A multi-cylinder plunger pump single-cylinder pressure state fusion discrimination method and system based on phase synchronization

Abstract

The application discloses a kind of based on phase synchronization's multi-cylinder plunger pump single cylinder pressure state fusion discrimination method and system, comprising the following steps: S1, in the operation process of multi-cylinder plunger pump, crankshaft phase angle signal is collected, and the phase reference datum of crank rotation is established;S2, the system total discharge pressure signal at high-pressure junction cavity or its communication oil channel place communicated with the discharge passage of multiple plunger cylinder chambers is collected, and the structure vibration signal of plunger pump structure part.The system structure configuration and phase synchronization processing mechanism of the present application can realize the phase separation and abnormal discrimination of single cylinder pressure response without changing the internal structure of plunger pump, without installing pressure sensor in the interior of plunger cylinder chamber.

Description

Technical Field

[0001] This invention belongs to the field of hydraulic equipment operation status monitoring and fault diagnosis technology, and in particular relates to a method and system for fusion judgment of single cylinder pressure status of multi-cylinder plunger pump based on phase synchronization. It is applicable to multi-cylinder plunger pump equipment with two or more plunger chambers and each plunger chamber is rigidly coupled through a crankshaft or equivalent mechanism. Background Technology

[0002] Multi-cylinder piston pumps, as key power components in hydraulic systems, are widely used in engineering machinery, mining equipment, metallurgical equipment, and hydraulic transmission systems. A multi-cylinder piston pump typically consists of multiple piston chambers connected to the same crankshaft via a connecting rod mechanism. During crankshaft rotation, each piston chamber sequentially completes the oil suction and discharge processes according to a fixed phase sequence.

[0003] During long-term operation, the oil discharge capacity of a single plunger chamber may decrease due to factors such as seal wear, valve leakage, cavitation, or abnormal flow distribution. However, because the plunger chambers in a multi-cylinder plunger pump are rigidly coupled through the crankshaft, when one plunger chamber malfunctions, the remaining normal chambers can still drive the crankshaft to continue rotating under the action of the drive unit, allowing the plunger pump as a whole to maintain its basic operating condition.

[0004] In existing technologies, the monitoring of the operating status of plunger pumps often relies on the total system pressure, flow rate, or drive motor parameters as the basis for judgment. This type of monitoring mainly reflects the overall operating status of the machine and is difficult to accurately identify abnormalities in a single plunger cylinder chamber when the plunger pump is still rotating normally. When a single cylinder abnormality has little impact on the total system pressure, it is often difficult to detect in time, leading to the expansion of equipment deterioration or sudden failure.

[0005] In addition, the method of directly installing pressure sensors inside the piston cylinder chamber generally suffers from problems such as limited structural space, poor sealing reliability, and high difficulty in modification, which is not conducive to engineering promotion and application.

[0006] Currently, there is no effective technical solution for separating the pressure response of a single cylinder based on crankshaft phase synchronization. Therefore, there is an urgent need for a method and system that can determine the pressure state of a single cylinder without installing a pressure sensor inside the piston cylinder chamber and without changing the internal structure of the piston pump. Summary of the Invention

[0007] The purpose of this invention is to provide a method and system for fusion and discrimination of single-cylinder pressure state of a multi-cylinder plunger pump based on phase synchronization, so as to solve the technical problems mentioned in the background art.

[0008] To achieve the above objectives, the specific technical solution of the present invention is as follows: A method for fusion and discrimination of single-cylinder pressure state of a multi-cylinder plunger pump based on phase synchronization, comprising the following steps:

[0009] S1. During the operation of the multi-cylinder plunger pump, the crankshaft phase angle signal is collected to establish a phase reference for crankshaft rotation;

[0010] S2. Collect the total system discharge pressure signal at the high-pressure manifold or its connecting oil passage that is connected to the discharge channels of multiple plunger cylinder chambers, as well as the structural vibration signal of the plunger pump structure.

[0011] S3. Based on the crankshaft phase angle signal, perform time synchronization processing on the system total oil discharge pressure signal and the structural vibration signal, and map the system total oil discharge pressure signal and the structural vibration signal from the time domain to the phase domain;

[0012] S4. Taking one complete rotation cycle of the crankshaft as the analysis cycle, the rotation cycle is divided into multiple phase intervals according to the number of piston cylinder chambers, so that each phase interval corresponds to the oil discharge and power-making stage of one piston cylinder chamber.

