Remote intelligent operation and maintenance system for diesel generator sets

Abstract

The invention discloses a remote intelligent operation and maintenance system for a diesel generator set, which relates to the technical field of diesel generator operation and maintenance, and comprises a contact surface image acquisition module, a contact surface contour acquisition module, a contact area acquisition module, a contact distribution coefficient acquisition module, a contact abnormality mark generation module, a deviation area marking module and a display terminal; by analyzing whether the contact area between a carbon brush and a rotor is kept within a certain range, once a contact abnormality is detected, a contact abnormality mark is generated, and a contact abnormality notification is sent to a remote monitoring terminal in real time, which is conducive to relevant personnel to take corresponding inspection and processing measures for the carbon brush in time, which includes but is not limited to replacing the carbon brush, cleaning the slip ring or adjusting the carbon brush pressure, so as to realize remote monitoring of the diesel generator set, effectively reduce the wear between the carbon brush and the rotor, reduce the failure rate of the diesel generator, and extend the service life of the diesel generator.

Description

Technical Field

[0001] The present invention relates to the technical field of diesel generator operation and maintenance, and in particular to a remote intelligent operation and maintenance system for a diesel generator set. Background Art

[0002] As an emergency backup power source and the main power source in certain specific scenarios, the stability and reliability of diesel generator sets are directly related to the safety of urban energy supply. As an important backup power source or independent power supply equipment, the stable operation of diesel generator sets is crucial. With the development of science and technology and the continuous improvement of the requirements for power supply reliability, remote intelligent operation and maintenance has become a key means to ensure the efficient and stable operation of diesel generator sets.

[0003] In actual operation, good contact between the carbon brush and the rotor plays a key role in the stable transmission of current and the normal operation of the unit. The carbon brush is a key component for transmitting current in a diesel generator. Its contact area with the rotor directly affects the current transmission efficiency and the performance of the generator. A small contact area may lead to poor current transmission and increased wear; a large contact area may affect the contact pressure and cause unstable current transmission. Therefore, it is necessary to regularly check the wear of the carbon brush to ensure that the contact area with the rotor meets the design requirements. For severely worn carbon brushes, they should be replaced in time, and the carbon brush holder and spring should be adjusted to ensure a stable contact area and contact pressure.

[0004] The patent publication number CN110430709A discloses a diesel generator control system, including a control cabinet and a control system, wherein a control cabinet door is installed at the edge of the control cabinet, a dehumidifier cabinet is installed at the upper end of the control cabinet, a front panel is installed at the front end of the control cabinet, a wire harness plate is installed parallel to the front panel, several groups of wiring terminals are installed on the front panel, and a control switch is installed above the wiring terminals; the diesel generator control system can facilitate the classified arrangement of connecting wires inside the control cabinet, and wrap and place spare or redundant connecting wires, so as to achieve tripping or shutdown protection to prevent the control system lines from being burned out. An alarm can be issued through a fault alarm module to remind the staff to perform maintenance in time, ensure a dry environment inside the control cabinet, effectively prevent the connecting wires from getting damp and leaking electricity, and facilitate the staff to intuitively understand the total power generation and stably output electrical energy to the electrical load.

[0005] However, since the contact area between the carbon brush and the slip ring will directly affect the efficiency and stability of current transmission, if the contact area is insufficient, the resistance between the carbon brush and the slip ring will increase, thereby generating more heat energy and unstable current output. Therefore, monitoring the contact area between the carbon brush and the diesel generator rotor and evaluating the contact status between the carbon brush and the rotor are of great significance to improving the stability and efficiency of equipment operation. Based on this, a remote intelligent operation and maintenance system for diesel generator sets is proposed. Summary of the invention

[0006] The purpose of the present invention is to provide a remote intelligent operation and maintenance system for a diesel generator set, which solves the technical problem of being unable to monitor the contact area between the carbon brush and the diesel generator rotor and evaluate the contact state between the carbon brush and the rotor.

