Pump station main unit fault monitoring method and system and computer program product

Abstract

The invention discloses a pump station main unit fault monitoring method and system and a computer program product, the pump station main unit is provided with a plurality of acceleration vibration sensors, and the method comprises the following steps: S1, obtaining vibration acceleration signals collected by the acceleration vibration sensors, and carrying out anti-aliasing digital filtering and data extraction; obtaining vibration waveform data; s2, inputting the vibration waveform data into an envelope algorithm module, and calculating a vibration envelope waveform; and S3, judging whether the vibration envelope peak-to-peak value is greater than a preset value, and if so, sending out a fault alarm. By adopting the method provided by the invention, the fault of the pump station main unit can be automatically monitored, the accuracy of fault alarm is improved, and safe and stable operation of the pump station is ensured.

Description

Technical Field

[0001] The present invention relates to the field of intelligent pumping stations in the water conservancy industry, and in particular to a method, system and computer program product for monitoring faults of a main engine group of a pumping station. Background Art

[0002] The water conservancy industry pump station is a water conservancy project that uses mechanical and electrical facilities such as the pump station host unit to transfer and convert energy and realize water transportation to achieve benefits and avoid harm, thereby realizing the effective use of water resources. For the impact signal caused by the failure of the low-speed rotating mechanical components of the water conservancy industry pump station host unit, it will excite the high-frequency natural frequency, showing a resonance band on the spectrum, that is, the low-frequency fault signal appears as the side frequency of a high-frequency carrier. For this kind of fault signal with modulation phenomenon, it is necessary to analyze and diagnose through the envelope. Summary of the invention

[0003] The purpose of the present invention is to provide a method, system and computer program product for monitoring the fault of a main unit of a pump station to solve the above problems. To this end, the technical solution adopted by the present invention is as follows:

[0004] According to one aspect of the present invention, a method for monitoring faults of a main unit of a pump station is provided, wherein the main unit of the pump station is equipped with a plurality of acceleration vibration sensors, wherein the method comprises the following steps:

[0005] S1. Obtain the vibration acceleration signal collected by the acceleration vibration sensor and perform anti-aliasing digital filtering and data extraction to obtain vibration waveform data;

[0006] S2. Input the vibration waveform data into the envelope algorithm module to calculate the vibration envelope waveform;

[0007] S3. Determine whether the peak-to-peak value of the vibration envelope is greater than a preset value. If so, issue a fault alarm.

[0008] Furthermore, S2 includes:

[0009] S21. Bandpass filtering the vibration waveform data, including second-order low-pass filtering and fourth-order high-pass filtering;

[0010] S22. Rectifying the vibration waveform data after bandpass filtering;

[0011] S23. Determine whether enhanced demodulation is required, if so, proceed to S24, otherwise proceed to S25;

[0012] S24. Perform the first envelope calculation to obtain vibration envelope waveform data;

[0013] S25. Perform second-order low-pass filtering, fourth-order low-pass filtering, and fourth-order high-pass filtering on the vibration waveform data or vibration envelope waveform data in sequence. Among them, the cut-off frequency of the second-order low-pass filtering is the same as the cut-off frequency of the fourth-order high-pass filtering in step S21. The cut-off frequency of the fourth-order low-pass filtering is from vHPF to eHPF, and the cut-off frequency of the fourth-order high-pass filtering is from 0.01 Hz to vLPF. Among them, eHPF is the cut-off frequency of the high-pass filter of the envelope and is the same as the cut-off frequency of the fourth-order high-pass filtering in step S21. vHPF is the variable cut-off frequency of the high-pass filter, and vLPF is the variable cut-off frequency of the low-pass filter;

[0014] S26. Perform the second envelope calculation to obtain the vibration envelope peak-to-peak value and peak value.

