A system and method for checking the effect of submersible pump vibration signal preprocessing

Abstract

The application discloses a kind of submersible pump vibration signal pre-processing effect verification system and method, system includes main controller, signal generator, power amplifier, exciter, converter transformer model, acceleration sensor, power supply, submersible pump, oil pipeline and data acquisition analyzer.Signal generator generates the excitation signal matched with the vibration characteristic of converter transformer, drives exciter by power amplifier, so that converter transformer model produces analog vibration;The vibration is coupled to the running submersible pump by oil pipeline and insulating oil truly, and acceleration sensor acquires vibration signal and is handled by data acquisition analyzer.By first obtaining the reference vibration signal of submersible pump body, then superimposing known converter transformer vibration interference, the application provides a comparison basis for the reference signal and the real mixed signal of pre-processing algorithm, and quantitatively evaluates the algorithm effect in combination with fault classification model.The application can truly reproduce the field vibration coupling working condition, and the verification result is accurate and reliable.

Description

Technical Field

[0001] This invention relates to the field of vibration testing technology for power equipment, and specifically to a system and method for verifying the preprocessing effect of vibration signals from a submersible pump. Background Technology

[0002] Submersible oil pumps are the core equipment in the oil circulation cooling system of large converter transformers, and their operational reliability directly affects the transformer's heat dissipation efficiency and insulation life. Vibration signal analysis is a key method for diagnosing mechanical faults such as bearing wear and impeller imbalance in submersible oil pumps. However, the signal-to-noise ratio of the vibration signals from submersible oil pumps collected on-site is low, mainly due to strong interference from the vibration of the converter transformer itself. This interference is transmitted through the insulating oil pipelines, resulting in severe superposition with the vibration signals from the submersible oil pump itself.

[0003] To extract effective fault features from mixed signals, the original vibration signal must be preprocessed (e.g., noise reduction, filtering, feature enhancement). Currently, evaluating the effectiveness of these preprocessing algorithms faces the following problems: First, it is impossible to obtain vibration signals containing only the characteristics of the submersible pump itself as a benchmark at the operating site, leading to inaccurate evaluations; second, there is a lack of effective interference simulation methods. Existing laboratory equipment often uses simplified mechanical connections or signal simulations, making it difficult to reproduce the real physical process of converter transformer vibration transmitted through complex oil circuit structures. This results in a severe disconnect between the algorithm testing environment and the field, leading to low reliability of the verification results. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a system and method for verifying the preprocessing effect of vibration signals of submersible pumps in response to the above-mentioned problems in the prior art. This system can simulate the vibration coupling conditions on site and accurately verify the preprocessing effect of vibration signals of submersible pumps in converter transformers. It has the advantages of real data and accurate verification results.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0006] A submersible pump vibration signal preprocessing effect verification system includes: a main controller, a signal generator, a power amplifier, a vibrator, a converter transformer model, an acceleration sensor, a power supply, a submersible pump, an oil pipeline, and a data acquisition and analysis instrument.

[0007] The signal generator is connected to the main controller and the power amplifier respectively, and is used to generate an excitation signal that matches the vibration characteristics of the converter transformer;

[0008] The power amplifier is connected to the exciter;

[0009] The converter transformer model is rigidly mounted on the vibrator;

[0010] The submersible pump is connected to the converter transformer model through an oil pipeline, forming a closed oil circuit circulation;

[0011] The power source is connected to the submersible pump;

[0012] The acceleration sensor is mounted on the submersible pump body;

[0013] The data acquisition and analysis instrument is connected to the accelerometer and the main controller, respectively.

[0014] The main controller is used to coordinate the operation of the control signal generator, power supply and data acquisition and analysis instrument according to a preset timing sequence.

[0015] In some embodiments, the excitation signal generated by the signal generator consists of frequency components that are integer multiples of 50Hz with frequencies below 2kHz, and the main frequency energy accounts for more than 70% of the total frequency band energy.

[0016] In some embodiments, the exciter is an electromagnetic exciter, with a quantity of 4 units, each with a vibration force of not less than 1500N, an excitation direction of vertical, an operating frequency of up to 2kHz, and a first-order natural frequency higher than 4kHz.

[0017] In some embodiments, the converter transformer model includes insulating oil and an oil tank, the oil tank and the exciter are rigidly connected by bolts, and valves are installed on the bottom of both sides of the oil tank.