[0013] S5. Extract pressure characteristic values ​​and vibration characteristic values ​​in each phase interval respectively;

[0014] S6. Based on the comparative analysis of the pressure characteristic values ​​in each phase interval, determine whether the pressure state of the corresponding plunger cylinder chamber is abnormal, and combine the vibration characteristic values ​​of the corresponding phase interval to verify or enhance the abnormality judgment result, and output the single cylinder pressure state discrimination result.

[0015] Preferably, in step S3, the mapping of the system's total discharge pressure signal and structural vibration signal to the phase domain is achieved by phase resampling or angle-triggered sampling.

[0016] Preferably, in step S4, the crankshaft rotation period is evenly divided into... One phase interval, This refers to the number of piston cylinder chambers.

[0017] Preferably, in step S5, the pressure characteristic value is a statistical characteristic quantity used to characterize the total oil discharge pressure response characteristics of the system within the corresponding phase interval. The statistical characteristic quantity includes at least one of the following: average value, peak value, integral value, or other numerical indicators that can reflect the pressure change characteristics within the phase interval.

[0018] The vibration characteristic value is a statistical characteristic quantity used to characterize the vibration response characteristics of the structure within the corresponding phase interval, including at least one of the root mean square value, energy value, spectral characteristic value, or other numerical indicators that can reflect the vibration change characteristics of the phase interval.

[0019] Preferably, in step S6, when the pressure characteristic value of a certain phase interval is lower than the average value of the pressure characteristic values ​​of the other phase intervals multiplied by a preset threshold coefficient, it is determined that the corresponding plunger cylinder chamber is in an abnormal pressure state.

[0020] Preferably, before determining an anomaly, the pressure characteristic values ​​of multiple consecutive rotation cycles are statistically analyzed, and when a preset number of consecutive cycles meet the anomaly determination conditions, an anomaly result is output.

[0021] This invention also relates to a single-cylinder pressure state fusion and discrimination system for a multi-cylinder plunger pump based on phase synchronization, comprising:

[0022] A plunger pump body, the plunger pump body including at least two plunger cylinder chambers, and multiple plunger cylinder chambers connected to the same crankshaft via a connecting rod mechanism;

[0023] A phase acquisition unit is installed on the crankshaft or a transmission component that rotates synchronously with the crankshaft, and is used to output the crankshaft phase angle signal;

[0024] The pressure acquisition unit is located in the high-pressure manifold or its connecting oil passage, which is connected to the oil discharge channels of multiple plunger cylinder chambers, and is used to acquire the total oil discharge pressure signal of the system.

[0025] The vibration acquisition unit is installed in the structure of the plunger pump and is used to acquire vibration signals of the plunger pump structure.

[0026] The signal acquisition and processing module is connected to the phase acquisition unit, pressure acquisition unit and vibration acquisition unit respectively, and is configured to perform the method described in any one of claims 1 to 6.

[0027] Preferably, the phase acquisition unit is an incremental rotary encoder or an absolute rotary encoder.

[0028] Preferably, the pressure acquisition unit is a high-frequency response pressure sensor and is installed at the pressure interface position corresponding to the high-pressure manifold or its connecting oil passage.

[0029] Preferably, the signal acquisition and processing module supports phase-synchronized triggering sampling and performs synchronous resampling processing on the system's total oil discharge pressure signal and structural vibration signal.

[0030] The present invention provides a method and system for fusion and discrimination of single-cylinder pressure state of a multi-cylinder plunger pump based on phase synchronization, which has the following advantages:

[0031] 1. The system structure configuration and phase synchronization processing mechanism of the present invention can achieve phase separation and anomaly detection of single-cylinder pressure response without changing the internal structure of the plunger pump or installing a pressure sensor inside the plunger cylinder chamber.

[0032] 2. The system of the present invention improves the reliability of single-cylinder anomaly detection by fusing the total system discharge pressure signal and the structural vibration signal, and avoids the problem of single-cylinder anomalies being masked by relying solely on the total system pressure. It has good engineering applicability and promotion value. Attached Figure Description

[0033] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0034] Figure 1 This is a side view schematic diagram of the structure of the single-cylinder pressure state fusion and discrimination system for a multi-cylinder plunger pump based on phase synchronization according to the present invention;

[0035] Figure 2 This is a top view schematic diagram of the single-cylinder pressure state fusion discrimination system for a multi-cylinder plunger pump based on phase synchronization, as presented in this invention.

