to the calibration module. The input range of the data acquisition card is ±10V, ±5V, ±2V, and ±1V.

[0013] According to one embodiment of the present invention, each Phoenix terminal includes a -24V power supply, a +24V power supply, a current signal input terminal, a voltage signal input terminal, and a ground terminal.

[0014] According to one embodiment of the present invention, the sensor group is a 32-channel sensor, the maximum sampling rate of the signal channel is 250K / s, and the AD resolution is 16 bits.

[0015] According to one embodiment of the present invention, the calibration module is an offline calibration module or an online calibration module.

[0016] According to one embodiment of the present invention, the test module includes multiple online monitoring units, which are used to monitor multiple state variables of the water pump or hydropower unit online, including vibration, noise, swing, flow rate, temperature, pressure, pressure pulsation, torque and rotational speed.

[0017] According to one embodiment of the present invention, the signal analysis module includes a time-domain analysis module and a frequency-domain analysis module. The time-domain analysis module is used to draw data lists, time-domain waveform diagrams, spectrum diagrams, waveform length diagrams, three-dimensional waterfall diagrams, axis trajectory diagrams, dynamic balance weight orientation diagrams, or data reports for the effective data. The frequency-domain analysis module is used to provide the maximum value, minimum value, average value, peak value, effective value, frequency, and signal trend analysis of the signal in the signal channel.

[0018] In summary, the technical solutions conceived in this invention have the following main technical advantages compared with the prior art:

[0019] 1. This invention simplifies the automatic testing of water pump units and hydroelectric generator units, avoids manual intervention in the waveform recording process, and subsequently sorts the valid data into different test conditions according to the operating conditions. Moreover, after each sensor is connected to a Phoenix terminal on the interface box, it forms an independent signal channel, which greatly reduces the probability of on-site errors. At the same time, it has the testing functions of water pump units and hydroelectric generator units, breaking through the limitation of existing technologies that cannot simultaneously possess the testing and analysis functions of hydroelectric generator units and water pump units.

[0020] 2. The sensor group of the present invention has a maximum of 32 groups, which can meet the signal capture of all types of physical quantities of the unit. Then, the data is uploaded to the test module in sequence through the signal conditioning circuit and the data acquisition card. The acquisition process is orderly and not prone to errors.

[0021] 3. The signal analysis module of the present invention includes a time domain analysis module and a frequency domain analysis module, which can display effective data in various different charts and graphs, while ensuring the completeness and intuitiveness of the test results analysis. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the test device according to an embodiment of the present invention.

[0023] Figure 2 This is a schematic diagram of the test apparatus according to an embodiment of the present invention.

[0024] Figure 3 This is a schematic diagram of the wiring of the Phoenix terminal in the interface box of the acquisition module in an embodiment of the present invention.

[0025] Figure 4 This is an example of channel configuration in the calibration module of this invention.

[0026] Figure 5 This is an example of channel calibration in the calibration module of this invention.

[0027] Figure 6 This is an example of signal overall monitoring in the experimental module of this invention.

[0028] Figure 7 This is an example of feature value monitoring in the experimental module of this invention.

[0029] Figure 8 This is an example of a pump efficiency monitoring configuration in the test module of this invention.

[0030] Figure 9 This is an example of pump efficiency monitoring in the test module of this invention.

[0031] Figure 10 This is an example of hydropower unit efficiency monitoring in the test module of this invention.

[0032] Figure 11 This is an example of multi-signal classification monitoring in the experimental module of this invention.

[0033] Figure 12 This is an example of axis trajectory monitoring in the test module of this invention.

[0034] Figure 13 This is an example of three-dimensional axis attitude monitoring in the test module of this invention.

[0035] Figure 14 This is an example of multi-signal bar graph monitoring in the experimental module of this invention.

[0036] Figure 15 This is an example of single-channel signal time-frequency monitoring in the experimental module of this invention.

[0037] Figure 16 This is an example of waveform spectrum analysis in the signal analysis module of this invention.

[0038] Figure 17 This is an example of three-dimensional waterfall plot analysis in the signal analysis module of this invention.

[0039] Figure 18 This is an example of axis trajectory analysis in the signal analysis module of this invention.

[0040] Figure 19 This is an example of trend analysis in the signal analysis module of this invention.

[0041] Figure 20 This is an example of correlation analysis in the signal analysis module of this invention.

[0042] Figure 21 This is an example of dynamic balance analysis in the signal analysis module of this invention.