[0007] The purpose of the present invention can be achieved through the following technical solutions:

[0008] Diesel generator remote intelligent operation and maintenance system, including:

[0009] A contact surface image acquisition module is used to acquire a contact surface image between the carbon brush and the rotor;

[0010] The contact surface profile acquisition module extracts and processes the contact surface image to obtain the contact surface profile between the carbon brush and the rotor;

[0011] The contact area acquisition module analyzes the coordinates of each contact point on the contact surface contour to obtain the contact area between the carbon brush and the rotor;

[0012] The contact distribution coefficient acquisition module calculates the contact distribution coefficient between the carbon brush and the rotor according to the coordinates of each contact point;

[0013] The contact abnormality mark generation module comprehensively analyzes the contact area and contact distribution coefficient between the carbon brush and the rotor to determine and generate the contact abnormality mark;

[0014] Deviation area marking module, when generating contact anomaly identification, divides the contact surface contour into multiple quadrant areas, analyzes the number of contact points in each quadrant area, and marks the deviation area according to the analysis results;

[0015] The display end displays the marked deviation area.

[0016] As a further solution of the present invention: the specific method of obtaining the contact area between the carbon brush and the rotor is:

[0017] A two-dimensional coordinate system is established on the contact surface contour, and the specific coordinates of each node on the edge line of the contact surface contour are defined as the contact point coordinates of the contact surface. The contact area SJ between the carbon brush and the rotor is calculated using the shoelace formula based on the coordinates of each contact point.

[0018] As a further solution of the present invention: the specific method of obtaining the contact distribution coefficient between the carbon brush and the rotor is:

[0019] The standard deviations HA and HB corresponding to the horizontal and vertical coordinates of each contact point are calculated respectively, and the mean between the two is defined as the contact distribution coefficient F between the carbon brush and the rotor.

[0020] As a further solution of the present invention: the specific method of determining and generating the contact abnormality mark is:

[0021] The absolute value of the difference between the contact area between the carbon brush and the rotor and the preset area threshold Q1, as well as the absolute value of the difference between the contact distribution coefficient and the preset distribution threshold Q2 are obtained, and the sum of the absolute values ​​of the difference between the two and the product of the preset parameter coefficients θ1 and θ2 is defined as the contact deviation value PC between the carbon brush and the rotor. When the contact deviation value PC is greater than the preset value Q3, a contact abnormality mark is generated. When the contact deviation value PC is less than or equal to the preset value Q3, no processing is performed.

[0022] As a further solution of the present invention: the specific method of marking the deviation area is:

[0023] The contact surface contour between the carbon brush and the rotor is divided into four quadrant areas, the contact points in each quadrant are counted, the mean Zp of the number of contact points in all quadrants is calculated, and then the absolute value Ev of the difference between the number of contact points in each quadrant and the mean Zp is calculated. The quadrant area where the absolute value of the difference Ev is greater than the preset threshold Q4 is marked as a deviation area, otherwise, no processing is performed, where v refers to the number of quadrant areas, v=1, 2,..., 4.

[0024] As a further solution of the present invention: the shoelace formula is specifically:

[0025] ;

[0026] The coordinates of each contact point are marked as Jn (Jxn, Jyn), where i represents the number of contact points, i is a positive integer, and i≥n≥1.

[0027] As a further solution of the present invention: the specific method of dividing the contact surface profile into four quadrants is:

[0028] The first quadrant area is: X>0, Y>0, the second quadrant area is: X<0, Y>0, the third quadrant area is: X<0, Y<0, and the fourth quadrant area is: X>0, Y<0;

[0029] Where X is the X-axis in the horizontal direction of the two-dimensional coordinate system, and Y is the Y-axis in the vertical direction of the two-dimensional coordinate system.

[0030] As a further solution of the present invention: the specific method of preprocessing the contact surface image is:

[0031] The contact surface edge contour of the contact surface image is extracted through grayscale conversion, denoising and edge detection technology.

