Fault diagnosis and self-healing system for horizontal plug flow reactor

Abstract

The invention relates to a fault diagnosis and self-healing system for a horizontal plug flow reactor, and solves the problem that an existing horizontal plug flow reactor is difficult to monitor, control and adjust in the early fault stage. Comprising a base, a reactor shell, a stirrer, a stirring shaft, a motor for driving the stirring shaft to rotate, a fault monitoring system and a fault self-healing system, the fault monitoring system comprises a controller and a sensor, the fault self-healing system comprises a fixed seat and a stirring shaft reset system, and the sensor and the stirring shaft reset system are both connected with the controller. The sensor is used for transmitting detected offset displacement information of the stirring shaft to the controller, the controller analyzes the information and then calculates the offset position of the stirring shaft, and then the controller controls a stirring shaft reset system in the self-healing system to generate a balance vector which is equal to the unbalance amount and opposite to the unbalance amount in direction so as to offset the unbalance amount. And faults are eliminated, and self-healing is realized, so that the faults of the horizontal plug flow reactor can be monitored and regulated in real time.

Description

Technical Field

[0001] The invention relates to the field of control and regulation of petrochemical and new material equipment, and in particular to a fault diagnosis and self-healing system for a horizontal plug flow reactor. Background Art

[0002] The most advanced polypropylene production processes in the world are gas phase process and bulk-gas phase combined process. The horizontal plug flow reactor is the key core equipment in the gas phase process, and its performance directly affects the grade and product performance of polypropylene.

[0003] Engineering practice shows that the occurrence of most equipment failures is a gradual process. Due to the lack of equipment fault diagnosis and self-healing, the best time to regulate and suppress the failure is missed, resulting in equipment failure or accidents, forced unplanned shutdowns, and causing huge economic losses to the device.

[0004] Therefore, in order to effectively help enterprises improve the instantaneous rate of equipment fault detection, reduce safety risks, improve production efficiency, and assist the normal production of the equipment, and truly achieve the goal of "long, stable, flat, full, and excellent" operation of the equipment, it has become an urgent problem to be solved in the early design of the horizontal plug flow reactor to set up a fault monitoring, control and adjustment system. Summary of the invention

[0005] The purpose of the invention is to solve the problem that the existing horizontal plug flow reactor is difficult to monitor and control in the early stage of failure.

[0006] The technical solution adopted to solve the technical problem proposed by the present invention is as follows: the fault diagnosis and self-healing system of a horizontal plug flow reactor of the present invention comprises a base, a reactor shell arranged on the base, an agitator, a stirring shaft and a motor for driving the stirring shaft to rotate, the motor is located on the base, the agitator is located in the reactor shell, the agitator is fixed on the stirring shaft, the stirring shaft is located in the shell, the two ends of the stirring shaft protrude from the two sides of the sealed cavity of the reactor shell, both sides of the reactor shell are sealed and rotatably connected with the stirring shaft, the left end of the stirring shaft passes through the reactor shell and is connected to the motor, the two ends of the stirring shaft are respectively provided with a left bearing and a right bearing, the horizontal plug flow reactor also comprises a fault monitoring system and a fault self-healing system, the fault monitoring system comprises a controller and a sensor for detecting the offset position of the stirring shaft, the sensor is installed on the reactor shell or the base, the fault self-healing system comprises a fixed seat arranged on the stirring shaft and a stirring shaft reset system for pulling the stirring shaft back to its original position, the sensor and the stirring shaft reset system are both connected to the controller, and the stirring shaft reset system is connected to the stirring shaft.

[0007] The technical solutions for further limiting the present invention include: The sensors include a vibration sensor and a displacement sensor. The bases at both ends of the stirring shaft are provided with the vibration sensor and the displacement sensor. Both ends of the stirring shaft are provided with a stirring shaft reset system.

[0008] The stirring shaft reset system is a hydraulically driven reset system, the fixed seat is a plurality of hydraulic cavities evenly arranged along the circumference of the stirring shaft, the stirring shaft reset system is a hydraulic servo system for controlling the hydraulic capacity in each hydraulic cavity, and the hydraulic servo system is connected to a controller.

