Air suspension fan control system and method

Abstract

The invention discloses an air suspension fan control system and method, and belongs to the technical field of air suspension centrifugal fan control. The controller is electrically connected with the communication unit, the input unit, the early warning unit and the magnetic suspension data acquisition unit; the communication unit is used for transmitting an external terminal to the controller and transmitting information needing to be transmitted by the controller to the external terminal; the input unit is used for inputting preset operation parameters of the air suspension centrifugal fan; the judgment unit is used for comparing and judging the data acquired by the magnetic suspension data acquisition unit with preset operation parameters of the air suspension centrifugal fan according to a judgment result; the early warning unit is used for warning the early warning information; the magnetic suspension data acquisition unit is used for acquiring magnetic suspension gap, current, temperature and vibration data of the air suspension centrifugal fan; key faults such as suspension failure and mechanical wear can be found in time, and actual use is facilitated.

Description

Technical Field

[0001] This invention relates to the field of air-suspended centrifugal fan control technology, specifically to an air-suspended fan control system and method. Background Technology

[0002] The air suspension fan adopts two core high-end technologies: "ultra-high speed direct-drive motor" and "air suspension bearing", which makes the total mechanical efficiency of the fan reach more than 88%. It has the characteristics of high efficiency, low noise, low vibration and low wear. It saves about 7% to 8% of electricity compared with the current centrifugal blower. It can also completely solve the problems of oil leakage and oil mist pollution caused by high-speed gearbox transmission. Therefore, it has been increasingly widely used.

[0003] For example, Chinese patent CN207740211U discloses an air-suspended centrifugal fan monitoring system, belonging to the field of fan control systems. It includes an equipment operation status monitoring unit, an equipment operation data unit, and an equipment operation curve recording unit for data processing and displaying data changes in curve form. The equipment operation status monitoring unit includes various sensors installed on the air-suspended centrifugal fan and three-phase multi-function meters electrically connected to corresponding interfaces in the power distribution cabinet. The equipment operation data unit includes a device PLC. The output terminals of each sensor are electrically connected to the input terminals of the device PLC. The equipment operation curve recording unit includes a PC host computer and a display electrically connected to it. The output terminal of the three-phase multi-function meter communicates with the PC host computer via a bus. The PC host computer communicates with the device PLC via Ethernet. The advantages of this invention are stability, reliability, and timely control.

[0004] The above structure is mainly for monitoring the working status, but it does not monitor the magnetic levitation rotating parts of the air-suspended centrifugal fan in real time, and cannot monitor levitation failure or mechanical wear in a timely manner.

[0005] Based on this, the present invention designs an air suspension fan control system to solve the above problems. Summary of the Invention

[0006] In view of the above-mentioned shortcomings of the existing technology, the present invention provides an air suspension fan control system and method.

[0007] To achieve the above objectives, the present invention provides the following technical solution:

[0008] An air-suspended fan control system includes a controller;

[0009] The controller is electrically connected to the communication unit, input unit, early warning unit, and magnetic levitation data acquisition unit;

[0010] Communication unit: used to transmit information from external terminals to the controller and to transmit information that the controller needs to transmit to external terminals;

[0011] Input unit: Used to input the preset operating parameters of the air suspension centrifugal fan;

[0012] Judgment Unit: Used to compare and judge the data collected by the magnetic levitation data acquisition unit with the preset operating parameters of the air-suspended centrifugal fan, and to make judgments based on the judgment results;

[0013] Early warning unit: used for issuing early warning information alerts;

[0014] Magnetic levitation data acquisition unit: used to collect data on the magnetic levitation gap, current, temperature and vibration of the air-suspended centrifugal fan.

[0015] Furthermore, the communication unit communicates with external terminals via wireless or wired networks.

[0016] Furthermore, the magnetic levitation data acquisition unit includes a levitation gap acquisition unit, a current acquisition unit, a temperature acquisition unit, and a vibration and displacement acquisition unit;

[0017] Suspension gap acquisition unit: used to acquire the radial / axial suspension gap between the rotor and stator of the air suspension centrifugal fan;

[0018] Current acquisition unit: used to acquire the operating current of the electromagnetic coil of the air-suspended centrifugal fan;

[0019] Temperature acquisition unit: used to acquire temperature data of the electromagnetic coil winding and bearing housing of the air-suspended centrifugal fan;

[0020] Vibration and displacement acquisition unit: used to acquire the radial / axial vibration acceleration and instantaneous displacement of the rotor of the air-suspended centrifugal fan.