[0036] The markings in the diagram are as follows: 1. Crankshaft assembly; 2. Drive gear; 3. Crankshaft connecting rod mechanism; 4. Multi-cylinder plunger block; 5. Pressure acquisition unit; 6. High-pressure valve block assembly; 7. Vibration acquisition unit; 8. Phase acquisition unit; 9. Drive input shaft. Detailed Implementation

[0037] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of the embodiments of the invention. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0038] In the description of the embodiments of the present invention, it should be understood that the terms "length", "vertical", "horizontal", "top", "bottom", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. They are only for the convenience of describing the embodiments of the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of the present invention.

[0039] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of embodiments of the present invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0040] In this embodiment of the invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this embodiment of the invention according to the specific circumstances.

[0041] The following disclosure provides many different implementations or examples for carrying out different structures of the embodiments of the present invention. To simplify the disclosure of the embodiments of the present invention, specific examples of components and arrangements are described below. Of course, these are merely examples and are not intended to limit the embodiments of the present invention. Furthermore, reference numerals and / or reference letters may be repeated in different examples of the embodiments of the present invention; such repetition is for simplification and clarity and does not in itself indicate a relationship between the various implementations and / or arrangements discussed.

[0042] To better understand the purpose, structure, and function of this invention, the following detailed description, in conjunction with the accompanying drawings, provides a method and system for determining the single-cylinder pressure state of a multi-cylinder plunger pump based on phase synchronization.

[0043] The present invention provides a method for fusion and discrimination of single-cylinder pressure state of a multi-cylinder plunger pump based on phase synchronization, comprising the following steps:

[0044] Step S1: Establishing the crankshaft phase reference

[0045] During the operation of the plunger pump, the phase angle signal during the rotation of the plunger pump is acquired in real time by a phase acquisition unit installed on the crankshaft or the drive end transmission component that maintains a fixed phase relationship with the crankshaft.

[0046] The acquired phase angle is used to characterize the rotational position of the crankshaft at any given moment, and under ideal constant angular velocity conditions, it can be expressed as:

[0047]

[0048] in:

[0049] The crankshaft phase angle corresponding to time t; The crankshaft angular velocity; This is the initial phase offset.

[0050] In actual operation, the phase angle signal is obtained by the phase acquisition unit in real time and is not limited to a constant angular velocity model.

[0051] Since each piston chamber in a multi-cylinder piston pump is rigidly connected to the same crankshaft through a connecting rod mechanism, the oil discharge and power-generating sequence of each piston chamber has a one-to-one correspondence with the crankshaft phase. Therefore, the crankshaft phase angle can be used as a unified reference benchmark for subsequent signal analysis.

[0052] Step S2: Acquisition of system pressure and structural vibration signals

[0053] During the operation of the plunger pump, the total discharge pressure signal of the plunger pump system is acquired by a pressure acquisition unit located in the high-pressure manifold or its connecting oil passage, which is connected to the discharge channels of multiple plunger cylinder chambers. .

[0054] Meanwhile, the structural vibration signals generated during the operation of the plunger pump are collected by a vibration acquisition unit installed on the plunger pump housing or a structural part rigidly connected to it. .

[0055] in:

[0056] System total discharge pressure signal This reflects the dynamic response of the pump body structure to the periodic work of the plunger cylinder chamber and the abnormal operation of a single cylinder.

[0057] Step S3: Phase-based signal synchronization and mapping

[0058] The collected system total discharge pressure signal and structural vibration signals With phase angle signal Perform synchronization processing.

[0059] By establishing time variables With phase variable Based on the correspondence, phase resampling or angle-triggered sampling is performed on the system's total discharge pressure signal and structural vibration signal to map them from the time domain to the phase domain, resulting in:

[0060]

[0061] Through the phase resampling process, each sampling point of the total oil discharge pressure signal or structural vibration signal of the system corresponds to a unique crankshaft phase position, thereby establishing a deterministic correspondence between the external monitoring signal and the working phase of the piston cylinder chamber.

[0062] Step S4: Establishing the phase interval division and cylinder chamber correspondence

[0063] Taking one complete crankshaft rotation cycle [0, 2π) as one analysis cycle, the rotation cycle is divided into N phase intervals based on the number of piston chambers N in the piston pump:

[0064]

[0065] Each phase interval This corresponds to the main oil discharge and power-generating stage of a plunger cylinder chamber.