[0015] Furthermore, the specific process of S24 is as follows: Assign the first data point of the waveform data to A0, and calculate the calculated envelope data of the next data point according to the constructed exponential decay coefficient function If the waveform data of the next data point is greater than the calculated envelope data, then assign the waveform data of this data point to A0, and assign the time corresponding to this data point to t0, and reconstruct the exponential decay coefficient function; if the waveform data of the next data point is less than the calculated envelope data, then use the calculated envelope data and the exponential decay coefficient function remains unchanged; calculate each waveform data point in sequence; among them, t0 refers to the time corresponding to the waveform data greater than the calculated envelope data, A0 is the waveform data at the t0 moment, t refers to the time starting from the t0 moment, τ is the time constant, and τ = 4.1 / eHPF seconds.

[0016] Furthermore, the frequency ranges of vHPF and eHPF are 0.01 - 4000 Hz, and vHPF < eHPF; the frequency range of vLPF is 0.01 - 4000 Hz.

[0017] Furthermore, the specific process of S26 is as follows: Assign the first data point of the waveform data to A0, and calculate the calculated envelope data of the next data point according to the constructed exponential decay coefficient function Calculate the calculated envelope data of the next data point ​If the waveform data of the next data point is greater than the calculated envelope data, the waveform data of the data point is assigned to A0, and the time corresponding to the data point is assigned to t0, and the exponential decay coefficient function is reconstructed; if the waveform data is less than the calculated envelope data, the calculated envelope data is used, and the exponential decay coefficient function remains unchanged; each waveform data point is calculated in turn, and after completion, the waveform data is subjected to a first-order low-pass filter; wherein, t0 refers to the time corresponding to the waveform data greater than the calculated envelope data, A0 is the waveform data at time t0, t refers to the time starting from time t0, τ is the time constant, when vHPF is greater than or equal to 2.5Hz, τ is 2.7 seconds, when vHPF is less than 2.5Hz, τ is 8.1 / vHPF seconds; the turning frequency of the first-order low-pass filter is 0.3Hz.

[0018] Furthermore, in S26, it also includes: performing a first-order low-pass filter on the waveform data after the envelope calculation is completed, wherein the turning frequency of the first-order low-pass filter is 0.3 Hz.

[0019] Furthermore, the corner frequency of the second-order low-pass filter in S21 is 100-20000 Hz, and the corner frequency of the fourth-order high-pass filter is 10-4000 Hz.

[0020] Furthermore, S22 specifically takes the mathematical absolute value of each data point of the waveform data.

[0021] According to another aspect of the present invention, a pump station main unit fault monitoring system is also provided, including a data collector, the data collector has a built-in processor and a memory, the memory stores a computer program, and when the computer program is executed by the processor, the steps of the pump station main unit fault monitoring method as described above are implemented.

[0022] According to another aspect of the present invention, there is also provided a computer program product, comprising a computer program / instruction, wherein when the computer program / instruction is executed by a processor, the steps of the pump station host group fault monitoring method as described in any one of claims 1-8 are implemented.

[0023] By adopting the method of the present invention, it is possible to realize automatic monitoring of the faults of the main unit of the pump station, improve the accuracy of the fault alarm, and ensure the safe and stable operation of the pump station. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 is a flow chart of a method for monitoring a pump station host unit failure according to the present invention;

[0025] Figure 2 yes Figure 1 Flow chart of step S2 is shown. DETAILED DESCRIPTION

[0026] The preferred embodiments of the present invention will be described in detail below in conjunction with the accompanying drawings so that the purpose, features and advantages of the present invention can be more clearly understood. It should be understood that the embodiments shown in the accompanying drawings are not intended to limit the scope of the present invention, but are only intended to illustrate the essential spirit of the technical solution of the present invention.