[0021] Furthermore, the suspension gap acquisition unit uses a non-contact eddy current sensor, and at least two suspension gap acquisition units are provided on the outside of the rotor of the air suspension centrifugal fan, and the suspension gap acquisition units are arranged symmetrically.

[0022] Furthermore, the current acquisition unit uses a closed-loop Hall current sensor, and the current acquisition unit is electrically connected to the electromagnetic coil of the air-suspended centrifugal fan.

[0023] Furthermore, the temperature acquisition unit uses a PT100 temperature sensor or an infrared temperature measurement element.

[0024] Furthermore, the sensing ends of multiple temperature acquisition units are respectively positioned opposite the ends of the electromagnetic coil and the sides of the radial midpoint of the bearing housing.

[0025] Furthermore, the vibration and displacement acquisition unit uses piezoelectric accelerometers and laser displacement sensors.

[0026] Furthermore, the sensing end of the piezoelectric accelerometer faces the outer circular surface of the rotor and the side of the rotor thrust disk; the sensing end of the laser displacement sensor faces the smooth cylindrical surface of the rotor and the center of the thrust disk end face.

[0027] Based on the same inventive concept, this application also provides an air-suspended fan control method, which includes the following steps:

[0028] Step 1: Input the preset allowable range of magnetic levitation gap, preset allowable range of electromagnetic coil operating current, preset allowable range of temperature of electromagnetic coil winding and bearing housing, and preset allowable range of rotor radial / axial vibration acceleration and instantaneous displacement of the air-suspended centrifugal fan to the controller through the input unit.

[0029] Step 2: The magnetic levitation data acquisition unit collects in real time the radial / axial magnetic levitation gap data between the rotor and stator of the air-suspended centrifugal fan, the electromagnetic coil operating current data, the electromagnetic coil winding temperature data, the bearing housing temperature data, and the rotor radial / axial vibration acceleration data and instantaneous displacement data.

[0030] Step 3: The judgment unit compares the real-time data collected in Step 2 with the corresponding preset allowable range input in Step 1 to determine whether each real-time data exceeds the corresponding preset allowable range, generates a judgment result containing "data normal" or "data exceeds limit", and transmits the judgment result to the controller.

[0031] Step 4: After receiving the judgment result, if the judgment result is "data exceeds the limit", the controller will control the early warning unit to issue the corresponding early warning information; at the same time, the controller will transmit the preset allowable range input in step 1, the real-time data collected in step 2 and the judgment result generated in step 3 to the external terminal through the communication unit; if the judgment result is "data is normal", the controller will only transmit the real-time data collected in step 2 to the external terminal through the communication unit.

[0032] Compared with the prior art, the beneficial effects of this invention are as follows:

[0033] The magnetic levitation data acquisition unit of this invention collects magnetic levitation gap, current, temperature and vibration data of an air-suspended centrifugal fan. Then, together with the judgment unit, early warning unit and controller, it accurately locks the magnetic levitation gap, electromagnetic coil current, core component temperature and rotor vibration displacement, which can promptly detect key faults such as levitation failure and mechanical wear, which is beneficial for practical use. Attached Figure Description

[0034] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0035] Figure 1 This is a diagram of an air suspension fan control system according to the present invention;

[0036] Figure 2 This is a diagram of the magnetic levitation data acquisition unit of the present invention.

[0037] The labels in the diagram represent:

[0038] 1. Controller 2. Communication Unit 3. Input Unit 4. Judgment Unit 5. Early Warning Unit 6. Magnetic Levitation Data Acquisition Unit 61. Suspension Gap Acquisition Unit 62. Current Acquisition Unit 63. Temperature Acquisition Unit 64. Vibration and Displacement Acquisition Unit. Detailed Implementation

[0039] 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.

[0040] The terms "left," "right," "front," "back," "up," and "down" used in the following description refer to the orientation from the perspective of the front view.