[0066] Since a multi-cylinder plunger pump typically has only one plunger chamber in the main oil discharge phase within any phase interval, the pressure response of a single cylinder can be separated within the phase domain.

[0067] Under normal operating conditions, the contribution of each plunger cylinder chamber to the system pressure and the excitation of structural vibration within its corresponding phase interval exhibit statistical stability.

[0068] Step S5: Signal feature extraction within the phase interval

[0069] In each phase interval Within this phase interval, feature extraction is performed on the total system discharge pressure signal and the structural vibration signal to obtain the pressure characteristic value. and vibration characteristic values It can be represented as:

[0070]

[0071]

[0072] in:

[0073] Indicates the first The interval length of each phase interval; Indicates the first Statistical characteristic values ​​of each plunger cylinder chamber within its oil discharge phase interval; This represents the interval statistical characteristic value of the structural vibration signal within the corresponding phase interval.

[0074] The above expression is an exemplary calculation method for pressure characteristic values ​​and vibration characteristic values, used to illustrate the method of obtaining statistical characteristics within the phase interval, and does not constitute a limitation on the form of characteristic calculation.

[0075] In practical applications, the eigenvalue can also be at least one of the following: peak value, integral value, root mean square value, energy value, spectral eigenvalue, or other statistical indicators that can characterize the response characteristics within the phase interval.

[0076] Step S6: Single-cylinder pressure status determination

[0077] By comparing and analyzing the pressure characteristic values ​​within the corresponding phase intervals of each plunger cylinder chamber, it can be determined that a plunger cylinder chamber is in an abnormal pressure state when it meets the following relationship:

[0078]

[0079] in:

[0080] The empirical threshold coefficient satisfies .

[0081] At the same time, if the vibration characteristic value corresponding to this phase interval The occurrence of abnormal changes can further enhance the reliability of the detection of abnormal pressure in the piston cylinder chamber.

[0082] In a preferred embodiment, the characteristic values ​​of multiple consecutive rotation cycles can be statistically analyzed, and an abnormal result is output only when the abnormality determination conditions are met for a preset number of consecutive cycles.

[0083] Through the above discrimination process, the pressure state of a single cylinder in a multi-cylinder plunger pump can be determined without relying on the internal pressure sensor of the plunger cylinder chamber.

[0084] This invention also provides a phase-synchronized single-cylinder pressure state fusion and discrimination system for a multi-cylinder plunger pump, comprising a plunger pump body, a phase acquisition unit, a pressure acquisition unit, a vibration acquisition unit, and a signal acquisition and processing module. The plunger pump body includes at least two plunger chambers, which are connected to the same crankshaft via a linkage mechanism, forming a rigidly coupled multi-cylinder working structure. During crankshaft rotation, each plunger chamber sequentially completes the oil suction and discharge processes according to a fixed phase sequence. The phase acquisition unit is installed on the crankshaft end or a transmission component that maintains a fixed phase relationship with the crankshaft, and is used to output the crankshaft phase angle signal in real time. The phase acquisition unit is located at the crankshaft drive end and coaxially connected to the crankshaft to obtain the real-time angular position information of the crankshaft. The phase acquisition unit is a rotary encoder capable of outputting the crankshaft angular position signal, including an incremental rotary encoder or an absolute rotary encoder. The phase angle signal output by the phase acquisition unit serves as a unified phase reference for the system, used for subsequent synchronous processing and phase domain mapping of the total system discharge pressure signal and structural vibration signal. A pressure acquisition unit is located in the high-pressure manifold or its connecting oil passage, which communicates with the oil discharge channels of multiple plunger cylinder chambers, to acquire the total discharge pressure signal of the plunger pump system. The pressure acquisition unit is a high-frequency response pressure sensor; the pressure sensor is installed at the pressure interface position corresponding to the high-pressure manifold or its connecting oil passage (e.g., the original mechanical pressure gauge interface position); the pressure acquisition unit is connected to the high-pressure manifold through a short pressure tapping channel. The acquired total system discharge pressure signal reflects the combined contribution of multiple plunger cylinder chambers to the system pressure at different phases. A vibration acquisition unit is located in the plunger pump body housing or its rigidly connected load-bearing structure. Preferably, the vibration acquisition unit is located near the pump body connection point close to the high-pressure manifold or its connecting oil passage to enhance the response sensitivity to abnormal excitation in a single cylinder. It is used to acquire structural vibration signals generated during the operation of the plunger pump. The vibration acquisition unit is an acceleration sensor; the preferred sensitive direction is the radial direction perpendicular to the crankshaft axis. The structural vibration signal is used to reflect the periodic work of the plunger cylinder chambers and the dynamic response of abnormal single-cylinder operation to the pump body structure. The signal acquisition and processing module is connected to the phase acquisition unit, pressure acquisition unit, and vibration acquisition unit, respectively. The signal acquisition and processing module includes:

[0085] The system includes a data acquisition interface unit, a phase synchronization triggering unit, a phase domain resampling unit, a phase interval division unit, a feature extraction unit, and a discriminant analysis unit.

[0086] The signal acquisition and processing module is configured to perform the following functions:

[0087] Receive crankshaft phase angle signals and establish a unified phase reference;

[0088] The total system discharge pressure signal and structural vibration signal are acquired synchronously.

[0089] Phase resampling processing is performed on the total system discharge pressure signal and structural vibration signal based on the phase reference.

[0090] Phase intervals are divided according to the number of piston cylinder chambers;

[0091] Within each phase interval, the interval statistical characteristic values ​​of the total system discharge pressure signal and the interval statistical characteristic values ​​of the structural vibration signal are extracted respectively.

[0092] The characteristic values ​​of each phase interval are compared and analyzed, and the single-cylinder pressure state discrimination result is output.

[0093] During system operation:

[0094] The phase acquisition unit outputs the crankshaft phase angle signal in real time as a unified time reference.

[0095] The pressure acquisition unit and the vibration acquisition unit synchronously acquire operating signals;

[0096] The signal acquisition and processing module is based on a phase synchronization mechanism, which maps the total system discharge pressure signal and the structural vibration signal to the phase domain and performs feature analysis within the phase interval.

[0097] The final output is the pressure status judgment result of each plunger cylinder chamber.

[0098] The system's total discharge pressure signal and structural vibration signal are acquired using a sampling frequency that meets the requirements of real-time diagnosis. The phase acquisition unit has an angle resolution capability that meets the phase synchronization accuracy requirements to ensure the accuracy of phase domain mapping and feature extraction.

[0099] The signal acquisition and processing module can realize phase synchronization triggering, signal resampling and real-time feature analysis to support online single-cylinder pressure status identification.

[0100] like Figure 1-2 As shown, this invention provides a single-cylinder pressure state fusion discrimination system for a multi-cylinder plunger pump based on phase synchronization. This system is applied to a multi-cylinder plunger pump structure, including a crankshaft assembly 1, a drive gear 2, a crank-connecting rod mechanism 3, and a multi-cylinder plunger block 4.

[0101] The crankshaft assembly 1 is connected to an external power unit via the drive input shaft 9, and power is transmitted through the drive gear 2 to rotate the crankshaft assembly 1. The crankshaft assembly 1 drives multiple piston chambers in the multi-cylinder piston block 4 to reciprocate through the crank-connecting rod mechanism 3, thereby completing the oil suction and discharge processes in a fixed phase sequence.

[0102] A high-pressure valve block assembly 6 is provided at one end of the multi-cylinder plunger cylinder body 4. The high-pressure valve block assembly 6 forms a high-pressure manifold that communicates with the oil discharge channels of multiple plunger cylinder chambers, and is used to collect the hydraulic oil output by each plunger cylinder chamber during the oil discharge stage.

[0103] The pressure acquisition unit 5 is located at the pressure interface position corresponding to the high-pressure valve block assembly 6 and is connected to the high-pressure manifold or its connecting oil passage. It is used to acquire the total system discharge pressure signal. The total system discharge pressure signal reflects the combined contribution of multiple plunger cylinder chambers to the system pressure at different phases.

[0104] The vibration acquisition unit 7 is installed on the high-pressure valve block assembly 6 or on a pump body structure rigidly connected to it, preferably near the high-pressure manifold, and is used to acquire structural vibration signals generated during the operation of the plunger pump. The structural vibration signals are used to reflect the dynamic response of the pump body structure to the periodic work of the plunger cylinder chamber and single-cylinder anomalies.