[0027] The first embodiment of the present invention provides a method for monitoring faults of a pump station main unit, wherein the pump station main unit is equipped with a plurality of acceleration vibration sensors, which can be installed on the housing of the guide bearing of the motor of the pump station main unit, for example, to detect the vibration of the guide bearing of the motor. The acceleration vibration sensor is commercially available and will not be described in detail here. Figure 1 and 2 As shown, the pump station host unit fault monitoring method may include the following steps:

[0028] S1. Obtain the vibration acceleration signal collected by the acceleration vibration sensor and perform anti-aliasing digital filtering and data extraction to obtain vibration waveform data. The output of the acceleration vibration sensor can be connected to a special data acquisition device (card), which performs anti-aliasing digital filtering on the collected vibration acceleration signal to reduce the aliasing frequency component in the signal to a negligible level and perform data extraction. Anti-aliasing digital filtering and data extraction are well known and will not be described in detail here.

[0029] S2. Input the vibration waveform data into the envelope algorithm module to calculate the vibration envelope waveform. Specifically, it includes:

[0030] S21. Perform bandpass filtering on the vibration waveform data, including second-order low-pass filtering and fourth-order high-pass filtering. Among them, due to the low speed of the main unit of the pump station, the characteristic frequency of the corresponding component failure is not high. Therefore, the upper limit of the low-pass filter turning frequency is selected as 20kHz, and the lower limit of the high-pass filter turning frequency is selected as 10Hz. Specifically, the turning frequency of the second-order low-pass filter can be selected between 100 and 20000Hz; the turning frequency of the fourth-order high-pass filter can be selected between 10 and 4000Hz.

[0031] S22. Rectify the vibration waveform data after bandpass filtering. Specifically, take the mathematical absolute value of each data point of the waveform data.

[0032] S23. Determine whether enhanced demodulation is needed. If so, enter S24, otherwise enter S25. In order to more effectively filter the interference of high-frequency signals on the low-frequency diagnostic signals of interest, it is possible to consider enhanced demodulation of the waveform data, that is, to perform an envelope calculation (also called the first envelope calculation). The enhanced demodulation function can be checked by the operator and is related to the specific components of the pump station host group to be monitored.

[0033] S24. Perform the first envelope calculation to obtain the vibration envelope waveform data. Specifically, construct an exponential decay coefficient function Assign the first data point of the waveform data to A0, and calculate the calculated envelope data of the next data point according to the constructed exponential decay coefficient function If the waveform data of the next data point is greater than the calculated envelope data, assign the waveform data of this data point to A0, and assign the time corresponding to this data point to t0, and reconstruct the exponential decay coefficient function; if the waveform data of the next data point is less than the calculated envelope data, use the calculated envelope data, that is, replace the waveform data of this data point with the calculated envelope data, and the exponential decay coefficient function remains unchanged; calculate each waveform data point in turn; where, t0 refers to the time corresponding to the waveform data greater than the calculated envelope data, A0 is the waveform data at the t0 moment, t refers to the time starting from the t0 moment, τ is the time constant, τ = 4.1 / eHPF seconds, eHPF is the cut-off frequency of the high-pass filter of the envelope, which is the same as the cut-off frequency of the fourth-order high-pass filter in S21, and the decay rate is the time constant τ in the exponential decay coefficient function.

[0034] S25. Perform second-order low-pass filtering, fourth-order low-pass filtering, and fourth-order high-pass filtering on the vibration waveform data (without enhanced demodulation) or the vibration envelope waveform data (after enhanced demodulation) in turn. Specifically, when enhanced demodulation is required, perform second-order low-pass filtering on the vibration envelope waveform data after the first envelope calculation, and when enhanced demodulation is not required, directly perform second-order low-pass filtering on the rectified waveform data; then perform fourth-order low-pass filtering, and finally perform fourth-order high-pass filtering to filter out the ringing ripples of the residual structural natural resonance frequency that may exist in the waveform data. Among them, the cut-off frequency of the second-order low-pass filter is the same as the cut-off frequency of the fourth-order high-pass filter in step S21, the cut-off frequency of the fourth-order low-pass filter is vHPF~eHPF, and the cut-off frequency of the fourth-order high-pass filter is 0.01Hz~vLPF, where, eHPF is the cut-off frequency of the high-pass filter of the envelope, which is the same as the cut-off frequency of the fourth-order high-pass filter in S21, vHPF is the variable cut-off frequency of the high-pass filter, and vLPF is the variable cut-off frequency of the low-pass filter. In a specific embodiment, the frequency ranges of vHPF and eHPF are 0.01~4000Hz, and vHPF < eHPF; the frequency range of vLPF is 0.01~4000Hz. In practice, the specific values of vHPF and vLPF are set according to experience and machine components.

