Method and device for detecting and maintaining the extent of damage to a compressor

Abstract

The application relates to a compressor damage degree detection and maintenance method and device, wherein the steps of the method comprise the following: in the case that it is detected that the compressor is in a reverse rotation state, a first target operating parameter of the compressor is collected, and it is judged whether an immediate shutdown condition is met according to the relationship between the first target operating parameter and a first preset threshold value; if the immediate shutdown condition is met, the compressor is immediately controlled to be shut down; after the compressor is switched to a forward rotation state and stably operates, a second target operating parameter of the compressor is collected, the second target operating parameter is converted into a quantitative score representing a damage degree, a plurality of quantitative scores are weighted and fused according to the contribution degree of the second target operating parameter to reverse damage, and a comprehensive health index representing the damage degree of the compressor is obtained; according to the matching relationship between the comprehensive health index and a plurality of preset damage grade threshold value intervals, the damage grade of the compressor after reverse rotation is determined, and a maintenance strategy corresponding to the damage grade is output.

Description

Technical Field

[0001] This application relates to the field of compressor technology, and in particular to a method and apparatus for detecting and maintaining the degree of damage to a compressor. Background Technology

[0002] As the core power component of air conditioning and other refrigeration and heating systems, the compressor's operational reliability directly determines the overall system's performance stability and service life. In practical applications, compressors can experience abnormal reverse rotation due to factors such as incorrect three-phase wiring, malfunctioning inverter control logic, external electromagnetic interference, or backflow impact during shutdown. This is a highly dangerous type of failure. Reverse compressor operation disrupts the rotor's axial and radial dynamic balance, damages the bearing's one-way lubrication mechanism, causes rotor axial movement, and damages the sealing end face structure, while also exacerbating mechanical friction losses. If not identified and intervened in time, it can lead to increased rotor wear, bearing overheating and burnout, and shaft seal leakage in the short term, and in the long term, it can cause the compressor to be completely scrapped, the entire system to shut down, resulting in high maintenance costs and production losses.

[0003] Current technical solutions for compressor fault diagnosis rely on a single dimension for judgment and have a rather one-sided assessment. Most technical solutions only rely on single parameters such as vibration and temperature for judgment, which makes them unable to adapt to more scenarios. Summary of the Invention

[0004] This application provides a method and apparatus for detecting and maintaining the degree of damage to a compressor, in order to solve the problem that the existing technology relies solely on a single parameter such as vibration and temperature for judgment, which makes it unsuitable for a wider range of scenarios.

[0005] Firstly, this application provides a method for detecting and maintaining the degree of damage to a compressor, including: When the compressor is detected to be in reverse operation, the first target operating parameter of the compressor is collected, and the relationship between the first target operating parameter and the first preset threshold is used to determine whether the immediate shutdown condition is met. If the immediate shutdown condition is met, the compressor is controlled to stop immediately; otherwise, the compressor is switched to forward operation. After the compressor switches to forward rotation and operates stably, the second target operating parameters of the compressor are collected. The second target operating parameters are converted into quantitative scores that characterize the degree of damage. Then, based on the contribution of the second target operating parameters to the reverse rotation damage, multiple quantitative scores are weighted and fused to obtain a comprehensive health index that characterizes the degree of damage to the compressor. Based on the matching relationship between the comprehensive health index and multiple preset damage level threshold ranges, the damage level of the compressor after reversal is determined, and a maintenance strategy corresponding to the damage level is output.

[0006] Secondly, this application provides a device for detecting and maintaining the degree of damage to a compressor, comprising: The first processing module is used to collect the first target operating parameters of the compressor when it is detected that the compressor is in reverse operation state, and determine whether the immediate shutdown condition is met according to the relationship between the first target operating parameters and the first preset threshold. If the immediate shutdown condition is met, the compressor is controlled to stop immediately; otherwise, the compressor is switched to forward operation state. The second processing module is used to collect the second target operating parameters of the compressor after the compressor switches to forward operation and runs stably, convert the second target operating parameters into a quantitative score characterizing the degree of damage, and then perform weighted fusion of multiple quantitative scores according to the contribution of the second target operating parameters to the reverse rotation damage to obtain a comprehensive health index characterizing the degree of damage to the compressor. The third processing module is used to determine the damage level of the compressor after reversal based on the matching relationship between the comprehensive health index and multiple preset damage level threshold ranges, and output a maintenance strategy corresponding to the damage level.

[0007] Thirdly, this application provides an electronic device, comprising: at least one communication interface; at least one bus connected to the at least one communication interface; at least one processor connected to the at least one bus; and at least one memory connected to the at least one bus, wherein the processor is configured to perform the compressor damage detection and maintenance method described in the first aspect of this application above.

[0008] Fourthly, this application also provides a computer storage medium storing computer-executable instructions for executing the compressor damage detection and maintenance method described in the first aspect of this application.

[0009] Compared with the prior art, the technical solution provided in this application has the following advantages: The method provided in this application, when detecting that the compressor is in reverse operation, collects the first target operating parameters of the compressor and determines whether the immediate shutdown condition is met based on the relationship between the first target operating parameters and the first preset threshold. If the immediate shutdown condition is met, the compressor is immediately shut down; otherwise, the compressor is switched to forward operation. Then, after the compressor switches to forward operation and runs stably, the second target operating parameters of the compressor are collected and converted into quantitative scores representing the degree of damage. Multiple quantitative scores are then weighted and fused based on the contribution of the second target operating parameters to the reverse damage to obtain a comprehensive health index representing the degree of compressor damage. Finally, based on the matching relationship between the comprehensive health index and multiple preset damage level threshold ranges, the damage level of the compressor after reverse operation is determined, and a maintenance strategy corresponding to the damage level is output. It can be seen that the first stage (reverse operation) achieves a faster emergency response through simple threshold comparison, avoiding the escalation of serious accidents; the second stage (forward operation) achieves a refined assessment through multi-parameter weighted fusion, avoiding production losses caused by erroneous shutdowns. Furthermore, a diagnostic process and parameter system were designed for the inversion failure mechanism. At the same time, multi-parameter weighted fusion was used to cover all dimensions of inversion damage, achieving accurate diagnosis of inversion damage. Attached Figure Description The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with the invention and, together with the description, serve to explain the principles of the invention.

[0010] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0011] One or more embodiments are illustrated by way of example with reference numerals in the accompanying drawings. These illustrations do not constitute a limitation on the embodiments. Elements with the same reference numerals in the drawings are denoted as similar elements. Unless otherwise stated, the figures in the drawings are not to be limited by scale.

[0012] Figure 1 A flowchart illustrating a method for detecting and maintaining the degree of damage to a compressor, as provided in an embodiment of this application; Figure 2 A flowchart illustrating a method for diagnosing the degree of damage after a compressor reverses, provided in an embodiment of this application; Figure 3 A flowchart for the five-dimensional health value scoring provided in the embodiments of this application; Figure 4A circuit diagram related to the diagnosis of the degree of damage after compressor reversal provided in an embodiment of this application; Figure 5 A schematic diagram of the structure of the compressor damage detection and maintenance device provided in the embodiments of this application; Figure 6 This is a schematic diagram of the structure of an electronic device provided in an embodiment of this application. Detailed Implementation

[0013] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0014] The following disclosure provides numerous different embodiments or examples for implementing various structures of the invention. To simplify the disclosure, specific examples of components and arrangements are described below. These are merely examples and are not intended to limit the scope of the invention. Furthermore, reference numerals and / or letters may be repeated in different examples. Such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed.

[0015] To address the problem that existing technologies rely solely on single parameters such as vibration and temperature for assessment, making them unsuitable for a wider range of scenarios, this application provides a method for detecting and maintaining the degree of compressor damage, such as... Figure 1 As shown, the steps of this method include: Step 101: When the compressor is detected to be in reverse operation, the first target operating parameters of the compressor are collected, and the relationship between the first target operating parameters and the first preset threshold is used to determine whether the immediate shutdown condition is met. If the immediate shutdown condition is met, the compressor is controlled to stop immediately; otherwise, the compressor is switched to forward operation. In this embodiment, the reverse operation state refers to an abnormal operating condition in which the compressor's rotation direction is opposite to the preset forward rotation direction. The triggering causes of this condition may include three-phase wiring errors, inverter control logic malfunctions, external electromagnetic interference, or shutdown backflow impacts.