[0041] Example 1

[0042] In some embodiments, please refer to the appendix to the instruction manual. Figure 1-2 An air suspension fan control system includes a controller 1;

[0043] The controller 1 is electrically connected to the communication unit 2, the input unit 3, the judgment unit 4, the early warning unit 5, and the magnetic levitation data acquisition unit 6;

[0044] Communication unit 2: used to transmit information from external terminals to controller 1 and to transmit information that controller 1 needs to transmit to external terminals;

[0045] Input unit 3: Used to input the preset operating parameters of the air suspension centrifugal fan;

[0046] Judgment Unit 4: Used to compare and judge the data collected by the magnetic levitation data acquisition unit 6 with the preset operating parameters of the air suspension centrifugal fan, and to make judgments based on the judgment results;

[0047] Early warning unit 5: Used for early warning information alerts;

[0048] Magnetic levitation data acquisition unit 6: Used to collect data on the magnetic levitation gap, current, temperature and vibration of the air-levitated centrifugal fan.

[0049] The preset operating parameters for the suspension gap are: gap 0.1-0.3mm, dynamic fluctuation ≤0.05mm;

[0050] If the gap collected by the magnetic levitation data acquisition unit 6 is consistently too large (>0.4mm), too small (<0.08mm), or fluctuates violently, the warning message is electromagnetic force imbalance or rotor deviation.

[0051] Preset operating parameters for current: within ±5% of rated range;

[0052] If the current collected by the magnetic levitation data acquisition unit 6 is lower than 95% of the rated range or higher than 105% of the rated range, the warning message is a short circuit between coil turns or an abnormal magnetic circuit.

[0053] The preset operating parameter for coil temperature is ≤120℃;

[0054] The preset operating parameter for bearing housing temperature is ≤80℃;

[0055] If the coil temperature collected by the magnetic levitation data acquisition unit 6 is higher than 120℃ or the bearing seat temperature is higher than 80℃, the warning message is to reduce the load or stop the machine.

[0056] The preset operating parameters for vibration data are: vibration acceleration < 2.5 mm / s², or instantaneous displacement exceeding the gap by less than 1.2 times.

[0057] If the vibration acceleration collected by the magnetic levitation data acquisition unit 6 is ≥2.5mm / s², or the instantaneous displacement exceeds 1.2 times the upper limit of the gap, the warning message is that the rotor vibration exceeds the standard.

[0058] Communication unit 2 communicates with external terminals via a wireless network or a wired network.

[0059] The magnetic levitation data acquisition unit 6 includes a levitation gap acquisition unit 61, a current acquisition unit 62, a temperature acquisition unit 63, and a vibration and displacement acquisition unit 64;

[0060] Suspension gap acquisition unit 61: used to acquire the radial / axial suspension gap between the rotor and stator of the air suspension centrifugal fan;

[0061] Current acquisition unit 62: used to acquire the operating current of the electromagnetic coil of the air-suspended centrifugal fan;

[0062] Temperature acquisition unit 63: used to acquire temperature data of the electromagnetic coil winding and bearing housing of the air suspension centrifugal fan;

[0063] Vibration and displacement acquisition unit 64: used to acquire the radial / axial vibration acceleration and instantaneous displacement of the rotor of the air-suspended centrifugal fan.

[0064] The suspension gap acquisition unit 61 uses a non-contact eddy current sensor. At least two suspension gap acquisition units 61 are provided on the outside of the rotor of the air suspension centrifugal fan, and the suspension gap acquisition units 61 are arranged symmetrically.

[0065] The current acquisition unit 62 is a closed-loop Hall current sensor, and the current acquisition unit 62 is electrically connected to the electromagnetic coil of the air-suspended centrifugal fan.

[0066] The temperature acquisition unit 63 uses a PT100 temperature sensor or an infrared temperature measuring element.

[0067] The sensing ends of the multiple temperature acquisition units 63 are respectively positioned opposite the ends of the electromagnetic coil and the sides of the radial midpoint of the bearing housing.

[0068] The vibration and displacement acquisition unit 64 uses a piezoelectric accelerometer and a laser displacement sensor.

[0069] The sensing end of the piezoelectric accelerometer faces the non-keyway, chamfer, or other discontinuous surfaces on the outer circular surface of the rotor and the axial force-bearing surface on the side of the rotor thrust disk.