[0043] Figure 22 This is an example of turning gear analysis in the signal analysis module of this invention.

[0044] Figure 23 This is an example of efficiency analysis in the signal analysis module of this invention. Detailed Implementation

[0045] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0046] like Figure 1 As shown, this embodiment of the invention provides a performance testing device and analysis method for water pumps or hydroelectric generators, with specific implementation steps as follows: Figure 2As shown, it includes: an acquisition module for capturing electrical quantities characterizing the operating performance of a water pump or hydropower unit; a calibration module for converting the electrical quantities acquired by the acquisition module into physical quantities representing the operating status of the water pump or hydropower unit; a testing module for online monitoring, testing, and waveform recording of the operating performance of the water pump or hydropower unit; a sorting module for trimming the waveform recording data from the testing module to obtain valid data corresponding to the test conditions; and a signal analysis module for analyzing and processing the sorted data.

[0047] The acquisition module includes a sensor unit, a power supply unit, a signal conditioning circuit, and a data acquisition unit. The sensor unit measures the electrical signals of the unit's operating performance status. The signal conditioning circuit connects the sensor unit, power supply unit, and data acquisition unit, and conditions the monitored electrical signals (voltage input range -20V to 20V; current input range 0 to 20mA, load resistance 250Ω). The data acquisition unit acquires the conditioned electrical signals and converts them into digital signals. Swing sensors, vibration sensors, pressure transmitters, pressure pulsation sensors, noise sensors, flow meters, and other types of sensors are installed at the measurement points on the unit, and third-party detection signals are also connected. A high-performance industrial switching power supply powers the system, capturing current or voltage signals corresponding to physical quantities such as unit vibration, noise, swing, flow rate, temperature, pressure, pressure pulsation, torque, and speed. These current or voltage signals are transmitted to the signal conditioning circuit, which conditions and converts them into electrical signals within the input range of the data acquisition card. The data acquisition card acquires the conditioned electrical signals, converts them into digital signals, and uploads them to the testing computer. The acquisition module has 32 independent signal channels (supporting channel expansion), each supporting current or voltage signal input; it supports continuous parallel real-time acquisition, with a maximum sampling rate of 250K / s per channel, and stable and reliable performance; the AD resolution is 16 bits; the data acquisition card input range is ±10V, ±5V, ±2V, and ±1V; it provides +24V and -24V sensor power supply levels by default, and supports extended power supply levels; the interface box uses a high-grade aluminum alloy carrying case, which is aesthetically pleasing, sturdy, and easy to carry; the connection between the interface box and the sensor uses Phoenix terminal blocks, each terminal block has ±24V power supply to power the sensor, and also has voltage and current signal input terminals, which can measure voltage signals within ±24V and current signals from 0 to 20mA, making wiring simple and reliable, reducing the probability of wiring errors in the field. Figure 3 This is a schematic diagram of the Phoenix terminal wiring of the interface box in the acquisition module of this invention, including the wiring method of voltage output type sensor, the wiring method of two-wire current type output sensor, the wiring method of voltage type monitoring signal, and the wiring method of current type monitoring signal.

[0048] The calibration module is used to name each channel, determine the correspondence between the sensor and the channel number, establish the correspondence between the physical quantities of the unit measured by each channel and the sensor output current or voltage value, and supports both offline and online sensor calibration methods. First, click "Sensor Calibration" to enter the sensor calibration program, then click the menu item "File" → "Open Configuration File," select the sensor calibration file with the extension "MCX," and enter the overall channel information setting window to set the information for each channel, such as... Figure 4 As shown. The calibration module includes the following information settings: channel number, channel name, channel unit, current and voltage, maximum and minimum values, coefficient 0 and coefficient 1, signal type, channel storage frequency, and acquisition card voltage range. There are two signal types: general waveform and rotational speed waveform. Except for the key phase signal, which is set to a rotational speed waveform, all other signals are set to general waveforms. For the rotational speed waveform, coefficient 0 is set to the pulse signal holding time, and coefficient 1 is set to the signal trigger threshold. After configuring the information, the sensor calibration window is entered. In this window, modifiable parameters can be modified, or the correspondence between physical quantities and electrical values ​​can be entered in the "Direct Input" field, or online calibration can be performed in the "Online Calibration" field. Figure 5 As shown.