[0032] Beneficial effects of the present invention:

[0033] (1) The present invention determines whether there is an obvious local dense or sparse phenomenon in the contact points between the carbon brush and the rotor by analyzing the contact points between the carbon brush and the rotor, and determines the stability and efficiency of the current transmission between the carbon brush and the rotor by analyzing whether the contact area between the carbon brush and the rotor is maintained within a certain range, and determines whether there is an abnormality in the contact between the carbon brush and the rotor. Once the contact abnormality is detected, a contact abnormality mark is generated, and a contact abnormality notification is sent to the remote monitoring end in real time, which is conducive to relevant personnel to take corresponding inspection and treatment measures for the carbon brush in time, including but not limited to replacing the carbon brush, cleaning the slip ring or adjusting the carbon brush pressure, so as to realize remote monitoring of the diesel generator set, which can effectively reduce the wear between the carbon brush and the rotor, reduce the failure rate of the diesel generator, and extend the service life of the diesel generator;

[0034] (2) The present invention divides the contact surface contour into four quadrants, counts the number of contact points in each quadrant, and marks the deviation area, which can guide maintenance personnel to quickly locate the area that requires key inspection and maintenance. This can not only reduce unnecessary inspection and maintenance work, but also improve the pertinence and efficiency of maintenance and reduce maintenance costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] The present invention will be further described below in conjunction with the accompanying drawings.

[0036] Figure 1 It is a schematic diagram of the system framework structure of the remote intelligent operation and maintenance system of the diesel generator set of the present invention;

[0037] Figure 2 It is a schematic diagram of the method framework structure of the remote intelligent operation and maintenance system of the diesel generator set of the present invention. DETAILED DESCRIPTION

[0038] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0039] Embodiment 1

[0040] See also Figure 1-Figure 2 As shown, the present invention is a remote intelligent operation and maintenance system for a diesel generator set, comprising:

[0041] A contact surface image acquisition module uses a high-definition camera or an infrared thermal imager to capture the contact surface image between the carbon brush and the rotor;

[0042] The contact surface profile acquisition module pre-processes the contact surface image between the carbon brush and the rotor through image processing software and image processing technology, thereby obtaining the contact surface profile between the carbon brush and the rotor;

[0043] The acquired contact surface image is preprocessed by image processing software and image processing technology, including grayscale conversion, denoising, edge detection and other steps, so as to obtain the contact surface contour between the carbon brush and the rotor. For example, the image edge is extracted by using edge detection algorithms such as Canny edge detection algorithm or Sobel operator, and then the image is segmented into single objects by using image segmentation algorithm, and finally the contour is approximated into a simpler shape by using contour approximation algorithm (such as polygonal approximation algorithm). The above processing methods are all existing and mature technologies, so no further description is made here.

[0044] The contact area acquisition module analyzes the contact surface profile and obtains the contact area between the carbon brush and the rotor based on the analysis results. The specific method is as follows:

[0045] A two-dimensional coordinate system is established on the contact surface contour, with the center point of the contact surface contour as the origin, the horizontal direction as the X axis, and the vertical direction as the Y axis. On the edge line of the contact surface contour, the specific coordinates of each node are identified and defined as the contact point coordinates of the contact surface, and the coordinates of each contact point are marked as Jn (Jxn, Jyn).

[0046] The contact area SJ between the carbon brush and the rotor is calculated based on the coordinates of each contact point using the shoelace formula. The shoelace formula is as follows:

[0047] ;

[0048] Where i refers to the number of contact points, i is a positive integer, i≥n≥1, and in the calculation, if the coordinates are out of range, the number is taken cyclically;

