A vibration monitoring method for power plant equipment based on multi-source vibration data fusion
By using a multi-source vibration data fusion method, the vibration of thermal power plant equipment is monitored in real time and automatically notified to inspection personnel for maintenance. This solves the problems of poor data timeliness and high false alarm rate in existing technologies, and realizes intelligent and efficient equipment vibration monitoring and inspection.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- TIANJIN UNIV OF TECH & EDUCATION (TEACHER DEV CENT OF CHINA VOCATIONAL TRAINING & GUIDANCE)
- Filing Date
- 2025-06-26
- Publication Date
- 2026-07-24
AI Technical Summary
Existing methods for monitoring vibration in thermal power plant equipment suffer from poor data timeliness, limited frequency response range of single sensors, reliance on manual experience for threshold alarms with a high false alarm rate, and a lack of intelligent positioning and early warning linkage capabilities.
A multi-source vibration data fusion method is adopted. Vibration sensors are distributed to collect and analyze vibration data in real time. Spectrum analysis is used to identify anomalies and automatically notify the nearest inspection personnel to carry out maintenance.
It realizes the intelligent linkage between equipment vibration monitoring and inspection, improves the degree of automation and inspection efficiency, reduces resource occupancy, and improves monitoring performance and real-time performance.
Smart Images
Figure CN120740745B_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of power plant monitoring technology, and in particular relates to a vibration monitoring method for thermal power plant equipment based on multi-source vibration data fusion. Background Technology
[0002] As a critical energy infrastructure, the operating status of equipment in thermal power plants directly affects power supply security and efficiency. Abnormal vibration of rotating machinery such as steam turbines, generators, and feedwater pumps is a major cause of shutdown failures. Currently, thermal power plants commonly use piezoelectric vibration sensors combined with offline data acquisition devices to obtain parameters such as vibration spectrum and time-domain waveforms through regular manual inspections, and then perform health assessments based on ISO 10816 standard thresholds. However, existing methods have significant limitations: offline monitoring results in poor data timeliness, making it difficult to promptly capture transient anomalies; the frequency response range of a single sensor is limited, making it impossible to accurately identify early high-frequency micro-impact signals (such as cracks in the inner ring of bearings); threshold alarms rely on human experience, have a high false alarm rate for combined fault modes (such as misalignment and loosening), and lack intelligent positioning and early warning linkage capabilities. Summary of the Invention
[0003] In view of this, the present invention aims to propose a vibration monitoring method for thermal power plant equipment based on multi-source vibration data fusion, so as to realize intelligent and automated linkage between equipment vibration monitoring and inspection.
[0004] To achieve the above objectives, the technical solution of the present invention is implemented as follows:
[0005] A vibration monitoring method for thermal power plant equipment based on multi-source vibration data fusion.
[0006] Furthermore, several vibration sensors are deployed to monitor the vibration of key equipment in the thermal power plant. The host computer analyzes the vibration data and identifies equipment with abnormal vibration. It receives and compares the location information of each inspection personnel and sends alarm information to the inspection personnel closest to the equipment with abnormal vibration.
[0007] Monitoring methods include:
[0008] T1. The vibration sensors are distributed and connected in parallel with the data acquisition card. The data acquisition card integrates the data from each channel and transmits the vibration data of all vibration sensors to the host computer via serial port. The inspection personnel use mobile devices to communicate bidirectionally with the host computer to collect the location information of the inspection personnel.
[0009] T2. The host computer receives vibration data in real time and analyzes the vibration data using spectrum analysis. When abnormal equipment vibration is detected, an alarm is issued and the location information of all inspection personnel is collected. The optimal inspection personnel are calculated and notified to go to the abnormal equipment point for repair.
[0010] T3. The inspection personnel report the maintenance status to the host computer to clear the alarm, and record the abnormal equipment vibration data and maintenance results.
[0011] Furthermore, T2 includes the following sub-steps:
[0012] T21. Establish a vibration data transmission thread, an inspection personnel communication thread, and a vibration and position synchronization thread, which run in parallel. Use a rendezvous point to manage the data synchronization of the three threads.
[0013] T22: The vibration data transmission thread collects vibration data from each sensor in real time, while the inspection personnel communication thread receives / sends information with the inspection personnel.
[0014] T23. The vibration and position synchronization thread sets up parallel consumer loops and producer loops. The producer loop combines the vibration data and the inspection personnel position data at the same moment into a continuous string. The consumer loop transmits the continuous string to the producer loop through a queue until the queue fails and stops the consumer loop.