[0018] In some embodiments, the acceleration sensor is mounted on the arc surface at 1 / 2 the height of the submersible pump via an arc-shaped conformal strong magnetic base.

[0019] In some implementations, the data acquisition and analysis instrument has a sampling accuracy of not less than 16 bits, a sampling rate of not less than 16 kHz, and includes a signal conditioning unit that supports IEPE sensors.

[0020] In some implementations, the data acquisition and analysis instrument is configured to receive verification instructions from the main controller, call a preprocessing algorithm to process the acquired raw mixed vibration signal, obtain a preprocessed signal, and generate a quantitative evaluation result of the preprocessing algorithm's effectiveness by comparing and analyzing it with a pre-stored reference vibration signal.

[0021] In some implementations, the main controller is configured to: send instructions to a signal generator to control the output of an excitation signal; send instructions to a power supply to control the start and stop of the submersible pump; and send instructions to a data acquisition and analysis instrument to control the start, stop, and trigger conditions of data acquisition.

[0022] A method for verifying the preprocessing effect of vibration signals from a submersible pump includes the following steps:

[0023] S1. Start the submersible pump, turn off the signal generator, and collect the reference vibration signal of the submersible pump body;

[0024] S2. Keep the submersible pump running, start the signal generator, and apply the characteristic vibration of the converter transformer through the exciter;

[0025] S3. Under vibration coupling conditions, collect the original mixed vibration signal containing interference;

[0026] S4. Input the original mixed signal into the preprocessing algorithm to be verified to obtain the preprocessed signal; evaluate the preprocessing effect by comparing it with the reference signal.

[0027] In some implementations, step S2 involves changing the amplitude or spectral components of the excitation signal to simulate different interference intensities, and steps S2 to S4 are repeated; the comparative analysis in step S4 includes inputting the reference signal, the original mixed signal, and the preprocessed signal into the fault classification model, and quantitatively evaluating the preprocessing effect based on the change in classification error.

[0028] Compared with existing technologies, this invention has the following advantages: by driving a converter transformer model containing real insulating oil through an exciter and transmitting vibration through an actual oil pipeline, the core physical process of converter transformer vibration coupled to the submersible pump through the oil circuit is reproduced in the laboratory, and the simulation environment has high realism; a reference signal is obtained first, and then known interference is superimposed on the same source system, which provides an objective basis for evaluating the algorithm effect; the preprocessing effect is quantitatively evaluated by using the fault classification error of the diagnostic model as an indicator, and the verification results are more accurate. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the structure of the test system according to an embodiment of the present invention.

[0030] Figure 2 This is a schematic flowchart of the test method in an embodiment of the present invention. Detailed Implementation

[0031] like Figure 1As shown, a submersible pump vibration signal preprocessing effect verification system includes: a main controller, a signal generator, a power amplifier, a vibrator, a converter transformer model, an accelerometer, a power supply, a submersible pump, valves, an oil pipeline, and a data acquisition and analysis instrument. The signal generator is connected to the main controller and the power amplifier to generate an excitation signal with the same vibration frequency characteristics as the converter transformer. The power amplifier is connected to the signal generator and the vibrator. The converter transformer model is rigidly mounted on the vibrator. The submersible pump is connected to the converter transformer model through the oil pipeline, forming a closed oil circuit circulation. The power supply is used to drive the submersible pump. The accelerometer is mounted on the submersible pump body. The data acquisition and analysis instrument is connected to the accelerometer and the main controller to collect and process signals. The main controller coordinates and controls the signal generator, power supply, and data acquisition and analysis instrument to operate according to a preset timing sequence.

[0032] The signal generator can generate excitation signals through programming. These excitation signals consist of a series of frequency components that are integer multiples of 50Hz, with frequency components below 2kHz. The dominant frequencies are 100Hz, 200Hz, 300Hz, or 400Hz, and the dominant frequency energy accounts for more than 70% of the total frequency band energy. In this embodiment, the signal generator is a programmable function generator, controlled via a GPIB bus, and its output signal is amplified by a power amplifier.

[0033] In this embodiment, the exciter is an electromagnetic exciter, with a quantity of 4 units. Each unit has a vibration force of no less than 1500N, the excitation direction is vertical, the working frequency can reach 2kHz, and the first natural frequency is higher than 4kHz, so as to avoid resonance distortion during vibration simulation.

