Reciprocating machine monitoring data acquisition system and reciprocating machine state monitoring method

Abstract

The invention relates to the technical field of equipment monitoring, and particularly provides a reciprocating machine monitoring data acquisition system and a reciprocating machine state monitoring method. The reciprocating machine monitoring data acquisition system comprises an upper computer, acceleration sensors and impact pulse sensors which are installed on each air cylinder, and key phase sensors installed at the position of a motor rotating shaft or a flywheel. The acceleration sensor is configured to collect acceleration waveform data corresponding to each cylinder; the impact pulse sensor is configured to collect impact pulse waveform data corresponding to each cylinder; the key phase sensor is configured to collect key phase pulse data; the upper computer is configured to determine the operation state of the reciprocating machine according to the acceleration waveform data, the impact pulse waveform data and the key phase pulse data. The system can obtain time domain waveform data of each cylinder; and based on the upper computer, the operation state of the reciprocating machine is more accurately determined according to the time domain waveform data, and the accuracy of monitoring the abnormity of the reciprocating machine is improved.

Description

Technical Field

[0001] The present application relates to the technical field of equipment monitoring, and in particular to a reciprocating machine monitoring data acquisition system and a reciprocating machine status monitoring method. Background Art

[0002] A reciprocating machine is a mechanical device that uses reciprocating motion to achieve work. The existing reciprocating machine data acquisition system directly collects single-turn angular domain data and realizes abnormal monitoring of the reciprocating machine based on the collected single-turn angular domain data.

[0003] Single-turn angular domain data can only provide partial information of a single cylinder, and it is difficult to fully reflect the overall operation of multiple cylinders. In addition, due to the large impact and transmission of reciprocating machines, single-turn angular domain data will be affected by the equipment operating conditions, crankcase components, and other cylinder crossheads and cylinder head components. Therefore, the accuracy of reciprocating machine abnormality monitoring based on single-turn angular domain data is low. Summary of the invention

[0004] In view of this, the purpose of the embodiments of the present application is to provide a reciprocating machine monitoring data acquisition system and a reciprocating machine status monitoring method to solve the technical problem of "the accuracy of reciprocating machine abnormality monitoring that can be achieved based on the existing reciprocating machine monitoring data acquisition system is low".

[0005] In a first aspect, an embodiment of the present application provides a reciprocating machine monitoring data acquisition system, the system comprising: a host computer, an acceleration sensor and a shock pulse sensor installed on each cylinder, and a key phase sensor installed at the motor shaft or flywheel position;

[0006] The acceleration sensor is configured to collect acceleration waveform data corresponding to each of the cylinders;

[0007] The shock pulse sensor is configured to collect shock pulse waveform data corresponding to each of the cylinders;

[0008] The key phase sensor is configured to collect key phase pulse data;

[0009] The host computer is configured to determine the operating state of the reciprocating machine according to the acceleration waveform data, the impact pulse waveform data and the key phase pulse data.

[0010] In the above implementation process, the reciprocating machine monitoring data acquisition system includes: a host computer, an acceleration sensor and a shock pulse sensor installed on each cylinder, and a key phase sensor installed at the motor shaft or flywheel position; the acceleration sensor is configured to collect acceleration waveform data corresponding to each cylinder; the shock pulse sensor is configured to collect shock pulse waveform data corresponding to each cylinder; the key phase sensor is configured to collect key phase pulse data; the host computer is configured to determine the operating state of the reciprocating machine based on the acceleration waveform data, the shock pulse waveform data and the key phase pulse data. Based on the reciprocating machine monitoring data acquisition system provided by the present application, the time domain waveform data (acceleration waveform data, shock pulse waveform data and key phase pulse data) of each cylinder can be obtained; based on the host computer, the operating state of the reciprocating machine can be more accurately determined according to the time domain waveform data, thereby improving the accuracy of abnormal monitoring of the reciprocating machine and solving the technical problem of "the accuracy of abnormal monitoring of the reciprocating machine that can be achieved based on the existing reciprocating machine monitoring data acquisition system is low".

[0011] Optionally, in an embodiment of the present application, the host computer is further configured to: determine primary index data based on the acceleration waveform data; wherein the primary index data includes the maximum acceleration value and / or the effective acceleration value; determine whether the reciprocating machine has a primary index abnormality based on the primary index data and the primary index condition; when the reciprocating machine has a primary index abnormality, determine secondary index data based on the acceleration waveform data, the impact pulse waveform data and the key phase pulse data; wherein the secondary index data includes: at least one time domain index data of the maximum acceleration value, the effective acceleration value, the acceleration change rate, the frequency band energy, the harmonic energy and the resonance spectrum peak energy, and at least one angular domain index data of the impact frequency, the impact pulse peak value and the impact pulse position; determine the operating state of the reciprocating machine based on the secondary index data and the secondary index condition.

[0012] In the above implementation process, since the secondary index data includes at least one time domain index data of the maximum acceleration, the effective value of acceleration, the rate of change of acceleration, the frequency band energy, the harmonic energy and the resonance spectrum peak energy, and at least one angular domain index data of the impact frequency, the impact pulse peak value and the impact pulse position; based on the secondary index data and the secondary index conditions, the host computer can accurately determine the operating state of the reciprocating machine, thereby improving the state monitoring accuracy of the reciprocating machine. In addition, by firstly judging the abnormality of the primary index of the reciprocating machine, in the case of the primary index abnormality, more complex secondary index data is obtained, and the operating state of the reciprocating machine is determined according to the secondary index data; while ensuring the state monitoring accuracy of the reciprocating machine, the computing power requirements of the host computer can be reduced.

[0013] Optionally, in an embodiment of the present application, the operating status of the reciprocating machine includes normal operation and abnormal operation; the primary indicator condition includes a primary indicator abnormal threshold range; the secondary indicator condition includes a secondary indicator abnormal threshold range, a secondary indicator abnormal change range and / or a secondary indicator abnormal combination judgment condition corresponding to a plurality of the secondary indicator data; the host computer is specifically configured as follows: in the case where the primary indicator data satisfies the primary indicator abnormal threshold range, it is determined that the reciprocating machine has a primary indicator abnormality; in the case where the secondary indicator data satisfies the secondary indicator abnormal threshold range or the secondary indicator abnormal change range, it is determined that the reciprocating machine has a secondary indicator abnormality; in the case where the reciprocating machine has a secondary indicator abnormality, it is determined whether the secondary indicator data satisfies the secondary indicator abnormal combination judgment condition; in the case where the secondary indicator data satisfies the secondary indicator abnormal combination judgment condition, it is determined that the reciprocating machine is operating abnormally.

