Diaphragm pump cone valve leakage fault monitoring system

Abstract

The diaphragm pump cone valve leakage fault monitoring system comprises a diaphragm pump, an inlet ore pulp pipeline is arranged on one side of the diaphragm pump, an outlet ore pulp pipeline is arranged on the other side of the diaphragm pump, a pressure transmitter is arranged on the inlet ore pulp pipeline, an outlet flow meter is arranged on the outlet ore pulp pipeline, and a controller is arranged on the outer side of the diaphragm pump. The pressure transmitter and the outlet flow meter are in signal connection with the input end of the controller, the controller is used for judging whether the diaphragm pump has a leakage fault or not according to data monitored by the outlet flow meter and the pressure transmitter, and the output end of the controller is connected with an alarm; according to the utility model, not only can better economic benefits be obtained from the labor cost and the equipment maintenance cost, but also more importantly, the economic benefits are considerable from the aspects of preventing imported equipment from being damaged to influence production and improving the stability of a production system; the practicability, the reliability and the stability of the system are worthy of being popularized and used in other domestic diaphragm pump conveying systems.

Description

Technical Field

[0001] The utility model relates to the technical field of diaphragm pump monitoring systems, and particularly to a monitoring system for the leakage fault of a conical valve of a diaphragm pump. Background Technique

[0002] Each diaphragm pump is equipped with 6 inlet and outlet valve boxes, and 6 sets of conical valve working units are built in, which are in a completely enclosed working environment, and the operating state of the conical valve of the diaphragm pump cannot be directly seen with the naked eye. At present, there is no mature automatic monitoring technology for the diaphragm pumps operating in China to accurately judge the operating state of the conical valve. The main discrimination method is to use a listening rod to detect the leakage sound in the valve box, and judge whether the conical valve is working properly one by one through manual experience. In addition, since the number of inlet and outlet conical valves of each diaphragm pump is large, and there is a lot of noise interference generated after the diaphragm pump operates, it increases the working difficulty and labor cost for timely and accurately judging the leakage fault point of the conical valve. To solve the above problems, a monitoring system for the leakage fault of a conical valve of a diaphragm pump is proposed. Summary of the Invention

[0003] To solve the above problems, a monitoring system for the leakage fault of a conical valve of a diaphragm pump is proposed.

[0004] The specific solution of the utility model is: a monitoring system for the leakage fault of a conical valve of a diaphragm pump, including: a diaphragm pump, a pressure transmitter is arranged on one side of the diaphragm pump, an outlet flowmeter is arranged on the other side, a controller is arranged outside the diaphragm pump, the pressure transmitter and the outlet flowmeter are signal-connected to the input end of the controller, the controller is used to judge whether the diaphragm pump has a leakage fault through the data monitored by the outlet flowmeter and the pressure transmitter, and an alarm is connected to the output end of the controller.

[0004]

[0005] Further, a frequency conversion cabinet is arranged on the diaphragm pump, and the frequency conversion cabinet is communicatively connected to the input end of the controller by PROFNET, and is used to monitor the working current data of the frequency conversion cabinet of the diaphragm pump and transmit the data to the controller.

[0006] Further, the controller is a PLC programmable controller.

[0005]

[0007] Further, the alarm is a buzzer alarm.

[0008] The utility model has the following beneficial effects:

[0006]

[0009] 1. The utility model greatly reduces the workload of patrol inspection by operating personnel and the workload of maintenance and inspection, and basically meets the technical requirements of unattended operation; the operation of the diaphragm pump conveying system is reduced from the initial 3 persons / shift to 1 person / shift. Secondly, the patrol inspection time is reduced from 2 times / hour to 1 time / hour, greatly reducing the workload of personnel patrol inspection;

[0010] 2. Relying on the timeliness and accuracy of fault monitoring, it can accurately judge which cone valve in the valve box has a fault, thus reducing the workload of equipment disassembly and inspection by the maintenance team and improving the work efficiency of maintenance;

