Explosion-proof motor redundancy sealing and vibration cooperative suppression system for petrochemical scene

Abstract

The application discloses a petrochemical scene-oriented explosion-proof motor redundant sealing and vibration cooperative suppression system and relates to the field of motor management, comprising: a monitoring module for monitoring the running state parameters of the explosion-proof motor in real time and recording the running state parameters of the explosion-proof motor; a diagnosis module for acquiring the latest monitored running state parameters of the explosion-proof motor in the monitoring module, diagnosing whether the explosion-proof motor is abnormal based on the comparison between each running state parameter of the explosion-proof motor and a preset safety threshold; and the application can accurately capture the changes of parameters such as pressure, temperature and vibration by monitoring the motor running state parameters in real time and dynamically adjusting the monitoring cycle, and the accuracy of abnormal diagnosis is improved by combining the deployment of sensors with self-defined weight coefficients.

Description

Technical Field

[0001] This invention relates to the field of motor management technology, specifically to a redundant sealing and vibration suppression system for explosion-proof motors in petrochemical applications. Background Technology

[0002] Explosion-proof motors are special motors that can operate safely in flammable and explosive environments. Through a special structural design, they prevent spark leakage, effectively preventing explosions, and are suitable for hazardous environments such as petroleum, chemical, and coal mines.

[0003] Patent application No. 202210154373.9 discloses a method for monitoring the operating status of a motor. The method includes: measuring the current and rotor position during a single operation of the motor; determining whether the value and rate of change of the current during the single operation exceed a predetermined first current threshold and a first rate of change threshold; if the current value or rate of change exceeds the first current threshold or the first rate of change threshold, determining that the motor's operation is in an abnormal state, and incrementing a counter; determining whether the counter increment exceeds a predetermined abnormal state value within a predetermined first cycle; if the counter increment exceeds the abnormal state threshold within the first cycle, issuing an alarm signal indicating that the motor requires maintenance. This application aims to solve the problem that "in industrial production (e.g., automobile production) assembly lines, the transfer of workpieces (e.g., automobile parts) relies on the transmission of multiple motors. If a motor malfunctions and stops, it will affect the transfer of workpieces on the assembly line, severely impacting production output. In particular, if a motor at a critical station on the assembly line malfunctions and stops, it may cause the production line to be shut down for a long time, resulting in huge losses for the enterprise."

[0004] However, for the application of explosion-proof motors in petrochemical scenarios, in order to improve operational safety, explosion-proof motors are often equipped with redundant structures, which are simply backup sealing structures. When the main sealing structure has a defect, the backup sealing structure can replace the main sealing structure to perform sealing and ensure the sealing performance of the motor. However, the current level of intelligence of this maintenance mechanism is low, making it difficult to achieve fully automated switching of sealing structures. Moreover, when the explosion-proof motor has operational abnormalities, it is difficult to find the source of the abnormality, making it impossible to quickly repair the explosion-proof motor, thus affecting the stable use of the explosion-proof motor.

[0005] To address this, a redundant sealing and vibration suppression system for explosion-proof motors designed for petrochemical applications was proposed. Summary of the Invention

[0006] In view of the above-mentioned shortcomings of the existing technology, the present invention provides an explosion-proof motor redundant sealing and vibration synergistic suppression system for petrochemical scenarios, which can effectively solve the problems of the existing technology.

[0007] To achieve the above objectives, the present invention is implemented through the following technical solutions;

[0008] This invention discloses a redundant sealing and vibration suppression system for explosion-proof motors in petrochemical applications, comprising:

[0009] The system comprises the following modules: a monitoring module for real-time monitoring and recording of the explosion-proof motor's operating status parameters; a diagnostic module for acquiring the latest monitored operating status parameters and comparing them with preset safety thresholds to diagnose any abnormalities; an evaluation module for receiving and storing the operating status parameters from the diagnostic module and evaluating for any potential abnormalities; a maintenance module for acquiring the diagnostic and evaluation results in real-time and performing maintenance on the motor based on these results; an interaction module for providing early warning information to the system's backend user; and a detection module for detecting the source of any abnormal tendencies in the explosion-proof motor.

[0010] Furthermore, the monitoring module is integrated with several sets of pressure, temperature and vibration sensors. During the operation of the monitoring module, the operating status parameters of the explosion-proof motor are monitored, including pressure value, temperature value and vibration spectrum. The number and location of the several sets of pressure, temperature and vibration sensors are defined by the system user and deployed on the surface of the explosion-proof motor.

[0011] The monitoring module is configured with monitoring cycle control logic, which follows the following:

[0012] The initial operating cycle, reduction ratio, and operating cycle extreme value are set. The operating cycle of the control monitoring module is changed once per hour. Each time, the operating cycle is shortened based on the reduction ratio. When the operating cycle is continuously reduced to the operating cycle extreme value based on the reduction ratio, the operating cycle extreme value is continuously applied until the explosion-proof motor stops and starts once, and the initial operating cycle is applied again.

[0013] When recording the operating status parameters of the explosion-proof motor, the monitoring module marks the source sensor number and name, and monitoring time for each operating status parameter.

[0014] Furthermore, the sensors deployed on the surface of the explosion-proof motor are all configured with weighting coefficients. The weighting coefficients of each sensor are defined by the system user and follow the following rules: the sum of the weighting coefficients configured for all pressure sensors is 1, and the weighting coefficients configured for temperature sensors and vibration sensors are configured in the same way.