[0009] The stirring shaft resetting system is a magnetic field driven resetting system. The fixing seat is a plurality of electromagnet fixing grooves evenly arranged along the circumference around the stirring shaft. The stirring shaft resetting system is an electromagnet arranged in each electromagnet fixing groove. Each electromagnet is connected to a controller. A shaft sleeve which is adsorbed by the energized electromagnet is provided on the base corresponding to the outer periphery of the stirring shaft.

[0010] The reactor shell includes a left head, a cylinder and an intermediate plate. A right head is provided on the right side of the reactor shell. One end of the left head is sealed and connected to the cylinder. A stirring shaft sleeve is provided on the other end of the left head. The stirring shaft sleeve is sealed and rotatably connected to the stirring shaft. The left bearing is located in the stirring shaft sleeve. The intermediate plate is sealed and connected to the right side of the cylinder. The intermediate plate is sealed and rotatably connected to the stirring shaft. The right head is sealed and connected to the intermediate plate. The right bearing is located in the right head.

[0011] The base includes a right bearing seat, the right bearing is located on the right bearing seat, the sensor is located on the stirring shaft sleeve and the right bearing seat, the right bearing seat is fixedly connected to the middle plate, and the right bearing seat is located in the right head.

[0012] The base also includes a saddle and a motor base arranged at the bottom of the reactor shell.

[0013] The left head cover is an arc-shaped cavity structure concave toward the left side, and the right head cover is an arc-shaped cavity structure concave toward the right side.

[0014] The stirring shaft is connected to the motor main shaft via a coupling.

[0015] The stirrer is a stirring blade arranged on a stirring shaft.

[0016] Through the above technical scheme, the beneficial effects of the present invention are as follows: the sensor of the fault monitoring system of the fault diagnosis and self-healing system of the horizontal plug flow reactor of the present invention is used to transmit the displacement information of the detected agitator shaft offset to the controller, the controller analyzes the displacement information of the agitator shaft offset and calculates the offset position of the agitator shaft, and then the controller controls the agitator shaft resetting system in the self-healing system to generate a balance vector equal to the imbalance in magnitude and opposite in direction to offset the imbalance, thereby eliminating the fault and achieving self-healing, thereby achieving real-time monitoring and regulation of the horizontal plug flow reactor fault. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 The present invention is a schematic structural diagram of a horizontal plug flow reactor fault diagnosis and self-healing system.

[0018] Figure 2 The present invention is a schematic structural diagram of a horizontal plug flow reactor fault diagnosis and self-healing system in which an agitator shaft reset system is a hydraulically driven reset system.

[0019] Figure 3 The present invention is a schematic structural diagram of a horizontal plug flow reactor fault diagnosis and self-healing system in which a stirring shaft reset system is a magnetic field driven reset system.

[0020] Figure 4 The present invention is a circuit block diagram of a fault diagnosis and self-healing system for a horizontal plug flow reactor.

[0021] In the figure, 10-base, 11-right bearing seat, 12-saddle, 13-motor base, 14-sleeve, 20-reactor shell, 21-left head, 211-stirring shaft sleeve, 22-cylinder, 23-middle plate, 24-right head, 30-stirrer, 40-stirring shaft, 50-motor, 60-coupling, 70-right bearing, 80-fault monitoring system, 81-controller, 82-sensor, 90-fault self-healing system, 91-solid Fixed seat, 911-upper hydraulic chamber, 912-lower hydraulic chamber, 913-left hydraulic chamber, 914-right hydraulic chamber, 915-upper electromagnet fixing groove, 916-lower electromagnet fixing groove, 917-left electromagnet fixing groove, 918-right electromagnet fixing groove, 92-agitation shaft reset system, 921-hydraulic servo system, 922-upper electromagnet, 923-lower electromagnet, 923-lower electromagnet, 924-left electromagnet, 925-right electromagnet. DETAILED DESCRIPTION

[0022] The structure of the present invention is further described below in conjunction with the accompanying drawings.

