Air leakage fault detection method for brake damper

Abstract

The invention relates to the technical field of brake air leakage detection, in particular to a brake air brake air leakage fault detection method, which comprises the following steps of: inquiring the time when an air brake is started and jacked up and the time when the rotating speed of a unit is reduced to 0 in a shutdown process by utilizing an upper computer monitoring system, and calculating to obtain an actual brake duration B1; a table is established, the actual braking duration B1 and the specified braking duration B2 are compared, and the deviation duration B3 when the actual threshold value is higher than the expected threshold value of the specified braking duration B2 is obtained; the unit water leakage C1 corresponding to each shutdown process is obtained through the upper computer monitoring system, and the actual water leakage C3 and the specified water leakage C2 corresponding to the deviation duration B3 are compared; if the actual water leakage amount C3 is approximately equal to the specified water leakage amount C2, air leakage exists, the starting time and the braking effective time can be rapidly and accurately detected and calculated, a maintenance team can directly position a specific air leakage point subsequently, and the repair efficiency and the overall operation safety of the system are greatly improved.

Description

Technical Field

[0001] The invention relates to the technical field of brake air leakage detection, in particular to a brake air brake air leakage fault detection method. Background Art

[0002] Air brake systems are widely used in a variety of industrial applications, especially in railways, large vehicles and some heavy machinery. These systems rely on air pressure to control the activation and release of the brake mechanism. The safety and reliability of the system are highly dependent on the integrity of the entire brake system air circuit. Air leakage is one of the common faults in air brake systems. It not only affects the braking performance, but may also cause greater safety hazards.

[0003] Conventional detection methods can only determine whether there is a leak, but cannot provide exact information about the leak location, which makes repair work complicated and time-consuming, increasing maintenance costs and system downtime.

[0004] Therefore, a brake damper leakage fault detection method is needed, which can not only quickly and accurately detect the presence of leakage, but also accurately locate the leakage point, save maintenance positioning and system downtime, and improve work efficiency. Summary of the invention

[0005] The purpose of this section is to summarize some aspects of the embodiments of the present invention and briefly introduce some preferred embodiments. Some simplifications or omissions may be made in this section and the abstract of the specification and the title of the invention of this application to avoid blurring the purpose of this section, the abstract of the specification and the title of the invention, and such simplifications or omissions cannot be used to limit the scope of the present invention.

[0006] In view of the above-mentioned prior art, air leakage is one of the common faults in the air brake brake system. Conventional detection methods can only determine whether there is a leakage, but cannot provide accurate information about the location of the leakage, resulting in complicated and time-consuming maintenance work, increasing maintenance costs and system downtime.

[0007] Therefore, the technical problem to be solved by the present invention is to design a brake air damper leakage fault detection method that can not only quickly and accurately detect the existence of air leakage, but also accurately locate the leakage point, save maintenance positioning and system downtime, and improve work efficiency to meet the needs of the existing environment.

[0008] In order to solve the above technical problems, the present invention provides the following technical solutions: a brake air brake leakage fault detection method, comprising:

[0009] Use the upper computer monitoring system to query the time of "the wind gate is put into operation and lifted" and the time of "the unit speed drops to 0" in the shutdown process, and calculate the actual braking time B1;

[0010] Establish a table, compare the actual braking time B1 with the specified braking time B2, and obtain a deviation time B3 where the actual threshold is higher than the expected threshold of the specified braking time B2;

[0011] The unit water leakage amount C1 corresponding to each shutdown process is obtained through the upper computer monitoring system, and the actual water leakage amount C3 corresponding to the deviation time B3 is compared with the specified water leakage amount C2;

[0012] If the actual water leakage amount C3 is approximately equal to the specified water leakage amount C2, there is a leak, otherwise re-test.

[0013] As an improvement of the present invention, the time when the unit speed drops to 0 is B4, the time when the wind brake is put into operation and lifted is B5, and the actual braking time B1 = B4-B5.