[0015] Furthermore, the latest explosion-proof motor operating status parameters obtained by the diagnostic module are the latest set of explosion-proof motor operating status parameters recorded in the monitoring module. The preset safety threshold applied during the operation of the diagnostic module corresponds one-to-one with the source sensor of each explosion-proof motor operating status parameter. When the diagnostic module detects that any explosion-proof motor operating status parameter does not match its corresponding preset safety threshold, it diagnoses that the explosion-proof motor is abnormal and simultaneously triggers the maintenance module to run.

[0016] When the diagnostic module detects that all operating status parameters of the explosion-proof motors match their corresponding preset safety thresholds, the evaluation module is triggered to run.

[0017] When the evaluation result of the evaluation module is "yes", the maintenance module is triggered to run simultaneously.

[0018] Furthermore, the evaluation module outputs the abnormal tendency value of the explosion-proof motor once each time it runs, and the evaluation module synchronously records the output abnormal tendency value of the explosion-proof motor based on the time sequence;

[0019] The evaluation module is equipped with a retrieval unit and a visualization unit. The retrieval unit is used to access the monitoring module. In the explosion-proof motor operating status parameters recorded by the monitoring module, it retrieves the explosion-proof motor operating status parameters obtained by the diagnostic module based on two sets of explosion-proof motor operating status parameters that are adjacent in time sequence. The visualization unit is used to traverse the explosion-proof motor abnormal tendency values ​​recorded in the evaluation module based on time sequence, and generate an explosion-proof motor abnormal tendency value change line graph based on the explosion-proof motor abnormal tendency values. The horizontal axis of the explosion-proof motor abnormal tendency value change line graph represents the monitoring time of the parameter corresponding to the abnormal tendency value, and the vertical axis represents the abnormal tendency value.

[0020] The abnormal tendency value of the explosion-proof motor output by the evaluation module is obtained based on the explosion-proof motor operating status parameters received by the evaluation module and retrieved by the retrieval unit. The evaluation module deletes the earliest explosion-proof motor operating status parameters received or retrieved by the retrieval unit based on the time sequence, so that the evaluation module always stores the latest three sets of explosion-proof motor operating status parameters, which can be used to evaluate whether the explosion-proof motor has an abnormal tendency.

[0021] Furthermore, during the operation of the maintenance module, when an abnormality occurs in the explosion-proof motor, the maintenance logic for the explosion-proof motor is expressed as follows:

[0022] Identifying the source of abnormalities in explosion-proof motors:

[0023] When the source of the anomaly is pressure, the redundant sealing assembly adjacent to all the sensors corresponding to the abnormal pressure is activated to provide a seal for the explosion-proof motor;

[0024] When the source of the anomaly is temperature, the redundant sealing components adjacent to all the sensors corresponding to the abnormal temperatures are activated to provide sealing and cooling for the explosion-proof motor, and the frequency converter is activated to perform speed adjustment.

[0025] When the source of the abnormality is vibration, the redundant sealing components adjacent to all sensors corresponding to the abnormal vibration are activated to provide vibration energy absorption for the explosion-proof motor. At the same time, the frequency converter is activated to perform speed gradient adjustment to avoid the resonance frequency point.

[0026] When the maintenance module performs maintenance on the explosion-proof motor, it simultaneously triggers the operation of the interactive module. When the source of the abnormality is pressure, the redundant sealing components activated are multi-stage labyrinth seals and spiral seals, which restore the pressure to a safe range. When the source of the abnormality is temperature, the redundant sealing components activated are cooling oil chamber seal components, which are cooled by circulating cooling oil, while the frequency converter is controlled to adjust the output frequency to the preset cooling range. When the source of the abnormality is vibration, the redundant sealing components activated are damping vibration reduction sealing rings, which absorb vibration energy through the shear damping effect of the damping fluid inside the ring, and the speed gradient is adjusted to reduce from the current speed to 80% of the rated speed at a rate of 2Hz / s.

[0027] Furthermore, during the operation of the maintenance module, when the explosion-proof motor exhibits abnormal tendencies, the maintenance logic for the explosion-proof motor is expressed as follows:

[0028] All redundant sealing components and frequency converters of the explosion-proof motor are controlled to operate according to the operating parameters applied during the last explosion-proof motor failure or the preset operating parameters, and the interactive module is triggered to operate synchronously.

[0029] Furthermore, the warning information in the interactive module is preset text and audio information, which is played in a loop in the background of the system.

[0030] The interactive module is triggered when there is an abnormality in the explosion-proof motor. The redundant sealing component is used as the center of the maintenance area, and the explosion-proof motor is manually inspected in a radiating order from the center outward.

[0031] The interaction module is triggered when the explosion-proof motor shows signs of abnormality, which in turn triggers the sniffing module to run.

[0032] Furthermore, during the operation of the sniffing module, redundant sealing components are continuously shut down, with the shutdown sequence and timing following the following rules:

[0033] The sensor corresponding to the adjacent redundant sealing assembly is configured with a weight coefficient. The adjacent redundant sealing assembly of the sensor with the larger weight coefficient is taken as the priority to shut down. After each redundant sealing assembly is shut down, the time interval of three consecutive operation of the sensor is used to shut down another redundant sealing assembly.