[0023] Reference Figures 1 to 4A horizontal plug flow reactor fault diagnosis and self-healing system includes a base 10, a reactor shell 20 arranged on the base 10, an agitator 30, an agitator shaft 40 and a motor 50 for driving the agitator shaft 40 to rotate. The motor 50 is located on the base 10, the agitator 30 is located in the reactor shell 20, the agitator 30 is fixed on the agitator shaft 40, and the agitator shaft 40 is located in the shell. In this embodiment, the agitator 30 is a stirring blade arranged on the agitator shaft 40. The two ends of the agitator shaft 40 protrude from the two sides of the reactor shell 20, and the two sides of the reactor shell 20 are sealed and rotatably connected with the agitator shaft 40. The reactor shell and the agitator shaft can be sealed and connected by a sealing rubber gasket. The left end of the agitator shaft 40 passes through the reactor shell 20 and is connected to the motor 50. The two ends of the agitator shaft 40 are respectively provided with a left bearing and a right bearing 70. In this embodiment, the agitator shaft 40 is connected to the motor main shaft through a coupling 60. The coupling 60 ensures that the motor main shaft and the agitator shaft 40 are coaxially arranged. In this embodiment, the reactor shell 20 includes a left end cap 21, a cylinder 22 and an intermediate plate 23. A right end cap 24 is provided on the right side of the reactor shell 20. One end of the left end cap 21 is sealed and connected to the cylinder 22. The other end of the left end cap 21 is provided with a stirring shaft sleeve 211. The stirring shaft sleeve 211 is sealed and rotatably connected to the stirring shaft 40. The left bearing is located in the stirring shaft sleeve 211. The intermediate plate 23 is sealed and connected to the right side of the cylinder 22. The intermediate plate 23 is sealed and rotatably connected to the stirring shaft 40. The right end cap 24 is sealed and connected to the intermediate plate 23. The right bearing 70 is located in the right end cap 24. The left end cap 21 is an arc-shaped cavity structure concave to the left, and the right end cap 24 is an arc-shaped cavity structure concave to the right. The left end cap 21, the cylinder 22 and the middle plate 23 form a sealed reaction chamber, and the right end cap 24 is sealed and connected to the middle plate 23. The sealed right end cap 24 forms a double seal insurance for the reaction chamber to ensure that the material in the reaction chamber will not leak out of the reactor shell.

[0024] The horizontal plug flow reactor also includes a fault monitoring system 80 and a fault self-healing system 90. The fault monitoring system 80 includes a controller 81 and a sensor 82 for detecting the offset position of the stirring shaft 40. The sensor 82 is installed on the reactor shell 20 or the base 10. The fault self-healing system 90 includes a fixing seat 91 arranged on the stirring shaft 40 and a stirring shaft reset system 92 for pulling the stirring shaft 40 back to its original position. The sensor 82 and the stirring shaft reset system 92 are both connected to the controller 81. In this embodiment, the sensor 82 includes a vibration sensor and a displacement sensor. The vibration sensor and the displacement sensor are installed on the stirring shaft sleeve 211 and the right bearing seat 11. The vibration sensor transmits the measured vibration parameter signal of the stirring shaft 40 to the controller 81, and the displacement sensor transmits the measured displacement parameter signal of the stirring shaft 40 to the controller 81. The controller 81 analyzes the received signal to obtain the offset position of the stirring shaft 40. Then the controller 81 starts the fault self-healing system 90. The stirring shaft reset system 92 is provided at both ends of the stirring shaft 40.

[0025] In this embodiment, the base 10 includes a right bearing seat 11, the right bearing 70 is located on the right bearing seat 11, the sensor 82 is located on the stirring shaft sleeve 211 and the right bearing seat 11, the right bearing seat 11 is fixedly connected to the middle plate 23, and the right bearing seat 11 is located in the right head 24. The base 10 also includes a saddle 12 and a motor base 13 arranged at the bottom of the reactor shell 20.

