Quality grading evaluation and service life prediction method for internal combustion generator set

Abstract

The invention discloses a quality grading evaluation and life prediction method for an internal combustion generator set, which comprises the following steps of: sampling electric quantity parameters, environmental parameters and the like of the internal combustion generator set, combining quality grading and life evaluation strategies of the internal combustion generator set, and superposing operation data records and maintenance and overhaul conditions of each stage of the internal combustion generator set; a set of comprehensive, scientific and efficient internal combustion generator set quality grading and service life evaluation is provided, and the problem that the quality and service life of the internal combustion generator set are difficult to effectively evaluate in existing discrete data is solved.

Description

Technical Field

[0001] The invention relates to the technical field of quality assessment of internal combustion generator sets, and is particularly applicable to a quality grading assessment and life prediction method of internal combustion generator sets. Background Art

[0002] As an important power device, the quality and life assessment of internal combustion generator sets are directly related to operating efficiency, economy and safety. However, the current assessment methods for the quality and life of internal combustion generator sets have significant limitations.

[0003] For example, the traditional bench test method has a long cycle, high cost, and is difficult to fully reflect complex working conditions; the experience-based evaluation method is highly subjective, lacks scientific basis, and cannot adapt to new technologies and design changes; although the sensor-based monitoring method can collect data in real time, the data processing is complex and the ability to identify early faults is limited. At the same time, the reliability and accuracy of the sensor itself may also affect the final evaluation results; although numerical simulation and simulation technology can predict life and performance, its accuracy depends on input parameters and boundary conditions, consumes a lot of computing resources, and is difficult to apply in real time. In addition, the existing methods are difficult to fully consider the coupling effects of multiple factors (such as ambient temperature and load ratio, maintenance conditions, working hours, etc.), resulting in limited accuracy and reliability of the evaluation results. These problems have seriously affected the scientificity and effectiveness of the quality and life assessment of internal combustion generator sets, and a more efficient and accurate solution is urgently needed. Summary of the invention

[0004] The present invention aims to provide a quality grading evaluation and life prediction method for an internal combustion generator set, so as to solve the problem of scientific evaluation of the quality and life of the internal combustion generator set.

[0005] To achieve the above object, the present invention adopts the following technical solutions: The method for quality grading assessment and life prediction of an internal combustion generator set of the present invention comprises a data acquisition unit, an original information storage unit, a history information processing unit, a quality grading assessment and life prediction unit and a display interaction unit; the specific steps include: S1, obtaining current characteristic data of the internal combustion generator set through a data acquisition unit; S2, the quality grading assessment and life prediction unit compares the current characteristic data with the new product data of the internal combustion generator set stored in the original information storage unit to obtain an initial comprehensive quality index of the internal combustion generator set; S3, obtaining history information and maintenance and overhaul information of the internal combustion generator set from the history information processing unit, and correcting the initial comprehensive quality index; S4, judging the quality status of the internal combustion generator set according to the corrected initial comprehensive quality index, and feeding back through the display interaction unit.

[0006] Furthermore, the data acquisition unit includes a water temperature sensor, a fuel consumption sensor, a voltage, current, and frequency sensor of the generator set, a winding temperature sensor, an ambient temperature sensor, a vibration sensor, an air intake sensor, a coolant flow sensor, a bearing temperature sensor, a battery voltage measurement sensor, an oil pressure sensor, and an oil temperature sensor.

[0007] Furthermore, step S2 specifically includes: S2.1, based on the ambient temperature and load ratio, compare the deviation of the engine and generator temperature of the internal combustion generator set with the new product data to obtain the first score; S2.2, compare the insulation resistance and leakage current of the internal combustion generator set with the deviations of the new product data, and obtain the second score; S2.3, based on the deviation between the system performance index of the internal combustion generator set and the new product data under the same load, the third score is obtained; S2.4, the fourth score is obtained based on the deviation of the vibration and noise of the internal combustion generator set under typical load from the new product data.

[0008] Furthermore, the initial comprehensive quality index in step S2 is a weighted value of the first score, the second score, the third score, and the fourth score.

[0009] Furthermore, in step S3, the correction of the initial comprehensive quality index specifically includes: S3.1, obtain the quality correction value according to the factory age of the internal combustion generator set and correct the initial comprehensive quality index; S3.2, based on the working hours and maintenance times of the internal combustion generator set, obtain the maintenance warranty positive value and correct the initial comprehensive quality index.

[0010] Furthermore, in S3.1, for an internal combustion generator set that has been manufactured for less than 5 years, the quality correction value is a starting value of 1; for an internal combustion generator set that has been manufactured for 5 to 10 years, the quality correction value is increased by 0.2 on the basis of the starting value for each additional year; for an internal combustion generator set that has been manufactured for 10 to 15 years, the quality correction value is increased by 0.4 on the basis of the starting value for each additional year; and for an internal combustion generator set that has been manufactured for more than 15 years, the quality correction value is increased by 0.8 on the basis of the starting value for each additional year.