[0034] Based on the above operations, the abnormal trend value change line graph of the explosion-proof motor is continuously observed and refreshed in real time in the visualization unit. When the line graph of the abnormal trend value change line graph of the explosion-proof motor shows an upward trend, the latest closed redundant sealing component is used as the center of the maintenance area, and the explosion-proof motor is manually inspected in the order of diverging outward from the center.

[0035] After manually inspecting the explosion-proof motor, it is simultaneously determined whether the latest value in the abnormal tendency value change line graph of the explosion-proof motor is still greater than or equal to the preset threshold. If the determination is yes, the continuous closing operation of the redundant sealing components continues, and the maintenance area center is determined again for manual inspection based on the above logic until the latest value in the abnormal tendency value change line graph of the explosion-proof motor is less than the preset threshold. If the determination is no, the process ends.

[0036] Furthermore, the monitoring module interacts with the diagnostic module and the evaluation module via a wireless network. The evaluation module's subordinate units interact with the retrieval unit and the visualization unit via a wireless network. The retrieval unit interacts with the monitoring module via a wireless network. The evaluation module interacts with the maintenance module via a wireless network. The maintenance module interacts with the diagnostic module via a wireless network. The maintenance module interacts with the interaction module and the sniffing module via a wireless network.

[0037] Compared with the known prior art, the technical solution provided by this invention has the following beneficial effects:

[0038] This invention provides a redundant sealing and vibration suppression system for explosion-proof motors in petrochemical environments. During operation, this system monitors motor operating parameters in real time and dynamically adjusts the monitoring cycle, accurately capturing changes in parameters such as pressure, temperature, and vibration. Combined with sensor deployment using custom weighting coefficients, it improves the accuracy of anomaly diagnosis. When an anomaly or an abnormal tendency is detected, the system intelligently activates corresponding redundant sealing components. For example, in case of pressure anomalies, it activates multi-stage labyrinth seals and spiral seals; in case of temperature anomalies, it activates the cooling oil chamber sealing component and adjusts the frequency converter; in case of vibration anomalies, it utilizes damping and vibration-damping sealing rings to absorb energy and adjusts the rotational speed to avoid resonance points, achieving coordinated sealing and vibration suppression. Simultaneously, through time-series recording and visualization analysis of abnormal tendency values, combined with the shutdown test logic of redundant sealing components, it can accurately locate the source of the anomaly, providing a clear direction for manual maintenance. This effectively improves the safety and reliability of explosion-proof motors operating in hazardous environments and reduces the probability of failure. Attached Figure Description

[0039] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0040] Figure 1 This is a structural schematic diagram of a redundant sealing and vibration suppression system for explosion-proof motors designed for petrochemical applications. Detailed Implementation

[0041] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0042] The present invention will be further described below with reference to embodiments.

[0043] Example:

[0044] This embodiment presents an explosion-proof motor redundant sealing and vibration collaborative suppression system for petrochemical scenarios, such as... Figure 1 As shown, it includes:

[0045] The monitoring module is used to monitor the operating status parameters of the explosion-proof motor in real time and record the operating status parameters of the explosion-proof motor.

[0046] The monitoring module is integrated with several sets of pressure, temperature and vibration sensors. During the operation of the monitoring module, the operating status parameters of the explosion-proof motor are monitored, including pressure value, temperature value and vibration spectrum. The number and location of the several sets of pressure, temperature and vibration sensors are defined by the system user and deployed on the surface of the explosion-proof motor.

[0047] The monitoring module has monitoring cycle control logic configured, which follows the following rules:

[0048] The initial operating cycle, reduction ratio, and operating cycle extreme value are set. The operating cycle of the control monitoring module is changed once per hour. Each time, the operating cycle is shortened based on the reduction ratio. When the operating cycle is continuously reduced to the operating cycle extreme value based on the reduction ratio, the operating cycle extreme value is continuously applied until the explosion-proof motor stops and starts once, and the initial operating cycle is applied again.

[0049] Among them, when recording the operating status parameters of the explosion-proof motor, the monitoring module marks the source sensor number and name, and monitoring time for each operating status parameter;

[0050] The sensors deployed on the surface of the explosion-proof motor are all configured with weight coefficients. The weight coefficients of each sensor are defined by the system user and follow the following rules: the sum of the weight coefficients configured for all pressure sensors is 1, and the weights configured for temperature sensors and vibration sensors are configured in the same way.

[0051] The diagnostic module is used to obtain the latest operating status parameters of the explosion-proof motor monitored by the monitoring module, and diagnose whether there is any abnormality in the explosion-proof motor based on the comparison of various operating status parameters of the explosion-proof motor with preset safety thresholds.

[0052] The latest explosion-proof motor operating status parameters obtained by the diagnostic module are the latest set of explosion-proof motor operating status parameters recorded in the monitoring module. The preset safety thresholds applied during the operation of the diagnostic module correspond one-to-one with the source sensors of each explosion-proof motor operating status parameter. When the diagnostic module detects that any explosion-proof motor operating status parameter does not match its corresponding preset safety threshold, it diagnoses that there is an abnormality in the explosion-proof motor and simultaneously triggers the operation of the maintenance module.

[0053] When the diagnostic module detects that all operating status parameters of the explosion-proof motors match their corresponding preset safety thresholds, it triggers the evaluation module to run.

[0054] When the evaluation result of the evaluation module is yes, the maintenance module is triggered to run synchronously.