[0070] The sensing end of the laser displacement sensor faces the smooth cylindrical surface of the rotor, free of scratches and oil stains, and is coaxial with the center of the thrust disk end face.

[0071] Based on the same inventive concept, this application also provides an air suspension fan control method, including the following steps:

[0072] Step 1: Input the preset allowable range of magnetic levitation gap, preset allowable range of electromagnetic coil operating current, preset allowable range of temperature of electromagnetic coil winding and bearing housing, and preset allowable range of rotor radial / axial vibration acceleration and instantaneous displacement of the air-suspended centrifugal fan to the controller 1 through the input unit 3.

[0073] Step 2: The magnetic levitation data acquisition unit 6 collects in real time the radial / axial magnetic levitation gap data between the rotor and stator of the air-suspended centrifugal fan, the electromagnetic coil operating current data, the electromagnetic coil winding temperature data, the bearing housing temperature data, and the rotor radial / axial vibration acceleration data and instantaneous displacement data.

[0074] Step 3: The judgment unit 4 compares the real-time data collected in step 2 with the corresponding preset allowable range input in step 1 to determine whether each real-time data exceeds the corresponding preset allowable range, generates a judgment result including "data normal" or "data exceeds limit", and transmits the judgment result to the controller 1.

[0075] Step 4: After receiving the judgment result, if the judgment result is "data exceeds the limit", the controller 1 will control the early warning unit 5 to issue the corresponding early warning information; at the same time, the controller 1 will transmit the preset allowable range input in step 1, the real-time data collected in step 2 and the judgment result generated in step 3 to the external terminal through the communication unit 2; if the judgment result is "data is normal", the controller 1 will transmit only the real-time data collected in step 2 to the external terminal through the communication unit 2.

[0076] The core function of this air-suspended fan monitoring method is to accurately solve the problem of insufficient monitoring of the magnetic levitation rotation parts of air-suspended fans through a closed-loop process of "preset parameters - real-time data acquisition - comparison and judgment - early warning transmission". Its specific functions are as follows:

[0077] Achieve precise monitoring of key data for magnetic levitation: Collect key data such as radial / axial levitation gap between rotor and stator, electromagnetic coil current, temperature of core components (coil windings, bearing housings) and rotor vibration displacement, covering the core indicators for stable operation of the magnetic levitation system, and avoiding missed fault diagnosis due to gaps in key data monitoring;

[0078] Timely warning of fault risks: By comparing the collected data with the preset allowable range in real time, problems such as abnormal suspension gap (such as imbalance or offset), abnormal current (such as coil short circuit or magnetic circuit problem), excessive temperature (such as component overheating) and excessive vibration (such as abnormal rotor vibration) can be quickly identified, triggering early warnings to prevent the expansion of faults such as suspension failure and mechanical wear, and reduce the risk of equipment damage.

[0079] Ensuring operational controllability: By transmitting preset parameters, real-time data, and judgment results to external terminals through communication unit 2, remote real-time control of the fan's operating status is achieved, facilitating timely intervention and adjustment by staff, improving the safety and reliability of fan operation, and adapting to the high-efficiency and low-wear operation requirements of air-suspended fans.

[0080] The magnetic levitation data acquisition unit 6 of this invention collects magnetic levitation gap, current, temperature and vibration data of the air-suspended centrifugal fan, and then, together with the judgment unit 4, the early warning unit 5 and the controller 1, accurately locks the magnetic levitation gap, electromagnetic coil current, core component temperature and rotor vibration displacement, which can promptly detect key faults such as levitation failure and mechanical wear, which is beneficial for practical use.

[0081] 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. An air-suspended fan control system comprising a controller (1), characterized in that: the controller (1) is electrically connected to a communication unit (2), an input unit (3), a warning unit (5), and a magnetic suspension data acquisition unit (6); the communication unit (2) is used to transmit information from an external terminal to the controller (1) and to transmit information from the controller (1) to the external terminal; the input unit (3) is used to input preset operating parameters of the air-suspended centrifugal fan; the judgment unit (4) is used to compare the data collected by the magnetic suspension data acquisition unit (6) with the preset operating parameters of the air-suspended centrifugal fan and to make a judgment based on the comparison result; the warning unit (5) is used to issue a warning; the magnetic suspension data acquisition unit (6) is used to collect magnetic suspension gap, current, temperature, and vibration data of the air-suspended centrifugal fan.

