Method, device and equipment for monitoring running state of reciprocating compressor and medium
By acquiring and analyzing the temperature and audio data of the reciprocating compressor in real time, calculating the operating state quantization value, accurately monitoring and fault warning of the operating state of the equipment is achieved, and the problem of difficulty in detecting faults in the existing technology is solved, and the reliability and production efficiency of the equipment are improved.
Patent Information
- Application Number
- CN202411610582.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-12
- Publication Date
- 2025-04-01
AI Technical Summary
The prior art is difficult to comprehensively evaluate the operating health status of reciprocating compressors, and it is impossible to detect potential fault characteristics early, resulting in unplanned parking, resulting in production losses and additional maintenance costs.
By obtaining the external temperature of the equipment measured by infrared thermal imaging cameras and the cylinder operation audio data measured by sound sensors in real time, performing real-time graphical display, and calculating the common weights corresponding to the threshold range of each type of operating status monitoring parameters to obtain the operating status quantization value for early warning.
It realizes accurate monitoring and tracking of key operating parameters of reciprocating compressor equipment, can detect potential faults early, avoid unplanned downtime, and improve equipment reliability and production efficiency.
Smart Images
Figure CN119737305A_ABST
Abstract
Description
Technical Field
[0001] The embodiments of the present invention relate to the technical field of petrochemical production equipment diagnosis, and in particular to a method, device, equipment and medium for monitoring the operating status of a reciprocating compressor. Background Art
[0002] In the field of petrochemical production, reciprocating compressors are a commonly used production equipment. The operating condition of the reciprocating compressor is related to the operating condition of the entire production process. If an unplanned shutdown occurs in a running reciprocating compressor, it will cause serious production losses, increase additional maintenance costs, and affect personnel, environmental and equipment safety. In the related art, the reciprocating compressor status monitoring method only sets monitoring measures for a small number of parameters such as vibration severity and watt temperature, and monitors whether the reciprocating compressor fails by setting thresholds. However, this type of monitoring scheme is difficult to comprehensively evaluate the current health status of the unit, and cannot detect potential fault characteristics of the unit operation at an early stage. Summary of the invention
[0003] The purpose of the present invention is to at least provide a method, device, equipment and medium for monitoring the operating status of a reciprocating compressor, which can at least solve the problem of early detection of potential operating faults of the reciprocating compressor equipment, and at least achieve the effect of accurately monitoring and tracking key operating parameters of the reciprocating compressor equipment.
[0004] To solve the above technical problems, at least one embodiment of the present application provides a method for monitoring the operating status of a reciprocating compressor, comprising:
[0005] During the production of the target material, real-time acquisition of operating status monitoring parameter data of the reciprocating compressor equipment, wherein the operating status monitoring parameter data includes the equipment external temperature measured by an infrared thermal imaging camera and the audio data of the cylinder operation measured by a sound sensor;
[0006] The operating status monitoring parameter data is graphically displayed in real time, and the operating status monitoring parameter data exceeding the reference threshold range is superimposed and displayed with the corresponding reference threshold range;
[0007] Calculating a quantified value of the operating state of the reciprocating compressor device based on commonality weights corresponding to different threshold ranges of each type of operating state monitoring parameter, wherein the quantified value of the operating state is the sum of commonality weights corresponding to the threshold range to which each type of operating state monitoring parameter data belongs, wherein the different threshold ranges include at least one fault threshold range and a reference threshold range;
[0008] A corresponding operation status warning is performed based on the operation status quantification value.
[0009] In some embodiments, the method further comprises:
[0010] Obtaining operating status monitoring parameter data of reciprocating compressor equipment during production of target materials;
[0011] Respectively extracting first operating state monitoring parameter data during a fault operation and second operating state monitoring parameter data during a non-fault operation from the operating state monitoring parameter data;
[0012] Determine at least one fault threshold range for each type of operating state monitoring parameter according to the first operating state monitoring parameter data, and determine a reference threshold range for each type of operating state monitoring parameter according to the second operating state monitoring parameter data;
[0013] For each type of operating status monitoring parameter, obtaining commonality weights corresponding to the at least one fault threshold range and the reference threshold range respectively;
[0014] The at least one fault threshold range is stored in a knowledge base.
[0015] In some embodiments, the operating status monitoring parameter further includes at least one of the following:
[0016] Cylinder pressure measured by pressure sensor;
[0017] The rotation speed of the shaft measured by the key phase sensor;
[0018] A first vibration sensor measures a crankcase body vibration;
[0019] The impact vibration of the crosshead is measured by a second vibration sensor;
[0020] The gas valve temperature of the cylinder measured by the temperature sensor, wherein the gas valve temperature is the internal temperature of the equipment;
[0021] The dynamic current of the motor measured by the current sensor;
[0022] A dynamic voltage of the motor measured by a first voltage sensor;
[0023] A dynamic voltage of the cylinder measured by a second voltage sensor;
[0024] The acceleration of the crankcase vibration measured by the first acceleration sensor;
[0025] The second acceleration sensor measures the acceleration of the cylinder vibration.
[0026] In some embodiments, the method further comprises: updating the at least one fault threshold range based on the operating status monitoring parameter data acquired in real time and storing the updated fault threshold range in a knowledge base.
[0027] In some implementations, before determining at least one fault threshold range of each type of operating status monitoring parameter according to the first operating status monitoring parameter data, the method further includes:
[0028] The first operating status monitoring parameter data is converted from the time domain to the frequency domain through Fourier transformation.
[0029] In some implementations, performing a corresponding operation status warning based on the operation status quantification value includes:
[0030] Determine the warning level of the running state quantization value according to the running state quantization value intervals corresponding to different warning levels;
[0031] A notification message is sent to the target person corresponding to the warning level through the notification method corresponding to the warning level.