[0014] In the above implementation process, the primary index condition includes the primary index abnormal threshold range; and the secondary index condition includes the secondary index abnormal threshold range, the secondary index abnormal change range and / or the secondary index abnormal combination judgment condition corresponding to the plurality of secondary index data. That is, by firstly making a simple primary index abnormal judgment on the reciprocating machine, and then making a more complex secondary index abnormal judgment in the case of primary index abnormality, and determining the operating state of the reciprocating machine according to the secondary index judgment result; the operating state of the reciprocating machine can be determined more accurately while reducing the computing power requirements of the host computer.

[0015] Optionally, in an embodiment of the present application, the host computer is also configured to: determine that the reciprocating machine is operating normally when the primary indicator data does not satisfy the primary indicator abnormal threshold range, or when the secondary indicator data does not satisfy the secondary indicator abnormal threshold range and the secondary indicator abnormal change range, or when the secondary indicator data does not satisfy the secondary indicator abnormal combination judgment condition.

[0016] Optionally, in an embodiment of the present application, the primary indicator abnormality threshold range corresponding to the same indicator data is greater than the secondary indicator abnormality threshold range.

[0017] In the above implementation process, since the primary indicator abnormality threshold range corresponding to the same indicator data is larger than the secondary indicator abnormality threshold range, the primary indicator abnormality (that is, the reciprocating machine may have abnormal operation) can be screened out through the relatively loose primary indicator conditions; and then the operating status of the reciprocating machine can be accurately determined based on the more stringent secondary indicator conditions. In this way, the computing power requirements for the host computer can be reduced while ensuring the accuracy of the reciprocating machine status monitoring.

[0018] Optionally, in an embodiment of the present application, the system further includes: a displacement sensor installed at a position of the piston rod near the stuffing box; the displacement sensor is configured to collect displacement waveform data of the piston rod; the host computer is specifically configured to: determine the primary index data based on the acceleration waveform data and the displacement waveform data; wherein the primary index data includes at least one of the maximum acceleration value, the effective acceleration value, the peak-to-peak value of the displacement and the mean displacement value; in the event that the reciprocating machine has a primary index abnormality, determine the secondary index data based on the acceleration waveform data, the displacement waveform data, the impact pulse waveform data and the key phase pulse data; wherein the secondary index data includes at least one time domain index data of the maximum acceleration value, the effective acceleration value, the acceleration change rate, the frequency band energy, the harmonic energy, the resonance spectrum peak energy, the peak-to-peak value of the displacement and the mean displacement value.

[0019] In the above implementation process, the reciprocating machine monitoring data acquisition system also includes a displacement sensor installed at the position of the piston rod near the stuffing box, and the displacement waveform data of the piston rod can be collected based on the displacement sensor; and the host computer determines the primary index data based on the acceleration waveform data and the displacement waveform data. Correspondingly, the primary index data includes at least one of the maximum acceleration value, the effective value of acceleration, the peak-to-peak value of displacement and the mean displacement value; based on the more abundant primary index data, it can be more accurately determined whether the reciprocating machine has a primary index abnormality. In the case of a primary index abnormality of the reciprocating machine, the secondary index data is determined based on the host computer according to the acceleration waveform data, the displacement waveform data, the impact pulse waveform data and the key phase pulse data. Since the secondary index data includes at least one time domain index data of the maximum acceleration value, the effective value of acceleration, the acceleration change rate, the frequency band energy, the harmonic energy, the resonance spectrum peak energy, the peak-to-peak value of displacement and the mean displacement value; based on the more abundant secondary index data, the operating state of the reciprocating machine can be more accurately determined.

[0020] Optionally, in an embodiment of the present application, the system further includes: a pressure sensor installed on each cylinder; the pressure sensor is configured to collect pressure waveform data corresponding to each of the cylinders; the host computer is specifically configured to: determine the primary index data based on the acceleration waveform data and the pressure waveform data; wherein the primary index data includes at least one of the maximum acceleration value, the effective acceleration value, the peak-to-peak pressure value and the effective pressure value; in the event that the reciprocating machine has a primary index abnormality, determine the secondary index data based on the acceleration waveform data, the pressure waveform data, the impact pulse waveform data and the key phase pulse data; wherein the secondary index data includes: at least one time domain index data of the maximum acceleration value, the effective acceleration value, the acceleration change rate, the frequency band energy, the harmonic energy, the resonance spectrum peak energy, the peak-to-peak pressure value and the effective pressure value, and at least one angular domain index data of the impact frequency, the impact pulse peak value, the impact pulse position and the single-turn pressure effective value.

[0021] In the above implementation process, the reciprocating machine monitoring data acquisition system also includes a pressure sensor installed on each cylinder, based on which the pressure sensor can collect pressure waveform data corresponding to each cylinder; and based on the host computer, the primary index data is determined according to the acceleration waveform data and the pressure waveform data. Correspondingly, the primary index data includes at least one of the maximum acceleration value, the effective value of acceleration, the peak-to-peak value of pressure, and the effective value of pressure; based on the more abundant primary index data, it can be more accurately determined whether the reciprocating machine has a primary index abnormality. In the case of a primary index abnormality in the reciprocating machine, the secondary index data is determined based on the host computer according to the acceleration waveform data, the pressure waveform data, the impact pulse waveform data, and the key phase pulse data. Since the secondary index data includes: at least one time domain index data of the maximum acceleration value, the effective value of acceleration, the acceleration change rate, the frequency band energy, the harmonic energy, the resonance spectrum peak energy, the peak-to-peak value of pressure, and the effective value of pressure, and at least one angular domain index data of the impact frequency, the impact pulse peak value, the impact pulse position, and the effective value of the single-turn pressure; based on the more abundant secondary index data, the operating state of the reciprocating machine can be more accurately determined.

