Water pump or hydroelectric generating set performance testing device

Abstract

The utility model belongs to the field of fluid mechanical performance testing, and particularly discloses a water pump or hydroelectric generating set operation performance testing device which comprises an acquisition module and a testing module, the acquisition module comprises a power supply unit, a signal conditioning circuit and a data acquisition card, and the power supply unit is packaged by a sensor group and a portable interface box. The interface box and the sensor group are connected through phoenix wiring terminals, so that each path of sensor forms an independent signal channel, the test module comprises a calibration module, a test module, a sorting module and a signal analysis module, the calibration module comprises calibration optical cables connected with the signal channels in a one-to-one correspondence manner, and the calibration optical cables are connected with the signal channels in a one-to-one correspondence manner. The test module comprises an online monitoring unit, a test unit and a test recording unit, the sorting module is used for obtaining effective test data from the test recording unit, and the signal analysis module comprises a time domain analysis module and a frequency domain analysis module and is used for drawing various data charts for the effective test data. According to the utility model, the unit test process is simplified, and the error probability is greatly reduced.

Description

Technical Field

[0001] The utility model belongs to the field of fluid mechanical performance testing and online monitoring, and in particular relates to a water pump or hydroelectric generator set performance testing device. Background Art

[0002] The increasing size and integration of water pumps or hydropower units have more stringent requirements for their stable operation, and the increasingly deteriorating service environment seriously threatens the health and safety of the units. Therefore, the testing of water pumps or hydropower units has important guiding significance for mastering the operating performance of the units, determining the working status, early warning of degradation trends, fault diagnosis, optimizing operation and formulating maintenance plans, and provides on-site measured data for improving the design level of water pumps or hydropower units.

[0003] There are three main methods for testing the operating performance of water pumps or hydropower units: handheld test instruments, portable multi-channel test devices, and online monitoring systems. In the early days, the operating performance of water pumps or hydropower units was mostly tested by test personnel using handheld test instruments to test different measuring points of the unit. A large amount of manpower was invested on site, the operation process was complicated, and the concurrency and real-time performance of the measurement signal reading were poor, resulting in low accuracy of subsequent signal correlation analysis and difficulty in accurately evaluating the operating performance of the unit. With the development of sensor technology, data acquisition technology, communication technology, and computer technology, portable multi-channel test devices and online monitoring systems have been gradually applied to the field of operating performance testing of water pumps or hydropower units. However, the online monitoring system is costly and difficult to promote in some pumping stations or hydropower plants. The wiring mode of the pre-installed on-site measuring points and acquisition units is solidified, and it is difficult to add sensor measuring points and wiring, making it difficult to carry out test projects that require additional measuring points. The existing portable multi-channel test devices have the following shortcomings: the test conditions and test time need to be recorded manually on site, the operation process is complicated and prone to errors; the wiring terminals of the acquisition interface box are set according to voltage or current signals, the functions are relatively simple, and the expandability is not strong; there is a lack of online monitoring function for the operating status of the unit; for a specific portable multi-channel test device, it is difficult to have the performance test and analysis functions of both the water pump unit and the hydropower unit.

[0004] At present, there is no portable multi-channel testing device developed for water pumps or hydropower units, which has both the online monitoring and testing functions of water pump units and hydropower units, especially the recording of test conditions and test time without human intervention during the test recording process, and is equipped with professional comprehensive testing and analysis software. Utility Model Content

[0005] The purpose of the present utility model is to provide a performance testing device for a water pump or a hydro-generator unit, so as to overcome the defects existing in the prior art, such as complex wiring, the need for manual intervention to record test conditions and test time during the test recording wave process, cumbersome test procedures prone to errors, inability to simultaneously have the functions of testing the operating performance of water pumps and hydro-generator units, inability to take into account the functions of on-line monitoring and performance testing, and single professional comprehensive analysis function. The present utility model integrates a power supply unit, a signal conditioning circuit and a data acquisition card into the interface box of the acquisition module, integrates a calibration module, a test module, a sorting module and a signal analysis module into the test module, and then connects the two major modules of the integrated module and the test module. The wiring method is simple and easy to carry. Then, a sensor group is used to perform multi-channel and continuous real-time sampling of data at the measuring points arranged for the water pump and the hydro-generator unit, and continuous recording of waves is realized according to the division of labor of each sub-module in the test module, without manual intervention to record the test time and test conditions, realizing the above-mentioned on-line monitoring and test functions of the operating performance of the water pump and the hydro-generator unit, and simplifying the test operation process.