[0011] 3. It avoids the shutdown of the system caused by serious equipment damage due to untimely discovery of leakage faults or misjudgment by manual experience, thereby further improving production efficiency and economic benefits; the utility model successfully solves the problem of accurate judgment of cone valve faults during the operation of the diaphragm pump and eliminates faults in a timely manner. At present, the system is very stable after being put into operation, and there is no longer the phenomenon that the valve box body is punctured due to untimely discovery of cone valve leakage; the application of the utility model not only obtains good economic benefits in terms of labor costs and equipment maintenance costs, but more importantly, the economic benefits obtained from preventing damage to imported equipment from affecting production and improving the stability of the production system are very considerable; the practicability, reliability and stability of the system are worthy of popularization and use in other domestic diaphragm pump conveying systems. Brief Description of the Drawings

[0012] Figure 1 is a schematic structural diagram of the utility model;

[0013] Figure 2 is a schematic diagram of the working principle of the utility model;

[0014] In the figure: 1. Diaphragm pump; 2. Inlet pulp pipeline; 3. Outlet pulp pipeline; 4. Pressure transmitter; 5. Outlet flowmeter; 6. Controller; 7. Frequency conversion cabinet; 8. Alarm. Detailed Embodiment

[0015] In the manufacturing industry, equipment that requires angle adjustment is often involved, such as the nozzles of oxygen cutting machines, laser cutting machines, nozzles for automatic painting, and various equipment that requires angle adjustment. The angle adjustment mechanisms in the prior art are either expensive or complex in structure, and there has never been an angle adjustment device that can meet the adjustment needs of users; to solve the above problems, a diaphragm pump cone valve leakage fault monitoring system is proposed. Embodiment

[0016] See Figure 1 - Figure 2, A monitoring system for the leakage fault of the cone valve of a diaphragm pump 1, comprising: a diaphragm pump 1, an inlet pulp pipeline 2 is provided on one side of the diaphragm pump 1, and an outlet pulp pipeline 3 is provided on the other side. A pressure transmitter 4 is provided on the inlet pulp pipeline 2, and an outlet flowmeter 5 is provided on the outlet pulp pipeline 3. A controller 6 is provided outside the diaphragm pump 1. The pressure transmitter 4 and the outlet flowmeter 5 are signal-connected to the input end of the controller 6. The controller 6 is used to judge whether the diaphragm pump 1 has a leakage fault through the data monitored by the outlet flowmeter 5 and the pressure transmitter 4. The output end of the controller 6 is connected to an alarm 8.

[0017] In this embodiment, a frequency conversion cabinet 7 is provided on the diaphragm pump 1. The frequency conversion cabinet 7 is communicatively connected to the input end of the controller 6 by PROFNET, and is used to monitor the working current data of the frequency conversion cabinet 7 of the diaphragm pump 1 and transmit the data to the controller 6.

[0018] In this embodiment, the controller 6 is a PLC programmable controller 6.

[0019] In this embodiment, the alarm 8 is a buzzer alarm 8.

[0020] The utility model has the following beneficial effects:

[0021] 1. The utility model greatly reduces the workload of patrol inspection by operating personnel and the workload of maintenance inspection, and basically meets the technical requirements of unattended operation; the operation of the diaphragm pump 1 conveying system has been reduced from 3 people / shift at the beginning to 1 person / shift. Secondly, the patrol inspection time has been reduced from 2 times / hour to 1 time / hour, greatly reducing the workload of personnel patrol inspection;

[0022] 2. Relying on the timeliness and accuracy of fault monitoring, it can accurately judge which valve box cone valve has a fault, thereby reducing the workload of equipment disassembly and inspection by the maintenance team and improving the work efficiency of maintenance;