[0022] Optionally, in an embodiment of the present application, the system further includes: a sound sensor installed in the surrounding area of ​​each cylinder, and / or a temperature sensor installed at the intake valve and exhaust valve positions; the sound sensor is configured to collect sound data of the surrounding area of ​​the cylinder; the temperature sensor is configured to collect temperature data at the intake valve and exhaust valve positions; wherein the primary index data also includes the sound data and / or the temperature data.

[0023] In the above implementation process, the reciprocating machine monitoring data acquisition system also includes a sound sensor installed in the surrounding area of ​​each cylinder, and / or a temperature sensor installed at the position of the intake valve and the exhaust valve. The sound sensor can collect sound data in the surrounding area of ​​the cylinder, and the temperature sensor can collect temperature data at the position of the intake valve and the exhaust valve. Correspondingly, the primary index data also includes sound data and / or temperature data; based on more abundant primary index data, it can be more accurately determined whether the reciprocating machine has a primary index abnormality.

[0024] Optionally, in an embodiment of the present application, the host computer is further configured to: send a synchronous acquisition signal to the acceleration sensor, the shock pulse sensor and the key phase sensor; wherein the synchronous acquisition signal includes a data acquisition interval; when it is determined that the reciprocating machine is operating abnormally, shorten the data acquisition interval and send an adjusted synchronous acquisition signal to the acceleration sensor, the shock pulse sensor and the key phase sensor.

[0025] In the above implementation process, the host computer can control the acceleration sensor, impact pulse sensor and key phase sensor, etc. to synchronously collect the monitoring data of the reciprocating machine. And by shortening the data collection interval in the case of abnormal operation of the reciprocating machine, a higher density of monitoring data can be obtained; based on the higher density of monitoring data, the abnormal analysis of the reciprocating machine can be more comprehensively realized.

[0026] In a second aspect, an embodiment of the present application provides a state monitoring method for a reciprocating machine, the method being applied to a reciprocating machine monitoring data acquisition system including a host computer, an acceleration sensor and a shock pulse sensor installed on each cylinder, and a key phase sensor installed at a motor shaft or a flywheel position; the method comprising:

[0027] Based on the acceleration sensor, collecting acceleration waveform data corresponding to each of the cylinders;

[0028] Based on the shock pulse sensor, collecting shock pulse waveform data corresponding to each of the cylinders;

[0029] Based on the key phase sensor, collecting key phase pulse data;

[0030] Based on the host computer, the operating state of the reciprocating machine is determined according to the acceleration waveform data, the impact pulse waveform data and the key phase pulse data.

[0031] Optionally, in an embodiment of the present application, the operation status of the reciprocating machine is determined based on the host computer according to the acceleration waveform data, the impact pulse waveform data and the key phase pulse data, including: based on the host computer, primary index data is determined according to the acceleration waveform data; wherein the primary index data includes the maximum acceleration value and / or the effective acceleration value; according to the primary index data and the primary index condition, whether there is a primary index abnormality in the reciprocating machine is determined; when there is a primary index abnormality in the reciprocating machine, secondary index data is determined according to the acceleration waveform data, the impact pulse waveform data and the key phase pulse data; wherein the secondary index data includes: at least one time domain index data of the maximum acceleration value, the effective acceleration value, the acceleration change rate, the frequency band energy, the harmonic energy and the resonance spectrum peak energy, and at least one angular domain index data of the impact frequency, the impact pulse peak value and the impact pulse position; according to the secondary index data and the secondary index condition, the operation status of the reciprocating machine is determined.

[0032] Optionally, in an embodiment of the present application, the operating status of the reciprocating machine includes normal operation and abnormal operation; the primary indicator condition includes a primary indicator abnormal threshold range; the secondary indicator condition includes a secondary indicator abnormal threshold range, a secondary indicator abnormal change range and / or a secondary indicator abnormal combination judgment condition corresponding to a plurality of the secondary indicator data; the operation status of the reciprocating machine is determined based on the host computer according to the acceleration waveform data, the impact pulse waveform data and the key phase pulse data, and also includes: based on the host computer, in the case that the primary indicator data satisfies the primary indicator abnormal threshold range, determining that the reciprocating machine has a primary indicator abnormality; in the case that the secondary indicator data satisfies the secondary indicator abnormal threshold range or the secondary indicator abnormal change range, determining that the reciprocating machine has a secondary indicator abnormality; in the case that the reciprocating machine has a secondary indicator abnormality, judging whether the secondary indicator data satisfies the secondary indicator abnormal combination judgment condition; in the case that the secondary indicator data satisfies the secondary indicator abnormal combination judgment condition, determining that the reciprocating machine is operating abnormally.

[0033] Optionally, in an embodiment of the present application, the operating status of the reciprocating machine is determined based on the host computer according to the acceleration waveform data, the impact pulse waveform data and the key phase pulse data, and also includes: when the primary indicator data does not satisfy the primary indicator abnormal threshold range, or when the secondary indicator data does not satisfy the secondary indicator abnormal threshold range and the secondary indicator abnormal change range, or when the secondary indicator data does not satisfy the secondary indicator abnormal combination judgment condition, determining that the reciprocating machine is operating normally.

[0034] The beneficial effects of the present application include at least: the reciprocating machine monitoring data acquisition system includes: a host computer, an acceleration sensor and a shock pulse sensor installed on each cylinder, and a key phase sensor installed at the motor shaft or flywheel position; the acceleration sensor is configured to collect acceleration waveform data corresponding to each cylinder; the shock pulse sensor is configured to collect shock pulse waveform data corresponding to each cylinder; the key phase sensor is configured to collect key phase pulse data; the host computer is configured to determine the operating state of the reciprocating machine according to the acceleration waveform data, the shock pulse waveform data and the key phase pulse data. Based on the reciprocating machine monitoring data acquisition system provided by the present application, the time domain waveform data (acceleration waveform data, shock pulse waveform data and key phase pulse data) of each cylinder can be obtained; based on the host computer, the operating state of the reciprocating machine can be more accurately determined according to the time domain waveform data, thereby improving the accuracy of abnormal monitoring of the reciprocating machine and solving the technical problem of "the accuracy of abnormal monitoring of the reciprocating machine that can be achieved based on the existing reciprocating machine monitoring data acquisition system is low".