[0006] In order to achieve the above purpose, the present utility model provides a performance testing device for a water pump or a hydro-generator unit, which is characterized in that it includes an acquisition module and a test module, the acquisition module and the test module are electrically connected, the acquisition module includes a sensor group, a power supply unit, a signal conditioning circuit and a data acquisition card, the power supply unit, the signal conditioning circuit and the data acquisition card are encapsulated in a portable interface box, the interface box and the sensor group are connected by a phoenix terminal, and after each sensor in the sensor group is connected to a phoenix terminal on the interface box, an independent signal channel is formed;

[0007] The test module includes a calibration module, a test module, a sorting module and a signal analysis module arranged in sequence from top to bottom;

[0008] Among them, the calibration module includes calibration optical cables connected to each signal channel one by one, and the other ends of the calibration optical cables are connected to the test module through data lines;

[0009] The test module includes an on-line monitoring unit, a test unit and a test recording wave unit connected in sequence. The on-line monitoring unit is used for on-line monitoring of multiple state quantities of the water pump or the hydro-generator unit;

[0010] The sorting module is used for trimming the recorded wave data of the test recording wave unit to obtain effective test data corresponding to the test unit;

[0011] The test module is used for on-line monitoring, testing and recording waves during the operation of the water pump or the hydro-generator unit, and obtaining recorded wave data;

[0012] The sorting module is used for trimming the recorded wave data of the test module to obtain effective data corresponding to the test conditions;

[0013] The signal analysis module is used to analyze and process the valid data.

[0014] According to an embodiment of the present invention, the sensor group is used to capture the current signal or voltage signal corresponding to the physical quantity of the water pump or the hydro-generator set, transmit the current signal or voltage signal to the signal conditioning circuit, and the signal conditioning circuit is used to condition and convert the current signal or voltage signal into an electrical signal within the input range of the data acquisition card. The data acquisition card is used to convert the electrical signal into a digital signal and upload it to the calibration module. The input range of the data acquisition card is ±10V, ±5V, ±2V, and ±1V.

[0015] According to an embodiment of the present invention, each Phoenix terminal block includes a -24V power supply, a +24V power supply, a current signal input terminal, a voltage signal input terminal, and a ground terminal.

[0016] According to an embodiment of the present invention, the sensor group is a 32-channel sensor, the maximum sampling rate of the signal channel is 250K / s, and the AD resolution is 16 bits.

[0017] According to an embodiment of the present invention, the calibration module is an offline calibration module or an online calibration module.

[0018] According to an embodiment of the present invention, the test module includes a plurality of online monitoring units, and the plurality of online monitoring units are used to perform online monitoring on a plurality of state variables of the water pump or the hydro-generator set. The plurality of state variables include vibration, noise, swing, flow rate, temperature, pressure, pressure pulsation, torque, and rotational speed.

[0019] According to an embodiment of the present invention, the signal analysis module includes a time-domain analysis module and a frequency-domain analysis module. The time-domain analysis module is used to draw a data list, a time-domain waveform diagram, a frequency spectrum diagram, a waveform length diagram, a three-dimensional waterfall diagram, an axis locus diagram, a dynamic balance counterweight azimuth diagram, or a data report for the valid data. The frequency-domain analysis module is used to provide the maximum value, minimum value, average value, peak value, effective value, frequency, and signal trend analysis of the signal in the signal channel.

[0020] Generally speaking, through the above technical solutions conceived by the present invention, compared with the prior art, the following technical advantages are mainly possessed:

[0021] 1. In the acquisition module of the present utility model, first, the power supply unit, signal conditioning circuit, and data acquisition card are integrated into one by an interface box, and then each sensor is connected to the Phoenix terminal on the interface box to form independent signal channels. These multiple signal channels are then connected to the calibration module in the test module one by one, greatly reducing the error probability of data transmission from the acquisition module to the test module. And through the subsequent test module, sorting module, and signal analysis module, the data transmitted from the acquisition module is sorted into valid data for different test conditions, realizing the automatic acquisition, monitoring, and test of the unit.

[0022] 2. The maximum number of sensor groups of the present utility model is 32 groups, which can capture signals of all types of physical quantities of the unit. Subsequently, they are uploaded to the test module through the signal conditioning circuit and data acquisition card in sequence, and the acquisition process is orderly and not prone to errors.

[0023] 3. The signal analysis module of the present utility model includes a time-domain analysis module and a frequency-domain analysis module, which can display the valid data in various appearance charts, while ensuring the integrity and intuitiveness of the analysis of test results. Brief Description of the Drawings

[0024] Figure 1 It is a schematic structural diagram of the test device according to the embodiment of the present utility model.

[0025] Figure 2 It is a schematic wiring diagram of the Phoenix terminal of the interface box in the acquisition module according to the embodiment of the present utility model. Detailed Embodiment

[0026] In order to make the purpose, technical solution, and advantages of the present utility model clearer, the present utility model will be further described in detail below with reference to the drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present utility model and are not used to limit the present utility model. In addition, the technical features involved in the various embodiments of the present utility model described below can be combined with each other as long as they do not conflict with each other.