[0032] At least one embodiment of the present application further provides a reciprocating compressor operating status monitoring device, comprising:
[0033] An acquisition module, used to acquire operating status monitoring parameter data of a reciprocating compressor device in real time during the production of a target material, wherein the operating status monitoring parameters include an external temperature of the device measured by an infrared thermal imaging camera and audio data of cylinder operation measured by a sound sensor;
[0034] A display module, used for real-time graphical display of the operating status monitoring parameter data, and superimposing the operating status monitoring parameter data exceeding the reference threshold range with the corresponding reference threshold range;
[0035] A calculation module, configured to calculate a quantized value of an operating state of the reciprocating compressor device based on commonality weights corresponding to different threshold ranges of each type of operating state monitoring parameter, wherein the quantized value of the operating state is the sum of commonality weights corresponding to the threshold ranges to which each type of operating state monitoring parameter data belongs, wherein the different threshold ranges include at least one fault threshold range and a reference threshold range;
[0036] The early warning module is used to make corresponding operation status early warning based on the operation status quantization value.
[0037] At least one embodiment of the present application also provides an electronic device, comprising: at least one processor; and a memory communicatively connected to the at least one processor; wherein the memory stores instructions executable by the at least one processor, and the instructions are executed by the at least one processor so that the at least one processor can execute the above-mentioned reciprocating compressor operating status monitoring method.
[0038] At least one embodiment of the present application further provides a computer-readable storage medium storing a computer program, wherein the computer program implements the above-mentioned method for monitoring the operating status of a reciprocating compressor when executed by a processor.
[0039] At least one embodiment of the present application further provides a computer program product, including a computer program, which implements the steps of the above-mentioned method for monitoring the operating status of a reciprocating compressor when executed by a processor.
[0040] The present application provides a reciprocating compressor operating status monitoring method, device, equipment and storage medium. By acquiring operating status monitoring parameter data of the reciprocating compressor equipment including infrared thermal imaging camera data and sound sensor data in real time during the production of target materials, real-time graphical display of the operating status monitoring parameter data is achieved, and the operating status monitoring parameter data in the case of a fault exceeding the benchmark threshold range is superimposed and displayed with the corresponding benchmark threshold range, thereby effectively and accurately monitoring and tracking the key operating parameters of the reciprocating compressor equipment; the sum of the common weights corresponding to the threshold range to which each type of operating status monitoring parameter data belongs is calculated to obtain an operating status quantization value, and the level of the operating status is determined based on this operating status quantization value to perform corresponding operating status warnings, which can comprehensively and accurately detect potential operating faults of the reciprocating compressor equipment at an early stage, and provide more scientific and accurate decision support for the operation management of the reciprocating compressor equipment. BRIEF DESCRIPTION OF THE DRAWINGS
[0041] One or more embodiments are exemplarily described by the pictures in the corresponding drawings, and these exemplary descriptions do not constitute limitations on the embodiments.
[0042] Figure 1 The process of a reciprocating compressor operating status monitoring method provided by an embodiment of the present application is Figure 1 ;
[0043] Figure 2 Another embodiment of the present invention provides a method for monitoring the operating status of a reciprocating compressor. Figure 2 ;
[0044] Figure 3 is a dynamic pressure distribution diagram of a reciprocating compressor within a unit operating cycle provided by another embodiment of the present application;
[0045] Figure 4 is a single-direction settlement distribution diagram of a piston rod provided by another embodiment of the present application;
[0046] Figure 5 It is a schematic diagram of a reciprocating compressor operating status monitoring device provided in another embodiment of the present application. DETAILED DESCRIPTION
[0047] To make the purpose, technical scheme and advantages of the embodiments of the present application clearer, the embodiments of the present application will be described in detail below in conjunction with the accompanying drawings. However, it will be appreciated by those skilled in the art that in the present application, many technical details are proposed in order to enable the reader to better understand the present application. However, even without these technical details and various changes and modifications based on the following embodiments, the technical scheme claimed in the present application can also be implemented. The division of the following embodiments is for the convenience of description, and the specific implementation of the present application should not be construed as any limitation, and the various embodiments can be combined and referenced with each other under the premise of no contradiction.
[0048] In the field of petrochemical production, reciprocating compressors are a commonly used production equipment. The operating status of reciprocating compressors is related to the operating status of the entire production process. If an unplanned stop occurs in a running reciprocating compressor, it will cause serious production losses, increase additional maintenance costs, and affect personnel, environment and equipment safety. Studies have shown that 80% of unplanned stops are caused by failures of valves, pistons / piston rods, packings, and piston rings / support rings.
[0049] In the related art, the reciprocating compressor status monitoring method only sets monitoring measures for a few parameters such as vibration severity and temperature, and monitors whether the reciprocating compressor has failed by setting thresholds, such as real-time monitoring of vibration data at a certain location, and alarming when the vibration amplitude exceeds the threshold; or monitoring the temperature at a certain location, etc. However, this type of monitoring scheme is difficult to fully evaluate the current health status of the unit and cannot detect potential fault characteristics of the unit's operation at an early stage.
[0050] The following is a specific description of the implementation details of a method for monitoring the operating status of a reciprocating compressor provided in this embodiment. The following content is only provided for the convenience of understanding the implementation details and is not necessary for implementing this solution.
[0051] Embodiment 1
[0052] The method for monitoring the operating status of a reciprocating compressor of this embodiment can be applied to electronic devices with communication, computing and data storage capabilities. The specific process can be as follows: Figure 1 As shown, including:
[0053] Step 101, during the production of the target material, real-time acquisition of operating status monitoring parameter data of the reciprocating compressor equipment.
[0054] In some cases, the reciprocating compressor device is a reciprocating compressor train consisting of at least two reciprocating compressors.
[0055] The operating status monitoring parameter data of the reciprocating compressor equipment includes the equipment external temperature measured by the infrared thermal imaging camera and the audio data of the cylinder operation measured by the sound sensor.