[0035] In addition, since the reciprocating machine monitoring data acquisition system can obtain the time domain waveform data of each cylinder, by comprehensively considering the time domain waveform data of multiple cylinders, it is possible to identify the associated abnormal states between multiple cylinders, thereby improving the accuracy of abnormal monitoring of the reciprocating machine. It is also possible to accurately locate the source of abnormal impact based on the impact pulse waveform data corresponding to each cylinder, analyze the impact sequence or impact amplitude, etc., and improve the accuracy of abnormal monitoring of the reciprocating machine. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required for use in the embodiments of the present application will be briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present application and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without paying creative work.

[0037] Figure 1 A schematic diagram of the structure of a reciprocating machine monitoring data acquisition system provided in an embodiment of the present application;

[0038] Figure 2 A structural schematic diagram of another reciprocating machine monitoring data acquisition system provided in an embodiment of the present application;

[0039] Figure 3 A schematic flow chart of a method for monitoring the state of a reciprocating machine provided in an embodiment of the present application.

[0040] Figure numerals: 100 - reciprocating machine monitoring data acquisition system; 101 - host computer; 102 - acceleration sensor; 103 - impact pulse sensor; 104 - key phase sensor; 105 - displacement sensor; 106 - pressure sensor; 107 - sound sensor; 108 - temperature sensor. DETAILED DESCRIPTION

[0041] The following embodiments of the technical solution of the present application are described in detail in conjunction with the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present application, and are therefore only used as examples, and cannot be used to limit the scope of protection of the present application.

[0042] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by technicians in the technical field to which this application belongs; the terms used herein are only for the purpose of describing specific embodiments and are not intended to limit this application.

[0043] In the description of the embodiments of the present application, the technical terms "first", "second", etc. are only used to distinguish different objects, and cannot be understood as indicating or implying relative importance or implicitly indicating the number, specific order or primary and secondary relationship of the indicated technical features. In the description of the embodiments of the present application, the meaning of "multiple" is two or more, unless otherwise clearly and specifically defined.

[0044] Please refer to Figure 1 , Figure 1 Schematic diagram of a reciprocating machine monitoring data acquisition system 100 provided in an embodiment of the present application. Figure 1 As shown, the reciprocating machine monitoring data acquisition system includes: a host computer 101, an acceleration sensor 102 and a shock pulse sensor 103 installed on each cylinder, and a key phase sensor 104 installed at the motor shaft or flywheel position;

[0045] The acceleration sensor 102 is configured to collect acceleration waveform data corresponding to each of the cylinders;

[0046] The shock pulse sensor 103 is configured to collect shock pulse waveform data corresponding to each of the cylinders;

[0047] The key phase sensor 104 is configured to collect key phase pulse data;

[0048] The host computer 101 is configured to determine the operating state of the reciprocating machine according to the acceleration waveform data, the impact pulse waveform data and the key phase pulse data.

[0049] Among them, the host computer 101 can be implemented by a computer, a micro control unit or a programmable logic control unit. The host computer 101 can realize the communication connection with the sensor based on wired / wireless communication. The number of acceleration sensors 102 and shock pulse sensors 103 can be multiple. Multiple acceleration sensors 102 can be installed at the cylinder head position of each cylinder, and can also be installed at the free end of the motor, the drive end of the motor, each main bearing position of the crankcase, etc. Multiple shock pulse sensors 103 can be installed at the crosshead position of each cylinder. By installing acceleration sensors 102 and shock pulse sensors 103 on each cylinder, the original time domain waveform data of multiple cylinders at the same level can be collected. The system can realize the time domain analysis of the collected time domain waveform data, and combine the key phase pulse data collected by the key phase sensor 104 to realize the angular domain analysis of the collected acceleration waveform data, shock pulse waveform data and other time domain waveform data; combined with multiple data analysis perspectives, the operating status of the reciprocating machine can be determined more accurately, and the accuracy of abnormal monitoring of the reciprocating machine can be improved. For example, based on the impact pulse waveform data corresponding to each cylinder, the impact sequence or impact amplitude can be analyzed to accurately locate the source of abnormal impact and improve the accuracy of abnormal monitoring of the reciprocating machine. It is also possible to divide the acceleration waveform data and the impact pulse waveform data into single-turn data or multi-turn data based on the key phase pulse data; by analyzing the changes in indicators in the single-turn data / multi-turn data, it is determined whether the reciprocating machine has a performance degradation or failure trend.

[0050] Among them, single-turn data / multi-turn data are extracted from the time domain waveform data directly collected by the sensor, and the angular domain data is not collected separately. Take multi-turn data extraction as an example: the outer dead point of the target cylinder can be used as the key phase zero point, and the other cylinders can be phase compensated according to the relative position of the crank, so that each cylinder can intercept multi-turn waveform data from 0° (i.e., the outer dead point) according to the phase compensation angle, ensuring that the multi-turn waveform data of each cylinder is complete multi-turn waveform data from the outer dead point to the inner dead point and then to the outer dead point (i.e., 0-360°). Single-turn data can be intercepted from multi-turn waveform data, or from the original collected waveform data.

[0051] It can be seen that, based on the reciprocating machine monitoring data acquisition system provided by the present application, the original time domain waveform data (acceleration waveform data, impact pulse waveform data and key phase pulse data) can be obtained; then based on the host computer, the operating state of the reciprocating machine can be more accurately determined according to the time domain waveform data, thereby improving the accuracy of abnormal monitoring of the reciprocating machine and solving the technical problem of "low accuracy of abnormal monitoring of the reciprocating machine based on the existing reciprocating machine monitoring data acquisition system". In addition, since the reciprocating machine monitoring data acquisition system can obtain the time domain waveform data of each cylinder, by comprehensively considering the time domain waveform data of multiple cylinders, the associated abnormal states between multiple cylinders can be identified, thereby improving the accuracy of abnormal monitoring of the reciprocating machine. It is also possible to analyze the order of impacts or the magnitude of impact amplitudes based on the impact pulse waveform data corresponding to each cylinder, so as to accurately locate the source of abnormal impacts and improve the accuracy of abnormal monitoring of the reciprocating machine.