[0026] In the first embodiment, the agitator shaft reset system 92 is a hydraulically driven reset system, the fixed seat 91 is four hydraulic chambers evenly arranged along the circumference of the agitator shaft 40, which are respectively an upper hydraulic chamber 911, a lower hydraulic chamber 912, a left hydraulic chamber 913 and a right hydraulic chamber 914, and the agitator shaft reset system 92 is a hydraulic servo system 921 for controlling the hydraulic capacity in the upper hydraulic chamber 911, the lower hydraulic chamber 912, the left hydraulic chamber 913 and the right hydraulic chamber 914, and the hydraulic servo system 921 is connected to the controller 81. The controller 81 adjusts the position of the agitator shaft 40 by controlling the hydraulic capacity in each hydraulic chamber through the hydraulic servo system 921, generates a balance vector equal to the imbalance and opposite in direction to offset the imbalance, thereby pulling the offset agitator shaft 40 back to its original position, and realizing the adjustment and control of the agitator shaft 40. In a specific implementation, the fixing seat 91 may be a plurality of hydraulic cavities evenly arranged along the circumference of the stirring shaft 40 , and the stirring shaft resetting system 92 is a hydraulic servo system 921 for controlling the hydraulic capacity in each hydraulic cavity.

[0027] In the second embodiment, the stirring shaft reset system 92 is a magnetic field driven reset system, and the fixed seat 91 is provided with four electromagnet fixing grooves evenly arranged along the circumference around the stirring shaft 40, namely an upper electromagnet fixing groove 915, a lower electromagnet fixing groove 916, a left electromagnet fixing groove 917 and a right electromagnet fixing groove 918. The stirring shaft reset system 92 is an upper electromagnet 922 provided in the upper electromagnet fixing groove 915, a lower electromagnet 923 provided in the lower electromagnet fixing groove 916, a left electromagnet 924 provided in the left electromagnet fixing groove 917 and a right electromagnet 925 provided in the right electromagnet fixing groove 918. Each electromagnet is connected to the controller 81, and a shaft sleeve 14 is provided on the base 10 corresponding to the outer periphery of the stirring shaft 40, which is adsorbed by the energized electromagnet. The controller 81 controls the position of the stirring shaft 40 by controlling the on and off of the electromagnet to generate magnetism of the electromagnet and generate attraction with the sleeve 14, thereby generating a balance vector equal to the imbalance and opposite in direction to offset the imbalance, thereby pulling the offset stirring shaft 40 back to its original position, and realizing the adjustment and control of the stirring shaft 40. In a specific implementation, the fixing seat 91 can be a plurality of electromagnet fixing grooves evenly arranged along the circumference around the stirring shaft 40, and the stirring shaft reset system 92 is an electromagnet provided in each electromagnet fixing groove, and each electromagnet is connected to the controller 81.

[0028] The fault monitoring system of the fault diagnosis and self-healing system of the horizontal plug flow reactor of the present invention When the horizontal plug flow reactor is in normal operation, the sensor 82 of the fault monitoring system 80 monitors its operating parameters in real time, and the controller 81 analyzes and judges the data. If a fault is found, the controller 81 starts the fault self-healing system 90, and the controller 81 controls the stirring shaft reset system 92 in the fault self-healing system 90 to generate a balance vector equal to the imbalance and opposite in direction to offset the imbalance, eliminate the fault, and achieve self-healing, thereby achieving real-time monitoring and regulation of the horizontal plug flow reactor fault. During this period, the equipment has been running and producing, ensuring continuous production operation, and truly achieving the purpose of "long, stable, flat, full, and excellent" operation of the equipment.

[0029] In the description of the present invention, it is to be understood that the terms “center”, “longitudinal”, “lateral”, “length”, “width”, “thickness”, “up”, “down”, “front”, “back”, “left”, “right”, “vertical”, “horizontal”, “top”, “bottom”, “inside”, “outside”, “clockwise”, “counterclockwise”, “axial”, “radial”, “circumferential”, etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0030] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In the description of the present invention, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0031] In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral one; it can be a mechanical connection, an electrical connection, or communication with each other; it can be a direct connection, or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0032] In the present invention, the terms "one embodiment", "some embodiments", "examples", "specific examples", or "some examples" etc. mean that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the described specific features, structures, materials or characteristics may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples, without contradiction.

[0033] Although the specific embodiments of the present invention are described in detail in conjunction with the accompanying drawings, it should not be understood as limiting the scope of protection of the present invention. Within the scope described in the claims, various modifications and variations that can be made by those skilled in the art without creative work still belong to the scope of protection of the present invention.