[0056] By installing multiple sensors on the reciprocating compressor unit, multi-source data is integrated to achieve effective monitoring of the operating status monitoring parameters of the reciprocating compressor unit. In the specific implementation, the infrared thermal imaging camera can be set up in the area above the cylinder to obtain the external temperature of the equipment by measuring the temperature of the cylinder area; the sound sensor can be installed in the cylinder area to measure the sound of the valve and cylinder during the operation of the cylinder to obtain the audio data of the cylinder operation, and the audio data can be obtained in the form of voiceprint atlas.
[0057] In some embodiments, the reciprocating compressor unit is also equipped with at least one of a variety of sensors such as pressure sensors, key phase sensors, vibration sensors, temperature sensors, current sensors, voltage sensors, acceleration sensors, etc., to obtain more operating status monitoring parameter data. Among them, the pressure sensor is installed in the cylinder area to measure the dynamic pressure of the cylinder; the key phase sensor is installed in the motor area, by setting a groove or convex key on the measured shaft as a key phase mark, when the key phase mark turns to the key phase sensor position, the distance between the key phase sensor and the measured surface suddenly changes to generate a pulse signal. Such a pulse signal will be generated every time the shaft rotates one circle, and the time of generation indicates the position of the shaft in each rotation cycle; the first vibration sensor is installed at the crankcase to measure the body vibration signal of the crankcase; the second vibration sensor is installed at the crosshead to measure the impact vibration signal of the crosshead; the temperature sensor is installed at the crankcase to measure the vibration signal of the crankcase; the second vibration sensor is installed at the crosshead to measure the impact vibration signal of the crosshead; the temperature sensor is installed at the crankcase to measure the vibration signal of the crankcase; the temperature sensor is installed at the crankcase to measure the ... crankcase; the temperature sensor is installed at the crankcase to measure the vibration signal of the crankcase; the temperature sensor is installed at the crank The valve area of the cylinder is used to measure the valve temperature of the cylinder, which is the internal temperature of the equipment; the current sensor is installed at the motor to measure the dynamic current of the motor; the first voltage sensor is installed at the motor to measure the dynamic voltage of the motor; the second voltage sensor is installed at the cylinder to measure the dynamic voltage of the cylinder; the first acceleration sensor is installed at the crankcase to measure the acceleration of the crankcase vibration; the second acceleration sensor is installed at the cylinder to measure the acceleration of the cylinder vibration; in some cases, an eddy current sensor is also installed at the piston rod of the reciprocating compressor unit to measure the piston rod settlement signal.
[0058] Furthermore, the operating status monitoring parameters also include at least one of the following: cylinder pressure measured by a pressure sensor, shaft rotation speed measured by a key phase sensor, crankcase body vibration measured by a first vibration sensor, crosshead impact vibration measured by a second vibration sensor, cylinder valve temperature measured by a temperature sensor, dynamic current of the motor measured by a current sensor, dynamic voltage of the motor measured by a first voltage sensor, dynamic voltage of the cylinder measured by a second voltage sensor, acceleration of crankcase vibration measured by a first acceleration sensor, acceleration of cylinder vibration measured by a second acceleration sensor, and a piston rod settlement signal measured by an eddy current sensor.
[0059] Step 102 : Real-time graphical display of the operating status monitoring parameter data is performed, and the operating status monitoring parameter data exceeding the reference threshold range is superimposed and displayed with the corresponding reference threshold range.
[0060] In a specific implementation, different threshold ranges are pre-set, including at least one fault threshold range and a reference threshold range, and the different threshold ranges are determined based on the daily acquired operation status monitoring parameter data. In some examples, as the daily acquired operation status monitoring parameter data is continuously updated, the different threshold ranges can be regularly updated.
[0061] While displaying the operating status monitoring parameter data in real-time graphics, the benchmark threshold range of the corresponding parameters is also superimposed and displayed to achieve real-time comparison to understand whether the corresponding parameters are in the non-fault threshold range, so as to facilitate timely judgment on whether the corresponding device has failed and the extent of the failure.
[0062] In some examples, the graphical display can be to integrate the operating status monitoring parameter data into a three-dimensional graph to show the changes of the operating status monitoring parameter data over time. In a specific implementation, the parameter options for real-time graphical display can be configured, and the user selects the operating status monitoring parameter to be displayed to display the data of the corresponding parameter in the displayed three-dimensional graph. Since the visualized graph data can only represent four dimensions through three coordinate axes + color or line segment shape, a maximum of four parameter options can be selected in this example.
[0063] In some examples, the graphical display can be to merge the operating status monitoring parameter data into a two-dimensional curve graph. In a specific implementation, for example, the body vibration of the crankcase measured by the first vibration sensor and the impact vibration of the crosshead measured by the second vibration sensor can be merged into a curve graph, and displayed with lines of different colors or different patterns respectively; the dynamic voltage of the motor measured by the first voltage sensor and the dynamic voltage of the cylinder measured by the second voltage sensor can also be merged into a curve graph, and displayed with lines of different colors or different patterns respectively; the acceleration of the crankcase vibration measured by the first acceleration sensor and the acceleration of the cylinder vibration measured by the second acceleration sensor can also be merged into a curve graph, and displayed with lines of different colors or different patterns respectively; in the two-dimensional curve graph, the horizontal axis is time, and the vertical axis is the above-mentioned dynamic voltage, vibration or acceleration.
[0064] Of course, the graphical display can also display one type of operating status monitoring parameter data in one graph.
[0065] When more than four operating status monitoring parameter data need to be displayed, multiple graphics can be displayed on the display interface at the same time to achieve synchronous display of the operating status monitoring parameter data and timely analysis of the data.
[0066] Step 103, calculating the operating state quantification value of the reciprocating compressor equipment based on the commonality weights corresponding to different threshold ranges of each type of operating state monitoring parameter, the operating state quantification value is the sum of the commonality weights corresponding to the threshold range to which each type of operating state monitoring parameter data belongs.