[0052] In some optional embodiments, the host computer 101 is further configured to: determine primary index data based on the acceleration waveform data; wherein the primary index data includes the maximum acceleration value and / or the effective acceleration value; determine whether the reciprocating machine has a primary index abnormality based on the primary index data and the primary index condition; in the case that the reciprocating machine has a primary index abnormality, determine secondary index data based on the acceleration waveform data, the impact pulse waveform data and the key phase pulse data; wherein the secondary index data includes: at least one time domain index data of the maximum acceleration value, the effective acceleration value, the acceleration change rate, the frequency band energy, the harmonic energy and the resonance spectrum peak energy, and at least one angular domain index data of the impact frequency, the impact pulse peak value and the impact pulse position; determine the operating state of the reciprocating machine based on the secondary index data and the secondary index condition.

[0053] Among them, the primary index data may include only the maximum value of acceleration, or only the effective value of acceleration, or both the maximum value of acceleration and the effective value of acceleration. The primary index condition may include a judgment condition for judging whether the primary index data is abnormal, for example, it may include a normal threshold range or an abnormal threshold range of the primary index, etc. It can be determined whether the reciprocating machine has a primary index abnormality according to whether the monitored primary index data meets the primary index condition. The secondary index condition may include a judgment condition for judging whether the secondary index data is abnormal, for example, it may include a normal threshold range, an abnormal threshold range, a normal change range, an abnormal change range, and a combination judgment condition of multiple index data, etc. The primary index condition and the secondary index condition may be adjusted according to the actual application scenario of the reciprocating machine. By judging the condition of the primary index data, reference information on "whether the reciprocating machine may run abnormally" can be quickly obtained; and in the case where the reciprocating machine may send an abnormal operation (that is, the reciprocating machine has a primary index abnormality), the data can be analyzed at a deeper level of secondary index data.

[0054] Since the secondary index data includes at least one time domain index data of the maximum acceleration, the effective value of acceleration, the rate of change of acceleration, the frequency band energy, the harmonic energy and the resonance spectrum peak energy, and at least one angular domain index data of the impact frequency, the impact pulse peak value and the impact pulse position (that is, compared with the primary index data, the secondary index data is more complex); based on the host computer 101, the operating state of the reciprocating machine can be accurately determined according to the secondary index data and the secondary index conditions, thereby improving the state monitoring accuracy of the reciprocating machine. In addition, by firstly judging the abnormality of the primary index of the reciprocating machine, in the case of the abnormality of the primary index, more complex secondary index data is obtained, and the operating state of the reciprocating machine is determined according to the secondary index data; while ensuring the accuracy of the state monitoring of the reciprocating machine, the computing power requirements of the host computer can be reduced. Therefore, the reciprocating machine monitoring data acquisition system can cooperate with the alarm device to realize the edge alarm function.

[0055] In some optional embodiments, the operating state of the reciprocating machine includes normal operation and abnormal operation; the primary index condition includes a primary index abnormal threshold range; the secondary index condition includes a secondary index abnormal threshold range, a secondary index abnormal variation range and / or a secondary index abnormal combination judgment condition corresponding to a plurality of the secondary index data;

[0056] The upper computer 101 is specifically configured as follows: when the primary indicator data satisfies the primary indicator abnormality threshold range, it is determined that the reciprocating machine has a primary indicator abnormality; when the secondary indicator data satisfies the secondary indicator abnormality threshold range or the secondary indicator abnormal change range, it is determined that the reciprocating machine has a secondary indicator abnormality; when the reciprocating machine has a secondary indicator abnormality, it is determined whether the secondary indicator data satisfies the secondary indicator abnormality combination judgment condition; when the secondary indicator data satisfies the secondary indicator abnormality combination judgment condition, it is determined that the reciprocating machine is operating abnormally.

[0057] Among them, the primary index abnormal threshold range, the secondary index abnormal threshold range, the secondary index abnormal change range, and the secondary index abnormal combination judgment conditions corresponding to multiple secondary index data can all be adjusted according to the actual reciprocating machine application scenario (reciprocating machine type, size, power, etc.), and this application does not make specific restrictions on this. The initial threshold range can be determined by combining the operation of the reciprocating machine for a period of time since the monitoring (which can be 7 days, 15 days or other reasonable time periods), and then the initial threshold range is automatically / manually adjusted according to the long-term operation trend of the reciprocating machine. When the primary index data is within the primary index abnormal threshold range, it can be considered that the reciprocating machine has a primary index abnormality. When the secondary index data is within the secondary index abnormal threshold range, or the change of the secondary index data is within the secondary index abnormal change range, or multiple secondary index data meet the corresponding secondary index abnormal combination judgment conditions, it can be considered that the reciprocating machine is running abnormally. The primary index condition includes the primary index abnormal threshold range; and the secondary index condition includes the secondary index abnormal threshold range, the secondary index abnormal change range and / or the secondary index abnormal combination judgment conditions corresponding to the multiple secondary index data. That is, by first making a simple primary indicator abnormality judgment on the reciprocating machine, and then making a more complex secondary indicator abnormality judgment when the primary indicator is abnormal, and determining the operating status of the reciprocating machine based on the secondary indicator judgment result; the operating status of the reciprocating machine can be determined more accurately while reducing the computing power requirements for the upper computer.

[0058] For example, in the case of a crosshead failure of a reciprocating machine at an actual site, sensors installed at the crosshead, cylinder head, crankcase and other positions can collect relatively sparse waveform data at equal intervals. If the primary index data rises significantly (for example, the rising rate and amplitude exceed the corresponding normal threshold range), it is judged that the primary index is abnormal. In the case of a preliminary judgment based on the primary index data that the reciprocating machine may be abnormal, high-density acquisition can be triggered (to collect more intensive waveform data). If the secondary index data collected by the sensors at the crosshead, cylinder head, crankcase and other positions rise significantly (for example, the rising rate and amplitude of the index data such as the impact pulse peak value and the frequency band energy exceed the corresponding normal threshold range), it can be judged that the reciprocating machine has a secondary index abnormality (that is, it can be basically determined that the reciprocating machine is abnormal, but the abnormal part of the reciprocating machine cannot be located at this time). Then analyze the impact pulse waveform data corresponding to each cylinder, analyze the impact sequence or impact amplitude, etc. If the impact amplitude at the crosshead position is the largest and is greater than the impact amplitude at other positions, it can be basically determined that the crosshead position is abnormal. Combined with the phase information, if the air valve is not in the open or closed position when the impact occurs (the possibility of an induction fault can be ruled out), it can be finally determined that an abnormality has occurred in the crosshead position and the site can be informed of this abnormal monitoring situation.