[0055] The evaluation module is used to receive the explosion-proof motor operating status parameters obtained by the diagnostic module, store the explosion-proof motor operating status parameters, and evaluate whether the explosion-proof motor has any abnormal tendencies based on the stored explosion-proof motor operating status parameters.

[0056] Each time the evaluation module runs, it outputs the abnormal tendency value of the explosion-proof motor once, and the evaluation module records the output abnormal tendency value of the explosion-proof motor based on the time sequence.

[0057] The evaluation module has a retrieval unit and a visualization unit at the lower level. The retrieval unit is used to access the monitoring module. In the explosion-proof motor operating status parameters recorded by the monitoring module, it retrieves the explosion-proof motor operating status parameters obtained by the diagnostic module based on two sets of explosion-proof motor operating status parameters that are adjacent in time sequence. The visualization unit is used to traverse the explosion-proof motor abnormal tendency values ​​recorded in the evaluation module based on time sequence. Based on the explosion-proof motor abnormal tendency values, it generates an explosion-proof motor abnormal tendency value change line graph. The horizontal axis of the explosion-proof motor abnormal tendency value change line graph represents the monitoring time of the parameter corresponding to the abnormal tendency value, and the vertical axis represents the abnormal tendency value.

[0058] Among them, the abnormal tendency value of the explosion-proof motor output by the evaluation module is obtained based on the explosion-proof motor operating status parameters received by the evaluation module and retrieved by the retrieval unit. The evaluation module deletes the earliest explosion-proof motor operating status parameters retrieved by itself or the retrieval unit based on the time sequence, so that the evaluation module always stores the latest three sets of explosion-proof motor operating status parameters, which can be used to evaluate whether the explosion-proof motor has an abnormal tendency.

[0059] The logic for obtaining the abnormal tendency value of explosion-proof motors is expressed as follows:

[0060]

[0061] In the formula: The reference value for abnormal tendencies of explosion-proof motors; n is the total number of pressure sensors deployed; P i P represents the pressure value sensed by the i-th pressure sensor. norm This is the standard pressure value; The weighting coefficient for the i-th pressure sensor is denoted by ; m represents the total number of temperature sensors deployed; C j C represents the temperature value sensed by the j-th temperature sensor. norm Standard temperature value; The weighting coefficient for the j-th temperature sensor is given by ; u is the total number of vibration sensors deployed; F v F represents the maximum difference in amplitude between adjacent values ​​in the vibration spectrum sensed by the v-th vibration sensor. norm This represents the standard deviation of amplitude fluctuation. Let be the weighting coefficient for the v-th vibration sensor;

[0062] The above formula is used to calculate the performance of each monitoring module operation. (That is, all sensors run synchronously once), then the abnormal tendency reference values ​​corresponding to the three sets of latest monitored explosion-proof motor operating status parameters are recorded as follows: The corresponding explosion-proof motor operating status parameters are sorted based on monitoring time, and the abnormal tendency value of the explosion-proof motor is expressed as follows:

[0063]

[0064] The calculation process of the explosion-proof motor abnormal tendency value χ is actually a correction of the explosion-proof motor abnormal tendency reference value calculated from the latest monitored explosion-proof motor operating status parameters. The explosion-proof motor abnormal tendency reference value calculated based on the latest monitored explosion-proof motor operating status parameters is used to represent the explosion-proof motor abnormal tendency value. This ensures that the explosion-proof motor abnormal tendency value is corrected at the same time as it is output, so that the curve (broken line) formed by the parameter values ​​in the final explosion-proof motor abnormal tendency value change graph can more realistically reflect the dynamic changes of the explosion-proof motor abnormal state.

[0065] The maintenance module is used to obtain in real time the diagnostic results and assessment results of whether there are any abnormalities in the explosion-proof motor from the diagnostic module and the evaluation module, and to perform maintenance on the explosion-proof motor based on the assessment results.

[0066] During the operation of the maintenance module, when an abnormality occurs in the explosion-proof motor, the maintenance logic for the explosion-proof motor is as follows:

[0067] Identifying the source of abnormalities in explosion-proof motors:

[0068] When the source of the anomaly is pressure, the redundant sealing assembly adjacent to all the sensors corresponding to the abnormal pressure is activated to provide a seal for the explosion-proof motor;

[0069] When the source of the anomaly is temperature, the redundant sealing components adjacent to all the sensors corresponding to the abnormal temperatures are activated to provide sealing and cooling for the explosion-proof motor, and the frequency converter is activated to perform speed adjustment.

[0070] When the source of the abnormality is vibration, the redundant sealing components adjacent to all sensors corresponding to the abnormal vibration are activated to provide vibration energy absorption for the explosion-proof motor. At the same time, the frequency converter is activated to perform speed gradient adjustment to avoid the resonance frequency point.

[0071] When the maintenance module performs maintenance on the explosion-proof motor, it simultaneously triggers the operation of the interactive module. When the source of the abnormality is pressure, the redundant sealing components activated are multi-stage labyrinth seals and spiral seals, which restore the pressure to a safe range. When the source of the abnormality is temperature, the redundant sealing components activated are cooling oil chamber seal components, which are cooled by circulating cooling oil, while the frequency converter is controlled to adjust the output frequency to the preset cooling range. When the source of the abnormality is vibration, the redundant sealing components activated are damping vibration reduction sealing rings, which absorb vibration energy through the shear damping effect of the damping fluid inside the ring, and the speed gradient is adjusted to reduce from the current speed to 80% of the rated speed at a rate of 2Hz / s.