[0014] As an improvement of the present invention, a table is used to store the actual braking duration B1 for multiple periods as historical data, and the prescribed braking duration B2 and an expected threshold value of the prescribed braking duration B2 are calculated.

[0015] As an improvement of the present invention, a table is used to retain the unit leakage amount C1 corresponding to each shutdown process of multiple periods as historical data, and the expected threshold value of the specified leakage amount C2 is calculated to obtain the specified leakage amount C2.

[0016] As an improvement of the present invention,

[0017] If the actual threshold value obtained by comparing the actual water leakage amount C3 with the specified water leakage amount C2 exceeds the expected threshold value of the specified water leakage amount C2, it is determined that there is a leak, otherwise re-detection is performed.

[0018] As an improvement of the present invention, the brake gas tank is connected to the initial pressure gauge, the main air intake valve is closed, and the initial pressure gauge is observed to obtain the tank pressure D1;

[0019] If the air tank pressure D1 drops, the brake air tank is leaking;

[0020] If the gas tank pressure D1 is stable, the brake gas tank is not leaking;

[0021] If the brake air tank is leaking, repair the brake air tank and repeat the test.

[0022] As an improvement of the present invention, if the gas tank pressure D1 is stable, open the main air intake valve, close the upper chamber air intake valve and the lower chamber air intake valve at the end of the air intake main pipeline, observe the transmission pressure gauge connected to the air intake main pipeline, and obtain the transmission pressure D2;

[0023] If the transmission pressure D2 drops, the main air intake pipe is leaking;

[0024] If the transmission pressure D2 is stable, there is no leakage in the main air intake pipe;

[0025] If there is a leak in the air intake main pipe, repair the air intake main pipe and repeat the test.

[0026] As an improvement of the present invention, if the transmission pressure D2 is stable, close the upper chamber air intake valve and the lower chamber exhaust valve, open the upper chamber exhaust valve and the lower chamber air intake valve for 30 seconds, and then close the lower chamber air intake valve alone;

[0027] The lower chamber of the wind brake is connected to a brake pressure gauge, and the lower chamber pressure D3 is obtained by observing the brake pressure gauge. The upper chamber of the wind brake is connected to a return pressure gauge, and the upper chamber pressure D4 is obtained by observing the return pressure gauge.

[0028] As an improvement of the present invention, if the lower chamber pressure D3 decreases, the lower chamber circuit leaks or the upper and lower chambers are cross-flowing;

[0029] Close the upper chamber exhaust valve. If the upper chamber pressure D4 increases and the lower chamber pressure D3 decreases, the upper and lower chambers will be gas-contaminated.

[0030] Close the upper chamber exhaust valve. If the upper chamber pressure D4 is stable and the lower chamber pressure D3 decreases, the lower chamber circuit is leaking.

[0031] Repeat the test after repairing the air leakage between the upper and lower chambers or the air leakage in the lower chamber circuit.

[0032] As an improvement of the present invention, the upper chamber exhaust valve and the lower chamber intake valve are closed, and the upper chamber intake valve and the lower chamber exhaust valve are opened for 30 seconds and then the upper chamber intake valve is closed alone;

[0033] If the upper chamber pressure D4 drops, the upper chamber circuit is leaking or there is gas leakage between the upper and lower chambers;

[0034] Close the exhaust valve of the lower chamber. If the pressure D3 of the lower chamber increases and the pressure D4 of the upper chamber decreases, the upper and lower chambers will be gas-contaminated.

[0035] Close the lower chamber exhaust valve. If the lower chamber pressure D3 is stable and the upper chamber pressure D4 decreases, the upper chamber circuit is leaking.

[0036] Repeat the test after repairing the air leakage between the upper and lower chambers or the air leakage in the upper chamber circuit.

[0037] The beneficial effects of the present invention are as follows: by being installed on the unit and the wind brake, the start time and the braking effective time can be detected and calculated quickly and accurately, and subsequent measures can be taken.