[0067] In a specific implementation, at least one fault threshold range and a reference threshold range are pre-set, as well as common weights corresponding to different threshold ranges, wherein the reference threshold range is the numerical range under normal operation of the reciprocating compressor, the weight corresponding to the reference threshold range is 0, the fault threshold range is the numerical range under faulty operation of the reciprocating compressor, when the fault threshold range is one, it indicates only one degree of fault, and when the fault threshold range is subdivided into multiple, it indicates multiple degrees of fault, and different weight values are set for multiple fault threshold ranges. By subdividing the fault threshold range into multiple types and assigning weight values respectively, the degree of fault of the corresponding parts can be accurately assessed, and the degree of fault can be characterized by weight values. The weight values of each part are further summed to obtain the quantified value of the operating state, and the degree of fault of the current reciprocating compressor can be predicted based on the quantified value of the operating state.
[0068] Step 104: Perform corresponding operation status warning based on the operation status quantification value.
[0069] In some implementations, performing corresponding operation status warning based on the operation status quantification value includes:
[0070] Step 104a, determining the warning level of the running state quantization value according to the running state quantization value intervals corresponding to different warning levels.
[0071] Step 104b: Send notification information to the target person corresponding to the warning level through the notification method corresponding to the warning level.
[0072] Preset the operation status quantization value interval corresponding to different warning levels. After calculating the operation status quantization value in the previous step, find the corresponding warning level to issue a warning. Preset the notification method corresponding to different warning levels. For example, the higher the level, the more urgent the corresponding notification method.
[0073] In the method of this embodiment, by acquiring the operating status monitoring parameter data of the reciprocating compressor equipment including the infrared thermal imaging camera data and the sound sensor data in real time during the production of the target material, the real-time graphical display of the operating status monitoring parameter data is realized, and the operating status monitoring parameter data in the case of a fault exceeding the benchmark threshold range is superimposed and displayed with the corresponding benchmark threshold range, thereby effectively and accurately monitoring and tracking the key operating parameters of the reciprocating compressor equipment; the sum of the common weights corresponding to the threshold range to which each type of operating status monitoring parameter data belongs is calculated to obtain the operating status quantification value, and the operating status level is determined based on this operating status quantification value to perform the corresponding operating status warning, which can comprehensively and accurately detect potential operating faults of the reciprocating compressor equipment at an early stage, and provide more scientific and accurate decision support for the operation management of the reciprocating compressor equipment.
[0074] Embodiment 2
[0075] The reciprocating compressor operating status monitoring method of this embodiment can be applied to electronic devices with communication, computing and data storage capabilities. The specific process can be as follows: Figure 2 As shown, based on the first embodiment, it also includes:
[0076] Step 201: Acquire operating status monitoring parameter data of a reciprocating compressor device during production of a target material.
[0077] Step 202: extract first operating status monitoring parameter data during a fault operation and second operating status monitoring parameter data during a non-fault operation from the operating status monitoring parameter data.
[0078] Step 203: Determine at least one fault threshold range for each type of operating status monitoring parameter according to the first operating status monitoring parameter data, and determine a reference threshold range for each type of operating status monitoring parameter according to the second operating status monitoring parameter data.
[0079] Step 204: For each type of operating status monitoring parameter, obtain the commonality weights corresponding to at least one fault threshold range and a reference threshold range.
[0080] Step 205: Store at least one fault threshold range into a knowledge base.
[0081] In this embodiment, before obtaining the operating status monitoring parameter data of the reciprocating compressor device in real time in step 101, the operating status monitoring parameter data of the reciprocating compressor device during the production of the target material obtained on a daily basis is first obtained to determine different threshold ranges, and at least the fault threshold range is stored in a pre-established knowledge base. From the operating status monitoring parameter data of the reciprocating compressor device during the production of the target material obtained, the first operating status monitoring parameter data during the fault operation period and the second operating status monitoring parameter data during the non-fault operation period are extracted, and the data under the two types of working conditions are distinguished to determine the corresponding threshold range.
[0082] In a specific implementation, the faulty operation period can be determined based on the operating status monitoring parameter data obtained daily. The faulty operation period may be one or more. The data during the faulty operation period is extracted from the operating status monitoring parameter data during the production of the target material by the reciprocating compressor equipment, and the fault threshold interval is divided according to the extracted data. For example, a threshold range analysis is performed based on the maintenance records during the faulty operation period. The higher the degree of maintenance, the corresponding operating status monitoring parameter data range is determined to be a fault threshold range that represents a higher degree of fault.
[0083] In some implementations, the method of this embodiment further includes: updating at least one fault threshold range based on the operating status monitoring parameter data acquired in real time and storing the data in a knowledge base.
[0084] In the case of continuously acquiring the operating status monitoring parameter data in real time in the first embodiment, a faulty operating interval may still occur. In this case, at least one fault threshold range for each type of operating status monitoring parameter can be re-determined based on the first operating status monitoring parameter data during the new faulty operating period to update at least one fault threshold range to the knowledge base.
[0085] It should also be noted that the knowledge base can store not only the fault threshold range, but also the reference threshold range, operating status monitoring parameter data, etc., for traceability. With the continuous updating of positive samples (the second operating status monitoring parameter data during non-fault operation) and negative samples (the first operating status monitoring parameter data during fault operation) in the operating status monitoring parameter data, the data stored in the knowledge base is continuously increased or replaced at a certain period.
[0086] In some embodiments, before determining at least one fault threshold range of each type of operating state monitoring parameter according to the first operating state monitoring parameter data, the method further includes:
[0087] The first operating status monitoring parameter data is converted from the time domain to the frequency domain through Fourier transformation.