2. The air suspension fan control system of claim 1, wherein, The communication unit (2) is connected to an external terminal through a wireless network or a wired network.

3. The air suspension fan control system of claim 2, wherein, The magnetic suspension data acquisition unit (6) comprises a suspension gap acquisition unit (61), a current acquisition unit (62), a temperature acquisition unit (63), and a vibration and displacement acquisition unit (64); the suspension gap acquisition unit (61) is used to collect the radial / axial suspension gap between the rotor and the stator of the air-suspended centrifugal fan; the current acquisition unit (62) is used to collect the working current of the electromagnetic coil of the air-suspended centrifugal fan; the temperature acquisition unit (63) is used to collect the temperature data of the electromagnetic coil winding and the bearing seat of the air-suspended centrifugal fan; the vibration and displacement acquisition unit (64) is used to collect the radial / axial vibration acceleration and instantaneous displacement of the rotor of the air-suspended centrifugal fan.

4. The air suspension blower control system of claim 3, wherein, The suspension gap acquisition unit (61) is a non-contact eddy current sensor, and at least two suspension gap acquisition units (61) are arranged symmetrically on the outer side of the rotor of the air-suspended centrifugal fan.

5. The air suspension fan control system of claim 4, wherein, The current acquisition unit (62) is a closed-loop Hall current sensor, and the current acquisition unit (62) is electrically connected to the electromagnetic coil of the air-suspended centrifugal fan.

6. The air suspension blower control system of claim 3, wherein, The temperature acquisition unit (63) is a PT100 temperature sensor or an infrared temperature measuring element.

7. The air suspension blower control system of claim 6, wherein, The sensing ends of multiple groups of temperature acquisition units (63) are respectively opposite to the side surfaces of the electromagnetic coil end and the bearing seat radial midpoint.

8. The air suspension blower control system of claim 3, wherein, The vibration and displacement acquisition unit (64) is a piezoelectric acceleration sensor and a laser displacement sensor.

9. The air suspension blower control system of claim 8, wherein, The sensing end of the piezoelectric acceleration sensor is opposite to the outer circular surface of the rotor of the air-suspended centrifugal fan and opposite to the side surface of the thrust disc of the rotor of the air-suspended centrifugal fan; the sensing end of the laser displacement sensor is opposite to the smooth cylindrical surface of the rotor of the air-suspended centrifugal fan and opposite to the center position of the end surface of the thrust disc of the rotor of the air-suspended centrifugal fan.

10. An air levitation fan control method based on the air levitation fan control system according to any one of claims 1 to 9, characterized by, The air-suspended fan control method comprises the following steps: Step 1: input the magnetic suspension gap preset allowable range, the electromagnetic coil working current preset allowable range, the electromagnetic coil winding and bearing seat temperature preset allowable range, and the rotor radial / axial vibration acceleration and instantaneous displacement preset allowable range of the air-suspended centrifugal fan to the controller (1) through the input unit (3); Step 2: real-time collect the rotor and stator radial / axial magnetic suspension gap data, electromagnetic coil working current data, electromagnetic coil winding temperature data, bearing seat temperature data, and rotor radial / axial vibration acceleration and instantaneous displacement data of the air-suspended centrifugal fan through the magnetic suspension data acquisition unit (6); Step 3: compare each item of real-time data collected in step 2 with the corresponding preset allowable range input in step 1 through the judgment unit (4), judge whether each item of real-time data exceeds the corresponding preset allowable range, generate a judgment result containing "data normal" or "data out of limit", and transmit the judgment result to the controller (1); Step 4: after receiving the judgment result, if the judgment result is "data out of limit", the controller (1) controls the warning unit (5) to issue the corresponding warning information; at the same time, the controller (1) transmits the preset allowable range input in step 1, the real-time data collected in step 2, and the judgment result generated in step 3 to the external terminal through the communication unit (2); if the judgment result is "data normal", the controller (1) only transmits the real-time data collected in step 2 to the external terminal through the communication unit (2).

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