[0059] In some optional embodiments, the reciprocating machine monitoring data acquisition system 100 may further include a collection station. The host computer 101 can issue the index information required to be collected to the collection station. The collection station can receive the monitoring data collected by different sensors according to the issued index information, calculate the corresponding index information according to the monitoring data, and send the calculated index information to the host computer 101. The host computer 101 also stores: index information involved in different abnormal judgments and abnormal judgment conditions such as threshold ranges corresponding to different index information. The host computer 101 can also receive the index information calculated by the collection station, and determine the monitoring status of the reciprocating machine according to the received index information and the stored abnormal judgment conditions.

[0060] In some optional embodiments, the upper computer 101 is also configured to: determine that the reciprocating machine is operating normally when the primary indicator data does not satisfy the primary indicator abnormal threshold range, or when the secondary indicator data does not satisfy the secondary indicator abnormal threshold range and the secondary indicator abnormal change range, or when the secondary indicator data does not satisfy the secondary indicator abnormal combination judgment condition.

[0061] Wherein, it can be determined that the reciprocating machine is operating normally when the primary index data does not meet the primary index abnormal threshold range. Alternatively, it can be determined that the reciprocating machine is operating normally when the primary index data meets the primary index abnormal threshold range and the secondary index data does not meet the secondary index abnormal threshold range and the secondary index abnormal change range. Alternatively, it can be determined that the reciprocating machine is operating normally when the secondary index data meets the secondary index abnormal threshold range or the secondary index abnormal change range and the secondary index data does not meet the secondary index abnormal combination judgment condition.

[0062] In some optional embodiments, the primary indicator abnormality threshold range corresponding to the same indicator data is greater than the secondary indicator abnormality threshold range.

[0063] Among them, taking the effective value of acceleration as an example, although both the primary index data and the secondary index data include the effective value of acceleration as an index data; however, the abnormal threshold range corresponding to the effective value of acceleration in the primary index data may be different from the abnormal threshold range corresponding to the effective value of acceleration in the secondary index data. Since the abnormal threshold range of the primary index corresponding to the same index data is larger than the abnormal threshold range of the secondary index, the situation of primary index abnormality (that is, the reciprocating machine may have abnormal operation) can be screened out through the relatively loose primary index conditions; and then the operating status of the reciprocating machine can be accurately determined based on the more stringent secondary index conditions. In this way, while ensuring the accuracy of the state monitoring of the reciprocating machine, the computing power requirements for the host computer can be reduced.

[0064] Please refer to Figure 2 , Figure 2 A schematic diagram of the structure of another reciprocating machine monitoring data acquisition system provided in an embodiment of the present application.

[0065] In some optional embodiments, the reciprocating machine monitoring data acquisition system 100 further includes: a displacement sensor 105 installed at a position of the piston rod close to the stuffing box; the displacement sensor 105 is configured to collect displacement waveform data of the piston rod;

[0066] The upper computer 101 is specifically configured as follows: determining the primary index data according to the acceleration waveform data and the displacement waveform data; wherein the primary index data includes at least one of the maximum acceleration value, the effective acceleration value, the peak-to-peak value of the displacement and the mean displacement value; in the case that there is a primary index abnormality in the reciprocating machine, determining the secondary index data according to the acceleration waveform data, the displacement waveform data, the impact pulse waveform data and the key phase pulse data; wherein the secondary index data includes at least one time domain index data among the maximum acceleration value, the effective acceleration value, the acceleration change rate, the frequency band energy, the harmonic energy, the resonance spectrum peak energy, the peak-to-peak value of the displacement and the mean displacement value.

[0067] Among them, the displacement sensor 105 can specifically include a horizontal displacement sensor arranged in the horizontal direction and a vertical displacement sensor arranged in the vertical direction. The horizontal displacement sensor can be specifically used to collect the swing amount of the piston rod, and the vertical displacement sensor can be specifically used to collect the settlement amount of the piston rod. The reciprocating machine monitoring data acquisition system 100 also includes a displacement sensor 105 installed at the position of the piston rod near the stuffing box, based on the displacement sensor 105, the displacement waveform data of the piston rod can be collected; and based on the host computer 101, the primary index data is determined according to the acceleration waveform data and the displacement waveform data. Correspondingly, the primary index data includes at least one of the maximum acceleration value, the effective value of acceleration, the peak-to-peak value of displacement and the mean displacement value; based on the more abundant primary index data, it can be more accurately determined whether the reciprocating machine has a primary index abnormality. In the case of a primary index abnormality in the reciprocating machine, the secondary index data is determined based on the host computer 101 according to the acceleration waveform data, the displacement waveform data, the impact pulse waveform data and the key phase pulse data. Since the secondary indicator data include at least one time domain indicator data of maximum acceleration, effective acceleration, acceleration change rate, frequency band energy, harmonic energy, resonance spectrum peak energy, displacement peak-to-peak value and displacement mean; based on richer secondary indicator data, the operating status of the reciprocating machine can be determined more accurately.

[0068] In some optional embodiments, the reciprocating machine monitoring data acquisition system 100 further includes: a pressure sensor 106 installed on each cylinder; the pressure sensor 106 is configured to collect pressure waveform data corresponding to each of the cylinders;

[0069] The upper computer 101 is specifically configured as follows: determining the primary index data according to the acceleration waveform data and the pressure waveform data; wherein the primary index data includes at least one of the maximum acceleration value, the effective acceleration value, the peak-to-peak pressure value and the effective pressure value; in the case that the reciprocating machine has a primary index abnormality, determining the secondary index data according to the acceleration waveform data, the pressure waveform data, the impact pulse waveform data and the key phase pulse data; wherein the secondary index data includes: at least one time domain index data among the maximum acceleration value, the effective acceleration value, the acceleration change rate, the frequency band energy, the harmonic energy, the resonance spectrum peak energy, the peak-to-peak pressure value and the effective pressure value, and at least one angular domain index data among the impact frequency, the impact pulse peak value, the impact pulse position and the effective pressure value of a single turn.