[0088] In a specific implementation, the first operating state monitoring parameter data can be finely cleaned and co-frequency superimposed, and the first operating state monitoring parameter data can be converted into a frequency domain signal through Fourier transform to obtain more detailed information. In one example, the co-frequency superposition of the first operating state monitoring parameter data can refer to superimposing the first operating state monitoring parameter data of different fault operation periods at the same frequency, for example, superimposing the first operating state monitoring parameter data of different fault operation periods in units of minutes to obtain several minutes of superimposed data.
[0089] Embodiment 3
[0090] This embodiment provides an application example of the above method.
[0091] In this application example, real-time graphical display of operating status monitoring parameter data can be used Figure 3 The two-dimensional graph shown can also be used Figure 4 The three-dimensional graph is shown. Figure 3 It is a dynamic pressure distribution diagram of the reciprocating compressor during a unit operating cycle. The dynamic pressure at different angles is displayed according to the different rotation angles of the compressor. Based on the dynamic pressure distribution at different angles, it can be determined whether the equipment is operating normally. Figure 4 It is the settlement distribution diagram of the piston rod in one direction. In practical applications, other forms of images can be used to display data, not limited to Figure 3 and Figure 4 shown.
[0092] In this application example, the reciprocating compressor equipment includes a unit consisting of two reciprocating compressors, one of which is the main unit and the other is the standby unit. The target material produced is material A. The catalyst used in the main unit is catalyst X, and the catalyst used in the standby unit is catalyst Y. The operating status monitoring parameters obtained for the two reciprocating compressors include key phase A1, vibration parameter A2, dynamic pressure A3, external temperature A4, internal temperature A5, and audio data B6. The parameters and the corresponding threshold ranges and weights are shown in the following table:
[0093]
[0094] In the above table, the threshold intervals marked as "normal" are the reference threshold intervals, and the rest are fault threshold intervals. It should be understood that the above table is only an example of partial data.
[0095] In this example, the operating status quantification value ranges corresponding to different warning levels are as follows:
[0096] level Interval Level 1 0-0.5 Level 2 0.5-1.0 Level 3 1.0-2.0 Level 4 2.0-3.0 Level 5 3.0+
[0097] When producing material A, the corresponding data threshold and weight are collected according to the corresponding sensor data, the operating status of the reciprocating compressor unit is calculated, the warning level is divided according to the value, the corresponding warning is prompted and the target personnel are notified, for example, by SMS to notify the target personnel of what kind of fault may occur at present, or which parameters are abnormal. The current warning level, operating status monitoring parameter data and the corresponding benchmark threshold range can also be viewed by installing the App on the terminal device of the target personnel.
[0098] Embodiment 4
[0099] The present embodiment relates to a reciprocating compressor operating status monitoring device. The implementation details of the reciprocating compressor operating status monitoring device of the present embodiment are specifically described below. The following content is only for the convenience of understanding the implementation details provided, and is not necessary for the implementation of the present solution. The schematic diagram of the reciprocating compressor operating status monitoring device of the present embodiment can be as follows: Figure 5 As shown, it includes an acquisition module 301, a display module 302, a calculation module 303 and an early warning module 304.
[0100] The acquisition module 301 is used to acquire the operating status monitoring parameter data of the reciprocating compressor equipment in real time during the production of the target material.
[0101] The display module 302 is used to display the operating status monitoring parameter data in real time graphically, and to display the operating status monitoring parameter data exceeding the reference threshold range by superimposing the corresponding reference threshold range.
[0102] The calculation module 303 is used to calculate the operating state quantification value of the reciprocating compressor equipment based on the common weights corresponding to the different threshold ranges of each type of operating state monitoring parameters. The operating state quantification value is the sum of the common weights corresponding to the threshold ranges to which each type of operating state monitoring parameter data belongs. The different threshold ranges include at least one fault threshold range and a baseline threshold range.
[0103] The warning module 304 is used to issue a corresponding running status warning based on the running status quantified value.
[0104] In some cases, the reciprocating compressor device is a reciprocating compressor train consisting of at least two reciprocating compressors.
[0105] The operating status monitoring parameter data of the reciprocating compressor equipment includes the equipment external temperature measured by the infrared thermal imaging camera and the audio data of the cylinder operation measured by the sound sensor.
[0106] By installing multiple sensors on the reciprocating compressor unit, multi-source data is integrated to achieve effective monitoring of the operating status monitoring parameters of the reciprocating compressor unit. In the specific implementation, the infrared thermal imaging camera can be set up in the area above the cylinder to obtain the external temperature of the equipment by measuring the temperature of the cylinder area; the sound sensor can be installed in the cylinder area to measure the sound of the valve and cylinder during the operation of the cylinder to obtain the audio data of the cylinder operation, and the audio data can be obtained in the form of voiceprint atlas.
[0107] In some embodiments, the reciprocating compressor unit is also equipped with at least one of a variety of sensors such as pressure sensors, key phase sensors, vibration sensors, temperature sensors, current sensors, voltage sensors, acceleration sensors, etc., to obtain more operating status monitoring parameter data. Among them, the pressure sensor is installed in the cylinder area to measure the dynamic pressure of the cylinder; the key phase sensor is installed in the motor area, by setting a groove or convex key on the measured shaft as a key phase mark, when the key phase mark turns to the key phase sensor position, the distance between the key phase sensor and the measured surface suddenly changes to generate a pulse signal. Such a pulse signal will be generated every time the shaft rotates one circle, and the time of generation indicates the position of the shaft in each rotation cycle; the first vibration sensor is installed at the crankcase to measure the body vibration signal of the crankcase; the second vibration sensor is installed at the crosshead to measure the impact vibration signal of the crosshead; the temperature sensor is installed at the crankcase to measure the vibration signal of the crankcase; the second vibration sensor is installed at the crosshead to measure the impact vibration signal of the crosshead; the temperature sensor is installed at the crankcase to measure the vibration signal of the crankcase; the temperature sensor is installed at the crankcase to measure the ... crankcase; the temperature sensor is installed at the crankcase to measure the vibration signal of the crankcase; the temperature sensor is installed at the crank The valve area of the cylinder is used to measure the valve temperature of the cylinder, which is the internal temperature of the equipment; the current sensor is installed at the motor to measure the dynamic current of the motor; the first voltage sensor is installed at the motor to measure the dynamic voltage of the motor; the second voltage sensor is installed at the cylinder to measure the dynamic voltage of the cylinder; the first acceleration sensor is installed at the crankcase to measure the acceleration of the crankcase vibration; the second acceleration sensor is installed at the cylinder to measure the acceleration of the cylinder vibration; in some cases, an eddy current sensor is also installed at the piston rod of the reciprocating compressor unit to measure the piston rod settlement signal.