[0035] S26. Perform a second envelope calculation to obtain the peak-to-peak value and peak value of the vibration envelope (peak-to-peak value divided by 2). To obtain the peak-to-peak value and peak value of the vibration envelope, another envelope calculation (also called the second envelope calculation) is required. The second envelope calculation is basically the same as the first envelope calculation, except that the selection of the time constant τ is different. The specific process is: assign the first data point of the waveform data to A0, and according to the exponential decay coefficient function Calculate the envelope data for the next data point If the waveform data of the next data point is greater than the calculated envelope data, the waveform data of the data point is assigned to A0, and the time corresponding to the data point is assigned to t0, and the exponential decay coefficient function is reconstructed; if the waveform data is less than the calculated envelope data, the calculated envelope data is used, and the exponential decay coefficient function remains unchanged; each waveform data point is calculated in turn, and after completion, the waveform data is subjected to a first-order low-pass filter to filter out the ripple. When vHPF is greater than or equal to 2.5Hz, τ is 2.7 seconds, and when vHPF is less than 2.5Hz, τ is 8.1 / vHPF seconds. In a specific embodiment, the turning frequency of the first-order low-pass filter is 0.3Hz.

[0036] S3. Determine whether the peak-to-peak value of the vibration envelope is greater than a preset value. If so, issue a fault alarm. Specifically, if the peak-to-peak value of the vibration envelope is greater than the preset alarm value, the system generates an alarm signal (e.g., sound, light, text, color, or a combination thereof) and the operator participates in the processing. It should be understood that whether the peak value is greater than the preset value can also be used as an alarm condition.

[0037] It should be noted that the above-mentioned envelope algorithm module can be implemented as an edge computing function in the vibration monitoring front data collector, or in the background host computer vibration monitoring fault analysis software. Preferably, the present invention implements the envelope algorithm module as an edge computing function in the vibration monitoring front data collector.

[0038] By adopting the method of the present invention, the corner frequency of the bandpass filter, the attenuation rate in the envelope calculation, the alarm value, etc. can be set according to the actual operation of the pump station, thereby realizing automatic monitoring of faults of the main unit of the pump station, improving the accuracy of fault alarms, and ensuring the safe and stable operation of the pump station.

[0039] According to a second embodiment of the present invention, a pump station main unit fault monitoring system is provided, including a data collector, wherein the data collector has a built-in processor and a memory, wherein the memory stores a computer program, and when the computer program is executed by the processor, the steps of the pump station main unit fault monitoring method as described above are implemented.

[0040] In addition, the pump station host unit fault monitoring system may also include a host computer, which is usually an industrial computer. The data collector may be integrated in the industrial computer or connected to the host computer by wired or wireless communication. Therefore, the above-mentioned envelope algorithm module may also be implemented in the vibration monitoring fault analysis software of the host computer.

[0041] Exemplarily, the computer program may be divided into one or more modules / units, which are stored in the memory and executed by the processor to implement the present invention. The one or more modules / units may be a series of computer program instruction segments capable of implementing specific functions, which are used to describe the execution process of the computer program in the data collector.