[0015] T24. The consumer continuously receives the continuous string and segments it into vibration data and location data. The spectrum analysis block monitors the vibration data in real time. When an abnormal vibration of the device is detected, a vibration buffer and a location buffer are established respectively. The vibration buffer data of this event are recorded and then transferred to T25.
[0016] T25. Use the interrupt mechanism to set up an event-driven inspection allocation notification thread. When the vibration is abnormal, start the inspection allocation notification thread, combine the vibration buffer and position buffer when the equipment vibration is abnormal into a continuous string and send it to the path calculation block. The path calculation block calculates the inspection personnel with the optimal distance and generates an inspection notification of abnormal equipment information.
[0017] T26. The inspection notification is wirelessly transmitted to the corresponding inspection personnel in the form of a byte stream. After the inspection personnel provide feedback and clear the alarm information, the vibration buffer and position buffer are cleared.
[0018] Furthermore, in T22, the waiting assembly point is located in the main loop of the vibration data transmission thread, which specifies the length of the serial port data bytes of the vibration sensor and the order of each channel. The vibration data is copied into two paths, one path of vibration data is stored in the vibration data buffer and refreshed cyclically, and the other path of vibration data is concatenated into a string array and stored in the cumulative buffer.
[0019] The vibration data buffer is used as a local variable to participate in the vibration and position synchronization thread, while the accumulation buffer is used for log recording.
[0020] The producer loop in the vibration and position synchronization thread includes a waiting rendezvous point. The vibration and position synchronization thread loop will be performed again after the vibration data transmission thread and the inspection personnel communication thread have both completed one main loop.
[0021] Furthermore, in T22, the inspection personnel communication thread includes a parallel data reading loop, a data sending loop, and a waiting assembly point that acts on the data reading loop. The inspection notification is sent to the inspection personnel through the data sending loop. The data reading loop sets the inspection personnel's position data buffer and participates in the vibration and position synchronization thread as a local variable.
[0022] Furthermore, in T24, when abnormal equipment vibration is detected, a vibration abnormality boolean is set, and the vibration abnormality boolean participates in the inspection allocation notification thread and the data reading loop;
[0023] When the vibration anomaly boolean is true, the inspection allocation notification thread and the data reading loop are activated and run; otherwise, the inspection allocation notification thread is closed, and the data reading loop initializes the inspection personnel location data buffer.
[0024] Furthermore, the T24 spectrum analysis block uses FFT to transform the vibration data in time and frequency, and compares the fault characteristic frequencies to determine whether there is abnormal equipment vibration. The fault characteristic frequencies include, but are not limited to, rotor imbalance frequency characteristics, bearing rupture frequency characteristics, and gear meshing fault frequency characteristics.
[0025] Furthermore, the T25 path calculation block identifies the inspector closest to the faulty equipment based on the vibration buffer, location buffer, and inspector location data, and pushes the equipment identifier and location information in the vibration buffer to the inspector's mobile device via TCP protocol.
[0026] Furthermore, an electronic device includes a processor and a memory communicatively connected to the processor and used to store executable instructions of the processor, the processor being used to execute the aforementioned method for monitoring vibration of thermal power plant equipment based on multi-source vibration data fusion.
[0027] Furthermore, a server includes at least one processor and a memory communicatively connected to the processor, the memory storing instructions executable by the at least one processor, the instructions being executed by the processor to enable the aforementioned method for monitoring vibration of thermal power plant equipment based on multi-source vibration data fusion.
[0028] Furthermore, a computer-readable storage medium stores a computer program, which, when executed by a processor, implements the aforementioned method for monitoring vibration of thermal power plant equipment based on multi-source vibration data fusion.
[0029] Compared with existing technologies, the vibration monitoring method for thermal power plant equipment based on multi-source vibration data fusion described in this invention has the following advantages:
[0030] (1) The monitoring method described in this invention realizes real-time monitoring of equipment vibration through parallel vibration data transmission thread, inspection personnel communication thread and vibration and position synchronization thread, automatically detects abnormal vibration and notifies the nearest inspection personnel, thereby improving the automation level of equipment monitoring and inspection efficiency.
[0031] (2) The vibration data transmission thread described in this invention specifies the length of the serial port data bytes of the vibration sensor and the order of each channel. The vibration data is copied into two paths. One path of vibration data is stored in the vibration data buffer and refreshed cyclically. The other path of vibration data is concatenated into a string array and stored in the cumulative buffer. The monitoring data of the distributed sensor is efficiently transmitted through the serial port protocol.