[0049] Here, the cyclic number acquisition refers to that if the value of a certain contact point coordinate exceeds the valid range set based on the established two-dimensional coordinate system when identifying the contact point coordinates according to the edge line of the contact surface contour (for example, the X-axis coordinate exceeds the boundary range of the contact surface contour in the X direction, or the Y-axis coordinate exceeds the boundary range of the contact surface contour in the Y direction), a cyclic number acquisition operation is performed, and the cyclic number acquisition operation means: if the X-axis coordinate exceeds the range, when the X-axis coordinate is greater than the maximum value of the contact surface contour in the X direction, the length value of the contact surface contour in the X direction is subtracted from the X-coordinate value to return it to the valid range; when the X-coordinate is less than the minimum value of the contact surface contour in the X direction, the length value of the contact surface contour in the X direction is added to the X-coordinate value to return it to the valid range. Similarly, for the Y-axis coordinate, if the Y-coordinate is greater than the maximum value of the contact surface contour in the Y direction, the height value of the contact surface contour in the Y direction is subtracted from the Y-coordinate value to return it to the valid range; when the Y-coordinate is less than the minimum value of the contact surface contour in the Y direction, the height value of the contact surface contour in the Y direction is added to the Y-coordinate value to return it to the valid range;

[0050] The size of the contact area reflects the size of the contact surface between the carbon brush and the rotor. As the carbon brush gradually wears, the contact area will change. The larger the contact area, the higher the current transfer efficiency between the carbon brush and the rotor. This is because a larger contact area can provide more electron flow channels, reduce resistance, and thus improve the efficiency of current transfer.

[0051] The contact distribution coefficient acquisition module calculates the contact distribution coefficient between the carbon brush and the rotor according to the coordinates of each contact point between the carbon brush and the rotor. The specific method is as follows:

[0052] Calculate the standard deviation using the formula and ; Calculate the standard deviations HA and HB corresponding to the horizontal and vertical coordinates of each contact point, and define the mean value between the two as the contact distribution coefficient F between the carbon brush and the rotor, that is, F = (HA + HB) / 2, where Jxp and Jyp are the means of the horizontal coordinate Jxc and the vertical coordinate Jyc of the contact point, respectively, i ≥ c ≥ 1;

[0053] The size of the contact distribution coefficient reflects the uniformity of the contact points between the carbon brush and the rotor. A smaller distribution coefficient value indicates that the contact points are more evenly distributed in the contact area, while a larger distribution coefficient value indicates that the contact points may be concentrated in a certain area or unevenly distributed. The size of the contact distribution coefficient directly affects the mechanical properties between the carbon brush and the rotor. Unevenly distributed contact points may cause local overheating, accelerated wear, and even unstable current transmission. By monitoring the changes in the contact distribution coefficient, potential faults between the carbon brush and the rotor can be predicted.

[0054] The contact abnormality identification generation module determines and generates the contact abnormality identification based on the comprehensive analysis of the contact area and contact distribution coefficient between the carbon brush and the rotor. The specific method is as follows:

[0055] Obtain the absolute value of the difference between the contact area between the carbon brush and the rotor and the preset area threshold Q1, and the absolute value of the difference between the contact distribution coefficient and the preset distribution threshold Q2, and define the sum of the absolute values ​​of the difference between the two and the product of the preset parameter coefficients θ1 and θ2 as the contact deviation value PC between the carbon brush and the rotor, that is, the contact deviation value PC between the carbon brush and the rotor is calculated by the formula: PC=|SJ-Q1|×θ1+|F-Q2|×θ2, wherein the specific values ​​of the preset parameter coefficients θ1 and θ2 are formulated by relevant personnel according to actual needs, satisfying 1=θ1+θ2 and θ1>θ2, and the specific values ​​of the preset area threshold Q1 and the preset distribution threshold Q2 are obtained by relevant personnel from the design parameters or design drawings of the diesel generator set;

[0056] The contact deviation value PC reflects the comprehensive deviation degree of the contact state between the carbon brush and the rotor. If the contact deviation value PC is large, it means that the contact area and contact distribution coefficient between the carbon brush and the rotor deviate greatly from the preset ideal value, which means that the contact is not stable enough, and current transmission fluctuations may occur, increasing the instability of system operation. By real-time monitoring of the contact deviation value PC, the contact problem between the carbon brush and the rotor can be discovered in time;

[0057] When the contact deviation value PC is greater than the preset value Q3, a contact abnormality mark is generated. When the contact deviation value PC is less than or equal to the preset value Q3, no processing is performed. The specific value of the preset value Q3 is determined by relevant personnel according to actual needs.