[0038] In the early stages of leakage, before it causes serious downtime or delays, judgments can be made based on data, and potential leakage risks can be predicted through continuous monitoring and data analysis, providing a scientific basis for brake system maintenance.

[0039] The maintenance team can then directly locate the specific leak point, which will help with the maintenance of the entire gas conduction process and greatly improve the repair efficiency and the overall operational safety of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative labor. Among them:

[0041] Figure 1 It is a schematic diagram of the brake gas transmission layout of the brake air damper leakage fault detection method in the present invention.

[0042] Figure 2 It is a data trend comparison chart of the brake air damper leakage fault detection method in the present invention.

[0043] Figure 3 It is a determination flow chart of the brake air damper leakage fault detection method in the present invention. DETAILED DESCRIPTION

[0044] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the accompanying drawings.

[0045] Example 1

[0046] Reference Figures 1-2 , this embodiment provides a brake air damper leakage fault detection method.

[0047] The host computer monitoring system uses an industrial computer installed with professional monitoring software. It has a high-performance processor and durability suitable for industrial environments. It can stably run the monitoring software and process large amounts of data. The host computer monitoring system is connected to the control system of the wind turbine generator set, and staff can use the host computer monitoring system to remotely read data.

[0048] The speed sensor is installed at the generator bearing to monitor the speed of the unit in real time, and cooperates with the host computer monitoring system to read the time when the speed of the unit drops to 0. A displacement sensor is fixedly installed at the wind gate to detect the exact position and time of the wind gate input and start-up. The displacement sensor also cooperates with the host computer monitoring system.

[0049] Query the time of "wind gate put into operation and start lifting" and the time of "unit speed drops to 0" in the shutdown process stored in the upper computer monitoring system, and subtract the time of "wind gate put into operation and start lifting" from the time of "unit speed drops to 0" to obtain the actual braking time B1.

[0050] Each shutdown process corresponds to an actual braking time B1. There are usually more than one units in a power station, and each unit cannot have only one shutdown process. Therefore, there are multiple data of the actual braking time B1, which can be stored by the host computer monitoring system.

[0051] First, create a table to record multiple actual braking durations B1 and compare them with the specified braking duration B2. The specified braking duration B2 has an expected threshold, because the actual braking duration B1 cannot be 100% consistent with the specified braking duration B2. As long as the deviation between the actual braking duration B1 and the specified braking duration B2 does not exceed the expected threshold of the specified braking duration B2, it means that the shutdown process is normal. Once the deviation between the actual braking duration B1 and the specified braking duration B2 exceeds the expected threshold of the specified braking duration B2, the actual braking duration B1 is marked as the deviation duration B3.

[0052] The unit leakage C1 corresponding to each shutdown process is obtained by the ultrasonic flow detection device, and the unit leakage C1 corresponding to the deviation duration B3 is marked as the actual leakage C3 to distinguish it from the reasonable unit leakage C1 in the normal shutdown process. The prescribed leakage C2 set by each power station is different. In the present invention, the prescribed leakage C2 can be 2 cubic meters per second. The actual leakage C3 is compared with the prescribed leakage C2.

[0053] If the actual leakage amount C3 is approximately equal to the specified leakage amount C2, it means that the actual leakage amount C3 is not the cause of the deviation duration B3, and the deviation duration B3 is caused by air leakage in the wind gate. Otherwise, it means that the deviation duration B3 is not necessarily caused by air leakage in the wind gate, and the data needs to be replaced for retesting.

[0054] Example 2

[0055] Reference Figures 1 to 3 This embodiment is based on the previous embodiment, and is different from the previous embodiment in that:

[0056] The time for "the unit speed drops to 0" is set as B4, and the time for "the wind gate is started and lifted" is set as B5. The actual braking time B1 is obtained by B4-B5.