[0032] (3) The three-thread data synchronization of the rendezvous point management described in this invention includes a waiting rendezvous point in the producer loop of the vibration and position synchronization thread. After the vibration data transmission thread and the inspection personnel communication thread have completed one main loop, the vibration and position synchronization thread loop is performed again to synchronize and correct the vibration data and inspection personnel position data at the same time, so as to improve the real-time performance and accuracy of the subsequent path calculation block.
[0033] (4) The inspection allocation notification thread described in this invention activates and runs the inspection allocation notification thread and the data reading loop according to the true or false of the vibration abnormality boolean, or the inspection allocation notification thread is closed and the data reading loop initializes the inspection personnel location data buffer. The advantage is that if there is no equipment vibration abnormality, the location information of all inspection personnel will not be collected, and the data reading loop in the inspection personnel communication thread will not participate in the collection, thereby reducing the resource occupancy rate, speeding up the scanning frequency of the vibration data transmission thread, the inspection allocation notification thread, and the vibration and location synchronization thread, and improving the monitoring performance of the monitoring system. Attached Figure Description
[0034] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:
[0035] Figure 1 This is a schematic diagram of a vibration monitoring method for thermal power plant equipment based on multi-source vibration data fusion, as described in an embodiment of the present invention.
[0036] Figure 2 This is a schematic diagram of the code for the vibration data transmission thread, vibration and position synchronization thread, and inspection allocation notification thread as described in an embodiment of the present invention;
[0037] Figure 3 This is a schematic diagram of the communication thread code for inspection personnel as described in an embodiment of the present invention. Detailed Implementation
[0038] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.
[0039] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.
[0040] A vibration monitoring method for thermal power plant equipment based on multi-source vibration data fusion, as follows: Figure 1 As shown, several vibration sensors are deployed to monitor the vibration of key equipment in the thermal power plant. The host computer analyzes the vibration data and identifies equipment with abnormal vibration. It receives and compares the location information of each inspection personnel and sends alarm information to the inspection personnel closest to the equipment with abnormal vibration.
[0041] Monitoring methods include:
[0042] T1. The vibration sensors are distributed and connected in parallel with the data acquisition card. The data acquisition card integrates the data from each channel and transmits the vibration data of all vibration sensors to the host computer via serial port. The inspection personnel use mobile devices to communicate bidirectionally with the host computer to collect the location information of the inspection personnel.
[0043] T2. The host computer receives vibration data in real time and analyzes the vibration data using spectrum analysis. When abnormal equipment vibration is detected, an alarm is issued and the location information of all inspection personnel is collected. The optimal inspection personnel are calculated and notified to go to the abnormal equipment point for repair.
[0044] T3. The inspection personnel report the maintenance status to the host computer to clear the alarm, and record the abnormal equipment vibration data and maintenance results.
[0045] In this embodiment, the vibration sensor is preferably an accelerometer, which can be installed on moving hardware such as gearboxes and isometrics in related equipment of thermal power plants. The data acquisition card can be an Advantech PCI-1716, the mobile device can be a Zebra TC57 terminal, and the host computer is a monitoring platform developed based on LabVIEW. Specifically, as follows... Figures 2 to 3 As shown, T2 includes the following sub-steps:
[0046] T21. Establish a vibration data transmission thread, an inspection personnel communication thread, and a vibration and position synchronization thread, which run in parallel. Use a rendezvous point to manage the data synchronization of the three threads.
[0047] T22: The vibration data transmission thread collects vibration data from each sensor in real time, while the inspection personnel communication thread receives / sends information with the inspection personnel.
[0048] T23. The vibration and position synchronization thread sets up parallel consumer loops and producer loops. The producer loop combines the vibration data and the inspection personnel position data at the same moment into a continuous string. The consumer loop transmits the continuous string to the producer loop through a queue until the queue fails and stops the consumer loop.
[0049] T24. The consumer continuously receives the continuous string and segments it into vibration data and location data. The spectrum analysis block monitors the vibration data in real time. When an abnormal vibration of the device is detected, a vibration buffer and a location buffer are established respectively. The vibration buffer data of this event are recorded and then transferred to T25.
[0050] T25. Use the interrupt mechanism to set up an event-driven inspection allocation notification thread. When the vibration is abnormal, start the inspection allocation notification thread, combine the vibration buffer and position buffer when the equipment vibration is abnormal into a continuous string and send it to the path calculation block. The path calculation block calculates the inspection personnel with the optimal distance and generates an inspection notification of abnormal equipment information.
[0051] T26. The inspection notification is wirelessly transmitted to the corresponding inspection personnel in the form of a byte stream. After the inspection personnel provide feedback and clear the alarm information, the vibration buffer and location buffer are cleared.