[0070] Among them, the pressure waveform data includes the pressure change data over time. The pressure sensor 106 can be installed on the shaft side or the cover side of each cylinder, or a pressure sensor 106 can be installed on the shaft side and the cover side of each cylinder. The dynamic pressure change on the cylinder shaft side and / or the cover side can be measured in real time by the pressure sensor 106. The reciprocating machine monitoring data acquisition system 100 also includes a pressure sensor 106 installed on each cylinder, and the pressure sensor 106 can collect the pressure waveform data corresponding to each cylinder; and based on the host computer 101, the primary index data is determined according to the acceleration waveform data and the pressure waveform data. Correspondingly, the primary index data includes at least one of the maximum acceleration value, the effective value of acceleration, the peak-to-peak value of pressure and the effective value of pressure; based on the more abundant primary index data, it can be more accurately determined whether the reciprocating machine has a primary index abnormality. In the case of a primary index abnormality in the reciprocating machine, the secondary index data is determined based on the acceleration waveform data, the pressure waveform data, the impact pulse waveform data and the key phase pulse data based on the host computer 101. Since the secondary indicator data include: at least one time domain indicator data of maximum acceleration, effective acceleration, acceleration change rate, frequency band energy, harmonic energy, resonance spectrum peak energy, peak-to-peak pressure and effective pressure value, and at least one angular domain indicator data of impact frequency, impact pulse peak value, impact pulse position and single-turn pressure effective value; based on richer secondary indicator data, the operating status of the reciprocating machine can be determined more accurately.

[0071] In some optional embodiments, the reciprocating machine monitoring data acquisition system 100 also includes: a sound sensor 107 installed in the surrounding area of ​​each cylinder, and / or a temperature sensor 108 installed at the intake valve and exhaust valve positions; the sound sensor 107 is configured to collect sound data of the area around the cylinder; the temperature sensor 108 is configured to collect temperature data at the intake valve and exhaust valve positions; wherein the primary indicator data also includes the sound data and / or the temperature data.

[0072] The specific installation position of the sound sensor 107 can be adjusted according to the actual application scenario of the reciprocating machine. The temperature sensor 108 can be implemented by a wireless temperature sensor, a wired temperature sensor, or a wireless temperature-vibration integrated sensor (which can simultaneously measure temperature data and acceleration data). Accordingly, the primary index data also includes sound data and / or temperature data; based on more abundant primary index data, it can be more accurately determined whether the reciprocating machine has a primary index abnormality.

[0073] In some optional embodiments, the host computer 101 is further configured to: send a synchronous acquisition signal to the acceleration sensor 102, the impact pulse sensor 103 and the key phase sensor 104; wherein the synchronous acquisition signal includes a data acquisition interval; when it is determined that the reciprocating machine is operating abnormally, shorten the data acquisition interval and send an adjusted synchronous acquisition signal to the acceleration sensor 102, the impact pulse sensor 103 and the key phase sensor 104.

[0074] Among them, by setting up a multi-channel acquisition station, the synchronous acquisition of monitoring data of multiple sensors can be realized. Based on the host computer 101, the acceleration sensor 102, the impact pulse sensor 103, and the key phase sensor 104 can be controlled to synchronously collect the monitoring data of the reciprocating machine. And by shortening the data collection interval in the case of abnormal operation of the reciprocating machine, a higher density of monitoring data can be obtained, and the complete fault degradation process can be captured as much as possible to further determine the abnormal nature and severity of the reciprocating machine; and based on the higher density of monitoring data, the abnormal analysis of the reciprocating machine can be more comprehensively realized.

[0075] In some optional embodiments, the reciprocating machine monitoring data acquisition system 100 further includes: an alarm device. The alarm device can make an abnormal alarm according to the alarm instruction issued by the host computer. The alarm type can include a single-point single-indicator trend alarm and a multi-point multi-indicator trend alarm. The single-point single-indicator trend alarm refers to a monitoring alarm applicable to a single key position or a specific parameter, and the multi-point multi-indicator trend alarm refers to a monitoring alarm combined with the indicator data of multiple cylinders at the same level.

[0076] Please refer to Figure 3 , Figure 3A flow chart of a state monitoring method for a reciprocating machine provided in an embodiment of the present application. The state monitoring method for a reciprocating machine can be applied to a reciprocating machine monitoring data acquisition system including a host computer, an acceleration sensor and a shock pulse sensor installed on each cylinder, and a key phase sensor installed at the motor shaft or flywheel position. The method may include the following steps:

[0077] S201, collecting acceleration waveform data corresponding to each of the cylinders based on the acceleration sensor;

[0078] S202, collecting shock pulse waveform data corresponding to each of the cylinders based on the shock pulse sensor;

[0079] S203, collecting key phase pulse data based on the key phase sensor;

[0080] S204, based on the host computer, determine the operating state of the reciprocating machine according to the acceleration waveform data, the impact pulse waveform data and the key phase pulse data.

[0081] The specific implementation of steps S201-S204 may refer to the above description of the reciprocating machine monitoring data acquisition system 100. To avoid repetition, the detailed description is appropriately omitted here.

[0082] In several embodiments provided by the embodiments of the present application, it should be understood that the disclosed device / system and method can also be implemented in other ways. The device embodiments described above are merely schematic. For example, the flowcharts and block diagrams in the accompanying drawings show the possible architecture, functions and operations of the devices, methods and computer program products according to the multiple embodiments of the embodiments of the present application. In this regard, each box in the flowchart or block diagram can represent a module, a program segment or a part of the code, and a part of the module, program segment or code contains one or more executable instructions for implementing the specified logical function. It should also be noted that in some alternative implementations, the functions marked in the box can also occur in a different order than the order marked in the accompanying drawings. For example, two consecutive boxes can actually be executed substantially in parallel, and they can sometimes be executed in the opposite order, depending on the functions involved. It should also be noted that each box in the block diagram and / or flowchart, and the combination of boxes in the block diagram and / or flowchart can be implemented with a dedicated hardware-based system that performs a specified function or action, or can be implemented with a combination of dedicated hardware and computer instructions.

[0083] In addition, the functional modules in each embodiment of the present application can be integrated together to form an independent part, or each module can exist separately, or two or more modules can be integrated to form an independent part.

[0084] The above description is only an optional implementation manner of the embodiments of the present application, but the protection scope of the embodiments of the present application is not limited thereto. Any technician familiar with the technical field can easily think of changes or replacements within the technical scope disclosed in the embodiments of the present application, which should be covered within the protection scope of the embodiments of the present application.