[0105] The phase acquisition unit 8 is located at the drive end of the crankshaft assembly 1 and is coaxially connected to the drive input shaft 9. It is used to output the crankshaft phase angle signal in real time. The phase acquisition unit 8 can be an incremental rotary encoder or an absolute rotary encoder. It is used to acquire the real-time angular position information of the crankshaft and serve as a unified phase reference for the system.

[0106] In some implementations, to enhance the system's ability to monitor transmission mechanism abnormalities, an auxiliary phase acquisition unit can be added to the end of the drive input shaft 9. This auxiliary phase acquisition unit collects the angular position information of the drive input shaft and compares it with the phase angle signal of the crankshaft assembly 1 to obtain the angular deviation between the input shaft and the crankshaft. By monitoring changes in the angular deviation, it can be used to determine changes in transmission clearance or abnormal gear conditions.

[0107] During system operation, phase acquisition unit 8 outputs crankshaft phase angle signal. Pressure acquisition unit 5 outputs the total oil discharge pressure signal of the system. The vibration acquisition unit 7 outputs the structural vibration signal V(t). The signal acquisition and processing module is connected to each of the above acquisition units to synchronously acquire and process the signals.

[0108] Specifically, the signal acquisition and processing module is based on the crankshaft phase angle signal. Establish the correspondence between time variables and phase variables, and analyze the total discharge pressure signal of the system. The structural vibration signal V(t) is subjected to phase resampling or angle-triggered sampling to map it from the time domain to the phase domain, thus obtaining the phase domain representation. and .

[0109] Subsequently, taking one complete crankshaft rotation cycle as the analysis period, the number of piston chambers in the multi-cylinder piston pump was considered. The rotation period is evenly divided into Each phase interval corresponds to the main oil discharge and power stroke stage of a piston cylinder chamber.

[0110] Within each phase interval, the phase domain representation of the system's total discharge pressure signal is given. and the phase domain representation of structural vibration signals Interval statistical feature extraction is performed to obtain the corresponding pressure and vibration feature values. The feature values ​​can be average values, peak values, integral values, root mean square values, energy values, spectral feature values, or other statistical indicators that can characterize the response characteristics within the phase interval.

[0111] Under normal operating conditions, the pressure characteristic values ​​of each plunger cylinder chamber within its corresponding phase interval exhibit statistical consistency. When the pressure characteristic value corresponding to a certain phase interval is lower than the average of the pressure characteristic values ​​of the other phase intervals multiplied by a preset threshold coefficient, the corresponding plunger cylinder chamber can be determined to be in an abnormal pressure state. Furthermore, verifying this by combining the vibration characteristic values ​​of the corresponding phase interval can improve the reliability of anomaly detection.

[0112] In a preferred embodiment, the pressure characteristic values ​​within multiple consecutive rotation cycles can be statistically analyzed. Only when the abnormal judgment conditions are met for a preset number of consecutive rotation cycles, the abnormal pressure state result of a single cylinder is output, thereby reducing the impact of occasional disturbances on the judgment result.

[0113] Through the above structural configuration and phase synchronization processing mechanism, phase separation and anomaly detection of single-cylinder pressure response can be achieved without installing pressure sensors inside the piston cylinder chamber or changing the internal structure of the piston pump, thereby improving the accuracy and reliability of monitoring the operating status of multi-cylinder piston pumps.

[0114] It is understood that the present invention has been described through some embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of the invention. Furthermore, under the teachings of the present invention, these features and embodiments can be modified to adapt to specific situations and materials without departing from the spirit and scope of the invention. Therefore, the present invention is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are within the protection scope of the present invention.

Claims

1. A method for fusion and discrimination of single-cylinder pressure state in a multi-cylinder plunger pump based on phase synchronization, characterized in that: Includes the following steps: S1. During the operation of the multi-cylinder plunger pump, the crankshaft phase angle signal is collected to establish a phase reference for crankshaft rotation; S2. Collect the total system discharge pressure signal at the high-pressure manifold or its connecting oil passage that is connected to the discharge channels of multiple plunger cylinder chambers, as well as the structural vibration signal of the plunger pump structure. S3. Based on the crankshaft phase angle signal, perform time synchronization processing on the system total oil discharge pressure signal and the structural vibration signal, and map the system total oil discharge pressure signal and the structural vibration signal from the time domain to the phase domain; S4. Taking one complete rotation cycle of the crankshaft as the analysis cycle, the rotation cycle is divided into multiple phase intervals according to the number of piston cylinder chambers, so that each phase interval corresponds to the oil discharge and power-making stage of one piston cylinder chamber. S5. Extract pressure characteristic values ​​and vibration characteristic values ​​in each phase interval respectively; S6. Based on the comparative analysis of the pressure characteristic values ​​in each phase interval, determine whether the pressure state of the corresponding plunger cylinder chamber is abnormal, and combine the vibration characteristic values ​​of the corresponding phase interval to verify or enhance the abnormality judgment result, and output the single cylinder pressure state discrimination result.