[0034] In this embodiment, the converter transformer model is a scaled-down simulated oil tank filled with insulating oil and rigidly connected to the common platform of four exciters by high-strength bolts. A valve is installed on each side of the bottom of the oil tank to control the oil flow and facilitate system maintenance.

[0035] In this embodiment, the submersible pump is a 3-phase 4-pole axial flow pump with a speed of 1420 r / min. Its inlet and outlet are connected to the oil tank of the converter transformer model through metal oil pipelines to form a closed loop.

[0036] In this embodiment, the sensor is an IEPE piezoelectric accelerometer, which is attached to a smooth part in the middle of the submersible pump housing by a specially made arc-shaped strong magnetic base (attraction force >200N).

[0037] In this embodiment, the data acquisition and analysis instrument uses a 24-bit high dynamic range data acquisition card with a maximum sampling rate of 51.2kHz. In this embodiment, the sampling rate is set to 16kHz. It has a built-in IEPE conditioning module that provides a 4mA constant current excitation.

[0038] The data acquisition and analysis instrument also has a built-in MATLAB-based signal processing algorithm library. After receiving the verification command from the main controller, it calls the embedded or connected preprocessing algorithm to process the acquired raw mixed vibration signal, obtains the preprocessed signal, and generates a quantitative evaluation result of the effect of the preprocessing algorithm by comparing and analyzing the preprocessed signal with the pre-stored reference vibration signal.

[0039] In this embodiment, the main controller is an industrial control computer running LabVIEW control software. It is responsible for the logic control and scheduling of the entire testing process and is configured to perform the following collaborative control:

[0040] 1) Send a command to the signal generator to control it to output an excitation signal that simulates the vibration characteristics of a converter transformer;

[0041] 2) Send commands to the power source to control the start-up, shutdown, and operating conditions of the submersible pump;

[0042] 3) Send instructions to the data acquisition and analysis instrument to control the start, stop and trigger conditions of its acquisition.

[0043] The timing control flow of the main controller is as follows:

[0044] 1) Control the power supply to start, drive the submersible pump to run and enter a stable operating condition;

[0045] 2) After the submersible pump has been running stably, control the data acquisition and analysis instrument to start acquiring data to obtain a reference vibration signal;

[0046] 3) While maintaining data acquisition, start the signal generator and apply simulated converter transformer vibration interference through the exciter;

[0047] 4) After the mixed signal acquisition of the preset duration is completed, control the signal generator and the data acquisition and analysis instrument to stop in sequence.

[0048] like Figure 2 As shown, the specific steps for verification using the above system are as follows:

[0049] S1) Reference Signal Acquisition: The signal generator is turned off, and the main controller starts the frequency converter power supply to drive the submersible pump to run at the rated voltage (380V). After running for 2 minutes, the insulating oil flows stably. At this time, the main controller sends a trigger signal to the data acquisition and analysis instrument to collect 10s of submersible pump vibration data at a sampling rate of 16kHz and store it as baseline.mat, which is the reference vibration signal.

[0050] S2) Composite Vibration Simulation: While the submersible pump remains operational, the main controller sends a command to the signal generator, instructing it to output a set of preset excitation signals. This signal is composed of superimposed sine waves of 100Hz (main frequency, accounting for 50% of energy), 200Hz (accounting for 20% of energy), 300Hz, and 400Hz (each accounting for 10% of energy), with a total bandwidth of 2kHz. The power amplifier amplifies this signal and drives four exciters to synchronously vibrate vertically, thus simulating the transformer model's body vibration. This vibration is transmitted to the submersible pump through insulating oil and pipes.

[0051] S3) Mixed signal acquisition: The main controller synchronously triggers the data acquisition and analysis instrument to acquire 10 seconds of raw mixed vibration signal and store it as mixed_raw.mat.

[0052] S4) After receiving the "Start Verification" command from the main controller, the data acquisition and analysis instrument calls the preprocessing algorithm to be tested to process mixed_raw.mat and generate processed.mat. In this embodiment, the preprocessing algorithm is a combination of adaptive notch filtering and wavelet threshold denoising. In this embodiment, the baseline, mixed_raw, and processed data are respectively input into a deep learning fault classification model pre-trained with historical data. This model can identify three states: normal, bearing wear, and impeller imbalance. The classification results and confidence levels of the model for the three states are recorded. By comparing the reduction in classification error of the model for the processed data relative to that for the mixed_raw data, the effect of the preprocessing algorithm on suppressing coupled vibration interference from the converter transformer is indirectly and comprehensively quantified and evaluated, and the results are uploaded to the main controller interface for display.