Claims

1. A reciprocating machine monitoring data acquisition system, characterized in that: The system comprises: a host computer, an acceleration sensor and a shock pulse sensor installed on each cylinder, and a key phase sensor installed at the motor shaft or flywheel position; The acceleration sensor is configured to collect acceleration waveform data corresponding to each of the cylinders; The shock pulse sensor is configured to collect shock pulse waveform data corresponding to each of the cylinders; The key phase sensor is configured to collect key phase pulse data; The host computer is configured to determine the operating state of the reciprocating machine according to the acceleration waveform data, the impact pulse waveform data and the key phase pulse data.

2. The system according to claim 1, characterized in that The host computer is also configured as: Determine primary index data according to the acceleration waveform data; wherein the primary index data includes a maximum acceleration value and / or an effective acceleration value; Determining whether the reciprocating machine has a primary indicator abnormality according to the primary indicator data and the primary indicator condition; In the case where the reciprocating machine has a primary index abnormality, secondary index data are determined according to the acceleration waveform data, the impact pulse waveform data and the key phase pulse data; wherein the secondary index data include: at least one time domain index data of the maximum acceleration value, the effective value of acceleration, the acceleration change rate, frequency band energy, harmonic energy and resonance spectrum peak energy, and at least one angular domain index data of the impact frequency, impact pulse peak value and impact pulse position; The operating state of the reciprocating machine is determined according to the secondary index data and the secondary index conditions.

3. The system according to claim 2, characterized in that in, The operating status of the reciprocating machine includes normal operation and abnormal operation; the primary index condition includes a primary index abnormal threshold range; the secondary index condition includes a secondary index abnormal threshold range, a secondary index abnormal change range and / or a secondary index abnormal combination judgment condition corresponding to a plurality of the secondary index data; The specific configuration of the host computer is: In the case where the primary indicator data satisfies the primary indicator abnormality threshold range, determining that the reciprocating machine has a primary indicator abnormality; In the case where the secondary index data satisfies the secondary index abnormality threshold range or the secondary index abnormality change range, determining that the reciprocating machine has a secondary index abnormality; In the case where the reciprocating machine has a secondary index abnormality, determining whether the secondary index data meets the secondary index abnormality combination determination condition; When the secondary index data meets the secondary index abnormal combination judgment condition, it is determined that the reciprocating machine is operating abnormally.

4. The system according to claim 3, characterized in that The host computer is also configured as: When the primary index data does not satisfy the primary index abnormal threshold range, or when the secondary index data does not satisfy the secondary index abnormal threshold range and the secondary index abnormal change range, or when the secondary index data does not satisfy the secondary index abnormal combination judgment condition, it is determined that the reciprocating machine is operating normally.

5. The system according to claim 3, characterized in that in, The primary indicator abnormality threshold range corresponding to the same indicator data is greater than the secondary indicator abnormality threshold range.

6. The system according to claim 2, characterized in that The system further comprises: a displacement sensor installed at a position of the piston rod close to the stuffing box; the displacement sensor is configured to collect displacement waveform data of the piston rod; The specific configuration of the host computer is: Determine the primary index data according to the acceleration waveform data and the displacement waveform data; wherein the primary index data includes at least one of the maximum acceleration value, the effective acceleration value, the peak-to-peak value of the displacement, and the mean displacement value; In the case where there is an abnormal primary index of the reciprocating machine, the secondary index data is determined according to the acceleration waveform data, the displacement waveform data, the impact pulse waveform data and the key phase pulse data; wherein the secondary index data includes: at least one time domain index data of the maximum acceleration value, the effective acceleration value, the acceleration change rate, the frequency band energy, the harmonic energy, the resonance spectrum peak energy, the displacement peak-to-peak value and the displacement mean value.

7. The system according to claim 2, characterized in that The system further comprises: a pressure sensor mounted on each cylinder; the pressure sensor is configured to collect pressure waveform data corresponding to each of the cylinders; The specific configuration of the host computer is: Determine the primary index data according to the acceleration waveform data and the pressure waveform data; wherein the primary index data includes at least one of the maximum acceleration value, the effective acceleration value, the peak-to-peak pressure value, and the effective pressure value; In the case where there is a primary indicator abnormality in the reciprocating machine, the secondary indicator data is determined according to the acceleration waveform data, the pressure waveform data, the impact pulse waveform data and the key phase pulse data; wherein the secondary indicator data include: at least one time domain indicator data of the maximum acceleration value, the effective acceleration value, the acceleration change rate, the frequency band energy, the harmonic energy, the resonance spectrum peak energy, the pressure peak-to-peak value and the pressure effective value, and at least one angular domain indicator data of the impact frequency, the impact pulse peak value, the impact pulse position and the single-turn pressure effective value.

8. The system according to claim 2, characterized in that The system further comprises: an acoustic sensor installed in the surrounding area of ​​each cylinder, and / or a temperature sensor installed at the location of the intake valve and the exhaust valve; The sound sensor is configured to collect sound data of the area around the cylinder; The temperature sensor is configured to collect temperature data at the positions of the intake valve and the exhaust valve; Wherein, the primary index data also includes the sound data and / or the temperature data.

9. The system according to claim 1, characterized in that The host computer is also configured as: Sending a synchronous acquisition signal to the acceleration sensor, the shock pulse sensor and the key phase sensor; wherein the synchronous acquisition signal includes a data acquisition interval; When it is determined that the reciprocating machine is operating abnormally, the data collection interval is shortened, and an adjusted synchronous collection signal is sent to the acceleration sensor, the impact pulse sensor, and the key phase sensor.

10. A method for monitoring the state of a reciprocating machine, characterized in that: The method is applied to a reciprocating machine monitoring data acquisition system including a host computer, an acceleration sensor and a shock pulse sensor installed on each cylinder, and a key phase sensor installed at the motor shaft or flywheel position; the method includes: Based on the acceleration sensor, collecting acceleration waveform data corresponding to each of the cylinders; Based on the shock pulse sensor, collecting shock pulse waveform data corresponding to each of the cylinders; Based on the key phase sensor, collecting key phase pulse data; Based on the host computer, the operating state of the reciprocating machine is determined according to the acceleration waveform data, the impact pulse waveform data and the key phase pulse data.

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