[0011] Furthermore, in step S3.2, the maintenance warranty value increases by 1 for every 2000 working hours of the internal combustion generator set; if scheduled maintenance is performed once or more within every 2000 working hours, the maintenance warranty value is reduced by 0.2.

[0012] Furthermore, in step S2.1, the first score is compared with the new product data based on the ambient temperature and load ratio when the load deviation of the internal combustion generator set is within 2% and the temperature rise is not greater than 2°C / h; if the increase compared to the new product is less than or equal to 50%, the first score is 1; if the increase compared to the new product is more than 50%, the first score is 2; the weight factor is 0.3.

[0013] Furthermore, in step S2.2, the second score is based on the average value of three tests after the internal combustion generator set is started and operated for 1 hour and compared with the new product data; if it is 50% lower than the new product and 2 times higher than the standard requirement, the second score is 1; if it is between 2 times and 1 times higher than the standard requirement, the second score is 2; the weight factor is 0.5.

[0014] Furthermore, in step S2.3, if the deviation between the system performance index of the internal combustion generator set and the new product data is within 20%, the third score is 1; if it is between 20% and 60%, the third score is 2; if it is higher than 60% and less than the standard range, the third score is 3; the weight factor is 0.8.

[0015] Furthermore, in step S2.4, if the vibration and noise are 20% higher than the new product data, the fourth score is 1; if they are 20% to 60% higher than the new product data, the fourth score is 2; if they are 60% higher than the new product data and less than the standard range, the fourth score is 3; the weight factor is 0.4.

[0016] The advantage of the present invention is that by sampling the electrical parameters, environmental parameters, etc. of the internal combustion generator set, combining the quality grading and life assessment strategy of the internal combustion generator set, and superimposing the operating data records and maintenance and overhaul conditions of the internal combustion generator set at each stage, a comprehensive, scientific and efficient quality grading and life assessment of the internal combustion generator set is provided, which solves the problem that it is difficult to effectively evaluate the quality and life of the internal combustion generator set with existing discrete data. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 The present invention provides a framework diagram of the internal combustion generator set quality grading assessment and life prediction method.

[0018] Figure 2 The present invention provides a flow chart of the internal combustion generator set quality grading assessment and life prediction method. DETAILED DESCRIPTION

[0019] The technical solutions in the embodiments of the present invention are described clearly and completely below. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0020] Internal combustion generator sets generally include engine, generator, control system, chassis, battery and other components, integrating fuel, electrical, liquid cooling, thermodynamics, noise reduction, vibration reduction and other related disciplines, and are a relatively complex system. According to relevant standards and combined with actual usage statistics, the quality status of internal combustion generator sets can be divided into four quality levels: new products, acceptable products, products to be repaired, and products to be scrapped. The quality level standards are shown in Table 1.

[0021] Table 1 The quality status of an internal combustion generator set can be characterized by operating conditions such as electrical performance indicators, environmental variable status, and fuel consumption. Status assessment and life estimation can be performed in combination with product history information and repair and maintenance records. The quality of the internal combustion generator sets can be graded to provide a reference for users of the internal combustion generator sets. Quality analysis can avoid waste caused by premature scrapping due to insufficient estimation, and power supply difficulties caused by low equipment reliability in emergency tasks. It can also provide a reference for manufacturers to conduct product life cycle management and reliability engineering improvement, in order to achieve the internal combustion generator set quality grading assessment and life prediction method described in the present invention.

[0022] like Figure 1 As shown, the method for quality grading assessment and life prediction of an internal combustion generator set described in the present invention specifically includes a data acquisition unit, an original information storage unit, a history information processing unit, a quality grading assessment and life prediction unit and a display interaction unit.

[0023] The original information storage unit stores the basic information of the internal combustion generator as a new product, including but not limited to basic configuration, test reports, etc. The quality grading assessment and life prediction unit GCPU contains the core algorithm, which is used to calculate and judge the quality grading and life of the internal combustion generator based on relevant data. The resume information processing unit contains the number of overhauls, maintenance information, etc. The display interaction unit is used to prompt the user with the quality grading and life information of the internal combustion generator set. The data acquisition unit is used to obtain the real-time data of the current internal combustion generator.

[0024] The specific steps of the internal combustion generator set quality classification assessment and life prediction method of the present invention are as follows: Figure 2 As shown, including: S1, obtaining the current characteristic data of the internal combustion generator set through the data acquisition unit. The data acquisition unit includes a water temperature sensor, a fuel consumption sensor, a voltage, current, and frequency sensor of the generator set, a winding temperature sensor, an ambient temperature sensor, a vibration sensor, an intake air volume sensor, a coolant flow sensor, a bearing temperature sensor, a battery voltage measurement sensor, an oil pressure sensor, and an oil temperature sensor.