[0057] The table is used to store multiple periods of actual braking time B1 as historical data. Because the data volume of multiple units is too large, only part of the data is displayed here. The table can not only calculate the actual braking time B1, but also compare the time error between the actual braking time B1 and the previous time, so as to better continuously monitor and analyze data to predict potential air leakage risks.

[0058]

[0059] The expected threshold of the specified braking time B2 is controlled between plus or minus 0.1 min. Once the deviation between the actual braking time B1 and the specified braking time B2 exceeds 0.1 min, the actual braking time B1 at this time is marked as the deviation time B3. The table is set to retain the unit leakage C1 corresponding to each shutdown process for multiple periods as historical data. The unit leakage C1 corresponding to each shutdown process is obtained through an ultrasonic flow detection device. The unit leakage C1 corresponding to the deviation time B3 is marked as the actual leakage C3 to distinguish it from the reasonable unit leakage C1 in the normal shutdown process. The specified leakage C2 set for each power station is different. The specified leakage C2 in the present invention can be 2 cubic meters per second.

[0060] The expected threshold of the specified leakage volume C2 is controlled between plus or minus 0.5 cubic meters per second. Once the deviation between the actual leakage volume C3 of the unit and the specified leakage volume C2 exceeds 0.5 cubic meters per second, it means that the deviation duration B3 is not necessarily caused by air leakage in the wind gate. The data needs to be replaced and tested again. The deviation duration B3 may be caused by reasons such as excessive or too small leakage.

[0061] Once the deviation between the actual leakage volume C3 of the unit and the specified leakage volume C2 is less than 0.5 cubic meters per second, it means that the actual leakage volume C3 is not the cause of the deviation duration B3, and the deviation duration B3 is caused by the air gate leakage. At this time, the air gate leakage can be determined based on this type of data, and subsequent actual leakage point detection and maintenance can be carried out after the unit is shut down.

[0062] Example 3

[0063] Reference Figures 1 to 3 This embodiment is based on the previous embodiment, and is different from the previous embodiment in that:

[0064] The brake gas required for the entire shutdown process flows from the brake gas tank to the main air intake pipe to the upper and lower chamber air intake to the air brake.

[0065] In the brake gas process required for the entire shutdown process, pressure gauges and sensors are installed at multiple key locations. The sensors are remotely electrically connected to the host computer monitoring system, and can directly read the pressure gauge data and upload it to the host computer monitoring system. The initial pressure gauge is fixedly connected to the brake gas tank. First, close the main air intake valve on one side of the brake gas tank to ensure that the brake gas tank is not in a state of outputting gas at this time. Then the staff can directly observe the initial pressure gauge data at this time through the host computer monitoring system to obtain the tank pressure D1.

[0066] If the air tank pressure D1 drops, the brake air tank is leaking; if the air tank pressure D1 is stable, the brake air tank is not leaking. If the brake air tank is indeed leaking after the inspection, first repair the airtightness of the brake air tank, and then repeat the steps to check whether there are still problems with the whole process and whether there is still air leakage in the air gate, because the leakage may not only exist in one place, the brake air tank and other locations may have problems at the same time.

[0067] If the gas tank pressure D1 is stable, open the main air intake valve, close the upper and lower air intake valves at the end of the main air intake pipeline, and ensure that the main air intake pipeline is not delivering gas to the air damper at this time. The main air intake pipeline is connected to a transmission pressure gauge, and the staff can directly observe the transmission pressure gauge at this time through the host computer monitoring system to obtain the transmission pressure D2.

[0068] If the transmission pressure D2 drops, the air intake main pipe is leaking. If the transmission pressure D2 is stable, the air intake main pipe is not leaking. If the air intake main pipe is indeed leaking after the inspection, first repair the airtightness of the air intake main pipe, and then repeat the steps to check.