[0023] 3. It avoids the shutdown of the system caused by serious equipment damage due to untimely discovery of leakage faults or incorrect manual experience judgment, thereby further improving production efficiency and economic benefits; the utility model successfully solves the problem of accurate judgment of the cone valve fault during the operation of the diaphragm pump 1 and eliminates the fault in time. At present, the system is very stable after being put into operation, and there has been no phenomenon that the valve box body is punctured due to untimely discovery of cone valve leakage; the application of the utility model not only obtains good economic benefits in terms of labor cost and equipment maintenance cost, but more importantly, it obtains very considerable economic benefits in terms of preventing damage to imported equipment from affecting production and improving the stability of the production system; the practicability, reliability and stability of this system are worthy of popularization and application in other diaphragm pump 1 conveying systems in China.

[0024] Logic principle of the cone valve fault monitoring system of the diaphragm pump 1

[0025] The most core part of the cone valve fault monitoring technology is the data acquisition, calculation and logical judgment. To ensure the accuracy of the collected data and that the analog quantity collected is not interfered by the outside world, we use KVVP (or RVSP) double-shielded cables to transmit signals. During construction, ensure that the signal cable is far away from the power cable to reduce electromagnetic interference. Secondly, in terms of the data calculation idea, when the collected data enters the PLC system, the system automatically converts the 4-20mA analog quantity into the corresponding pressure value, current value and flow value within the measuring range. Take the average value of the first ten collected values and perform a difference calculation with the current instantaneous value collected, and the current data fluctuation value can be obtained. When the calculated fluctuation value is greater than the set fluctuation critical value, the PLC system outputs a DQ alarm signal. It should be noted that this calculation program segment should be written in the Cyclic intevrupt and the cyclic interrupt time should be adjusted to 100000us; by periodically starting this calculation program segment without executing the loop program; the calculation formula is as follows (taking the pressure value calculation as an example):

[0026] ;

[0027] ;

[0028] : The average value of the first ten pressures; : The pressure fluctuation amplitude value;

[0029] : The current instantaneous pressure value; : The set fluctuation critical value;

[0030] Through calculation and analysis, when it indicates that there is a large fluctuation in the inlet pressure of the diaphragm pump 1. Intuitively judge that the cone valve has leaked. At this time, the PLC outputs an alarm signal, triggering the audible and visual alarm system, and promptly reminding the personnel in the central control room to immediately notify the maintenance team to troubleshoot the fault; the current and flow acquisition and calculation methods are the same as those for the pressure value calculation.

[0031] Of course, when adjusting the working frequency of the diaphragm pump 1 or adjusting the working frequency of the upstream slurry transfer pump of the diaphragm pump 1 according to production requirements, it will also cause large changes in the inlet pressure of the diaphragm pump 1, the working current of the diaphragm pump 1, and the outlet flow value. After normal regulation, the data value will return to a stable state within a short time. To eliminate the system false alarm triggered by normal process regulation, in the PLC program, the unit time counting method can be used to set that the number of consecutive occurrences within 2 minutes exceeds 5-10 times, triggering the alarm system. At the same time, comprehensively considering the absolute values of the current value and flow value fluctuations, accurately judge the working state of the cone valve.

[0032] Fault handling measures and methods to reduce the failure rate

[0033] Fault Disposal Measures

[0034] When the monitoring system alarms due to leakage of a cone valve in a certain diaphragm pump 1, at this time, the leakage of the cone valve is small, causing minor milling damage to the cone valve unit, and the valve body has not been damaged yet. The leakage fault is still in the initial stage. After accurately judging the faulty cone valve unit according to the alarm information, the operator immediately performs an emergency shutdown operation, and at the same time increases the working load of other diaphragm pumps 1 or starts the standby pump. After the system is normal and stable, the maintenance worker replaces the new cone valve unit in time according to the maintenance regulations to maintain the sustainability of system production.