[0025] The water temperature sensor is installed at the outlet of the engine water pipe or near the thermostat to detect the engine water temperature; the fuel consumption sensor is installed at the inlet of the oil pipe to detect the fuel consumption of the fuel; the voltage, current and frequency sensors (transmitters) are installed inside the control box of the internal combustion generator set to detect the voltage and frequency of the generator; the temperature sensor is installed on the outer shell of the generator outlet box, away from high-temperature parts such as the engine exhaust and the generator body, to detect the real-time ambient temperature; the winding temperature sensor is installed inside the generator near the main power generation winding to detect the temperature of the generator winding; the vibration sensor adopts a magnetic interface and is arranged at the upper end of the generator outlet box to detect the vibration of the generator set; the air intake sensor is installed on the engine intake pipe to measure the engine intake volume; the coolant flow sensor is installed at the connecting pipe between the engine water outlet and the radiator tank to measure the water outlet flow of the coolant; the bearing temperature sensor is installed at the bearing position of the generator end cover to detect the temperature of the generator bearing; the battery voltage measurement sensor is arranged near the battery to detect the battery voltage; the oil temperature sensor is installed at the interface of the engine oil filter to detect the temperature of the engine oil.

[0026] S2, the quality grading assessment and life prediction unit compares the current characteristic data with the new product data of the internal combustion generator set stored in the original information storage unit to obtain an initial comprehensive quality index of the internal combustion generator set.

[0027] Specifically include: S2.1, based on the ambient temperature and load ratio, compare the deviation of the engine and generator temperature of the internal combustion generator set with the new product data to obtain the first score.

[0028] The first score is based on the ambient temperature and load ratio when the load deviation of the internal combustion generator set is within 2% and the temperature rise is not greater than 2°C / h and is compared with the new product data; if the increase compared to the new product is less than or equal to 50%, the first score is 1; if the increase compared to the new product is more than 50%, the first score is 2; the weight factor is 0.3.

[0029] S2.2, compare the insulation resistance and leakage current of the internal combustion generator set with the deviations of the new product data to obtain the second score.

[0030] The second score is based on the average of three tests after the internal combustion generator set has been started and run for 1 hour and compared with the new product data; if it is 50% lower than the new product and 2 times higher than the standard requirement, the second score is 1; if it is between 2 times and 1 times higher than the standard requirement, the second score is 2; the weight factor is 0.5.

[0031] S2.3, the third score is obtained based on the deviation between the system performance indicators of the internal combustion generator set and the new product data under the same load.

[0032] If the deviation between the system performance indicators of the internal combustion generator set and the new product data is within 20%, the third score is 1; if the deviation is between 20% and 60%, the third score is 2; if the deviation is higher than 60% and less than the standard range, the third score is 3; the weighting factor is 0.8.

[0033] S2.4, the fourth score is obtained based on the deviation of the vibration and noise of the internal combustion generator set under typical load from the new product data.

[0034] If the vibration and noise are 20% higher than the new product data, the fourth score is 1; if they are 20% to 60% higher than the new product data, the fourth score is 2; if they are 60% higher than the new product data and smaller than the standard range, the fourth score is 3; the weighting factor is 0.4.

[0035] The initial comprehensive quality index is a weighted value of the first score, the second score, the third score, and the fourth score.

[0036] S3, obtaining the history information and maintenance and overhaul information of the internal combustion generator set from the history information processing unit, and correcting the initial comprehensive quality index.

[0037] The revised initial comprehensive quality index specifically includes: S3.1, obtain the quality correction value based on the factory age of the internal combustion generator set and correct the initial comprehensive quality index.

[0038] For internal combustion generator sets within 5 years of leaving the factory, the quality correction value is a starting value of 1; for 5-10 years after leaving the factory, the quality correction value will be increased by 0.2 on the basis of the starting value for each additional year; for 10-15 years after leaving the factory, the quality correction value will be increased by 0.4 on the basis of the starting value for each additional year; for more than 15 years after leaving the factory, the quality correction value will be increased by 0.8 on the basis of the starting value for each additional year.

[0039] S3.2, based on the working hours and maintenance times of the internal combustion generator set, obtain the maintenance warranty positive value and correct the initial comprehensive quality index.

[0040] For every 2000 working hours of the internal combustion generator set, the maintenance warranty value will increase by 1; if the maintenance is carried out once or more on schedule within every 2000 working hours, the maintenance warranty value will be reduced by 0.2.

[0041] S4, judging the quality status of the internal combustion generator set according to the corrected initial comprehensive quality index, and feeding back through the display interaction unit.