[0072] During the maintenance module's operation, when the explosion-proof motor exhibits abnormal tendencies, the maintenance logic for the explosion-proof motor is as follows:

[0073] All redundant sealing components and frequency converters of the explosion-proof motor are controlled to operate according to the operating parameters applied during the last explosion-proof motor failure or the preset operating parameters, and the interactive module is triggered to operate synchronously.

[0074] The interaction module is used to provide early warning information to users in the system backend.

[0075] The warning information in the interactive module consists of preset text and audio information, which is played in a loop in the background of the system.

[0076] When the interactive module is triggered by an abnormality in the explosion-proof motor, the redundant sealing component that is started will be used as the center of the maintenance area, and the explosion-proof motor will be manually inspected in a radiating order from the center outward.

[0077] The interaction module is triggered when the explosion-proof motor shows signs of abnormality, thus triggering the sniffing module to run.

[0078] The sniffing module is used to detect the source of abnormal tendencies in explosion-proof motors;

[0079] During the sniffing module's operation, redundant sealing components are continuously shut down, with the shutdown sequence and timing following the following rules:

[0080] The sensor corresponding to the adjacent redundant sealing assembly is identified by a weighting coefficient. The adjacent redundant sealing assembly of the sensor with the larger weighting coefficient is taken as the priority to shut down. After each redundant sealing assembly is shut down, the time interval of three consecutive operation of the sensor is used to shut down another redundant sealing assembly.

[0081] Based on the above operations, the abnormal trend value change line graph of the explosion-proof motor is continuously observed and refreshed in real time in the visualization unit. When the line graph of the abnormal trend value change line graph of the explosion-proof motor shows an upward trend, the latest closed redundant sealing component is used as the center of the maintenance area, and the explosion-proof motor is manually inspected in the order of diverging outward from the center.

[0082] Among them, after manually inspecting the explosion-proof motor, it is simultaneously determined whether the latest value in the abnormal tendency value change line graph of the explosion-proof motor is still greater than or equal to the preset threshold. If it is determined to be yes, the continuous closing operation of the redundant sealing components is continued, and the maintenance area center is determined again based on the above logic for manual inspection until the latest value in the abnormal tendency value change line graph of the explosion-proof motor is less than the preset threshold. If it is determined to be no, the operation ends.

[0083] The monitoring module interacts with the diagnostic and evaluation modules via a wireless network. The evaluation module's subordinate modules interact with the retrieval and visualization units via a wireless network. The retrieval unit interacts with the monitoring module via a wireless network. The evaluation module interacts with the maintenance module via a wireless network. The maintenance module interacts with the diagnostic module via a wireless network. The maintenance module interacts with the interaction module and sniffing module via a wireless network.

[0084] In this embodiment, the monitoring module monitors the operating status parameters of the explosion-proof motor in real time and records these parameters. The diagnostic module then retrieves the latest monitored operating status parameters from the monitoring module. Based on a comparison of these parameters with preset safety thresholds, it diagnoses whether the explosion-proof motor exhibits any abnormalities. The evaluation module further receives the operating status parameters from the diagnostic module, stores them, and evaluates whether the explosion-proof motor shows any abnormal tendencies based on the stored parameters. The retrieval unit synchronously accesses the monitoring module to retrieve the recorded operating status parameters of the explosion-proof motor. The parameters retrieve the explosion-proof motor operating status parameters obtained by the diagnostic module based on two sets of explosion-proof motor operating status parameters that are adjacent in time. The visualization unit traverses the explosion-proof motor abnormal tendency values ​​recorded in the evaluation module in real time based on time sequence. Based on the explosion-proof motor abnormal tendency values, a line graph of the change of explosion-proof motor abnormal tendency values ​​is generated. Then, the maintenance module obtains the diagnostic results of whether the explosion-proof motor has abnormalities and the evaluation results of whether there are abnormal tendencies in the diagnostic module and evaluation module in real time. Based on the evaluation results, the explosion-proof motor is maintained. Through the interaction module, early warning information is fed back to the system backend user. Finally, the sniffing module sniffs out the source of the explosion-proof motor abnormal tendency.

[0085] The system described in the above embodiments maintains explosion-proof motors by real-time monitoring of operating parameters such as pressure, temperature, and vibration. It diagnoses anomalies by comparing them with preset safety thresholds, assesses abnormal tendencies based on historical data, and triggers corresponding maintenance measures, such as activating redundant sealing components or adjusting the inverter speed. Simultaneously, it provides early warning information through an interactive module and can locate the source of abnormal tendencies using a sniffing module. This enables comprehensive monitoring and precise maintenance of the operating status of explosion-proof motors in petrochemical scenarios, ensuring their safe and stable operation.

[0086] It is important to note that:

[0087] The system is manually turned on in sync with the operation of the explosion-proof motor, and manually turned off in sync with the end of operation of the explosion-proof motor;

[0088] The sensor weighting coefficient is configured manually by the user on the system side, and must comply with: the component position of the explosion-proof motor where the sensor is located. The more important the component is to the stability of the explosion-proof motor, or the more critical the component is, the larger the weighting value should be, and vice versa.