[0016] The first target operating parameters refer to key physical quantities collected at the instant of reverse rotation for emergency hazard assessment, such as rotor vibration value, bearing temperature value, and operating noise value. These parameters can instantly reflect the most direct mechanical shock and heat accumulation effects during the reverse rotation process. The first preset threshold is a pre-set critical value for danger. When the operating parameters reach or exceed this value, it indicates that the reverse rotation has caused serious damage to the compressor that could immediately lead to catastrophic failure. In a specific example, after the compressor reverses, the vibration sensor measures a rotor vibration value of 8.5 mm / s, while the preset rotor vibration danger threshold is 7.1 mm / s. Since 8.5 > 7.1, the system immediately determines that the immediate shutdown conditions are met and executes an emergency shutdown.

[0017] Step 102: After the compressor switches to forward rotation and runs stably, the second target operating parameters of the compressor are collected, and the second target operating parameters are converted into quantitative scores that characterize the degree of damage. Then, based on the contribution of the second target operating parameters to the reverse rotation damage, multiple quantitative scores are weighted and fused to obtain a comprehensive health index that characterizes the degree of compressor damage. In this embodiment, "stable operation" refers to a stage where the compressor's speed, load, and other operating states reach a relatively stable state after a preset buffer period following switching to forward rotation. This avoids collecting data during the transient fluctuations of the switching transition, ensuring that the parameters used in subsequent evaluations accurately reflect the continuous damage caused by reverse rotation, rather than the instantaneous disturbances of the transition process. The second target operating parameters refer to a set of parameters used for a detailed assessment of the degree of reverse rotation damage. These parameters may partially overlap with the first target operating parameters used for emergency judgment in the first stage, but are preferably more comprehensive and targeted. The second target operating parameters may include rotor vibration values, bearing temperature values, operating noise values, bearing lubrication pressure values, and rotor axial movement values.

[0018] Reverse rotation damage is gradual and delayed; that is, some damage does not immediately manifest as a danger signal at the moment of reverse rotation, but gradually becomes apparent after forward rotation resumes (e.g., damage to the bearing lubrication film leading to a drop in lubrication pressure, or increased axial movement of the rotor due to reverse impact). Therefore, collecting parameters again after switching to forward rotation and stabilizing operation can capture this delayed damage information, enabling a more comprehensive assessment. For example, after a compressor reverses, the vibration value collected during the reverse phase is 5.5 mm / s and the temperature is 85℃, neither of which reaches the danger threshold, so the system switches it to forward rotation. After 3 minutes of stable forward operation, the system collects a second set of target operating parameters and finds that the bearing lubrication pressure is only 65% ​​of the rated pressure and the axial movement reaches 0.25 mm. This means that these two parameters were not fully exposed at the moment of reverse rotation, but only revealed substantial damage caused by the reverse rotation after forward rotation stabilizes.

[0019] Furthermore, in this embodiment, the conversion refers to converting operating parameters with different physical dimensions (such as mm / s, ℃, dB, MPa, mm) into dimensionless standardized score values ​​through a preset mapping relationship (such as linear or nonlinear mapping). Quantitative scoring refers to mapping each dimension's operating parameter to a specific value within the range of 0 to 100 points, where 0 points represent the most severe damage state of that dimension, and 100 points represent complete health and no damage. Through this conversion, parameters with originally different physical meanings obtain a unified comparable scale. For example, if the measured rotor vibration value is 5.0 mm / s, the preset health benchmark value is 1.0 mm / s, and the severe damage threshold is 7.1 mm / s, then through the linear mapping formula, this vibration value is converted to approximately 65 points; if the measured bearing temperature is 85℃, the preset health benchmark value is 60℃, and the severe damage threshold is 100℃, then it is converted to approximately 75 points.

[0020] Furthermore, in this embodiment, contribution refers to the difference in sensitivity and importance of each operating parameter in reflecting the severity of reverse rotation damage. For example, reverse rotation most directly and significantly damages the rotor's dynamic balance, therefore the rotor vibration value contributes the most to reverse rotation damage; while the rotor axial movement only changes significantly when reverse rotation causes axial impact, and its contribution is relatively low. Weighted fusion refers to assigning weight coefficients matching their contribution to each quantitative score, multiplying each score by its corresponding weight, and summing the results to obtain a comprehensive single value. The comprehensive health index is a quantitative indicator that comprehensively reflects the overall damage level of the compressor, obtained through weighted fusion. This index is a dimensionless value, and its level directly represents the quality of the remaining health level of the equipment. That is to say, the actual damage caused by reverse rotation is often multifaceted—the rotor's dynamic balance is disrupted, the bearing lubrication film is sheared, the sealing structure is impacted, etc., and no single parameter can fully reflect the overall damage level. Through weighted fusion, damage information from various dimensions can be integrated into a comprehensive index, achieving a quantitative grasp of the overall health status. For example, if the vibration score is 65 (weight 30%), the temperature score is 75 (weight 25%), the noise score is 80 (weight 20%), the lubrication pressure score is 50 (weight 15%), and the axial movement score is 60 (weight 10%), then the comprehensive health index HI = 65×30% + 75×25% + 80×20% + 50×15% + 60×10% = 67.75 points. It can be seen that by achieving synergistic integration of multi-dimensional damage information through the above method, the one-sidedness and unreliability of single-parameter assessment are overcome. Through differentiated weighting of contributions, the assessment results are made more closely aligned with the actual physical mechanism of inversion damage.

[0021] Step 103: Based on the matching relationship between the comprehensive health index and multiple preset damage level threshold ranges, determine the damage level after the compressor reverses, and output the maintenance strategy corresponding to the damage level.

[0022] In this embodiment, the damage level threshold range refers to dividing the comprehensive health index range into several continuous but non-overlapping sub-ranges according to multiple preset threshold values ​​(i.e., health thresholds), with each sub-range corresponding to a damage level. For example, it can be divided into four levels: normal (HI≥85), mild damage (70≤HI<85), moderate damage (50≤HI<70), and severe damage (HI<50). The maintenance strategy refers to a pre-defined differentiated maintenance action plan for different damage levels, including but not limited to: no maintenance required, enhanced monitoring and preventative maintenance, scheduled maintenance, and immediate shutdown for emergency repairs. For example, if the calculated HI=67.75 falls within the 50≤HI<70 range, the system determines it to be in a moderate damage state and outputs a maintenance strategy to schedule maintenance work. Maintenance personnel can then schedule maintenance during the nearest production break, avoiding unplanned downtime caused by sudden failures.

[0023] As can be seen, through steps 101 to 103 above, when the compressor is detected to be in reverse operation, the first target operating parameters of the compressor are collected, and the relationship between the first target operating parameters and the first preset threshold is used to determine whether the immediate shutdown condition is met. If the immediate shutdown condition is met, the compressor is controlled to stop immediately; otherwise, the compressor is switched to forward operation. Then, after the compressor switches to forward operation and runs stably, the second target operating parameters of the compressor are collected, and the second target operating parameters are converted into quantitative scores representing the degree of damage. Then, based on the contribution of the second target operating parameters to the reverse damage, multiple quantitative scores are weighted and fused to obtain a comprehensive health index representing the degree of compressor damage. Finally, based on the matching relationship between the comprehensive health index and multiple preset damage level threshold ranges, the damage level of the compressor after reverse operation is determined, and a maintenance strategy corresponding to the damage level is output. It can be seen that the first stage (reverse operation) achieves a faster emergency response through simple threshold comparison, avoiding the expansion of serious accidents; the second stage (forward operation) achieves a more refined assessment through multi-parameter weighted fusion, avoiding production losses caused by accidental shutdown. Furthermore, a diagnostic process and parameter system were designed for the inversion failure mechanism. At the same time, multi-parameter weighted fusion was used to cover all dimensions of inversion damage, achieving accurate diagnosis of inversion damage.

[0024] In an optional embodiment of this application, the method of collecting the first target operating parameters of the compressor and determining whether the immediate shutdown condition is met based on the relationship between the first target operating parameters and the first preset thresholds corresponding to the first target operating parameters in step 101 above may further include: Step 11: Collect the compressor's rotor vibration value, bearing temperature value, and operating noise value as the first target operating parameters; In this embodiment, the rotor vibration value refers to the radial or axial vibration amplitude generated by the compressor rotor during rotation, typically collected by a vibration sensor attached to the compressor bearing. When reverse rotation occurs, the rotor's dynamic balance is instantly disrupted, and the clearance between the rotor and the bearing changes abnormally, leading to a sharp increase in vibration amplitude. The vibration value directly reflects the intensity of the mechanical impact caused by reverse rotation and the degree of stability degradation of the rotor system.