[0042] The processor may be a central processing unit (CPU), or other general-purpose processors, digital signal processors (DSP), application-specific integrated circuits (ASIC), field-programmable gate arrays (FPGA) or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor may be a microprocessor or any conventional processor, etc. The processor is the control center of the pump station host group fault monitoring system, and uses various interfaces and lines to connect various parts of the entire pump station host group fault monitoring system.

[0043] The memory can be used to store the computer program and / or module, and the processor realizes various functions of the data collector by running or executing the computer program and / or module stored in the memory, and calling the data stored in the memory. The memory can mainly include a program storage area and a data storage area, wherein the program storage area can store an operating system, an application required for at least one function, etc.; the data storage area can store data received and processed by the pump station host group fault monitoring system (for example, original waveform data, calculated envelope data, etc.) and user input data (for example, parameter settings), etc. In addition, the memory can include a high-speed random access memory, and can also include a non-volatile memory, such as a hard disk, a memory, a plug-in hard disk, a smart memory card (Smart Media Card, SMC), a secure digital (SecureDigital, SD) card, a flash card (Flash Card), at least one disk storage device, a flash memory device, or other volatile solid-state storage devices.

[0044] A third embodiment of the present invention provides a computer-readable storage medium having a computer program / instruction stored thereon, wherein the computer program / instruction implements the steps of the method described above when executed by a processor.

[0045] If each module / unit of the system is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the present invention implements all or part of the processes in the above-mentioned embodiment method, and can also be completed by instructing the relevant hardware through a computer program. The computer program can be stored in a computer-readable storage medium, and the computer program can implement the steps of the above-mentioned various method embodiments when executed by the processor. Among them, the computer program includes computer program code, and the computer program code can be in source code form, object code form, executable file or some intermediate form. The computer-readable medium may include: any entity or device capable of carrying the computer program code, recording medium, U disk, mobile hard disk, disk, optical disk, computer memory, read-only memory (ROM, Read-Only Memory), random access memory (RAM, Random Access Memory), electric carrier signal, telecommunication signal and software distribution medium. It should be noted that the content contained in the computer-readable medium can be appropriately increased or decreased according to the requirements of legislation and patent practice in the jurisdiction. For example, in some jurisdictions, according to legislation and patent practice, computer-readable media do not include electric carrier signals and telecommunication signals.

[0046] A fourth embodiment of the present invention provides a computer program product, including a computer program / instruction, wherein the computer program / instruction implements the steps of the above method when executed by a processor. Specifically, the computer program product may be vibration monitoring fault analysis software.

[0047] Those skilled in the art will appreciate that embodiments of the present invention may be provided as methods, systems, or computer program products. Therefore, the present invention may take the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware. Moreover, the present invention may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0048] The preferred embodiments of the present invention have been described in detail above, but it should be understood that after reading the above teachings of the present invention, those skilled in the art may make various changes or modifications to the present invention. These equivalent forms also fall within the scope defined by the appended claims of this application.

Claims

1. A method for monitoring faults of a pump station main unit, wherein the pump station main unit is equipped with a plurality of acceleration vibration sensors, characterized in that: The method includes the following steps: S1. Obtain the vibration acceleration signal collected by the acceleration vibration sensor and perform anti-aliasing digital filtering and data extraction to obtain vibration waveform data; S2. Input the vibration waveform data into the envelope algorithm module to calculate the vibration envelope waveform; S3. Determine whether the peak-to-peak value of the vibration envelope is greater than a preset value. If so, issue a fault alarm.

