A collection circuit for ship rotating machinery faults
By designing a collection circuit for ship rotating mechanical failures, combined with acceleration sensors and anti-noise filtering technology, the problems of poor anti-interference performance and high misdiagnosis rate in the existing technology are solved, more accurate fault diagnosis and part positioning are achieved, online conditioning and reasonable maintenance are supported, fault losses and maintenance costs are reduced.
Patent Information
- Application Number
- CN202411833040.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-13
- Publication Date
- 2025-04-01
AI Technical Summary
The prior art has problems in the diagnosis of rotating mechanical equipment with poor anti-interference performance, inaccurate sampling accuracy and high misdiagnosis rate in the fault diagnosis of rotating mechanical equipment. It is impossible to accurately and promptly detect early signs of equipment failure, and it is impossible to provide an accurate scientific basis for online conditioning and shutdown maintenance of equipment.
A collection circuit for ship rotating mechanical failures was designed, using ICP acceleration sensors and piezoelectric acceleration sensors, combining constant current source, operational amplifiers, analog switching chips, program-controlled amplifiers, anti-mixing filtering circuits and control chips, and accurately capture frequency characteristics in different frequency ranges through hardware integration and anti-noise filtering technology.
The acquisition circuit can capture vibration signals more accurately, reduce noise interference, improve the true reliability of the signals, provide more accurate equipment fault diagnosis and location positioning, support online conditioning and reasonable maintenance, effectively curbing fault losses and maintenance costs.
Smart Images
Figure CN119738632A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to a collection circuit for ship rotating machinery faults, belonging to the technical field of ship machinery equipment safety. Background Art
[0002] Rotating machinery is the most widely used type of mechanical equipment in the industrial field and is also an important part of the ship system. The fault diagnosis technology of rotating machinery equipment can be traced back to the 1960s. The United States established the American Mechanical Failure Prevention Group, whose main tasks are to study fault diagnosis and prevention technology, explore and test fault mechanisms, and study reliability theory. In the 1970s, the field of fault diagnosis began to study condition-based maintenance methods and monitoring equipment. Many large companies invented some simple impact pulse meters to detect the resonance wave waveform caused by the fault, and then use the amplitude of the extracted detection signal to evaluate the degree of bearing damage. Its biggest disadvantage is that it cannot shield interference, the sampling accuracy is not accurate, and the misdiagnosis rate is high.
[0003] Domestic research on rotating machinery equipment status detection and fault diagnosis instruments has long been carried out, and they are widely used in industrial fields such as steel metallurgy, petrochemicals, automobile manufacturing, and machinery manufacturing. They can be used to detect the operating status and fault analysis of rotating machinery equipment in factories. Although they can diagnose some mechanical equipment failures, the detection system has poor anti-interference performance during data sampling and transmission, inaccurate sampling accuracy, and a high misdiagnosis rate, which cannot meet the requirements of the operating working environment of rotating machinery equipment. Summary of the invention
[0004] In view of the shortcomings of the prior art in that it is unable to more accurately and timely discover the early signs of equipment failure, accurately analyze the abnormal operating status of the equipment, accurately locate the parts, and cannot provide an accurate scientific basis for the online adjustment and shutdown maintenance of the equipment, the present invention provides a collection circuit for ship rotating machinery failures, which provides correct technical support for the normal operation and reasonable maintenance of maintenance equipment, and effectively curbs failure losses and maintenance costs.
[0005] The technical solution adopted by the present invention is: a collection circuit for ship rotating machinery faults, including an ICP acceleration sensor, a piezoelectric acceleration sensor, a constant current source, an operational amplifier I, an analog switch chip I, an operational amplifier II, an operational amplifier III, an operational amplifier IV, an analog switch chip II, a programmable amplifier, an anti-aliasing filter circuit, a control chip, and a data display; The ICP acceleration sensor is connected to the analog switch chip I through a constant current source, the piezoelectric acceleration sensor is connected to the analog switch chip I through an operational amplifier I, the analog switch chip I is connected to the operational amplifier II, the operational amplifier II is connected to the operational amplifier IV through an operational amplifier III, the analog switch chip II is connected to the anti-aliasing filter through a programmable amplifier, and the control chip is respectively connected to the analog switch chip I, the analog switch chip II, the programmable amplifier, the anti-aliasing filter and the data display.