[0089] When an explosion-proof motor exhibits abnormal tendencies, the explosion-proof motor maintenance logic, during the application phase, controls all redundant sealing components and frequency converters of the explosion-proof motor to operate according to the operating parameters used during the last explosion-proof motor failure or the preset operating parameters. The operating target is all redundant sealing components and frequency converters. Only at the operating parameter level, one source is the previous explosion-proof motor failure, and the other is the preset parameters.

[0090] The following is an example application instance of the system described in the above embodiments:

[0091] In the catalytic cracking unit of XX Petrochemical Company, the core explosion-proof motor undertakes the critical task of conveying high-temperature, high-pressure oil and gas media. This motor operates for extended periods in a complex petrochemical environment, facing risks of media leakage and potential equipment failures due to vibration, posing a significant challenge to the safe and stable operation of the unit. To effectively address these issues and ensure production continuity, the company introduced a redundant sealing and vibration suppression system for explosion-proof motors designed for petrochemical scenarios.

[0092] I. System Deployment

[0093] Sensor Configuration: Multiple sets of pressure, temperature, and vibration sensors are deployed in key areas of the explosion-proof motor, such as bearing housings, stator housings, and sealed cavities. There are 8 pressure sensors, 6 temperature sensors, and 4 vibration sensors. The system user has customized weighting coefficients for these sensors based on the importance of each monitoring point. The sum of the weighting coefficients for all pressure sensors is 1, and the sum of the weighting coefficients for the temperature and vibration sensors is also 1 each.

[0094] Monitoring cycle setting: The initial operating cycle is set to 30 minutes, with a reduction rate of 10%, and the maximum operating cycle value is 10 minutes. According to the monitoring cycle control logic, the monitoring module changes the operating cycle every hour, shortening it each time based on the reduction rate. Once the operating cycle reaches the maximum value of 10 minutes through continuous reduction, this maximum value remains in effect until the explosion-proof motor stops and starts once, at which point the initial 30-minute operating cycle will be applied again.

[0095] II. Operation Process

[0096] (a) Monitoring and Data Recording

[0097] The monitoring module monitors the operating status parameters of the explosion-proof motor in real time according to a set cycle, including pressure values, temperature values, and vibration spectrum. Simultaneously, each operating status parameter is labeled with the sensor number and name, as well as the monitoring time, for subsequent data traceability and analysis.

[0098] (II) Diagnostic Module Operation

[0099] The diagnostic module acquires the latest set of operating status parameters recorded in the monitoring module and compares each parameter with the preset safety threshold of the corresponding sensor. During a certain operating period, if the diagnostic module detects that the vibration spectrum parameters do not match the preset safety threshold, it immediately diagnoses an anomaly in the explosion-proof motor and simultaneously triggers the maintenance module to operate.

[0100] (III) Maintenance Module Response

[0101] Anomaly source identification: The maintenance module first identifies the source of the anomaly in the explosion-proof motor and determines it to be an abnormal vibration.

[0102] Specific maintenance procedures:

[0103] The redundant sealing assembly, a damping and vibration reduction sealing ring adjacent to the sensors corresponding to all abnormal vibrations, is activated to absorb vibration energy through the shear damping effect of the damping fluid inside the ring.

[0104] At the same time, the frequency converter is started to perform speed gradient adjustment, reducing the current speed to 80% of the rated speed at a rate of 2Hz / s, thereby avoiding the resonance frequency point.

[0105] Interactive module trigger: While the maintenance module is performing maintenance, it triggers the interactive module to run. The interactive module uses the activated damping and vibration reduction sealing ring as the center of the maintenance area and prompts the staff to manually inspect the explosion-proof motor in a radiating order from the center outwards.

[0106] (IV) Evaluation Module Analysis

[0107] During maintenance, the evaluation module outputs an abnormal tendency value for the explosion-proof motor each time it runs, and records the output abnormal tendency value based on time sequence. Its subordinate retrieval unit accesses the monitoring module and retrieves the operating status parameters obtained from the diagnostic module based on two sets of parameters with adjacent time sequences. The visualization unit then iterates through the recorded abnormal tendency values ​​and generates a line graph of abnormal tendency value changes, with the horizontal axis representing the monitoring time and the vertical axis representing the abnormal tendency value, to visually observe the changing trend of the abnormal tendency.

[0108] (v) Sniffing module operation (if any abnormal tendencies are observed)

[0109] Assuming that after maintenance, the evaluation module determines that the explosion-proof motor still exhibits abnormal tendencies, the interaction module will trigger the sniffing module to operate. The sniffing module will continuously shut down redundant sealing components, with the shutdown sequence and timing following these rules:

[0110] The sensor corresponding to the adjacent redundant sealing assembly is configured with a weight coefficient, and the redundant sealing assembly adjacent to the sensor with the larger weight coefficient is selected as the priority to be shut down.

[0111] After each redundant sealing component is shut down, the time interval between three consecutive sensor operations is maintained before shutting down the next redundant sealing component.

[0112] During operation, the abnormal trend value change line graph in the visualization unit is continuously monitored in real time. When an upward trend appears in the line graph, the most recently closed redundant sealing component is taken as the maintenance area center, and the explosion-proof motor is manually inspected in a radiating order from the center outward.