[0058] By judging whether the contact points between the carbon brush and the rotor are evenly distributed, whether there is obvious local dense or sparse phenomenon between the contact points between the carbon brush and the rotor, and by analyzing whether the contact area between the carbon brush and the rotor is maintained within a certain range, the stability and efficiency of the current transmission between the carbon brush and the rotor are determined, and whether there is abnormal contact between the carbon brush and the rotor is judged. Once a contact abnormality is detected, a contact abnormality mark is generated, and a contact abnormality notification is sent to the remote monitoring end in real time, which is conducive to relevant personnel to take corresponding inspection and treatment measures for the carbon brush in time, including but not limited to replacing carbon brushes, cleaning slip rings or adjusting carbon brush pressure, and realizing remote monitoring of diesel generator sets, which can effectively reduce the wear between the carbon brush and the rotor, reduce the failure rate of diesel generators, and extend the service life of diesel generators. Through real-time remote monitoring and notification mechanism, it is ensured that the operation and maintenance personnel can respond and deal with potential problems quickly, thereby ensuring the stable operation of the generator set.

[0059] Embodiment 2

[0060] As the second embodiment of the present invention, when the present application is specifically implemented, compared with the first embodiment, the technical solution of the present embodiment is different from the first embodiment only in that the present embodiment further includes a deviation area marking module;

[0061] The deviation area marking module, when generating the contact abnormality mark, divides the contact surface contour between the carbon brush and the rotor into four quadrants, counts the number of contact points corresponding to each quadrant, analyzes the number of contact points in each quadrant, and marks the deviation area according to the analysis results. The specific method is as follows:

[0062] The specific method of dividing the contact surface contour into four quadrants is:

[0063] The first quadrant area is: X>0, Y>0;

[0064] The second quadrant area is: X<0, Y>0;

[0065] The third quadrant area is: X<0, Y<0;

[0066] The fourth quadrant area is: X>0, Y<0;

[0067] Where X refers to the horizontal X-axis in the two-dimensional coordinate system, and Y refers to the vertical Y-axis in the two-dimensional coordinate system;

[0068] Count the number of contact points in each quadrant and mark them as Zv, where v refers to the number of quadrants, v=1, 2, ..., 4;

[0069] Obtain the mean value Zp of the number of contact points in each quadrant area, obtain the absolute value Ev of the difference between the number of contact points in each quadrant area and the mean value Zp, and mark the quadrant area where the absolute value of the difference Ev is greater than the preset value Q4 as a deviation area, otherwise, no processing is performed. The specific value of the preset value Q4 is formulated by relevant personnel according to actual needs;

[0070] The display terminal displays the marked deviation area, which is convenient for relevant personnel to carry out targeted maintenance and adjustment of the corresponding area of ​​the carbon brush in time and take corresponding inspection and treatment measures;

[0071] By dividing the contact surface contour into four quadrants and counting the number of contact points in each quadrant, if the number of contact points in a quadrant is significantly greater than that in other quadrants, it means that the area may have problems such as excessive contact pressure, excessive wear or poor lubrication. This helps to quickly locate the source of the problem and provide a strong basis for subsequent repairs and maintenance. By marking the deviation area, maintenance personnel can be guided to quickly locate the areas that require key inspection and maintenance. This can not only reduce unnecessary inspection and maintenance work, but also improve the pertinence and efficiency of maintenance and reduce maintenance costs.

[0072] Embodiment 3

[0073] As the third embodiment of the present invention, when the present application is specifically implemented, compared with the first and second embodiments, the technical solution of this embodiment is to combine the solutions of the first and second embodiments mentioned above for implementation.

[0074] The above formulas are all dimensionless and numerical calculations. The formula is a formula for the most recent real situation obtained by collecting a large amount of data and performing software simulation. The preset parameters and thresholds in the formula are set by technicians in this field according to actual conditions.

[0075] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art who is familiar with the present technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims.