[0006] The technical effect produced by the present invention is: the vibration displacement specifically reflects the magnitude of the vibration amplitude, the vibration velocity reflects the magnitude of the energy, and the vibration acceleration reflects the magnitude of the impact force. It can also be considered that in the low-frequency range, the vibration intensity is proportional to the displacement; in the medium-frequency range, the vibration intensity is proportional to the velocity; in the high-frequency range, the vibration intensity is proportional to the acceleration. This acquisition circuit can more accurately capture the frequency characteristics in different frequency ranges, and the advantages are as follows: 1. The hardware integration method used in this circuit is closer to the actual vibration of the equipment than the software integration, and is more accurate. The lower the frequency of the conventional software integration algorithm, the greater the calculation error. 2. This circuit adopts the function of program-controlled amplification, which can more effectively restrain noise interference and make the measured signal more real and reliable. 3. The anti-aliasing filter used in this circuit is an 8th-order filter, which has a better effect in filtering out high-frequency signals. 4. This circuit provides correct technical support for the normal operation and reasonable maintenance of maintenance equipment, and effectively curbs failure losses and maintenance costs.
[0007] This application provides curve and graphic visualization information or digital information to assist technicians in diagnosing faults such as rotor imbalance, shaft cracks, dynamic and static friction, rotor thermal bending, blade loss, bearing misalignment, rotor instability, oil film vortex, surge, etc.
[0008] This application is highly targeted at the parts where the equipment fails. During repair, only the parts that are about to be or have been damaged need to be repaired or replaced, thereby effectively avoiding unexpected failures and preventing accidents, saving the cost of equipment operation and maintenance, and improving equipment maintenance efficiency. BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Figure 1 A circuit connection block diagram for implementing the present invention. DETAILED DESCRIPTION
[0010] like Figure 1 As shown, a collection circuit for ship rotating machinery faults includes an ICP acceleration sensor, a piezoelectric acceleration sensor, a constant current source, an operational amplifier I, an analog switch chip I, an operational amplifier II, an operational amplifier III, an operational amplifier IV, an analog switch chip II, a programmable amplifier, an anti-aliasing filter circuit, a control chip, and a data display.
[0011] ICP acceleration sensor is used to convert vibration and impact signals into AC voltage output; Piezoelectric accelerometer is used to convert vibration signal into electric charge output; The constant current source 8050 is used to power the ICP acceleration sensor and provide a current of 4mA to ensure the constant current; Operational amplifier I TLV2262 is used to amplify the charge of the piezoelectric acceleration sensor and convert it into an AC voltage; Analog switch chip ICD4052 is a 4-channel digital control analog switch, which is used to select the sensor type. According to the printed circuit board circuit, 0 is an ICP acceleration sensor and 1 is a piezoelectric acceleration sensor. Operational amplifier II TLV2262 is used to amplify the AC voltage signal after the analog switch chip I is selected and convert it into an acceleration waveform in cooperation with the resistor and capacitor; Operational amplifier III TLV2262 is used to operate, amplify and convert the acceleration waveform signal converted by operational amplifier II into a velocity waveform in cooperation with resistors and capacitors; Operational amplifier IV TLV2262 is used to operate, amplify and convert the speed waveform signal converted by operational amplifier III into a displacement waveform in cooperation with resistors and capacitors; Analog switch chip II CD4052 is a 4-channel digital control analog switch, which is used to select the sampling type. According to the printed circuit board, 0 is acceleration (no integration), 1 is velocity (1 integration), and 2 is displacement (2 integrations). The first calculus converts the original acceleration signal into velocity value after 1 integration; the second calculus converts the velocity signal generated by 1 integration into displacement value again. The programmable amplifier MCP6S26 is a programmable gain amplifier used for waveform amplification. After amplification, it will effectively reduce the impact of noise interference signals on vibration signals. The anti-aliasing filter MAX293 is an 8th-order switched capacitor low-pass filter with a programmable cutoff frequency to filter out unwanted high-frequency signals. The control chip MSP430F1611 is a microcontroller and the core of the acquisition board. The control chip is used to control the operation and acquisition of each circuit. The specific functions are: controlling analog switch chip I and analog switch chip II, controlling the gain multiplier of the programmable amplifier, controlling the cutoff frequency of the anti-aliasing filter, controlling AD acquisition and display data transmission; the data display is used to receive and process the acquisition board data and display it to the user.
[0012] Embodiment 1, a method for realizing a collection circuit for detecting a fault of a ship rotating machinery, the operation flow of the device is as follows: an ICP acceleration sensor or a piezoelectric acceleration sensor is magnetically adsorbed on a non-rotating component and is perpendicular to the axis direction of the ship rotating machinery or parallel to the axis direction or axial direction of the ship rotating machinery; When using an ICP accelerometer: The control chip controls the gear position 0 of the analog switch chip Ⅰ to turn on the constant current source; the constant current source supplies power to the ICP type sensor, 18-24V, 4mA; the ICP acceleration sensor outputs an AC voltage signal; the AC voltage signal outputs an acceleration AC signal through the operational amplifier Ⅱ; the acceleration AC signal is converted into a speed AC signal through the output of the operational amplifier Ⅲ; the speed AC signal is converted into a displacement AC signal through the output of the operational amplifier Ⅳ; the control chip controls the gear position of the analog switch chip Ⅱ to acceleration gear position 0 or speed gear position 1 or displacement gear position 2, and transmits the signal to be tested to the programmable amplifier; the control chip controls the programmable amplifier (up to 32 times amplification), proportionally amplifies and transmits the signal to the anti-mixing filter; the control chip controls the anti-mixing filter to perform low-pass filtering and transmits the signal to the control chip; the control chip starts the ADC to collect data and transmits it to the display, thereby realizing the detection of vibration faults of rotating machinery of the ship.