[0113] After manual inspection, determine whether the latest value in the abnormal trend value change line graph is still greater than or equal to the preset threshold. If so, continue the continuous shutdown operation of the redundant sealing components and manually inspect the maintenance area center again until the latest value is less than the preset threshold; otherwise, end the operation.

[0114] In summary, the system in the above embodiments can accurately capture changes in parameters such as pressure, temperature, and vibration by monitoring the motor's operating status parameters in real time and dynamically adjusting the monitoring cycle. Combined with the deployment of sensors with custom weighting coefficients, the accuracy of anomaly diagnosis is improved. When an anomaly or an abnormal tendency is detected, the system can intelligently activate the corresponding redundant sealing components. For example, when the pressure is abnormal, the multi-stage labyrinth seal and spiral seal are activated; when the temperature is abnormal, the cooling oil chamber sealing component is activated and the frequency converter is adjusted; when the vibration is abnormal, the damping and vibration reduction sealing ring is used to absorb energy and the speed is adjusted to avoid the resonance point, realizing the coordinated work of sealing and vibration suppression. At the same time, by recording and visually analyzing the time sequence of abnormal tendency values, combined with the closing test logic of the redundant sealing components, the source of the anomaly can be accurately located, providing a clear direction for manual maintenance. This effectively improves the safety and reliability of the explosion-proof motor operating in hazardous environments and reduces the probability of failure.

[0115] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. 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 of the technical features. Such modifications or substitutions will not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A redundant sealing and vibration suppression system for explosion-proof motors in petrochemical applications, characterized in that, include: The monitoring module is used to monitor the operating status parameters of the explosion-proof motor in real time and record the operating status parameters of the explosion-proof motor. The monitoring module is integrated with several sets of pressure, temperature and vibration sensors. During the operation of the monitoring module, the operating status parameters of the explosion-proof motor are monitored, including pressure value, temperature value and vibration spectrum. The number and location of the several sets of pressure, temperature and vibration sensors are defined by the system user and deployed on the surface of the explosion-proof motor. The monitoring module is configured with monitoring cycle control logic, which follows the following: The initial operating cycle, reduction ratio, and operating cycle extreme value are set. The operating cycle of the control monitoring module is changed once per hour. Each time, the operating cycle is shortened based on the reduction ratio. When the operating cycle is continuously reduced to the operating cycle extreme value based on the reduction ratio, the operating cycle extreme value is continuously applied until the explosion-proof motor stops and starts once, and the initial operating cycle is applied again. Among them, when recording the operating status parameters of the explosion-proof motor, the monitoring module marks the source sensor number and name, and monitoring time for each operating status parameter; The diagnostic module is used to obtain the latest operating status parameters of the explosion-proof motor monitored by the monitoring module, and diagnose whether there is any abnormality in the explosion-proof motor based on the comparison of various operating status parameters of the explosion-proof motor with preset safety thresholds. The evaluation module is used to receive the explosion-proof motor operating status parameters obtained by the diagnostic module, store the explosion-proof motor operating status parameters, and evaluate whether the explosion-proof motor has any abnormal tendencies based on the stored explosion-proof motor operating status parameters. The maintenance module is used to obtain in real time the diagnostic results and assessment results of whether there are any abnormalities in the explosion-proof motor from the diagnostic module and the evaluation module, and to perform maintenance on the explosion-proof motor based on the assessment results. During the operation of the maintenance module, when an abnormality occurs in the explosion-proof motor, the maintenance logic for the explosion-proof motor is as follows: Identifying the source of abnormalities in explosion-proof motors: When the source of the anomaly is pressure, the redundant sealing assembly adjacent to all the sensors corresponding to the abnormal pressure is activated to provide a seal for the explosion-proof motor; When the source of the anomaly is temperature, the redundant sealing components adjacent to all the sensors corresponding to the abnormal temperatures are activated to provide sealing and cooling for the explosion-proof motor, and the frequency converter is activated to perform speed adjustment. When the source of the abnormality is vibration, the redundant sealing components adjacent to all sensors corresponding to the abnormal vibration are activated to provide vibration energy absorption for the explosion-proof motor. At the same time, the frequency converter is activated to perform speed gradient adjustment to avoid the resonance frequency point. When the maintenance module performs maintenance on the explosion-proof motor, it simultaneously triggers the operation of the interactive module. If the source of the anomaly is pressure, the redundant sealing components activated are a multi-stage labyrinth seal and a spiral seal, restoring the pressure to a safe range. If the source of the anomaly is temperature, the redundant sealing components activated are a cooling oil chamber sealing component, which uses circulating cooling oil for cooling, while simultaneously controlling the frequency converter to adjust the output frequency to a preset cooling range. If the source of the anomaly is vibration, the redundant sealing components activated are a damping vibration-damping sealing ring, which absorbs vibration energy through the shear damping effect of the damping fluid within the ring, adjusting the speed gradient to reduce from the current speed to 80% of the rated speed at a rate of 2Hz / s. The interaction module is used to provide early warning information to users in the system backend. The sniffing module is used to detect the source of abnormal tendencies in explosion-proof motors.

2. The explosion-proof motor redundant sealing and vibration coordinated suppression system for petrochemical scenarios according to claim 1, characterized in that, The sensors deployed on the surface of the explosion-proof motor are all configured with weight coefficients. The weight coefficients of each sensor are defined by the system user and follow the following rules: the sum of the weight coefficients configured for all pressure sensors is 1, and the weights configured for temperature sensors and vibration sensors are configured in the same way.