[0049] The test module is used to monitor state parameters such as vibration, sway, pressure, temperature, and noise of water pumps or hydropower units. It displays real-time characteristic values, waveforms, spectra, shaft center trajectories, three-dimensional shaft center attitudes, and overall diagrams of signals from each test channel, enabling online monitoring and analysis of the unit's real-time operating performance. It is used for vibration testing, noise testing, energy characteristics, start-up, shutdown, steady-state operation, variable flow rate, variable blades, turning gear operation, dynamic balancing, efficiency, and load shedding tests. It is also used for data acquisition and storage, as well as for efficiency test curve plotting and data storage. In the test module, clicking the menu item "File" → "Open Sensor Information File," selecting a calibration file with the "MCX" extension, enters the HSJ data acquisition program. Double-clicking the item in the navigation bar allows you to view relevant information. Figures 6-15 These are example diagrams for signal overview, feature value list, pump efficiency monitoring configuration, pump efficiency monitoring, hydropower unit efficiency monitoring, multi-signal classification monitoring, shaft center trajectory monitoring, three-dimensional shaft center attitude monitoring, multi-signal bar graph, and single-channel signal time-frequency monitoring.

[0050] The sorting module is used to cut valid data corresponding to each test condition from the continuously acquired waveform data file according to the operating condition parameters, so that the signal analysis module can further analyze and process it. This simplifies the test process and avoids the cumbersome operation of manually recording test conditions and test time at the test site, which is required in existing technologies. This ensures that the continuous waveform recording method in the test module of this invention can be carried out without manual intervention, reducing the probability of errors. Clicking "Data Sorting" in the sorting module will enter the data sorting program. Clicking the menu item "System Configuration" → "Work Directory Selection" will select the work directory. The system will automatically open the available data files, and then select the sorting reference channel to sort the test condition data. Theoretically, any signal in the navigation bar can be used as the basis for data sorting. Generally, active power signals are selected for variable load tests, and speed signals are selected for variable speed tests. The sorting module window includes several tools to help complete sorting tasks: drag the cursor, stretch the X coordinate, stretch the XY coordinate, pan the area, refresh data, directly save sorting data, output sorting data, save sorting records, load sorting records, clear sorting, restore sorting, add sorting segments, etc.

[0051] The signal analysis module is used to analyze and process the test data after sorting, and obtain the test analysis results. It supports both whole-cycle and non-whole-cycle analysis modes. Employing time-domain and frequency-domain analysis methods, it provides data lists, time-domain waveform diagrams, spectrum diagrams, waveform length diagrams, 3D waterfall diagrams, shaft center trajectory diagrams, dynamic balance weight orientation diagrams, data reports, and customized output functions for corresponding data files. It also provides analysis functions such as maximum value, minimum value, average value, peak-to-peak value, effective value, frequency, trend analysis, and correlation analysis. The signal analysis module supports both whole-cycle and non-whole-cycle signal analysis modes. (Whole-cycle analysis: One rotation of the unit is called a cycle. Data selection during analysis is based on the key phase point. The data length always starts at the key phase point and ends at another key phase point, ensuring accurate generation of unit speed and frequency. Non-whole-cycle analysis is defined by time as the starting point of the data. Time can be the length of time during sorting or a manually selected time length.) In the signal analysis module, click "File" → "Open Sorting File" to load the data to be analyzed into the window for signal analysis of the relevant test data. Figure 16 The signal waveform spectrum analysis diagram in the signal analysis module provides the following functions: picking up floating points, picking up nearby points, translating the XY axis, zooming in on the X axis, zooming in on the Y axis, zooming in on the XY axis, undoing, labeling, redrawing, etc.; integer-period FFT and non-integer-period FFT of the signal, displaying key phases, adding channel data, adding movement trends, waveform filtering, restoring data before filtering, etc.; customized batch storage of graphics and data. Figure 17 This is an example diagram of 3D waterfall plot analysis in the signal analysis module. Figure 18 This is an example diagram of axis trajectory analysis in the signal analysis module. Figure 19 This is a trend analysis diagram in the signal analysis module, reflecting the relationship between the unit's vibration amplitude and unit operating parameters such as load, speed, or excitation voltage. Figure 20 This is a schematic diagram of signal correlation analysis in the signal analysis module. Figure 21 This is a schematic diagram of dynamic balance analysis in the signal analysis module. Figure 22 This is a schematic diagram of the turning gear analysis in the signal analysis module. Figure 23 This is a schematic diagram for efficiency analysis.