[0052] In another embodiment, such as Figure 2 As shown, in T22, the waiting assembly point is located in the main loop of the vibration data transmission thread. The length of the serial port data bytes of the vibration sensor and the order of each channel are specified. The vibration data is copied into two paths. One path of vibration data is stored in the vibration data buffer and refreshed cyclically. The other path of vibration data is concatenated into a string array and stored in the accumulation buffer. The vibration data buffer is used as a local variable to participate in the vibration and position synchronization thread, and the accumulation buffer is used for log recording.
[0053] In another embodiment, such as Figure 3 As shown in T22, the patrol personnel communication thread includes parallel data reading and data sending loops, polling the location information of all patrol personnel based on the TCP protocol. The waiting assembly point is used in the data reading loop, and patrol notifications are sent to patrol personnel through the data sending loop. The data reading loop sets the patrol personnel location data buffer and uses it as a local variable in the vibration and location synchronization thread.
[0054] In another embodiment, such as Figure 2 As shown, the producer loop in the vibration and position synchronization thread also includes a waiting rendezvous point. After the vibration data transmission thread and the inspection personnel communication thread have both completed one main loop, another vibration and position synchronization thread loop is performed to synchronize and correct the vibration data and inspection personnel position data at the same moment, so as to improve the real-time performance and accuracy of subsequent path calculation blocks.
[0055] In another embodiment, in T24, when abnormal equipment vibration is detected, a vibration abnormality boolean is set. This boolean value participates in the inspection allocation notification thread and the data reading loop. When the vibration abnormality boolean is true, the inspection allocation notification thread and the data reading loop are activated; otherwise, the inspection allocation notification thread is closed, and the data reading loop initializes the inspection personnel location data buffer. The advantage is that if no abnormal equipment vibration occurs, the location information of all inspection personnel will not be collected, and the data reading loop in the inspection personnel communication thread will not participate in the collection, thus reducing resource consumption, accelerating the scanning frequency of the vibration data transmission thread, the inspection allocation notification thread, and the vibration and location synchronization thread, and improving the monitoring performance of the monitoring system.
[0056] Specifically, the T24 spectrum analysis block uses FFT to transform the vibration data in time and frequency, and compares the fault characteristic frequencies to determine whether there is abnormal equipment vibration. The fault characteristic frequencies include, but are not limited to, rotor imbalance frequency characteristics, bearing rupture frequency characteristics, and gear meshing fault frequency characteristics.
[0057] Specifically, the T25 path calculation block uses the vibration buffer, location buffer, and inspection personnel location data to find the inspection personnel closest to the faulty equipment, and pushes the equipment identifier and location information in the vibration buffer to the inspection personnel's mobile device via TCP protocol.
[0058] Those skilled in the art will recognize that the units and method steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of this invention.
[0059] In the several embodiments provided in this application, it should be understood that the disclosed methods and systems can be implemented in other ways. For example, the division of units described above is merely a logical functional division, and in actual implementation, there may be other division methods. For instance, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. The aforementioned units may or may not be physically separated. The components shown as units may or may not be physical units, that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of the embodiments of the present invention according to actual needs.
[0060] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention, and they should all be covered within the scope of the claims and specification of the present invention.
[0061] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.