Claims

1. Diesel generator remote intelligent operation and maintenance system, characterized by: include: A contact surface image acquisition module is used to acquire a contact surface image between the carbon brush and the rotor; The contact surface profile acquisition module extracts and processes the contact surface image to obtain the contact surface profile between the carbon brush and the rotor; The contact area acquisition module analyzes the coordinates of each contact point on the contact surface contour to obtain the contact area between the carbon brush and the rotor; The contact distribution coefficient acquisition module calculates the contact distribution coefficient between the carbon brush and the rotor according to the coordinates of each contact point; The contact abnormality mark generation module comprehensively analyzes the contact area and contact distribution coefficient between the carbon brush and the rotor to determine and generate the contact abnormality mark; Deviation area marking module, when generating contact anomaly identification, divides the contact surface contour into multiple quadrant areas, analyzes the number of contact points in each quadrant area, and marks the deviation area according to the analysis results; The display end displays the marked deviation area.

2. The remote intelligent operation and maintenance system for diesel generator sets according to claim 1 is characterized in that: The specific method of obtaining the contact area between the carbon brush and the rotor is: A two-dimensional coordinate system is established on the contact surface contour, and the specific coordinates of each node on the edge line of the contact surface contour are defined as the contact point coordinates of the contact surface. The contact area SJ between the carbon brush and the rotor is calculated using the shoelace formula based on the coordinates of each contact point.

3. The remote intelligent operation and maintenance system for diesel generator sets according to claim 2 is characterized in that: The specific method of obtaining the contact distribution coefficient between the carbon brush and the rotor is: The standard deviations HA and HB corresponding to the horizontal and vertical coordinates of each contact point are calculated respectively, and the mean between the two is defined as the contact distribution coefficient F between the carbon brush and the rotor.

4. The remote intelligent operation and maintenance system for diesel generator sets according to claim 3 is characterized in that: The specific method for determining and generating a contact abnormality mark is as follows: The absolute value of the difference between the contact area between the carbon brush and the rotor and the preset area threshold Q1, as well as the absolute value of the difference between the contact distribution coefficient and the preset distribution threshold Q2 are obtained, and the sum of the absolute values ​​of the difference between the two and the product of the preset parameter coefficients θ1 and θ2 is defined as the contact deviation value PC between the carbon brush and the rotor. When the contact deviation value PC is greater than the preset value Q3, a contact abnormality mark is generated. When the contact deviation value PC is less than or equal to the preset value Q3, no processing is performed.

5. The remote intelligent operation and maintenance system for diesel generator sets according to claim 4 is characterized in that: The specific method of marking the deviation area is as follows: The contact surface contour between the carbon brush and the rotor is divided into four quadrant areas, the contact points in each quadrant are counted, the mean Zp of the number of contact points in all quadrants is calculated, and then the absolute value Ev of the difference between the number of contact points in each quadrant and the mean Zp is calculated. The quadrant area where the absolute value of the difference Ev is greater than the preset threshold Q4 is marked as a deviation area, otherwise, no processing is performed, where v refers to the number of quadrant areas, v=1, 2,..., 4.

6. The remote intelligent operation and maintenance system for diesel generator sets according to claim 2 is characterized in that: The shoelace formula is: ； The coordinates of each contact point are marked as Jn (Jxn, Jyn), where i represents the number of contact points, i is a positive integer, and i≥n≥1.

7. The remote intelligent operation and maintenance system for diesel generator sets according to claim 5 is characterized in that: The specific method of dividing the contact surface contour into four quadrants is: The first quadrant area is: X>0, Y>0, the second quadrant area is: X<0, Y>0, the third quadrant area is: X<0, Y<0, and the fourth quadrant area is: X>0, Y<0; Where X is the X-axis in the horizontal direction of the two-dimensional coordinate system, and Y is the Y-axis in the vertical direction of the two-dimensional coordinate system.

8. The remote intelligent operation and maintenance system for diesel generator sets according to claim 1 is characterized in that: The specific method of preprocessing the contact surface image is as follows: The contact surface edge contour of the contact surface image is extracted through grayscale conversion, denoising and edge detection technology.

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