[0052] In summary, the pump or hydropower unit performance testing device and analysis method disclosed in this invention can perform multi-channel continuous parallel real-time monitoring, waveform recording, performance testing, and analysis of measuring points arranged in the pump or hydropower unit. It simplifies the testing process, eliminating the need for operator intervention during waveform recording. Continuous waveform recording allows for subsequent sorting of the continuous waveform data into valid data corresponding to different test conditions based on operating parameters. This avoids the cumbersome manual recording of test conditions and times required in existing technologies, reducing the probability of errors. It combines the testing functions of pump units and hydropower units with online monitoring functions; it is equipped with professional comprehensive testing and analysis software; the wiring is simple and reliable; and it is compact and portable.

[0053] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A performance testing device for a water pump or hydroelectric generator set, characterized in that, It includes a data acquisition module and a test module, which are electrically connected. The data acquisition module includes a sensor group, a power supply unit, a signal conditioning circuit, and a data acquisition card. The power supply unit, the signal conditioning circuit, and the data acquisition card are packaged in a portable interface box. The interface box and the sensor group are connected by Phoenix terminal blocks. Each sensor in the sensor group is connected to a Phoenix terminal block on the interface box to form an independent signal channel. The testing module includes, from top to bottom, a calibration module, a testing module, a sorting module, and a signal analysis module; The calibration module is used to name each signal channel, determine the correspondence between each sensor and each signal channel in the sensor group, and establish the correspondence between the physical quantities of the water pump or hydropower unit measured by each signal channel and the output current or voltage values ​​of the sensor. The test module is used for online monitoring, testing, and waveform recording during the operation of water pumps or hydropower units, and obtains continuously acquired waveform data. The test module includes multiple online monitoring units, which are used to monitor multiple state variables of water pumps or hydropower units online, including vibration, noise, sway, flow rate, temperature, pressure, pressure pulsation, torque, and speed. The sorting module is used to cut the valid data corresponding to each test condition from the continuously collected waveform data file according to the working condition parameters. The signal analysis module is used to analyze and process the valid data.

2. The performance testing device for a water pump or hydroelectric generator unit according to claim 1, characterized in that, The sensor group is used to capture current or voltage signals corresponding to physical quantities of a water pump or hydroelectric generator, and transmits the current or voltage signals to a signal conditioning circuit. The signal conditioning circuit is used to condition the current or voltage signals into electrical signals within the input range of a data acquisition card. The data acquisition card is used to convert the electrical signals into digital signals and upload them to the calibration module. The input range of the data acquisition card is ±10V, ±5V, ±2V, and ±1V.

3. The performance testing device for a water pump or hydropower unit according to claim 1, characterized in that, Each Phoenix terminal block includes a -24V power supply, a +24V power supply, a current signal input terminal, a voltage signal input terminal, and a ground terminal.

4. The performance testing device for a water pump or hydroelectric generator unit according to claim 1, characterized in that, The sensor group consists of 32 sensors, the maximum sampling rate of the signal channel is 250K / s, and the AD resolution is 16 bits.

5. A performance testing device for a water pump or hydropower unit according to any one of claims 1-4, characterized in that, The calibration module can be an offline calibration module or an online calibration module.

6. A performance testing device for a water pump or hydropower unit according to any one of claims 1-4, characterized in that, The signal analysis module includes a time-domain analysis module and a frequency-domain analysis module. The time-domain analysis module is used to draw data lists, time-domain waveform diagrams, spectrum diagrams, waveform length diagrams, three-dimensional waterfall diagrams, axis trajectory diagrams, dynamic balance weight orientation diagrams, or data reports for the effective data. The frequency-domain analysis module is used to provide the maximum value, minimum value, average value, peak value, effective value, frequency, and signal trend analysis of the signal in the signal channel.

7. A method for testing the performance of a water pump or hydropower unit, the method utilizing the testing apparatus as described in any one of claims 1-6, specifically comprising the following steps: S1: The acquisition module captures electrical quantities that characterize the operating performance of water pumps or hydropower units; S2: The calibration module converts the electrical quantities acquired by the acquisition module into physical quantities representing the unit's operating status. S3: The test module is used for online monitoring, testing, and waveform recording during unit operation; S4: The sorting module trims the waveform recording data of the test module to obtain the valid data corresponding to the test conditions; S5: The signal analysis module analyzes and processes the valid data to complete the test.

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