Claims
1. A vibration monitoring method for thermal power plant equipment based on multi-source vibration data fusion, characterized in that: Several vibration sensors are deployed to monitor the vibration of key equipment in thermal power plants. The host computer analyzes the vibration data and identifies equipment with abnormal vibration. It receives and compares the location information of each inspection personnel and sends alarm information to the inspection personnel closest to the equipment with abnormal vibration. Monitoring methods include: T1. The vibration sensors are distributed and connected in parallel with the data acquisition card. The data acquisition card integrates the data from each channel and transmits the vibration data of all vibration sensors to the host computer via serial port. The inspection personnel use mobile devices to communicate bidirectionally with the host computer to collect the location information of the inspection personnel. T2. The host computer receives vibration data in real time and analyzes the vibration data using spectrum analysis. When abnormal equipment vibration is detected, an alarm is issued and the location information of all inspection personnel is collected. The optimal inspection personnel are calculated and notified to go to the abnormal equipment point for repair. T3. The inspection personnel report the maintenance status to the host computer to clear the alarm, and record the abnormal equipment vibration data and maintenance results. T2 includes the following steps: T21. Establish a vibration data transmission thread, an inspection personnel communication thread, and a vibration and position synchronization thread, which run in parallel. Use a rendezvous point to manage the data synchronization of the three threads. T22: The vibration data transmission thread collects vibration data from each sensor in real time, while the inspection personnel communication thread receives / sends information with the inspection personnel. T23. The vibration and position synchronization thread sets up a parallel consumer loop and a producer loop. The producer loop combines the vibration data and the inspection personnel position data at the same moment into a continuous string and stores it in a queue. The consumer loop receives the continuous string through the queue until the queue fails and stops the consumer loop. T24. The consumer continuously receives the continuous string and segments it into vibration data and location data. The spectrum analysis block monitors the vibration data in real time. When an abnormal vibration of the device is detected, a vibration buffer and a location buffer are established respectively. The vibration buffer data of this event are recorded and then transferred to T25. T25. Use the interrupt mechanism to set up an event-driven inspection allocation notification thread. When the vibration is abnormal, start the inspection allocation notification thread, combine the vibration buffer and position buffer when the equipment vibration is abnormal into a continuous string and send it to the path calculation block. The path calculation block calculates the inspection personnel with the optimal distance and generates an inspection notification of abnormal equipment information. T26. The inspection notification is wirelessly transmitted to the corresponding inspection personnel in the form of a byte stream. After the inspection personnel provide feedback and clear the alarm information, the vibration buffer and position buffer are cleared.
2. The vibration monitoring method for thermal power plant equipment based on multi-source vibration data fusion according to claim 1, characterized in that: In T22, the waiting assembly point is located in the main loop of the vibration data transmission thread. The length of the serial port data bytes of the vibration sensor and the order of each channel are specified. The vibration data is copied into two paths. One path of vibration data is stored in the vibration data buffer and refreshed in a loop. The other path of vibration data is concatenated into a string array and stored in the accumulation buffer. The vibration data buffer is used as a local variable to participate in the vibration and position synchronization thread, while the accumulation buffer is used for log recording.
3. The vibration monitoring method for thermal power plant equipment based on multi-source vibration data fusion according to claim 1, characterized in that: In the T22, the patrol personnel communication thread includes a parallel data reading loop, a data sending loop, and a waiting assembly point that acts on the data reading loop. The patrol notification is sent to the patrol personnel through the data sending loop. The data reading loop sets the patrol personnel's position data buffer and participates in the vibration and position synchronization thread as a local variable. The producer loop in the vibration and position synchronization thread includes a waiting rendezvous point. The vibration and position synchronization thread loop will be performed again after the vibration data transmission thread and the inspection personnel communication thread have both completed one main loop.
4. The vibration monitoring method for thermal power plant equipment based on multi-source vibration data fusion according to claim 3, characterized in that: In T24, when abnormal equipment vibration is detected, a vibration abnormality boolean is set, and the vibration abnormality boolean participates in the inspection allocation notification thread and the data reading loop; When the vibration anomaly boolean is true, the inspection allocation notification thread and the data reading loop are activated and run; otherwise, the inspection allocation notification thread is closed, and the data reading loop initializes the inspection personnel location data buffer.
5. The vibration monitoring method for thermal power plant equipment based on multi-source vibration data fusion according to claim 1, characterized in that: The T24 spectrum analysis block uses FFT to transform the vibration data in time and frequency, and compares the fault characteristic frequencies to determine whether there is abnormal equipment vibration. The fault characteristic frequencies include, but are not limited to, rotor imbalance frequency characteristics, bearing rupture frequency characteristics, and gear meshing fault frequency characteristics.
6. The vibration monitoring method for thermal power plant equipment based on multi-source vibration data fusion according to claim 1, characterized in that: The T25 path calculation block identifies the inspector closest to the faulty equipment based on the vibration buffer, location buffer, and inspector location data, and pushes the equipment identifier and location information in the vibration buffer to the inspector's mobile device via TCP protocol.
7. An electronic device comprising a processor and a memory communicatively connected to the processor and used for storing processor-executable instructions, characterized in that: The processor is used to execute the vibration monitoring method for thermal power plant equipment based on multi-source vibration data fusion as described in any one of claims 1-6.
8. A server, characterized in that: The device includes at least one processor and a memory communicatively connected to the processor. The memory stores instructions executable by the at least one processor, which are executed by the processor to cause the at least one processor to perform a vibration monitoring method for thermal power plant equipment based on multi-source vibration data fusion as described in any one of claims 1-6.
9. A computer-readable storage medium storing a computer program, characterized in that: When the computer program is executed by the processor, it implements the vibration monitoring method for thermal power plant equipment based on multi-source vibration data fusion as described in any one of claims 1-6.