2. The method for monitoring the failure of a main unit of a pump station according to claim 1, characterized in that S2 Including: S21. Perform band-pass filtering on the vibration waveform data, including second-order low-pass filtering and fourth-order high-pass filtering; S22. Rectify the vibration waveform data after band-pass filtering; S23. Determine whether enhanced demodulation is required. If so, enter S24; otherwise, enter S25; S24. Perform the first envelope calculation to obtain vibration envelope waveform data; S25. Sequentially perform second-order low-pass filtering, fourth-order low-pass filtering, and fourth-order high-pass filtering on the vibration waveform data or the vibration envelope waveform data. Among them, the cut-off frequency of the second-order low-pass filtering is the same as the cut-off frequency of the fourth-order high-pass filtering in step S21. The cut-off frequency of the fourth-order low-pass filtering is vHPF~eHPF, and the cut-off frequency of the fourth-order high-pass filtering is 0.01Hz~vLPF. Among them, eHPF is the cut-off frequency of the high-pass filter of the envelope and is the same as the cut-off frequency of the fourth-order high-pass filtering in step S21. vHPF is the variable cut-off frequency of the high-pass filter, and vLPF is the variable cut-off frequency of the low-pass filter; S26. Perform the second envelope calculation to obtain the peak-to-peak value and peak value of the vibration envelope.

3. The method for monitoring failure of a main unit of a pump station according to claim 2, characterized in that: The specific process of S24 is: assign the first data point of the waveform data to A0, and then construct an exponential decay coefficient function Calculate the envelope data for the next data point If the waveform data of the next data point is greater than the calculated envelope data, the waveform data of the data point is assigned to A0, and the time corresponding to the data point is assigned to t0, and the exponential decay coefficient function is reconstructed; if the waveform data of the next data point is less than the calculated envelope data, the calculated envelope data is used, and the exponential decay coefficient function remains unchanged; Calculate each waveform data point in sequence; where t0 refers to the time corresponding to the waveform data greater than the calculated envelope data, A0 is the waveform data at time t0, t refers to the time starting from time t0, and τ is the time constant, τ = 4.1 / eHPF seconds.

4. The method for monitoring failure of a main unit of a pump station according to claim 2, characterized in that: The frequency ranges of vHPF and eHPF are 0.01~4000Hz, and vHPF < eHPF; the frequency range of vLPF is 0.01~4000Hz.

5. The method for monitoring failure of a main unit of a pump station according to claim 2, characterized in that: The specific process of S26 is: assign the first data point of the waveform data to A0, and then Calculate the envelope data for the next data point If the waveform data of the next data point is greater than the calculated envelope data, the waveform data of the data point is assigned to A0, and the time corresponding to the data point is assigned to t0, and the exponential decay coefficient function is reconstructed; if the waveform data of the next data point is less than the calculated envelope data, the calculated envelope data is used, and the exponential decay coefficient function remains unchanged; Calculate each waveform data point in sequence; where t0 refers to the time corresponding to the waveform data greater than the calculated envelope data, A0 is the waveform data at time t0, t refers to the time starting from time t0, and τ is the time constant. When vHPF is greater than or equal to 2.5Hz, τ is 2.7 seconds. When vHPF is less than 2.5Hz, τ is 8.1 / vHPF seconds.

6. The method for monitoring failure of a main unit of a pump station according to claim 5, characterized in that: In S26, it also includes: performing first-order low-pass filtering on the waveform data after the envelope calculation is completed, where the cut-off frequency of the first-order low-pass filtering is 0.3Hz.

7. The method for monitoring failure of a main unit of a pump station according to claim 2, characterized in that: The cut-off frequency of the second-order low-pass filtering in S21 is 100~20000Hz, and the cut-off frequency of the fourth-order high-pass filtering is 10~4000Hz.

8. The method for monitoring failure of a main unit of a pump station according to claim 2, characterized in that: S22 specifically takes the mathematical absolute value of each data point of the waveform data.

9. A pump station main unit fault monitoring system, characterized in that: Including a data collector, the data collector is built-in with a processor and a memory. The memory stores a computer program. When the computer program is executed by the processor, it realizes the steps of the fault monitoring method for the pumping station main unit group as described in any one of claims 1-8.

10. A computer program product comprising a computer program / instructions, characterized in that When the computer program / instructions are executed by the processor, it realizes the steps of the fault monitoring method for the pumping station main unit group as described in any one of claims 1-8.

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