[0025] The bearing temperature refers to the operating temperature of the compressor bearing, collected by a temperature sensor attached to the outer ring of the bearing or the nearby housing. During reverse operation, the one-way lubrication mechanism of the bearing is disrupted (the lubricating oil film cannot be properly established), and the friction between the rotor and the bearing increases dramatically, causing the bearing temperature to rise rapidly. The bearing temperature directly reflects the degree of heat load accumulation caused by reverse operation and the severity of lubrication failure.

[0026] Operating noise refers to the intensity of sound radiation generated during compressor operation, collected by acoustic sensors. When reverse rotation occurs, abnormal impacts between mechanical components, abnormal changes in fluid pulsation, and increased friction all produce significant noise increases. Operating noise reflects both the mechanical structural abnormalities caused by reverse rotation and the degree of deviation between reverse and normal operation.

[0027] The three parameters mentioned above together constitute the three-dimensional index system for real-time damage monitoring during reversal: vibration represents mechanical impact damage, which is the most direct and rapid form of damage at the moment of reversal; temperature represents thermal accumulation damage, which is the form of damage that gradually intensifies during the continuous reversal; and noise represents structural anomalies, which is a comprehensive representation of the deviation of the overall operating state caused by reversal. The time response characteristics of these three parameters are complementary: vibration response is the fastest (milliseconds), temperature response is relatively slow (seconds to minutes), and noise response is in between. This complementarity ensures that the system can capture abnormal signals at the first moment, regardless of the time scale at which the reversal damage develops.

[0028] Step 12: Determine whether the rotor vibration value reaches or exceeds the preset rotor vibration danger threshold, whether the bearing temperature value reaches or exceeds the preset bearing temperature danger threshold, and whether the operating noise value reaches or exceeds the preset operating noise danger threshold. As can be seen, in this embodiment, the first-stage judgment method is to judge each parameter independently. Each of the three parameters corresponds to an independent preset danger threshold: rotor vibration danger threshold (e.g., 7.1 mm / s), bearing temperature danger threshold (e.g., 100°C), and operating noise danger threshold (e.g., 65 dB). The judgments of each parameter are independent and do not affect each other—each parameter is compared separately with its respective threshold. At the instant of reversal, once any single-dimensional damage reaches a dangerous level, it indicates that the compressor is facing an immediate equipment safety risk. For example, vibration exceeding the threshold means that the rotor has become severely eccentric and may soon rub against the rotor; temperature exceeding the threshold means that the bearing lubrication has completely failed and may soon seize up. Therefore, in such an emergency scenario, it is not advisable to use a comprehensive judgment that takes the best of each parameter and compensates for its weaknesses. Instead, a "weakest link" judgment should be used—if any parameter touches the danger line, emergency intervention should be triggered.

[0029] Step 13: If any one of the rotor vibration value, bearing temperature value, and operating noise value reaches or exceeds its corresponding danger threshold, it is determined that the immediate shutdown condition is met; if the rotor vibration value, bearing temperature value, and operating noise value are all less than their respective danger thresholds, it is determined that the immediate shutdown condition is not met.

[0030] As can be seen, in this embodiment, the logic for determining the immediate shutdown condition is an OR relationship. That is, if any one of the three parameters reaches or exceeds the corresponding danger threshold, the immediate shutdown condition is met, avoiding the dilemma of comprehensive scoring masking extreme risks. If a weighted comprehensive scoring model is used, there might be situations where the vibration value severely exceeds the threshold (indicating severe rotor eccentricity) but the temperature and noise values ​​are still within the normal range. The comprehensive score might be inflated to the conclusion that shutdown is unnecessary due to other dimensions being normal, thus delaying emergency intervention and leading to catastrophic consequences such as rotor rubbing. By using the logic of shutting down at any exceeding limit, it ensures that severe anomalies in any dimension are not masked by normal values ​​in other dimensions, fundamentally eliminating the blind spot in assessment where comprehensive indicators mask local fatal risks. Only when none of the three parameters reach their respective danger thresholds does the system determine that the immediate shutdown condition is not met, allowing the compressor to switch to forward operation and enter the second stage of detailed evaluation.

[0031] In an optional embodiment of this application, the method of converting the second target operating parameters of the compressor involved in step 102 above into a quantitative score characterizing the degree of damage may further include: Step 21: Collect the compressor's rotor vibration value, bearing temperature value, operating noise value, bearing lubrication pressure value, and rotor axial movement value as the second target operating parameters; Step 22: Using the preset rotor vibration health benchmark value and rotor vibration severe damage threshold as boundaries, map the collected rotor vibration values ​​to the first scoring interval to obtain the rotor vibration score. Step 23: Using the preset bearing temperature health benchmark value and bearing temperature severe damage threshold as boundaries, map the collected bearing temperature values ​​to the second scoring interval to obtain the bearing temperature score. Step 24: Using the preset operating noise health benchmark value and operating noise severe damage threshold as boundaries, map the collected operating noise values ​​to the third scoring interval to obtain the operating noise score; Step 25: Using the preset bearing lubrication pressure health benchmark value and bearing lubrication pressure severe damage threshold as boundaries, map the collected bearing lubrication pressure value to the fourth scoring interval to obtain the bearing lubrication pressure score. Step 26: Using the preset healthy baseline value of rotor axial movement and the severe damage threshold of rotor axial movement as boundaries, map the collected rotor axial movement value to the fifth scoring interval to obtain the rotor axial movement score.

[0032] The same parameter uses the same physical boundary value in both stages, but this value serves as the boundary for determining whether to trigger an emergency shutdown in the first stage, and as the physical boundary for scoring zero in this dimension in the second stage. The two functions are different and independent of each other. For example, the rotor vibration uses a danger threshold of 7.1 mm / s in the first stage, and also uses a severe damage threshold of 7.1 mm / s in the second stage as the scoring boundary.

[0033] As can be seen, in this embodiment, each second target operating parameter is scored and mapped according to its own preset health baseline value and severe damage threshold. The core logic of the scoring is: when the parameter is at the health baseline value, the corresponding score is full (100 points), indicating that the dimension has not suffered any substantial damage; when the parameter reaches or exceeds the severe damage threshold (for positive degradation parameters such as vibration, temperature, noise, and axial movement) or reaches or falls below the severe damage threshold (for negative degradation parameters such as lubrication pressure), the corresponding score is zero (0 points), indicating that the dimension is in the most severe damage state; parameter values ​​between the two are assigned a score value between 0 and 100 points according to a preset mapping relationship (such as linear mapping and nonlinear mapping).

[0034] In specific examples, the physical cumulative characteristics of reversed damage are better suited to a nonlinear mapping approach. Taking bearing temperature as an example: when the bearing temperature rises from 60℃ to 70℃, the decrease in lubricating oil viscosity is limited, and the bearing remains in a mixed lubrication state, with a relatively slow damage development rate. However, when the bearing temperature rises from 90℃ to 100℃, the lubricating oil film is nearly completely ruptured, and direct metal-to-metal contact intensifies. The damage increment represented by each 1℃ increase in temperature is far higher than that in the low-temperature range. Similarly, when rotor vibration increases from 2.0 mm / s to 3.0 mm / s, the deterioration of rotor dynamic balance is still gradual and controllable. However, when it increases from 6.0 mm / s to 7.1 mm / s, the rotor is close to the critical state of rubbing against the stator, and the danger represented by a unit increase in vibration rises sharply. In other words, the sensitivity is higher on the side closer to the severe damage threshold than on the side farther from the severe damage threshold, meaning the rate of decrease in the score shows an increasing trend.

[0035] Let the health baseline value for a certain parameter be H, the severe damage threshold be D, and the measured value be X. For positively deteriorating parameters (the larger the measured value, the more severe the damage, such as vibration, temperature, noise, and axial runout), the normalized damage ratio r is defined as: r = (X H) / (D H), where X ∈ [H, D] When X=H, r=0, representing no damage; when X=D, r=1, representing severe damage.

[0036] The nonlinear mapping uses a power function to map r to a score S: S = 100 × (1 r^n), where n>1 Where n is a nonlinear exponent, the value of which determines the curvature of the mapping curve. When n=1, the above formula degenerates into a linear mapping; when n>1, the rate of decrease in score increases with the increase of r.