[0013] When using a piezoelectric sensor: The control chip controls the gear 1 of the analog switch chip Ⅰ, turns on the charge amplifier of the operational amplifier Ⅰ; the charge amplifier amplifies the charge signal of the piezoelectric acceleration sensor and converts it into an AC voltage signal; the AC voltage signal outputs an acceleration AC signal through the operational amplifier Ⅱ; the acceleration AC signal is converted into a velocity AC signal through the output of the operational amplifier Ⅲ; the velocity AC signal is converted into a displacement AC signal through the output of the operational amplifier Ⅳ; the control chip controls the gear 0 of the analog switch chip Ⅱ, the velocity gear 1 or the displacement gear 2, and transmits the signal to be tested to the programmable amplifier; the control chip controls the programmable amplifier (up to 32 times amplification), proportionally amplifies and transmits the signal to the anti-mixing filter; the control chip controls the anti-mixing filter to perform low-pass filtering and transmits the signal to the control chip; the control chip starts the ADC to collect data and transmits it to the display, thereby realizing the detection of vibration faults of rotating machinery of the ship.
Claims
1. A circuit for collecting faults of rotating machinery of ships, characterized in that: Including ICP acceleration sensor, Piezoelectric acceleration sensor, constant current source, operational amplifier I, analog switch chip I, operational amplifier II, operational amplifier III, operational amplifier IV, analog switch chip II, programmable amplifier, anti-aliasing filter circuit, control chip, data display; The ICP acceleration sensor is connected to the analog switch chip I through a constant current source, the piezoelectric acceleration sensor is connected to the analog switch chip I through an operational amplifier I, the analog switch chip I is connected to the operational amplifier II, the operational amplifier II is connected to the operational amplifier IV through an operational amplifier III, the analog switch chip II is connected to the anti-aliasing filter through a programmable amplifier, and the control chip is respectively connected to the analog switch chip I, the analog switch chip II, the programmable amplifier, the anti-aliasing filter and the data display.
2. The circuit for collecting faults of rotating machinery of a ship according to claim 1, characterized in that: The models of the operational amplifier I, operational amplifier II, operational amplifier III, and operational amplifier IV are all TLV2262; the models of the analog switch chip I and analog switch chip II are both CD4052; the model of the programmable amplifier is MCP6S26; the model of the constant current source is 8050; the model of the anti-aliasing filter is MAX293; and the model of the control chip is MSP430F1611.
3. The circuit for collecting faults of rotating machinery of a ship according to claim 1, characterized in that: The functions of each device are as follows: the ICP acceleration sensor is used to convert vibration and impact signals into AC voltage output; The piezoelectric acceleration sensor is used to convert the vibration signal into an electric charge output; The constant current source is used to power the ICP acceleration sensor and provide a current of 4 mA; The operational amplifier I is used to amplify the charge of the piezoelectric acceleration sensor and convert it into an AC voltage; The analog switch chip I is used to select the sensor type, 0 is an ICP acceleration sensor, and 1 is a piezoelectric acceleration sensor; The operational amplifier II amplifies the AC voltage signal after the analog switch chip I is switched on and converts it into an acceleration waveform; The operational amplifier III is used to operate, amplify and convert the acceleration waveform signal converted by the operational amplifier II into a velocity waveform; The operational amplifier IV is used to operate, amplify and convert the velocity waveform signal converted by the operational amplifier III into a displacement waveform; The analog switch chip II is used to select the sampling type, 0 is acceleration, 1 is velocity, and 2 is displacement; The program-controlled amplifier is used for waveform amplification, which can effectively reduce the influence of noise interference signals on vibration signals after amplification; The anti-aliasing filter can set a cut-off frequency to filter out unnecessary high-frequency signals; The control chip is used to control the operation and acquisition of each circuit, and its specific functions are: controlling analog switch chip I and analog switch chip II, controlling the gain multiplier of the programmable amplifier, controlling the cutoff frequency of the anti-aliasing filter, and controlling AD acquisition and display data transmission; The data display is used to receive data and present it to the user.