[0053] To test the stability of the algorithm under different interference intensities, steps S2) to S4) can be repeated. During each repetition, the total amplitude of the signal generator output signal is changed (e.g., by varying it to -6dB, 0dB, and +6dB) or the energy ratio of each harmonic component is adjusted via programming the main controller to simulate the transformer vibration state under different loads. Finally, the robustness of the algorithm is determined based on the stability of its evaluation indicators under various interference conditions.

[0054] Furthermore, the present invention also provides a computer-readable storage medium storing a computer program programmed or configured to perform the submersible pump vibration signal preprocessing effect verification method.

[0055] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A system for verifying the preprocessing effect of vibration signals from a submersible pump, characterized in that, include: Main controller, signal generator, power amplifier, vibrator, converter transformer model, accelerometer, power supply, submersible pump, oil pipeline and data acquisition and analysis instrument; The signal generator is connected to the main controller and the power amplifier respectively, and is used to generate an excitation signal that matches the vibration characteristics of the converter transformer; The power amplifier is connected to the exciter; The converter transformer model is rigidly mounted on the vibrator; The submersible pump is connected to the converter transformer model through an oil pipeline, forming a closed oil circuit circulation; The power source is connected to the submersible pump; The acceleration sensor is mounted on the submersible pump body; The data acquisition and analysis instrument is connected to the accelerometer and the main controller, respectively. The main controller is used to coordinate the operation of the control signal generator, power supply and data acquisition and analysis instrument according to a preset timing sequence.

2. The system according to claim 1, characterized in that, The excitation signal generated by the signal generator consists of frequency components that are integer multiples of 50Hz with frequencies below 2kHz, and the main frequency energy accounts for more than 70% of the total frequency band energy.

3. The system according to claim 1, characterized in that, The exciter is an electromagnetic exciter, with a quantity of 4 units. Each unit has a vibration force of no less than 1500N, an excitation direction of vertical, an operating frequency of up to 2kHz, and a first-order natural frequency higher than 4kHz.

4. The system according to claim 1, characterized in that, The converter transformer model includes insulating oil and an oil tank. The oil tank and the exciter are rigidly connected by bolts, and valves are installed on the bottom of both sides of the oil tank.

5. The system according to claim 1, characterized in that, The acceleration sensor is mounted on the arc surface at 1 / 2 the height of the submersible pump via an arc-shaped conformal strong magnetic base.

6. The system according to claim 1, characterized in that, The data acquisition and analysis instrument has a sampling accuracy of no less than 16 bits, a sampling rate of no less than 16 kHz, and includes a signal conditioning unit that supports IEPE sensors.

7. The system according to claim 1, characterized in that, The data acquisition and analysis instrument is configured to receive verification instructions from the main controller, call the preprocessing algorithm to process the acquired raw mixed vibration signal, obtain the preprocessed signal, and generate a quantitative evaluation result of the preprocessing algorithm effect by comparing and analyzing it with the pre-stored reference vibration signal.

8. The system according to claim 1, characterized in that, The main controller is configured to: send commands to the signal generator to control the output of the excitation signal; send commands to the power supply to control the start and stop of the submersible pump; and send commands to the data acquisition and analysis instrument to control the start, stop, and trigger conditions of data acquisition.

9. A method for verifying the preprocessing effect of vibration signals from a submersible pump, characterized in that, Includes the following steps: S1. Start the submersible pump, turn off the signal generator, and collect the reference vibration signal of the submersible pump body; S2. Keep the submersible pump running, start the signal generator, and apply the characteristic vibration of the converter transformer through the exciter; S3. Under vibration coupling conditions, collect the original mixed vibration signal containing interference; S4. Input the original mixed signal into the preprocessing algorithm to be verified to obtain the preprocessed signal; evaluate the preprocessing effect by comparing it with the reference signal.

10. The method according to claim 9, characterized in that, In step S2, the amplitude or spectral components of the excitation signal are changed to simulate different interference intensities, and steps S2 to S4 are repeated; the comparative analysis in step S4 includes inputting the reference signal, the original mixed signal and the preprocessed signal into the fault classification model, and quantitatively evaluating the preprocessing effect based on the change in classification error.

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