[0037] Taking bearing temperature as an example, let the healthy baseline value H = 60℃, the severe damage threshold D = 100℃, and the nonlinear exponent n = 2: When the measured temperature is 70℃, r = (70 60) / (100 60) = 0.25, S = 100 × (1 0.25²) = 93.75 points. Compared with the linear mapping (75 points), the nonlinear mapping scores higher in the low-temperature range, reflecting the physical characteristic of slow damage development in the low-temperature range, that is, a slight temperature rise does not quickly trigger an excessively low score.

[0038] When the measured temperature is 90℃, r = (90 60) / (100 60) = 0.75, S = 100 × (1 (0.75²) = 43.75 points. Compared to the linear mapping (25 points), the nonlinear mapping scores slightly higher in the high-temperature range. However, it is important to note that within the 10°C interval from 90°C to 100°C, the score rapidly drops from 43.75 points to 0 points, with a decrease rate of 4.375 points per degree Celsius, far exceeding the linear mapping's 2.5 points per degree Celsius in the same interval. This reflects the design intention that the scoring sensitivity increases as the distance from the severe injury threshold increases.

[0039] Furthermore, the value of the nonlinear exponent n determines the curvature of the mapping curve and should be set according to the physical damage accumulation characteristics of each parameter: The rotor vibration value can be taken as n=1.5 to 2.5. Vibration damage exhibits a significant accelerated deterioration characteristic when approaching the critical value of rotor rubbing, and a moderate degree of nonlinearity can reasonably reflect this trend.

[0040] The bearing temperature value can be taken as n=2.0 to 3.0. The effect of temperature on the lubricating oil film is exponential—when the temperature exceeds the upper limit of the allowable temperature of the lubricating oil, the oil film strength drops sharply, so a high degree of nonlinearity is required to capture this abrupt change.

[0041] The operating noise value can be taken as n=1.5 to 2.0. The noise variation is relatively continuous, and the degree of nonlinearity can be appropriately reduced.

[0042] The bearing lubrication pressure can be taken as n = 2.5 to 3.5. Once the lubrication pressure drops below the critical value, the bearing will immediately enter a dry friction state, and the damage will deteriorate precipitously. The highest degree of nonlinearity is required to accurately describe this sudden change.

[0043] The rotor axial movement can be taken as n = 1.5 to 2.0. The accumulation process of axial movement is relatively gradual, and the degree of nonlinearity can be kept moderate.

[0044] As can be seen, through the above method, five parameters comprehensively assess reversal damage from five independent physical dimensions: mechanical vibration, heat accumulation, structural anomalies, lubrication failure, and axial impact. These dimensions complement and corroborate each other, overcoming the limitations of single-parameter assessments. After each parameter is scored independently, maintenance personnel can directly and intuitively determine which dimension's damage is most severe based on the individual scores (e.g., in the example, a runout score of 40 indicates that axial impact is the most significant form of damage in this reversal), providing clear direction for subsequent precise maintenance. More importantly, extending the use of vibration, temperature, and noise from the first stage to the second stage allows for differentiated use of the same parameter in both emergency judgment and detailed assessment stages, fully leveraging the application value of the same physical quantity in different decision-making scenarios. The introduction of bearing lubrication pressure and axial runout further expands the assessment dimensions to the most core and characteristic physical characteristics of reversal damage, significantly improving the diagnostic specificity of the assessment system for reversal faults.

[0045] In an optional embodiment of this application, the method of weighting and fusing multiple quantitative scores based on the contribution of the second target operating parameters to the reversal damage in step 102 above to obtain a comprehensive health index characterizing the degree of compressor damage may further include: Step 31: Assign preset weight coefficients to the rotor vibration score, bearing temperature score, operating noise score, bearing lubrication pressure score, and rotor axial movement score, respectively. The magnitude of the weight coefficient is positively correlated with the contribution of each parameter to the reverse damage. Step 32: Multiply each quantitative score by its corresponding weight coefficient and sum them to obtain the comprehensive health index.

[0046] In the embodiments of this application, the rotor vibration value contributes the most to the reverse rotation damage because at the moment the reverse rotation occurs, the rotor dynamic balance is forcibly disrupted, the gap between the rotor and the bearing changes abnormally, and the vibration amplitude increases sharply. This response is the most direct and fastest physical consequence of the reverse rotation, and there is a clear positive correlation between the magnitude of the vibration amplitude and the severity of the mechanical damage.

[0047] The bearing temperature contributes less to the damage caused by reverse rotation, because reverse rotation disrupts the bearing's unidirectional lubrication mechanism, leading to increased friction and temperature rise. However, the temperature rise is a result of frictional work and is a secondary effect of the damage rather than an initial manifestation, and there is a certain time lag.

[0048] Operating noise ranks third in its contribution to reverse rotation damage. This is because structural anomalies and component impacts caused by reverse rotation generate additional noise radiation. However, noise is also affected by various factors such as ambient background noise and installation foundation conditions, and its specificity to reverse rotation damage is relatively limited.

[0049] The contribution of bearing lubrication pressure to reverse damage ranks fourth, because although the decrease in lubrication pressure reflects the damage to the lubricating oil film caused by reverse rotation, the change in lubrication pressure is also affected by a variety of factors such as oil temperature, oil quality, and the condition of the oil supply system.

[0050] The axial runout of the rotor contributes the least to the damage caused by reverse rotation, because the axial runout reflects the reverse impact of the axial force caused by reverse rotation. However, its measurement is limited by the installation position and accuracy of the sensor, and it only changes significantly when the axial force caused by reverse rotation is large enough. Its sensitivity and universality are relatively low.

[0051] The aforementioned contribution ranking forms the logical basis for weight allocation in this method: the higher the contribution, the larger the weight coefficient; the lower the contribution, the smaller the weight coefficient. This contribution-oriented weight allocation strategy ensures that the parameters most representative of reversal damage dominate in the composition of the comprehensive health index, while parameters with limited representativeness play only an auxiliary role. That is, the comprehensive health index will not deviate from the true degree of damage due to unreasonable weight allocation.

[0052] In this specific example, the five scores are: vibration score 65 points, temperature score 75 points, noise score 60 points, lubrication pressure score 73 points, and axial movement score 40 points. The corresponding weighting coefficients are set according to the aforementioned contribution ranking as follows: vibration score 30%, temperature score 25%, noise score 20%, lubrication pressure score 15%, and axial movement score 10%. The comprehensive health index HI is then calculated as follows: HI = 65×30% + 75×25% + 60×20% + 73×15% + 40×10% = 19.5 + 18.75 + 12.0 + 10.95 + 4.0 = 65.2 points The overall health index falls within the range of 50 ≤ HI < 70, classifying it as a moderate damage level. The calculation results clearly show that while the axial runout score (40 points) has the lowest weight (10%), its low score still dragged down the overall health index by approximately 4 points. Conversely, the vibration score, although having the highest weight (30%), has a relatively balanced impact on the overall health index due to its score of 65 points, placing it at a moderate level among the five scores. This traceable calculation structure allows maintenance personnel to intuitively identify axial runout as the most prominent problem dimension in this reversal damage.

[0053] It is evident that by assigning weight coefficients matching the contribution of each score and performing multiply-addition fusion operations, a synergistic synthesis of multi-dimensional damage information is achieved. Different parameters exhibit fundamentally different characterization abilities for inversion damage: vibration reflects the most direct mechanical impact of inversion; temperature reflects the thermal accumulation consequences of lubrication failure; noise reflects the comprehensive characterization of structural anomalies; lubrication pressure reflects the directness of oil film damage; and axial displacement reflects the axial impact unique to inversion. In other words, through differentiated weight allocation based on contribution, the contribution of each parameter in the comprehensive health index precisely reflects its due importance in inversion damage assessment. This solves the assessment distortion problem caused by equal-weighted averaging (treating parameters with different contributions equally) and avoids misjudgments that may result from arbitrary weight allocation without a physical understanding of the inversion damage mechanism. The transparency and traceability of the multiply-addition operation method provide maintenance personnel with a clear calculation path for identifying the main dimensions of damage in inversion.