Claims

1. A method for quality grading assessment and life prediction of an internal combustion generator set, characterized in that: It includes a data acquisition unit, an original information storage unit, a history information processing unit, a quality grading assessment and life prediction unit, and a display interaction unit; the specific steps include: S1, obtaining current characteristic data of the internal combustion generator set through a data acquisition unit; S2, the quality grading assessment and life prediction unit compares the current characteristic data with the new product data of the internal combustion generator set stored in the original information storage unit to obtain an initial comprehensive quality index of the internal combustion generator set; S3, obtaining history information and maintenance and overhaul information of the internal combustion generator set from the history information processing unit, and correcting the initial comprehensive quality index; S4, judging the quality status of the internal combustion generator set according to the corrected initial comprehensive quality index, and feeding back through the display interaction unit.

2. The method for quality grading assessment and life prediction of an internal combustion generator set according to claim 1 is characterized in that: The data acquisition unit includes a water temperature sensor, a fuel consumption sensor, a generator set voltage, current, and frequency sensor, a winding temperature sensor, an ambient temperature sensor, a vibration sensor, an intake air volume sensor, a coolant flow sensor, a bearing temperature sensor, a battery voltage measurement sensor, an oil pressure sensor, and an oil temperature sensor.

3. The method for quality grading assessment and life prediction of an internal combustion generator set according to claim 1, characterized in that: Step S2 specifically includes: S2.1, based on the ambient temperature and load ratio, compare the deviation of the engine and generator temperature of the internal combustion generator set with the new product data to obtain the first score; S2.2, compare the insulation resistance and leakage current of the internal combustion generator set with the deviation of the new product data, and obtain the second score; S2.3, based on the deviation between the system performance index of the internal combustion generator set and the new product data under the same load, the third score is obtained; S2.4, obtaining a fourth score based on the deviation of the vibration and noise of the internal combustion generator set under a typical load from the new product data; the initial comprehensive quality index is a weighted value of the first score, the second score, the third score and the fourth score.

4. The method for quality grading assessment and life prediction of an internal combustion generator set according to claim 1, characterized in that: In step S3, the modification of the initial comprehensive quality index specifically includes: S3.1, obtain the quality correction value according to the factory age of the internal combustion generator set and correct the initial comprehensive quality index; S3.2, based on the working hours and maintenance times of the internal combustion generator set, obtain the maintenance warranty positive value and correct the initial comprehensive quality index.

5. The method for quality grading assessment and life prediction of an internal combustion generator set according to claim 4 is characterized in that: In S3.1, for internal combustion generator sets within 5 years of leaving the factory, the quality correction value is a starting value of 1; for 5-10 years after leaving the factory, the quality correction value is increased by 0.2 on the basis of the starting value for each additional year; for 10-15 years after leaving the factory, the quality correction value is increased by 0.4 on the basis of the starting value for each additional year; for more than 15 years after leaving the factory, the quality correction value is increased by 0.8 on the basis of the starting value for each additional year.

6. The method for quality grading assessment and life prediction of an internal combustion generator set according to claim 4, characterized in that: In step S3.2, for every 2000 working hours of the internal combustion generator set, the maintenance warranty value increases by 1; if the scheduled maintenance is performed once or more within every 2000 working hours, the maintenance warranty value will be reduced by 0.

2.

7. The method for quality grading assessment and life prediction of an internal combustion generator set according to claim 3 is characterized in that: In step S2.1, the first score is compared with the new product data based on the ambient temperature and load ratio when the load deviation of the internal combustion generator set is within 2% and the temperature rise is not greater than 2°C / h; if the increase compared to the new product is less than or equal to 50%, the first score is 1; if the increase compared to the new product is more than 50%, the first score is 2; the weight factor is 0.

3.

8. The method for quality grading assessment and life prediction of an internal combustion generator set according to claim 3 is characterized in that: In step S2.2, the second score is based on the average of three tests after the internal combustion generator set is started and operated for 1 hour and compared with the new product data; if it is 50% lower than the new product and 2 times higher than the standard requirement, the second score is 1; if it is between 2 times and 1 times higher than the standard requirement, the second score is 2; the weight factor is 0.

5.

9. The method for quality grading assessment and life prediction of an internal combustion generator set according to claim 3, characterized in that: In step S2.3, if the deviation between the system performance index of the internal combustion generator set and the new product data is within 20%, the third score is 1; if it is between 20% and 60%, the third score is 2; if it is higher than 60% and less than the standard range, the third score is 3; the weight factor is 0.

8.

10. The method for quality grading assessment and life prediction of an internal combustion generator set according to claim 3, characterized in that: In step S2.4, if the vibration and noise are 20% higher than the new product data, the fourth score is 1; if they are 20% to 60% higher than the new product data, the fourth score is 2; if they are 60% higher than the new product data and less than the standard range, the fourth score is 3; the weight factor is 0.4.

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