[0069] If the transmission pressure D2 is stable, close the upper chamber intake valve and the lower chamber exhaust valve, open the upper chamber exhaust valve and the lower chamber intake valve, and the brake gas starts to enter the damper. After the upper chamber exhaust valve and the lower chamber intake valve are opened for 30 seconds, the lower chamber intake valve can be closed separately. The gas delivered within 30 seconds can be used to detect the operation of the lower chamber of the damper.

[0070] The lower chamber of the air brake is connected to a brake pressure gauge, and the upper chamber of the air brake is connected to a return pressure gauge. Both the brake pressure gauge and the return pressure gauge can read data through sensors by the host computer monitoring system. The lower chamber pressure D3 is obtained by observing the brake pressure gauge, and the upper chamber pressure D4 is obtained by observing the return pressure gauge.

[0071] If the lower chamber pressure D3 drops, there are two possibilities: the lower chamber circuit is leaking or there is gas cross-talk between the upper and lower chambers. At this time, closing the upper chamber exhaust valve can lead to a conclusion. Since the closing of the upper chamber exhaust valve blocks the exhaust channel of the upper chamber gas of the damper, if the upper chamber pressure D4 increases and the lower chamber pressure D3 drops, it means that the gas in the lower chamber circuit is being conducted to the upper chamber. The problem at this time is gas cross-talk between the upper and lower chambers, and the gas tightness maintenance of the upper and lower gas cross-talk phenomenon inside the damper is required.

[0072] If the upper chamber pressure D4 remains stable and has not increased, it means that the gas in the lower chamber circuit has not been transmitted to the upper chamber. The decrease in the lower chamber pressure D3 indicates that the lower chamber circuit has started to leak directly. At this time, the airtightness of the lower chamber needs to be maintained and repaired.

[0073] After the air leakage between the upper and lower chambers or the air leakage in the lower chamber circuit is repaired, the steps need to be repeated for detection and troubleshooting.

[0074] Close the upper chamber exhaust valve and the lower chamber intake valve, then open the upper chamber intake valve and the lower chamber exhaust valve for 30 seconds, and then close the upper chamber intake valve alone.

[0075] If the upper chamber pressure D4 drops at this time, it means that there is leakage in the upper chamber circuit or gas cross-talk between the upper and lower chambers. At this time, closing the lower chamber exhaust valve can make a judgment, because the closing of the lower chamber exhaust valve blocks the exhaust channel of the gas in the lower chamber of the wind brake.

[0076] After closing the lower chamber exhaust valve, if the lower chamber pressure D3 increases and the upper chamber pressure D4 decreases, it means that the gas in the upper chamber circuit is being conducted to the lower chamber. The problem at this time is that the upper and lower chambers are cross-flowing, and the airtight maintenance of the upper and lower air cross-flow inside the damper is required.

[0077] After closing the lower chamber exhaust valve, if the lower chamber pressure D3 is not stable and the upper chamber pressure D4 drops, it means that there is leakage in the upper chamber circuit.

[0078] After repairing the upper and lower chamber air leakage or the upper chamber circuit leakage, you need to repeat the steps to detect and troubleshoot

[0079] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A brake air brake leakage fault detection method, characterized in that: The steps include: Use the upper computer monitoring system to query the time when the wind brake is put into operation and the time when the unit speed drops to 0 during the shutdown process, and calculate the actual braking time B1; Establish a table, compare the actual braking time B1 with the specified braking time B2, and obtain a deviation time B3 where the actual threshold is higher than the expected threshold of the specified braking time B2; The unit water leakage amount C1 corresponding to each shutdown process is obtained through the upper computer monitoring system, and the actual water leakage amount C3 corresponding to the deviation time B3 is compared with the specified water leakage amount C2; If the actual water leakage amount C3 is approximately equal to the specified water leakage amount C2, there is a leak, otherwise re-test.

2. The brake air brake leakage fault detection method according to claim 1 or 2, characterized in that: The time when the unit speed drops to 0 is B4, the time when the wind brake is started and lifted is B5, and the actual braking time B1 = B4-B5.