2. The method for fusion and discrimination of single-cylinder pressure state of a multi-cylinder plunger pump based on phase synchronization according to claim 1, characterized in that: In step S3, the mapping of the system's total oil discharge pressure signal and structural vibration signal to the phase domain is achieved through phase resampling or angle-triggered sampling.

3. The method for fusion and discrimination of single-cylinder pressure state of a multi-cylinder plunger pump based on phase synchronization according to claim 1, characterized in that: In step S4, the crankshaft rotation period is evenly divided into... One phase interval, This refers to the number of piston cylinder chambers.

4. The method for fusion and discrimination of single-cylinder pressure state of a multi-cylinder plunger pump based on phase synchronization according to claim 1, characterized in that: In step S5, the pressure characteristic value is a statistical characteristic quantity used to characterize the total oil discharge pressure response characteristics of the system within the corresponding phase interval. The statistical characteristic quantity includes at least one of the following: average value, peak value, integral value, or other numerical indicators that can reflect the pressure change characteristics within the phase interval. The vibration characteristic value is a statistical characteristic quantity used to characterize the vibration response characteristics of the structure within the corresponding phase interval, including at least one of the root mean square value, energy value, spectral characteristic value, or other numerical indicators that can reflect the vibration change characteristics of the phase interval.

5. The method for fusion and discrimination of single-cylinder pressure state of a multi-cylinder plunger pump based on phase synchronization according to claim 1, characterized in that: In step S6, when the pressure characteristic value of a certain phase interval is lower than the average value of the pressure characteristic values ​​of the other phase intervals multiplied by a preset threshold coefficient, it is determined that the corresponding plunger cylinder chamber is in an abnormal pressure state.

6. The method for fusion and discrimination of single-cylinder pressure state of a multi-cylinder plunger pump based on phase synchronization according to claim 1, characterized in that: Before determining an anomaly, statistical analysis is performed on the pressure characteristic values ​​of multiple consecutive rotation cycles. When the anomaly determination conditions are met for a preset number of consecutive cycles, the anomaly result is output.

7. A single-cylinder pressure state fusion and discrimination system for a multi-cylinder plunger pump based on phase synchronization, characterized in that: include: A plunger pump body, the plunger pump body including at least two plunger cylinder chambers, and multiple plunger cylinder chambers connected to the same crankshaft via a connecting rod mechanism; A phase acquisition unit (8) is installed on the crankshaft or a transmission component that rotates synchronously with the crankshaft and is used to output the crankshaft phase angle signal; The pressure acquisition unit (5) is located in the high-pressure manifold or its connecting oil passage that is connected to the oil discharge passage of multiple plunger cylinder chambers, and is used to acquire the total oil discharge pressure signal of the system. Vibration acquisition unit (7) is installed in the structure of the plunger pump and is used to acquire vibration signals of the plunger pump structure; The signal acquisition and processing module is connected to the phase acquisition unit (8), pressure acquisition unit (5) and vibration acquisition unit (7) respectively, and is configured to perform the method described in any one of claims (1) to (6).

8. The single-cylinder pressure state fusion and discrimination system for a multi-cylinder plunger pump based on phase synchronization according to claim (7), characterized in that: The phase acquisition unit (8) is an incremental rotary encoder or an absolute rotary encoder.

9. The single-cylinder pressure state fusion and discrimination system for a multi-cylinder plunger pump based on phase synchronization according to claim (7), characterized in that: The pressure acquisition unit (5) is a high-frequency response pressure sensor and is installed at the pressure interface position corresponding to the high-pressure manifold or its connecting oil passage.

10. The single-cylinder pressure state fusion and discrimination system for a multi-cylinder plunger pump based on phase synchronization as described in claim (7), characterized in that: The signal acquisition and processing module supports phase-synchronized triggering sampling and performs synchronous resampling processing on the system's total oil discharge pressure signal and structural vibration signal.

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