[0108] Furthermore, the operating status monitoring parameters also include at least one of the following: cylinder pressure measured by a pressure sensor, shaft rotation speed measured by a key phase sensor, crankcase body vibration measured by a first vibration sensor, crosshead impact vibration measured by a second vibration sensor, cylinder valve temperature measured by a temperature sensor, dynamic current of the motor measured by a current sensor, dynamic voltage of the motor measured by a first voltage sensor, dynamic voltage of the cylinder measured by a second voltage sensor, acceleration of crankcase vibration measured by a first acceleration sensor, acceleration of cylinder vibration measured by a second acceleration sensor, and a piston rod settlement signal measured by an eddy current sensor.
[0109] In a specific implementation, different threshold ranges are pre-set, including at least one fault threshold range and a reference threshold range, and the different threshold ranges are determined based on the daily acquired operation status monitoring parameter data. In some examples, as the daily acquired operation status monitoring parameter data is continuously updated, the different threshold ranges can be regularly updated.
[0110] While displaying the operating status monitoring parameter data in real-time graphics, the benchmark threshold range of the corresponding parameters is also superimposed and displayed to achieve real-time comparison to understand whether the corresponding parameters are in the non-fault threshold range, so as to facilitate timely judgment on whether the corresponding device has failed and the extent of the failure.
[0111] In some examples, the graphical display can be to integrate the operating status monitoring parameter data into a three-dimensional graph to show the changes of the operating status monitoring parameter data over time. In a specific implementation, the parameter options for real-time graphical display can be configured, and the user selects the operating status monitoring parameter to be displayed to display the data of the corresponding parameter in the displayed three-dimensional graph. Since the visualized graph data can only represent four dimensions through three coordinate axes + color or line segment shape, a maximum of four parameter options can be selected in this example.
[0112] In some examples, the graphical display can be to merge the operating status monitoring parameter data into a two-dimensional curve graph. In a specific implementation, for example, the body vibration of the crankcase measured by the first vibration sensor and the impact vibration of the crosshead measured by the second vibration sensor can be merged into a curve graph, and displayed with lines of different colors or different patterns respectively; the dynamic voltage of the motor measured by the first voltage sensor and the dynamic voltage of the cylinder measured by the second voltage sensor can also be merged into a curve graph, and displayed with lines of different colors or different patterns respectively; the acceleration of the crankcase vibration measured by the first acceleration sensor and the acceleration of the cylinder vibration measured by the second acceleration sensor can also be merged into a curve graph, and displayed with lines of different colors or different patterns respectively; in the two-dimensional curve graph, the horizontal axis is time, and the vertical axis is the above-mentioned dynamic voltage, vibration or acceleration.
[0113] Of course, the graphical display can also display one type of operating status monitoring parameter data in one graph.
[0114] When more than four operating status monitoring parameter data need to be displayed, multiple graphics can be displayed on the display interface at the same time to achieve synchronous display of the operating status monitoring parameter data and timely analysis of the data.
[0115] In a specific implementation, at least one fault threshold range and a reference threshold range are pre-set, as well as common weights corresponding to different threshold ranges, wherein the reference threshold range is the numerical range under normal operation of the reciprocating compressor, the weight corresponding to the reference threshold range is 0, the fault threshold range is the numerical range under faulty operation of the reciprocating compressor, when the fault threshold range is one, it indicates only one degree of fault, and when the fault threshold range is subdivided into multiple, it indicates multiple degrees of fault, and different weight values are set for multiple fault threshold ranges. By subdividing the fault threshold range into multiple types and assigning weight values respectively, the degree of fault of the corresponding parts can be accurately assessed, and the degree of fault can be characterized by weight values. The weight values of each part are further summed to obtain the quantified value of the operating state, and the degree of fault of the current reciprocating compressor can be predicted based on the quantified value of the operating state.
[0116] In some implementations, performing corresponding operation status warning based on the operation status quantification value includes:
[0117] According to the operation status quantization value intervals corresponding to different warning levels, the warning level of the operation status quantization value is determined, and the notification information is sent to the target personnel corresponding to the warning level through the notification method corresponding to the warning level.
[0118] Preset the operation status quantization value interval corresponding to different warning levels. After calculating the operation status quantization value in the previous step, find the corresponding warning level to issue a warning. Preset the notification method corresponding to different warning levels. For example, the higher the level, the more urgent the corresponding notification method.
[0119] In some embodiments, the device of this embodiment may further include an analysis module for: obtaining operating status monitoring parameter data during the production of target materials by the reciprocating compressor equipment; respectively extracting first operating status monitoring parameter data during the fault operation period and second operating status monitoring parameter data during the non-fault operation period from the operating status monitoring parameter data; determining at least one fault threshold range for each type of operating status monitoring parameter based on the first operating status monitoring parameter data, and determining a baseline threshold range for each type of operating status monitoring parameter based on the second operating status monitoring parameter data; for each type of operating status monitoring parameter, obtaining the commonality weights corresponding to at least one fault threshold range and a baseline threshold range respectively; and storing at least one fault threshold range in a knowledge base.