3. The explosion-proof motor redundant sealing and vibration coordinated suppression system for petrochemical scenarios according to claim 1, characterized in that, The latest explosion-proof motor operating status parameters obtained by the diagnostic module are the latest set of explosion-proof motor operating status parameters recorded in the monitoring module. The preset safety threshold applied during the operation of the diagnostic module corresponds one-to-one with the source sensor of each explosion-proof motor operating status parameter. When the diagnostic module detects that any explosion-proof motor operating status parameter does not match its corresponding preset safety threshold, it diagnoses that there is an abnormality in the explosion-proof motor and simultaneously triggers the operation of the maintenance module. When the diagnostic module detects that all operating status parameters of the explosion-proof motors match their corresponding preset safety thresholds, the evaluation module is triggered to run. When the evaluation result of the evaluation module is "yes", the maintenance module is triggered to run simultaneously.

4. The explosion-proof motor redundant sealing and vibration coordinated suppression system for petrochemical scenarios according to claim 1, characterized in that, Each time the evaluation module runs, it outputs the abnormal tendency value of the explosion-proof motor once, and the evaluation module records the output abnormal tendency value of the explosion-proof motor based on the time sequence. The evaluation module is equipped with a retrieval unit and a visualization unit. The retrieval unit is used to access the monitoring module. In the explosion-proof motor operating status parameters recorded by the monitoring module, it retrieves the explosion-proof motor operating status parameters obtained by the diagnostic module based on two sets of explosion-proof motor operating status parameters that are adjacent in time sequence. The visualization unit is used to traverse the explosion-proof motor abnormal tendency values ​​recorded in the evaluation module based on time sequence, and generate an explosion-proof motor abnormal tendency value change line graph based on the explosion-proof motor abnormal tendency values. The horizontal axis of the explosion-proof motor abnormal tendency value change line graph represents the monitoring time of the parameter corresponding to the abnormal tendency value, and the vertical axis represents the abnormal tendency value. The abnormal tendency value of the explosion-proof motor output by the evaluation module is obtained based on the explosion-proof motor operating status parameters received by the evaluation module and retrieved by the retrieval unit. The evaluation module deletes the earliest explosion-proof motor operating status parameters received or retrieved by the retrieval unit based on the time sequence, so that the evaluation module always stores the latest three sets of explosion-proof motor operating status parameters, which can be used to evaluate whether the explosion-proof motor has an abnormal tendency.

5. The explosion-proof motor redundant sealing and vibration coordinated suppression system for petrochemical scenarios according to claim 1, characterized in that, During the operation of the maintenance module, when the explosion-proof motor exhibits abnormal tendencies, the maintenance logic for the explosion-proof motor is as follows: All redundant sealing components and frequency converters of the explosion-proof motor are controlled to operate according to the operating parameters applied during the last explosion-proof motor failure or the preset operating parameters, and the interactive module is triggered to operate synchronously.

6. The explosion-proof motor redundant sealing and vibration coordinated suppression system for petrochemical scenarios according to claim 1, characterized in that, The warning information in the interactive module consists of preset text and audio information, which is played in a loop in the background of the system. The interactive module is triggered when there is an abnormality in the explosion-proof motor. The redundant sealing component is used as the center of the maintenance area, and the explosion-proof motor is manually inspected in a radiating order from the center outward. The interaction module is triggered when the explosion-proof motor shows signs of abnormality, which in turn triggers the sniffing module to run.

7. The explosion-proof motor redundant sealing and vibration coordinated suppression system for petrochemical scenarios according to claim 1, characterized in that, During the operation of the sniffing module, redundant sealing components are continuously shut down, with the shutdown sequence and timing following the following rules: The sensor corresponding to the adjacent redundant sealing assembly is identified by a weighting coefficient. The adjacent redundant sealing assembly of the sensor with the larger weighting coefficient is taken as the priority to shut down. After each redundant sealing assembly is shut down, the time interval of three consecutive operation of the sensor is used to shut down another redundant sealing assembly. Based on the above operations, the abnormal trend value change line graph of the explosion-proof motor is continuously observed and refreshed in real time in the visualization unit. When the line graph of the abnormal trend value change line graph of the explosion-proof motor shows an upward trend, the latest closed redundant sealing component is used as the center of the maintenance area, and the explosion-proof motor is manually inspected in the order of diverging outward from the center. After manually inspecting the explosion-proof motor, it is simultaneously determined whether the latest value in the abnormal tendency value change line graph of the explosion-proof motor is still greater than or equal to the preset threshold. If the determination is yes, the continuous closing operation of the redundant sealing components continues, and the maintenance area center is determined again for manual inspection based on the above logic until the latest value in the abnormal tendency value change line graph of the explosion-proof motor is less than the preset threshold. If the determination is no, the process ends.

8. The explosion-proof motor redundant sealing and vibration coordinated suppression system for petrochemical scenarios according to claim 1, characterized in that, The monitoring module interacts with the diagnostic module and the evaluation module via a wireless network. The evaluation module's subordinate units interact with the retrieval unit and the visualization unit via a wireless network. The retrieval unit interacts with the monitoring module via a wireless network. The evaluation module interacts with the maintenance module via a wireless network. The maintenance module interacts with the diagnostic module via a wireless network. The maintenance module interacts with the interaction module and the sniffing module via a wireless network.

Images