[0054] In this embodiment of the application, the method may further include: Step 41: Obtain the current ambient temperature value and historical cumulative runtime value of the compressor; In this embodiment, ambient temperature refers to the air temperature of the compressor's operating environment, measured by a temperature sensor installed near the compressor. Historical cumulative runtime refers to the total operating time of the compressor since it was put into use, recorded and accumulated by a timer within the control system. These two figures respectively represent the compressor's current external thermal environment conditions and its own service life.

[0055] Step 42: Perform temperature correction on the rotor vibration hazard threshold, bearing temperature hazard threshold, and operating noise hazard threshold based on the current ambient temperature value. The magnitude of the deviation of the ambient temperature value from the preset standard ambient temperature value is positively correlated with the correction magnitude. When the ambient temperature deviates from the standard condition, the physical parameters of the compressor, such as the bearing temperature, will systematically shift under the same operating conditions. In high-temperature environments, heat dissipation deteriorates, and the bearing temperature may be several degrees or even tens of degrees higher than in normal temperatures. Even if reversing the compressor does not generate additional heat accumulation, the reference value for bearing temperature measurement will still rise due to the increase in ambient temperature. If this shift is not considered, in high-temperature environments, the bearing temperature may not reach the actual dangerous level, but the measured value may touch a fixed threshold due to the rise in ambient temperature, triggering an erroneous shutdown. In low-temperature environments, the bearing temperature may have reached a relatively dangerous level, but the measured value may not touch the fixed threshold due to the drop in ambient temperature, delaying protection.

[0056] Therefore, the deviation of the ambient temperature value from the preset standard ambient temperature value is positively correlated with the correction range. When the ambient temperature is higher than the standard ambient temperature, the three danger thresholds are adjusted upwards according to the deviation range—because the normal background values ​​of the parameters are already high under high-temperature conditions, the upper limit of the allowable normal fluctuation should be appropriately relaxed to avoid accidental triggering of the solenoid valve shutdown. When the ambient temperature is lower than the standard ambient temperature, the three danger thresholds are adjusted downwards according to the deviation range—because the background values ​​of the parameters are low under low-temperature conditions, the upper limit of the allowable normal fluctuation should be appropriately tightened to ensure that dangerous conditions can be identified in a timely manner.

[0057] Taking the bearing temperature danger threshold as an example: The preset standard ambient temperature is 25℃, and the bearing temperature danger threshold under this condition is 100℃. If the current ambient temperature is 40℃ (15℃ higher than the standard), the background bearing temperature of the compressor under normal operation may increase by about 5-8℃, and the system will correspondingly raise the bearing temperature danger threshold to about 105℃; if the current ambient temperature is -5℃ (30℃ lower than the standard), the absolute value of the compressor bearing temperature measurement may be systematically low, and the system will correspondingly lower the bearing temperature danger threshold to about 95℃.

[0058] Step 43: Based on the historical cumulative running time value, perform aging correction on the rotor vibration danger threshold, bearing temperature danger threshold and operating noise danger threshold, where the historical cumulative running time value is positively correlated with the correction magnitude.

[0059] As compressors operate over time, their mechanical components (including bearings, rotors, and seals) inevitably undergo progressive wear. Aging phenomena such as increased bearing clearance, decreased rotor dynamic balance, and reduced seal elasticity cause deviations or increased fluctuations in background values ​​of parameters like vibration, temperature, and noise during normal operation. Under identical operating conditions, a 10-year-old compressor will often exhibit higher vibration measurements than a brand-new compressor. Without considering this aging effect, fixed threshold values ​​may frequently trigger false alarms due to increased background values ​​caused by normal equipment aging.

[0060] Therefore, the historical cumulative runtime is positively correlated with the correction range. When the runtime is short (i.e., the equipment is in the early stages of its lifespan), the background values ​​of each parameter are relatively ideal, and the danger threshold can be kept at a high level of stringency. As the runtime increases, the background values ​​of each parameter gradually deteriorate with the increase in wear, and the danger threshold should be relaxed accordingly to avoid frequent false alarms caused by normal aging. For example, if the compressor's historical cumulative runtime is 8 years, and the system determines that it has entered the middle to late stages of its lifespan, then based on the ambient temperature correction, the bearing temperature danger threshold will be further increased by 3-5℃ to reflect the increase in the temperature background value caused by equipment aging.

[0061] Three hazardous thresholds, after temperature and aging correction, replace the aforementioned fixed preset thresholds and serve as the actual basis for determining whether the immediate shutdown conditions are met in the first stage. At this point, the thresholds used to determine the first target operating parameters are no longer factory-preset fixed values, but rather dynamic values ​​that are adaptively adjusted based on the current working environment and the actual state of the equipment.

[0062] By introducing environmental temperature correction and aging correction mechanisms, the immediate shutdown judgment benchmark in the first stage is upgraded from a fixed preset value to an adaptive dynamic value, improving the environmental adaptability of the judgment. The compressor's operating environment is not a constant standard condition, and a fixed threshold is prone to misjudgment in extreme temperature environments. The temperature correction mechanism allows the threshold to adaptively adjust with the ambient temperature, avoiding false triggering of the solenoid valve for shutdown in high-temperature environments and missed judgments or delays in low-temperature environments. Furthermore, it improves the life-cycle applicability of the judgment. Newly manufactured compressors and old compressors that have been in operation for many years have significant differences in physical condition; a fixed threshold cannot adequately address both ends of the equipment's life cycle—being too lenient for new equipment and too strict for old equipment. The aging correction mechanism gradually adjusts the threshold with the equipment's service life, ensuring stable accuracy of the diagnostic method throughout its life cycle. The physical meaning and mathematical processing of the two corrections are independent and do not interfere with each other. The corrected threshold, after their combined effect, can simultaneously reflect the compressor's operating environment and service status, maintaining an applicable judgment benchmark in complex engineering scenarios and reducing the dual interference of external and internal variables on the diagnostic results.

[0063] In optional embodiments of this application, the method may further include: Step 51: Obtain the historical fault database, which includes multiple sets of historical reversal fault samples. Each set of historical reversal fault samples records the measured values ​​of the second target's operating parameters and the corresponding actual damage level labeling results when the reversal fault occurred. The historical fault database serves as the data foundation for data-driven optimization. This database stores complete historical sample data of compressor reversal faults that occurred during actual operation. Each group of historical reversal fault samples contains two types of information: the first type is the measured values ​​of the second target operating parameters at the time of the reversal fault, namely, the measured data of five parameters: rotor vibration, bearing temperature, operating noise, bearing lubrication pressure, and rotor axial movement; the second type is the actual damage level labeling result corresponding to this reversal fault.

[0064] The actual damage level refers to the true extent of damage confirmed after manual verification or disassembly inspection of the reverse failure. The labeling method is consistent with the four damage levels defined in this application (normal, minor damage, moderate damage, and severe damage). This labeling result is determined by professional technicians during equipment maintenance based on objective evidence such as the actual wear and tear and component damage during disassembly inspection, and serves as the benchmark for evaluating the merits of the weighting coefficient configuration.

[0065] Step 52: With the goal of minimizing the deviation between the calculated comprehensive health index of historical reverse fault samples and the actual damage level labeling results, the weight coefficients corresponding to rotor vibration score, bearing temperature score, operating noise score, bearing lubrication pressure score and rotor axial movement score are iteratively optimized respectively. The optimization objective is to minimize the deviation between the calculated Comprehensive Health Index (HI) and the actual injury level labeling. It's important to note that the HI is a continuous value ranging from 0 to 100, while the actual injury level labeling is a discrete level label. To compare the deviations, the optimization algorithm maps the calculated HI value to the corresponding injury level range, forming a "calculated injury level," and then compares it with the actual injury level labeling. If the mapped level matches the labeled level, the deviation is 0; otherwise, the deviation reflects the difference in levels between the two.

[0066] Step 53: Use the iteratively optimized weight coefficients as the basis for weight allocation in subsequent weighted fusion steps.

[0067] As can be seen, the system sets initial values ​​for the five weight coefficients (i.e., the aforementioned preset fixed weights), and then uses a specific optimization algorithm (such as gradient descent or particle swarm optimization) to iteratively adjust each weight coefficient multiple times under the constraint that the sum of each weight coefficient is 100%. In each iteration, the system recalculates the comprehensive health index of all samples in the database using the current weight combination, calculates the total deviation from the actual labeled results, and then adjusts each weight coefficient according to the direction and magnitude of the deviation before proceeding to the next iteration. After multiple iterations, the system judges the trend of the deviation. When the rate of change of the total deviation between two adjacent iterations is less than the preset convergence threshold (i.e., further adjustment of the weights can no longer significantly reduce the deviation), the system determines that the current weight combination has reached the optimal or near-optimal state, terminates the iteration, and outputs the weight combination as the basis for the actual weight allocation in the subsequent weighted fusion step.