3. The brake air brake leakage fault detection method according to claim 2, characterized in that: The actual braking duration B1 for multiple periods is stored in a table as historical data, and the prescribed braking duration B2 and an expected threshold value of the prescribed braking duration B2 are calculated.

4. The brake air brake leakage fault detection method according to claim 3 is characterized in that: The table is used to retain the unit water leakage C1 corresponding to each shutdown process of multiple periods as historical data, and the expected threshold value of the specified water leakage C2 is calculated to obtain the specified water leakage C2.

5. The brake air brake leakage fault detection method according to claim 4, characterized in that: If the actual threshold value obtained by comparing the actual water leakage amount C3 with the specified water leakage amount C2 exceeds the expected threshold value of the specified water leakage amount C2, it is determined that there is a leak, otherwise re-detection is performed.

6. The brake air brake leakage fault detection method according to claim 5, characterized in that: Connect the brake air tank to the initial pressure gauge, close the main air inlet valve, and observe the initial pressure gauge to obtain the tank pressure D1; If the air tank pressure D1 drops, the brake air tank is leaking; If the gas tank pressure D1 is stable, the brake gas tank is not leaking; If the brake air tank is leaking, repair the brake air tank and repeat the test.

7. The brake air brake leakage fault detection method according to claim 6, characterized in that: If the gas tank pressure D1 is stable, open the main air intake valve, close the upper air intake valve and the lower air intake valve at the end of the main air intake pipe, observe the transmission pressure gauge connected to the main air intake pipe, and obtain the transmission pressure D2; If the transmission pressure D2 drops, the main air intake pipe is leaking; If the transmission pressure D2 is stable, there is no leakage in the main air intake pipe; If there is a leak in the air intake main pipe, repair the air intake main pipe and repeat the test.

8. The brake air brake leakage fault detection method according to claim 7, characterized in that: If the transmission pressure D2 is stable, close the upper chamber air intake valve and the lower chamber exhaust valve, open the upper chamber exhaust valve and the lower chamber air intake valve for 30 seconds, and then close the lower chamber air intake valve alone; The lower chamber of the wind brake is connected to a brake pressure gauge, and the lower chamber pressure D3 is obtained by observing the brake pressure gauge. The upper chamber of the wind brake is connected to a return pressure gauge, and the upper chamber pressure D4 is obtained by observing the return pressure gauge.

9. The brake air brake leakage fault detection method according to claim 8, characterized in that: If the lower chamber pressure D3 drops, the lower chamber circuit is leaking or there is gas leakage between the upper and lower chambers; Close the upper chamber exhaust valve. If the upper chamber pressure D4 increases and the lower chamber pressure D3 decreases, the upper and lower chambers will be gas-contaminated. Close the upper chamber exhaust valve. If the upper chamber pressure D4 is stable and the lower chamber pressure D3 decreases, the lower chamber circuit is leaking. Repeat the test after repairing the air leakage between the upper and lower chambers or the air leakage in the lower chamber circuit.

10. The brake air brake leakage fault detection method according to claim 9, characterized in that: Close the upper chamber exhaust valve and the lower chamber intake valve, open the upper chamber intake valve and the lower chamber exhaust valve for 30 seconds, then close the upper chamber intake valve alone; If the upper chamber pressure D4 drops, the upper chamber circuit is leaking or there is gas leakage between the upper and lower chambers; Close the exhaust valve of the lower chamber. If the pressure D3 of the lower chamber increases and the pressure D4 of the upper chamber decreases, the upper and lower chambers will be gas-contaminated. Close the lower chamber exhaust valve. If the lower chamber pressure D3 is stable and the upper chamber pressure D4 decreases, the upper chamber circuit is leaking. Repeat the test after repairing the air leakage between the upper and lower chambers or the air leakage in the upper chamber circuit.

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