[0120] In this embodiment, before obtaining the operating status monitoring parameter data of the reciprocating compressor device in real time, the operating status monitoring parameter data of the reciprocating compressor device during the production of the target material obtained on a daily basis is first obtained to determine different threshold ranges, and at least the fault threshold range is stored in a pre-established knowledge base. From the operating status monitoring parameter data of the reciprocating compressor device during the production of the target material obtained, the first operating status monitoring parameter data during the fault operation period and the second operating status monitoring parameter data during the non-fault operation period are extracted, and the data under the two types of working conditions are distinguished to determine the corresponding threshold range.
[0121] In a specific implementation, the faulty operation period can be determined based on the operating status monitoring parameter data obtained daily. The faulty operation period may be one or more. The data during the faulty operation period is extracted from the operating status monitoring parameter data during the production of the target material by the reciprocating compressor equipment, and the fault threshold interval is divided according to the extracted data. For example, a threshold range analysis is performed based on the maintenance records during the faulty operation period. The higher the degree of maintenance, the corresponding operating status monitoring parameter data range is determined to be a fault threshold range that represents a higher degree of fault.
[0122] In some implementations, the analysis module is further used to: update at least one fault threshold range based on the operating status monitoring parameter data acquired in real time and store it in a knowledge base.
[0123] When the operating status monitoring parameter data is continuously acquired in real time, faulty operating intervals may still occur. In this case, at least one fault threshold range for each type of operating status monitoring parameter can be re-determined based on the first operating status monitoring parameter data during the new faulty operating period to update at least one fault threshold range to the knowledge base.
[0124] It should also be noted that the knowledge base can store not only the fault threshold range, but also the reference threshold range, operating status monitoring parameter data, etc., for traceability. With the continuous updating of positive samples (the second operating status monitoring parameter data during non-fault operation) and negative samples (the first operating status monitoring parameter data during fault operation) in the operating status monitoring parameter data, the data stored in the knowledge base is continuously increased or replaced at a certain period.
[0125] In some embodiments, before determining at least one fault threshold range of each type of operating state monitoring parameter according to the first operating state monitoring parameter data, the method further includes:
[0126] The first operating status monitoring parameter data is converted from the time domain to the frequency domain through Fourier transformation.
[0127] In a specific implementation, the first operating state monitoring parameter data can be finely cleaned and co-frequency superimposed, and the first operating state monitoring parameter data can be converted into a frequency domain signal through Fourier transform to obtain more detailed information. In one example, the co-frequency superposition of the first operating state monitoring parameter data can refer to superimposing the first operating state monitoring parameter data of different fault operation periods at the same frequency, for example, superimposing the first operating state monitoring parameter data of different fault operation periods in units of minutes to obtain several minutes of superimposed data.
[0128] It is worth mentioning that all modules involved in this embodiment are logic modules. In practical applications, a logic unit can be a physical unit, a part of a physical unit, or a combination of multiple physical units. In addition, in order to highlight the innovative part of this application, this embodiment does not introduce units that are not closely related to solving the technical problems proposed by this application, but this does not mean that there are no other units in this embodiment.
[0129] Embodiment 5
[0130] Another embodiment of the present application relates to an electronic device, comprising: at least one processor; and a memory communicatively connected to the at least one processor; wherein the memory stores instructions executable by the at least one processor, and the instructions are executed by the at least one processor so that the at least one processor can execute the reciprocating compressor operating status monitoring method in the above-mentioned embodiments.
[0131] Among them, the memory and the processor are connected in a bus manner, and the bus may include any number of interconnected buses and bridges, and the bus connects various circuits of one or more processors and memories together. The bus can also connect various other circuits such as peripherals, voltage regulators, and power management circuits, which are well known in the art and are therefore not further described herein. The bus interface provides an interface between the bus and the transceiver. The transceiver can be one element or multiple elements, such as multiple receivers and transmitters, providing a unit for communicating with various other devices on a transmission medium. The data processed by the processor is transmitted on a wireless medium via an antenna, and further, the antenna also receives data and transmits the data to the processor.
[0132] The processor is responsible for managing the bus and general processing, and can also provide various functions, including timing, peripheral interfaces, voltage regulation, power management, and other control functions. Memory can be used to store data used by the processor when performing operations.
[0133] Embodiment 6
[0134] Another embodiment of the present application relates to a computer-readable storage medium storing a computer program, which implements the above method embodiment when executed by a processor.
[0135] Those skilled in the art can understand that all or part of the steps in the above-mentioned embodiment method can be completed by instructing the relevant hardware through a program, and the program is stored in a storage medium, including a number of instructions to enable a device (which can be a single-chip microcomputer, chip, etc.) or a processor to execute all or part of the steps of the method described in each embodiment of the present application. The aforementioned storage medium includes: U disk, mobile hard disk, read-only memory (Read-Only Memory, referred to as: ROM), random access memory (Random Access Memory, referred to as: RAM), disk or optical disk and other media that can store program codes.
[0136] In some embodiments, the present application also provides a computer program product, including a computer program, characterized in that when the computer program is executed by a processor, the steps of the method in the above embodiment are implemented.
[0137] The reciprocating compressor operating status monitoring method, device, equipment and medium provided in the embodiment of the present application can confirm the root cause of equipment failure at an early stage, extend the operating cycle of the compressor, avoid unplanned downtime, improve the reliability of the compressor, reduce operating costs, reduce maintenance time, increase production, increase potential profits, and increase the safety of personnel and equipment. The fault point (fault location), fault type and its impact can be intelligently confirmed based on the superposition display of data, and the frequency of common faults of the equipment, environmental conditions or process conditions, parts, maintenance time and effectiveness can be further counted. Through real-time monitoring of the operating status of the equipment, the detection and diagnosis capabilities of early faults can be achieved, which can be used to guide correct operation, avoid major failures of the equipment, and effectively extend the operating time of the equipment. Due to the improved targeted maintenance, it is not easy to cause excessive maintenance or insufficient maintenance problems, which can greatly reduce maintenance costs.