[0068] For example, a large central air conditioning system has accumulated 120 historical samples of compressor reverse rotation failures. Each sample includes measured values ​​of five parameters, and the actual damage level was confirmed through disassembly and inspection. The system begins iterative optimization with the fixed weights preset in claim 4 (vibration 30%, temperature 25%, noise 20%, lubrication pressure 15%, axial movement 10%) as initial values.

[0069] Under the initial weight combination, the system calculated the comprehensive health index and mapped the damage level to each of the 120 samples, achieving a consistency rate of 76% with the actual damage level. In the first iteration, the optimization algorithm discovered that 82% of samples with axial runout scores below 40 were actually labeled as having moderate or severe damage, but because their weight was only 10%, their comprehensive health index was often inflated to the mild damage range, leading to an underestimation of the damage severity. Therefore, the algorithm increased the weight of axial runout from 10% to 15% and correspondingly decreased the weight of noise scores (from 20% to 17%), with minor adjustments to other weights. After multiple iterations, the weight coefficients were adjusted to: vibration 28%, temperature 24%, noise 16%, lubrication pressure 14%, and axial runout 18%. The consistency rate of the 120 samples increased to 91%, and the change in consistency rate between adjacent iterations was less than 0.1%, meeting the convergence condition. The system terminated the iteration, using this optimized weight set as the basis for subsequent diagnostic weight allocation.

[0070] The above approach achieves an upgrade in weight allocation from expert-driven to data-driven. Initial weights rely on qualitative judgments of the contribution of each parameter by humans, which is highly subjective and difficult to be precise. Optimized weights, on the other hand, automatically converge to the optimal combination based on the statistical patterns of historical data, eliminating subjective biases from human experience. Furthermore, it enables adaptive evolution of the evaluation model. As the number of samples in the database continues to accumulate and actual operating conditions change, the system can periodically re-execute iterative optimizations to ensure that the weight coefficients remain at the optimal configuration under current operating conditions, thus resolving the mismatch between fixed weight configurations and changing operating conditions.

[0071] In an optional embodiment of this application, the method of determining the damage level after compressor reversal based on the matching relationship between the comprehensive health index and multiple preset damage level threshold ranges involved in step 103 above may further include: Step 61: If the comprehensive health index is greater than or equal to the first health threshold, the compressor is determined to be in normal condition. Step 62: If the comprehensive health index is greater than or equal to the second health threshold and less than the first health threshold, the compressor is determined to be in a state of mild damage. Step 63: If the comprehensive health index is greater than or equal to the third health threshold and less than the second health threshold, the compressor is determined to be in a state of moderate damage. Step 64: If the comprehensive health index is less than the third health threshold, the compressor is determined to be in a state of severe damage. Among them, the first health threshold is greater than the second health threshold, and the second health threshold is greater than the third health threshold.

[0072] In this embodiment, the entire range of values ​​for the comprehensive health index is divided into four consecutive but non-overlapping sub-ranges, each corresponding to a damage level. Three health thresholds are defined as the first health threshold, the second health threshold, and the third health threshold, with the first health threshold being greater than the second health threshold, and the second health threshold being greater than the third health threshold. The design logic behind classifying damage into four levels instead of two or three stems from reversing the depth of correlation between damage severity and maintenance decisions: the ultimate goal of diagnosis is to guide maintenance actions, and maintenance actions naturally exhibit a tiered difference between no maintenance required, enhanced monitoring, planned maintenance, and emergency repair. A two-level classification (normal / abnormal) cannot distinguish the difference in urgency between anomalies requiring planned maintenance and anomalies requiring immediate shutdown, easily leading to delayed fault handling or excessive emergency response; a three-level classification (normal / mild / severe) still lacks intermediate transition levels. If mild damage directly corresponds to enhanced monitoring and severe damage to emergency repair, then there is a lack of clear action guidance for moderate damage in between. The four-level classification perfectly matches the hierarchical nature of maintenance actions: normal → no intervention required, light → preventive maintenance, moderate → planned maintenance, and severe → emergency repair. Each level has a clear and differentiated maintenance meaning, avoiding the ambiguity of one level corresponding to multiple different action plans.

[0073] In this specific example, the damage level assessment criteria for a compressor are preset as follows: a first health threshold of 85 points, a second health threshold of 70 points, and a third health threshold of 50 points. After weighted fusion, the system calculates the comprehensive health index for different scenarios, which fall into different level ranges: Example 1: After a reversal, all five parameters performed well, and the weighted average score was HI = 91. Since 91 ≥ 85, the system is determined to be in a normal state, and the compressor can continue to operate normally without any maintenance. This indicates that although the reversal occurred, it did not cause any substantial measurable damage to the compressor.

[0074] Example 2: After a certain reversal, the overall health index HI = 78 points. Since 70 ≤ 78 < 85, the system determines it to be in a state of minor damage. The compressor can still continue to operate, but the system will issue a prompt to strengthen operational monitoring and perform preventative maintenance. For example, it may suggest adding inspection items to the compressor in the next routine maintenance cycle, or appropriately shortening the interval between maintenance sessions. This level of maintenance strategy falls within the scope of planning and will not affect current normal production.

[0075] Example 3: After a certain reversal, the overall health index HI = 62 points. Since 50 ≤ 62 < 70, the system determines it to be a moderate damage state. At this time, the system will issue a prompt to schedule maintenance, suggesting that a comprehensive overhaul of the compressor be arranged during the nearest production break (e.g., the next downtime window or the scheduled maintenance day). Although this level of maintenance strategy does not require immediate shutdown, intervention needs to be arranged in the short term to prevent the damage from further deteriorating to a severe level.

[0076] Example 4: After a certain reversal, the overall health index HI = 38 points. Since 38 < 50, the system determines it to be in a severely damaged state. At this time, the system will issue an immediate shutdown and emergency repair command, controlling the compressor to stop immediately and sending an emergency maintenance alarm. Maintenance personnel need to respond immediately. This level means that the compressor is facing serious safety risks, and continued operation may lead to equipment failure or even secondary disasters.

[0077] As can be seen, in this embodiment of the application, the continuous range of values ​​of the comprehensive health index is divided into four damage levels by using three threshold levels, thereby achieving an accurate mapping from continuous values ​​to discrete levels.

[0078] The present application will be explained and described below with reference to specific embodiments, which provide a method for diagnosing the degree of damage after a compressor reverses, such as... Figure 2 As shown, the steps of this method include: Step 201: Monitor the compressor rotation direction in real time; Step 202: Determine if the value is reversed; if the result is yes, proceed to step 203. Step 203: Initiate the rapid early warning and interception process; Step 204: Real-time acquisition of rotor vibration values, bearing temperature, and operating noise; Step 205: Determine whether any parameter exceeds the safety threshold. If yes, proceed to step 206; otherwise, proceed to step 207. Step 206: Trigger a forced shutdown and send an emergency maintenance alarm; Step 207: Control the compressor to switch to forward rotation mode; Step 208: After the forward rotation stabilizes, collect five-dimensional health parameters; Step 209: Standardize the scoring of each individual parameter from 0 to 100 points; Step 210: Calculate the HI Comprehensive Health Index using fixed-weight fusion. Step 211: Determine the damage level based on the HI score; Step 212: Output the corresponding maintenance decision instruction.

[0079] Combination Figure 3 and Figure 4 Through the above steps 201 to 212, the degree of damage after compressor reversal is diagnosed in two stages in this application: the reversal rapid interception stage and the forward comprehensive evaluation stage.

[0080] 1) Reversal and rapid interception phase The system monitors the compressor's operating status in real time. When the compressor reverses direction, it immediately collects parameter values ​​synchronously. Vibration sensors are attached to the compressor bearings to collect rotor vibration signals and obtain rotor vibration values ​​in real time; temperature sensors obtain bearing temperature values ​​in real time; and acoustic sensors collect operating noise and obtain noise values ​​in real time. Danger thresholds are set for rotor vibration exceeding 7.1 mm / s, bearing temperature exceeding 100℃, and noise exceeding 65 dB. When any of these parameters reaches a dangerous value, the system immediately triggers a forced shutdown command and sends an emergency maintenance alarm. If none of the three parameters are dangerous values, the compressor control is switched to forward rotation, and the system enters the comprehensive evaluation phase.