Claims

1. A fault diagnosis and self-healing system for a horizontal plug flow reactor, comprising a base, a reactor shell disposed on the base, an agitator, an agitator shaft, and a motor for driving the agitator shaft to rotate, wherein the motor is disposed on the base, the agitator is disposed in the reactor shell, and the agitator is fixed on the agitator shaft, and characterized in that: The stirring shaft is located in the shell, and the two ends of the stirring shaft protrude from the two sides of the sealed cavity of the reactor shell. Both sides of the reactor shell are sealed and rotatably connected with the stirring shaft. The left end of the stirring shaft passes through the reactor shell and is connected to the motor. The two ends of the stirring shaft are respectively provided with a left bearing and a right bearing. The horizontal plug flow reactor also includes a fault monitoring system and a fault self-healing system. The fault monitoring system includes a controller and a sensor for detecting the offset position of the stirring shaft. The sensor is installed on the reactor shell or the base. The fault self-healing system includes a fixed seat arranged on the stirring shaft and a stirring shaft reset system for pulling the stirring shaft back to its original position. The sensor and the stirring shaft reset system are both connected to the controller.

2. A horizontal plug flow reactor fault diagnosis and self-healing system as claimed in claim 1, characterized in that: The sensors include a vibration sensor and a displacement sensor. The bases at both ends of the stirring shaft are provided with the vibration sensor and the displacement sensor. Both ends of the stirring shaft are provided with a stirring shaft reset system.

3. A horizontal plug flow reactor fault diagnosis and self-healing system as claimed in claim 1, characterized in that: The stirring shaft reset system is a hydraulically driven reset system, the fixed seat is a plurality of hydraulic cavities evenly arranged along the circumference of the stirring shaft, the stirring shaft reset system is a hydraulic servo system for controlling the hydraulic capacity in each hydraulic cavity, and the hydraulic servo system is connected to a controller.

4. A horizontal plug flow reactor fault diagnosis and self-healing system as claimed in claim 1, characterized in that: The stirring shaft resetting system is a magnetic field driven resetting system. The fixing seat is a plurality of electromagnet fixing grooves evenly arranged along the circumference around the stirring shaft. The stirring shaft resetting system is an electromagnet arranged in each electromagnet fixing groove. Each electromagnet is connected to a controller. A shaft sleeve which is adsorbed by the energized electromagnet is provided on the base corresponding to the outer periphery of the stirring shaft.

5. A horizontal plug flow reactor fault diagnosis and self-healing system as claimed in claim 1, characterized in that: The reactor shell includes a left head, a cylinder and an intermediate plate. A right head is provided on the right side of the reactor shell. One end of the left head is sealed and connected to the cylinder. A stirring shaft sleeve is provided on the other end of the left head. The stirring shaft sleeve is sealed and rotatably connected to the stirring shaft. The left bearing is located in the stirring shaft sleeve. The intermediate plate is sealed and connected to the right side of the cylinder. The intermediate plate is sealed and rotatably connected to the stirring shaft. The right head is sealed and connected to the intermediate plate. The right bearing is located in the right head.

6. A horizontal plug flow reactor fault diagnosis and self-healing system as claimed in claim 5, characterized in that: The base includes a right bearing seat, the right bearing is located on the right bearing seat, the sensor is located on the stirring shaft sleeve and the right bearing seat, the right bearing seat is fixedly connected to the middle plate, and the right bearing seat is located in the right head.

7. A horizontal plug flow reactor fault diagnosis and self-healing system as claimed in claim 5, characterized in that: The base also includes a saddle and a motor base arranged at the bottom of the reactor shell.

8. A horizontal plug flow reactor fault diagnosis and self-healing system as claimed in claim 5, characterized in that: The left head cover is an arc-shaped cavity structure concave toward the left side, and the right head cover is an arc-shaped cavity structure concave toward the right side.

9. A horizontal plug flow reactor fault diagnosis and self-healing system as claimed in claim 1, characterized in that: The stirring shaft is connected to the motor main shaft via a coupling.

10. A horizontal plug flow reactor fault diagnosis and self-healing system as claimed in claim 1, characterized in that: The stirrer is a stirring blade arranged on a stirring shaft.

Images