[0035] Methods to Reduce the Failure Rate of Cone Valves

[0036] There are several main reasons for the leakage failure of the cone valve unit. First, the cone valve is normally worn due to long-term scouring by ore pulp during normal operation; second, the particle size of the transported ore pulp is large, and there are large and hard particles mixed in the ore pulp, causing abnormal damage to the sealing surface during the operation of the cone valve, resulting in failure; third, the machining accuracy of the cone surface of the cone valve unit is insufficient, and the tightness is low; fourth, the hardness, strength, and plasticity of the material of the cone valve unit are insufficient, and the wear resistance of the cone valve is low, resulting in a high failure frequency.

[0037] Improvement methods: First, reduce the working load of a single diaphragm pump 1. During normal production, change the working mode of two in use and one standby to three working simultaneously. After the total load is evenly distributed, the number of times the valve cone opens and closes per unit time becomes less, which can effectively extend the working time of the cone valve; Second, replace periodically. Through long-term operation data analysis and experience accumulation, summarize the normal working cycle of the cone valve, and the maintenance personnel replace the cone valve regularly according to the normal working cycle; Third, reduce the particle size of the ore pulp and prevent abnormal large particles. A sieve plate with a size of less than 1 mm can be used for screening. The particle size of the transported ore pulp becomes smaller, reducing the normal wear of the cone valve. At the same time, the conveying line is fully enclosed to prevent abnormal large particles from mixing into the ore pulp, reducing the probability of abnormal wear of the cone valve; Fourth, improve the wear resistance of the cone valve material. Through research on materials, improve the wear resistance of the rubber sealing ring and metal cone surface of the cone valve, increase the strength from the process material, extend the normal working time of the cone valve, and reduce the failure rate.

[0038] Conclusion

[0039] The technical development and application of the conical valve fault monitoring system for diaphragm pump 1 aims to detect and accurately judge the initial leakage stage of the conical valve of diaphragm pump 1 in a timely manner, enabling early warning, timely maintenance and replacement, improving the operation stability and safety of diaphragm pump 1, and avoiding equipment accidents such as slurry piercing the valve box due to conical valve wear. At the same time, it further deepens the degree of equipment automation monitoring, reduces the workload of manual inspection, realizes unattended operation, improves production efficiency and reduces production costs in the long run, bringing good economic benefits to the owner in the future. In the tailings conveying system of Xichang Mining of Chongqing Iron and Steel, through the development and application of the conical valve fault monitoring system technology for diaphragm pump 1, the problem of accurately judging the conical valve fault during system operation has been successfully solved, and the fault has been eliminated in a timely manner. At present, the system operates very stably after transformation, and there is no longer the phenomenon of the valve box being pierced due to conical valve wear. The reliability and stability of the application of the conical valve fault monitoring system technology for diaphragm pump 1 are worthy of popularization and application in other domestic diaphragm pump 1 conveying systems.

Claims

1. A diaphragm pump cone valve leakage fault monitoring system, comprising: Diaphragm pump, characterized in that: an inlet pulp pipeline is provided on one side of the diaphragm pump, and an outlet pulp pipeline is provided on the other side. A pressure transmitter is provided on the inlet pulp pipeline, and an outlet flowmeter is provided on the outlet pulp pipeline. A controller is provided outside the diaphragm pump. The pressure transmitter and the outlet flowmeter are signal-connected to the input end of the controller. The controller is used to judge whether the diaphragm pump has a leakage fault based on the data monitored by the outlet flowmeter and the pressure transmitter. An alarm is connected to the output end of the controller.

2. The diaphragm pump cone valve leakage fault monitoring system according to claim 1, wherein: A frequency conversion cabinet is provided on the diaphragm pump. The frequency conversion cabinet is communicatively connected to the input end of the controller by PROFNET, and is used to monitor the working current data of the frequency conversion cabinet of the diaphragm pump and transmit the data to the controller.

3. A diaphragm pump cone valve leakage fault monitoring system according to claim 1, characterized in that: The controller is a PLC programmable controller.

4. The diaphragm pump cone valve leakage fault monitoring system according to claim 1, characterized in that: The alarm is a buzzer alarm.

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