[0081] 2) Comprehensive evaluation phase Once the compressor switches to forward rotation and stabilizes, five parameters are collected in real time: rotor vibration value, bearing temperature value, noise value, bearing lubrication pressure, and rotor axial movement. The actual parameter values ​​are converted into standardized scores using a calculation formula. Each parameter has a score range of 0-100, with 0 representing severe damage and 100 representing no damage. The specific formula is as follows.

[0082] Rotor vibration value scoring formula:

[0083] Among them, the rotor vibration value is set at 7.1 mm / s as the threshold for severe damage. When the vibration value is ≥7.1 mm / s, the score is 0.

[0084] Bearing temperature rating formula:

[0085] Among them, the bearing temperature is set to 60℃ as the optimal lubrication temperature and 100℃ as the severe damage threshold. When the bearing temperature is ≥100℃, the score is 0.

[0086] Operating noise scoring formula:

[0087] Among them, the operating noise is set at 45dB(A) as the healthy baseline value and 65dB(A) as the severe damage threshold. When the noise is ≥65dB(A), the score is 0.

[0088] Bearing lubrication pressure scoring formula:

[0089] Among them, the bearing lubrication pressure is based on the rated lubrication pressure as the health benchmark value, and 70% of the rated pressure is the severe damage threshold. When the bearing lubrication pressure is ≤70% of the rated pressure value, the score is 0.

[0090] Formula for scoring rotor axial movement:

[0091] Among them, the rotor axial movement is set at 0.1 mm as the healthy baseline value and 0.3 mm as the severe damage threshold. When the movement is ≥0.3 mm, the score is 0.

[0092] Based on the contribution of reverse rotation damage, five parameters were weighted as follows: rotor vibration value -30%, bearing temperature -25%, operating noise -20%, bearing lubrication pressure -15%, and rotor axial movement -10%. The comprehensive health index HI was calculated by weighted summation, as shown in the following formula.

[0093]

[0094] Finally, based on the Comprehensive Health Index (HI), four damage levels are defined. When HI ≥ 85, the system is in normal condition with no obvious damage and requires no maintenance. When 70 ≤ HI < 85, the system is in a state of mild damage and requires enhanced monitoring and preventative maintenance. When 50 ≤ HI < 70, the system is in a state of moderate damage and requires scheduled maintenance. When HI < 50, the system is in a state of severe damage, and the system must be shut down immediately for emergency repairs.

[0095] Corresponding to the above Figure 1 This application provides a device for detecting and maintaining the degree of damage to a compressor, such as... Figure 5 As shown, the device includes: The first processing module 502 is used to collect the first target operating parameters of the compressor when the compressor is detected to be in reverse operation, and to determine whether the immediate shutdown condition is met according to the relationship between the first target operating parameters and the first preset threshold. If the immediate shutdown condition is met, the compressor is controlled to stop immediately; otherwise, the compressor is switched to forward operation. The second processing module 504 is used to collect the second target operating parameters of the compressor after the compressor switches to forward operation and runs stably, convert the second target operating parameters into quantitative scores that characterize the degree of damage, and then perform weighted fusion of multiple quantitative scores according to the contribution of the second target operating parameters to the reverse rotation damage to obtain a comprehensive health index that characterizes the degree of compressor damage. The third processing module 506 is used to determine the damage level after the compressor reverses based on the matching relationship between the comprehensive health index and multiple preset damage level threshold ranges, and output the maintenance strategy corresponding to the damage level.

[0096] In an optional embodiment of this application, the first processing module in this application includes: The first processing unit is used to collect the compressor's rotor vibration value, bearing temperature value, and operating noise value as the first target operating parameters; The second processing unit is used to determine whether the rotor vibration value reaches or exceeds the preset rotor vibration danger threshold, whether the bearing temperature value reaches or exceeds the preset bearing temperature danger threshold, and whether the operating noise value reaches or exceeds the preset operating noise danger threshold. The third processing unit is used to determine whether the immediate shutdown condition is met when any one of the rotor vibration value, bearing temperature value, and operating noise value reaches or exceeds its corresponding danger threshold; and to determine whether the immediate shutdown condition is not met when all three values ​​are less than their respective danger thresholds.

[0097] In an optional embodiment of this application, the second processing module includes: The fourth processing unit is used to collect the compressor's rotor vibration value, bearing temperature value, operating noise value, bearing lubrication pressure value, and rotor axial movement value as the second target operating parameters; The fifth processing unit is used to map the collected rotor vibration values ​​to the first scoring interval using preset rotor vibration health benchmark values ​​and rotor vibration severe damage thresholds as boundaries, so as to obtain rotor vibration scores. The sixth processing unit is used to map the collected bearing temperature values ​​to the second scoring interval, using the preset bearing temperature health benchmark value and bearing temperature severe damage threshold as boundaries, to obtain the bearing temperature score. The seventh processing unit is used to map the collected operating noise values ​​to the third scoring interval using preset operating noise health benchmark values ​​and operating noise severe damage thresholds as boundaries, so as to obtain an operating noise score. The eighth processing unit is used to map the collected bearing lubrication pressure value to the fourth scoring interval, using the preset bearing lubrication pressure health benchmark value and bearing lubrication pressure severe damage threshold as boundaries, to obtain the bearing lubrication pressure score. The ninth processing unit is used to map the collected rotor axial movement value to the fifth scoring interval, using the preset rotor axial movement health benchmark value and rotor axial movement severe damage threshold as boundaries, to obtain the rotor axial movement score.

[0098] In an optional embodiment of this application, the second processing module includes: The tenth processing unit is used to assign preset weight coefficients to the rotor vibration score, bearing temperature score, operating noise score, bearing lubrication pressure score and rotor axial movement score, respectively. The magnitude of the weight coefficient is positively correlated with the contribution of each parameter to the reverse damage. The eleventh processing unit is used to multiply each quantitative score by its corresponding weight coefficient and then sum them to obtain the comprehensive health index.

[0099] In optional embodiments of this application, the apparatus further includes: The first acquisition module is used to acquire the current ambient temperature value and the historical cumulative running time value of the compressor; The first correction module is used to correct the rotor vibration danger threshold, bearing temperature danger threshold and operating noise danger threshold according to the current ambient temperature value. The magnitude of the deviation of the ambient temperature value from the preset standard ambient temperature value is positively correlated with the correction magnitude. The second correction module is used to perform aging correction on the rotor vibration danger threshold, bearing temperature danger threshold and operating noise danger threshold based on the historical cumulative running time value, wherein the historical cumulative running time value is positively correlated with the correction magnitude.

[0100] In optional embodiments of this application, the apparatus further includes: The second acquisition module is used to acquire a historical fault database, which includes multiple sets of historical reversal fault samples. Each set of historical reversal fault samples records the measured values ​​of the second target's operating parameters and the corresponding actual damage level labeling results when the reversal fault occurred. The fourth processing module is used to iteratively optimize the weight coefficients corresponding to rotor vibration score, bearing temperature score, operating noise score, bearing lubrication pressure score and rotor axial movement score, with the goal of minimizing the deviation between the comprehensive health index calculation value of historical reverse fault samples and the actual damage level labeling result. The fifth processing module is used to use the iteratively optimized weight coefficients as the basis for weight allocation in the subsequent weighted fusion step.

[0101] In an optional embodiment of this application, the third processing module includes: The twelfth processing unit is used to determine that the compressor is in normal condition when the comprehensive health index is greater than or equal to the first health threshold. The thirteenth processing unit is used to determine that the compressor is in a state of mild damage when the comprehensive health index is greater than or equal to the second health threshold and less than the first health threshold. The fourteenth processing unit is used to determine that the compressor is in a moderate damage state when the comprehensive health index is greater than or equal to the third health threshold and less than the second health threshold. The fifteenth processing unit is used to determine that the compressor is in a severely damaged state when the comprehensive health index is less than the third health threshold. The sixteenth processing unit is used in which the first health threshold is greater than the second health threshold, and the second health threshold is greater than the third health threshold.

[0102] like Figure 6 As shown in the figure, this application provides an electronic device, including a processor 611, a communication interface 612, a memory 613, and a communication bus 614, wherein the processor 611, the communication interface 612, and the memory 613 communicate with each other through the communication bus 614. Memory 613 is used to store computer programs; In one embodiment of this application, when the processor 611 executes the program stored in the memory 613, it implements the compressor damage detection and maintenance method provided in any of the aforementioned method embodiments, and its function is similar, so it will not be described again here.