[0138] A large part of the equipment life cycle cost is maintenance cost, and a considerable part of it is caused by excessive maintenance. The main reason for excessive maintenance is that it is impossible to confirm the type, location and severity of the fault, and therefore it is impossible to accurately determine the maintenance load.
[0139] Therefore, the role of this application in reducing maintenance costs is reflected in:
[0140] ① Eliminate excessive maintenance costs caused by random maintenance through accurate early fault diagnosis;
[0141] ② Improve the efficiency of driving workflow flow through the application of smart terminal devices App, ensure that the workflow flow is completed in the "shortest time" when problems arise, and put it into practice.
[0142] Those skilled in the art will appreciate that the above embodiments are specific embodiments for implementing the present application, and in actual applications, various changes may be made thereto in form and detail without departing from the spirit and scope of the present application.
Claims
1. A method for monitoring the operating status of a reciprocating compressor, characterized in that: include: During the production of the target material, real-time acquisition of operating status monitoring parameter data of the reciprocating compressor equipment, wherein the operating status monitoring parameters include the equipment external temperature measured by an infrared thermal imaging camera and the audio data of the cylinder operation measured by a sound sensor; The operating status monitoring parameter data is graphically displayed in real time, and the operating status monitoring parameter data exceeding the reference threshold range is superimposed and displayed with the corresponding reference threshold range; Calculating a quantified value of the operating state of the reciprocating compressor device based on commonality weights corresponding to different threshold ranges of each type of operating state monitoring parameter, wherein the quantified value of the operating state is the sum of commonality weights corresponding to the threshold range to which each type of operating state monitoring parameter data belongs, wherein the different threshold ranges include at least one fault threshold range and a reference threshold range; A corresponding operation status warning is performed based on the operation status quantification value.
2. The method for monitoring the operating status of a reciprocating compressor according to claim 1, characterized in that: Also includes: Obtaining operating status monitoring parameter data of reciprocating compressor equipment during production of target materials; Respectively extracting first operating state monitoring parameter data during a fault operation and second operating state monitoring parameter data during a non-fault operation from the operating state monitoring parameter data; Determine at least one fault threshold range for each type of operating state monitoring parameter according to the first operating state monitoring parameter data, and determine a reference threshold range for each type of operating state monitoring parameter according to the second operating state monitoring parameter data; For each type of operating status monitoring parameter, obtaining commonality weights corresponding to the at least one fault threshold range and the reference threshold range respectively; The at least one fault threshold range is stored in a knowledge base.
3. The method for monitoring the operating status of a reciprocating compressor according to claim 2, characterized in that: The operating status monitoring parameters also include at least one of the following: Cylinder pressure measured by pressure sensor; The rotation speed of the shaft measured by the key phase sensor; A first vibration sensor measures a crankcase body vibration; The impact vibration of the crosshead is measured by a second vibration sensor; The gas valve temperature of the cylinder measured by the temperature sensor, wherein the gas valve temperature is the internal temperature of the equipment; The dynamic current of the motor measured by the current sensor; A dynamic voltage of the motor measured by a first voltage sensor; A dynamic voltage of the cylinder measured by a second voltage sensor; The acceleration of the crankcase vibration measured by the first acceleration sensor; The second acceleration sensor measures the acceleration of the cylinder vibration.
4. The method for monitoring the operating status of a reciprocating compressor according to claim 2, characterized in that: Also includes: The at least one fault threshold range is updated based on the operating status monitoring parameter data acquired in real time and stored in the knowledge base.
5. The method for monitoring the operating status of a reciprocating compressor according to claim 2, characterized in that: Before determining at least one fault threshold range of each type of operating state monitoring parameter according to the first operating state monitoring parameter data, the method further includes: The first operating status monitoring parameter data is converted from the time domain to the frequency domain through Fourier transformation.
6. The method for monitoring the operating status of a reciprocating compressor according to claim 1, characterized in that: Based on the quantified value of the operating state, a corresponding operating state warning is performed, including: Determine the warning level of the running state quantization value according to the running state quantization value intervals corresponding to different warning levels; A notification message is sent to the target person corresponding to the warning level through the notification method corresponding to the warning level.
7. A reciprocating compressor operating status monitoring device, characterized in that: include: An acquisition module, used to acquire operating status monitoring parameter data of a reciprocating compressor device in real time during the production of a target material, wherein the operating status monitoring parameters include an external temperature of the device measured by an infrared thermal imaging camera and audio data of cylinder operation measured by a sound sensor; A display module, used for real-time graphical display of the operating status monitoring parameter data, and superimposing the operating status monitoring parameter data exceeding the reference threshold range with the corresponding reference threshold range; A calculation module, configured to calculate a quantized value of an operating state of the reciprocating compressor device based on commonality weights corresponding to different threshold ranges of each type of operating state monitoring parameter, wherein the quantized value of the operating state is the sum of commonality weights corresponding to the threshold ranges to which each type of operating state monitoring parameter data belongs, wherein the different threshold ranges include at least one fault threshold range and a reference threshold range; The early warning module is used to make corresponding operation status early warning based on the operation status quantization value.
8. An electronic device, characterized in that: include: at least one processor; as well as, a memory communicatively connected to the at least one processor; wherein, The memory stores instructions executable by the at least one processor, and the instructions are executed by the at least one processor so that the at least one processor can execute the reciprocating compressor operating status monitoring method according to any one of claims 1 to 6.
9. A computer-readable storage medium storing a computer program, characterized in that: When the computer program is executed by a processor, the method for monitoring the operating status of a reciprocating compressor according to any one of claims 1 to 6 is implemented.
10. A computer program product, comprising a computer program, characterized in that When the computer program is executed by a processor, the steps of the method for monitoring the operating status of a reciprocating compressor according to any one of claims 1 to 6 are implemented.