[0103] This application also provides a computer-readable storage medium storing a computer program thereon, which, when executed by a processor, implements the steps of the compressor damage detection and maintenance method provided in any of the foregoing method embodiments.

[0104] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0105] Through the above description of the embodiments, those skilled in the art can clearly understand that each embodiment can be implemented using software plus a general-purpose hardware platform, or of course, using hardware. Based on this understanding, the above technical solutions, in essence or the parts that contribute to the related technology, can be embodied in the form of a software product. This computer software product can be stored in a computer-readable storage medium, such as ROM / RAM, magnetic disk, optical disk, etc., and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute the methods described in the various embodiments or some parts of the embodiments.

[0106] It should be understood that the terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. Unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “described” as used herein may also include the plural forms. The terms “comprising,” “including,” “containing,” and “having” are inclusive and therefore indicate the presence of the stated features, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or combinations thereof. The method steps, processes, and operations described herein are not construed as requiring them to be performed in a particular order described or illustrated unless the order of performance is explicitly indicated. It should also be understood that additional or alternative steps may be used.

[0107] The above description is merely a specific embodiment of the present invention, enabling those skilled in the art to understand or implement the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

Claims

1. A method for detecting and maintaining the degree of damage to a compressor, characterized in that, include: When the compressor is detected to be in reverse operation, the first target operating parameter of the compressor is collected, and the relationship between the first target operating parameter and the first preset threshold is used to determine whether the immediate shutdown condition is met. If the immediate shutdown condition is met, the compressor is controlled to stop immediately; otherwise, the compressor is switched to forward operation. After the compressor switches to forward rotation and operates stably, the second target operating parameters of the compressor are collected. The second target operating parameters are converted into quantitative scores that characterize the degree of damage. Then, based on the contribution of the second target operating parameters to the reverse rotation damage, multiple quantitative scores are weighted and fused to obtain a comprehensive health index that characterizes the degree of damage to the compressor. Based on the matching relationship between the comprehensive health index and multiple preset damage level threshold ranges, the damage level of the compressor after reversal is determined, and a maintenance strategy corresponding to the damage level is output.

2. The method according to claim 1, characterized in that, Collecting the first target operating parameters of the compressor, and determining whether the immediate shutdown condition is met based on the relationship between the first target operating parameters and a first preset threshold, including: The rotor vibration value, bearing temperature value, and operating noise value of the compressor are collected as the first target operating parameters; The rotor vibration value, the bearing temperature value, and the operating noise value are respectively determined to be at or above a preset rotor vibration danger threshold, a preset bearing temperature danger threshold, and a preset operating noise danger threshold. If any one of the rotor vibration value, bearing temperature value, and operating noise value reaches or exceeds its corresponding danger threshold, the immediate shutdown condition is determined to be met; if the rotor vibration value, bearing temperature value, and operating noise value are all less than their respective danger thresholds, the immediate shutdown condition is determined not to be met.

3. The method according to claim 1, characterized in that, The process of collecting the second target operating parameters of the compressor and converting these parameters into a quantitative score characterizing the degree of damage includes: The rotor vibration value, bearing temperature value, operating noise value, bearing lubrication pressure value, and rotor axial movement value of the compressor are collected as the second target operating parameters; Using preset rotor vibration health benchmark value and rotor vibration severe damage threshold as boundaries, the collected rotor vibration values ​​are mapped to the first scoring interval to obtain the rotor vibration score; Using the preset bearing temperature health benchmark value and bearing temperature severe damage threshold as boundaries, the collected bearing temperature values ​​are mapped to the second scoring interval to obtain the bearing temperature score. Using preset operating noise health benchmark values ​​and operating noise severe damage thresholds as boundaries, the collected operating noise values ​​are mapped to a third scoring interval to obtain an operating noise score; Using the preset bearing lubrication pressure health benchmark value and bearing lubrication pressure severe damage threshold as boundaries, the collected bearing lubrication pressure values ​​are mapped to the fourth scoring interval to obtain the bearing lubrication pressure score. Using the preset healthy baseline value of rotor axial movement and the severe damage threshold of rotor axial movement as boundaries, the collected rotor axial movement values ​​are mapped to the fifth scoring interval to obtain the rotor axial movement score.

4. The method according to claim 3, characterized in that, The multiple quantitative scores are weighted and fused based on the contribution of the second target operating parameters to the reversal damage to obtain a comprehensive health index characterizing the degree of compressor damage, including: The rotor vibration score, bearing temperature score, operating noise score, bearing lubrication pressure score, and rotor axial movement score are each assigned a preset weighting coefficient, wherein the magnitude of the weighting coefficient is positively correlated with the contribution of each parameter to the reverse damage. The comprehensive health index is obtained by multiplying each quantitative score by its corresponding weight coefficient and then summing the results.

5. The method according to claim 3, characterized in that, The method further includes: Obtain the current ambient temperature value and the historical cumulative running time value of the compressor; The rotor vibration hazard threshold, the bearing temperature hazard threshold, and the operating noise hazard threshold are corrected for temperature based on the current ambient temperature value, wherein the magnitude of the deviation of the ambient temperature value from the preset standard ambient temperature value is positively correlated with the correction magnitude. The rotor vibration hazard threshold, the bearing temperature hazard threshold, and the operating noise hazard threshold are aged and corrected based on the historical cumulative running time value, wherein the historical cumulative running time value is positively correlated with the correction magnitude.

6. The method according to claim 4, characterized in that, The method further includes: Obtain a historical fault database, wherein the historical fault database includes multiple sets of historical reversal fault samples, and each set of historical reversal fault samples records the measured values ​​of the second target operating parameters and the corresponding actual damage level labeling results when the reversal fault occurred. With the goal of minimizing the deviation between the calculated comprehensive health index of the historical reverse fault samples and the actual damage level labeling results, the weight coefficients corresponding to the rotor vibration score, bearing temperature score, operating noise score, bearing lubrication pressure score and rotor axial movement score are iteratively optimized respectively. The optimized weight coefficients will be used as the basis for weight allocation in subsequent weighted fusion steps.

7. The method according to claim 1, characterized in that, Based on the matching relationship between the comprehensive health index and multiple preset damage level threshold ranges, the damage level after the compressor reverses is determined to include: If the comprehensive health index is greater than or equal to the first health threshold, the compressor is determined to be in a normal state. If the comprehensive health index is greater than or equal to the second health threshold and less than the first health threshold, the compressor is determined to be in a state of mild damage. If the comprehensive health index is greater than or equal to the third health threshold and less than the second health threshold, the compressor is determined to be in a state of moderate damage. If the overall health index is less than the third health threshold, the compressor is determined to be in a state of severe damage. Wherein, the first health threshold is greater than the second health threshold, and the second health threshold is greater than the third health threshold.

8. A device for detecting and maintaining the degree of damage to a compressor, characterized in that, include: The first processing module is used to collect the first target operating parameters of the compressor when it is detected that the compressor is in reverse operation state, and determine whether the immediate shutdown condition is met according to the relationship between the first target operating parameters and the first preset threshold. If the immediate shutdown condition is met, the compressor is controlled to stop immediately; otherwise, the compressor is switched to forward operation state. The second processing module is used to collect the second target operating parameters of the compressor after the compressor switches to forward operation and runs stably, convert the second target operating parameters into a quantitative score characterizing the degree of damage, and then perform weighted fusion of multiple quantitative scores according to the contribution of the second target operating parameters to the reverse rotation damage to obtain a comprehensive health index characterizing the degree of damage to the compressor. The third processing module is used to determine the damage level of the compressor after reversal based on the matching relationship between the comprehensive health index and multiple preset damage level threshold ranges, and output a maintenance strategy corresponding to the damage level.

9. An electronic device, characterized in that, include: The system includes a processor, a communication interface, a memory, and a communication bus, wherein the processor, the communication interface, and the memory communicate with each other via the communication bus; the memory is used to store computer programs; and the processor is used to execute the computer programs to implement the compressor damage detection and maintenance method according to any one of claims 1-7.

10. A storage medium having a computer program stored thereon, characterized in that, When executed by a processor, the computer program implements the method for detecting and maintaining the degree of compressor damage as described in any one of claims 1-7.

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