[0027] As Figure 1 shown, the embodiment of the present utility model provides a performance test device for a water pump or a water turbine generator set, which includes: an acquisition module for capturing electrical quantities representing the operating performance of the water pump or the water turbine generator set; a calibration module for converting the electrical quantities obtained by the acquisition module into physical quantities of the operating state of the water pump or the water turbine generator set; a test module for online monitoring, testing, and wave recording of the operating performance of the water pump or the water turbine generator set; a sorting module for trimming the wave recording data of the test module to obtain valid data corresponding to the test conditions; and a signal analysis module for analyzing and processing the sorted data.

[0028] The acquisition module includes a sensor unit, a power supply unit, a signal conditioning circuit, and a data acquisition unit. Among them, the sensor unit measures the electrical signals of the operating performance status variables of the unit; the function of the signal conditioning circuit is to connect the sensor unit, the power supply unit, and the data acquisition unit together and condition the monitored electrical signals (voltage signal input range: -20V to 20V; current signal input range: 0 to 20mA, load resistance: 250Ω); the data acquisition unit completes the acquisition of the conditioned electrical signals and the conversion of digital signals. Install a swing sensor, a vibration sensor, a pressure transmitter, a pressure pulsation sensor, a noise sensor, a flowmeter, other types of sensors, and access third-party detection signals at the measuring points arranged on the unit. Use a high-performance industrial switching power supply to supply power to them, capture the current signals or voltage signals corresponding to physical quantities such as vibration, noise, swing, flow, temperature, pressure, pressure pulsation, torque, and speed of the unit, and transmit the above current or voltage signals to the signal conditioning circuit, which conditions and converts them into electrical signals within the input range of the data acquisition card. The data acquisition card completes the acquisition of the conditioned electrical signals and simultaneously converts them into digital signals and uploads them to the test computer. The acquisition module has 32 independent signal channels (supporting channel expansion function), and each independent channel supports the input of current or voltage signals; it supports continuous parallel real-time acquisition, with a maximum sampling rate of 250K / s for a single channel, and has stable and reliable performance; the AD resolution is 16 bits; the input range of the data acquisition card is ±10V, ±5V, ±2V, and ±1V; the default provides sensor power supply levels of +24V and -24V, and supports extended power supply levels; the interface box uses a high-grade aluminum alloy portable case, which is beautiful, strong, and easy to carry; the connection between the interface box and the sensor uses Phoenix terminals. Each terminal supplies power to the sensor with ±24V power, and has voltage and current signal input terminals, which can measure voltage signals within ±24V and current signals of 0 to 20mA. The wiring is simple and reliable, reducing the probability of wiring errors on site. Figure 2 It is the wiring schematic diagram of the Phoenix terminals of the interface box in the acquisition module of this embodiment, including the wiring methods of voltage output type sensors, two-wire current output type sensors, voltage type monitoring signals, and current type monitoring signals.

[0029] The calibration module is used to name each channel, determine the correspondence between the sensor and the channel number; establish the correspondence between the physical quantities of the measured unit of each channel and the output current or voltage value of the sensor; support two sensor calibration methods: offline and online. First, click "Sensor Calibration" to enter the sensor calibration program, then click the menu item "File" → "Open Configuration File", select the sensor calibration file with the extension "MCX", enter the overall channel information setting window, and set the information for each channel. The information setting content in the calibration module includes: channel number, channel name, channel unit, current / voltage, maximum and minimum values, coefficient 0 and coefficient 1, signal type, channel save frequency, acquisition card voltage range, etc. There are two types of signals. One is the general waveform, and the other is the rotational speed waveform. Except for the key phase signal which is set to the rotational speed waveform, the rest of the signals are set to the general waveform. For the rotational speed waveform, coefficient 0 is set to the holding time of the pulse signal, and coefficient 1 is set to the trigger threshold value of the signal. After the information configuration is completed, enter the sensor calibration window. In this window, the modification of modifiable parameters can be completed, or the correspondence between the physical quantity and the electrical quantity value can be input in the "Direct Input" column, or online calibration can be performed in the "Online Calibration" column.

[0030] The test module is used to monitor the state quantities such as vibration, swing, pressure, temperature, noise, etc. of the water pump or hydro-generator unit, customize and display the real-time characteristic values, waveforms, spectra, shaft center trajectories, three-dimensional shaft center postures, overall views, etc. of the signals of each test channel, and realize the online monitoring and analysis functions of the real-time operation performance of the unit; used for tests such as vibration test, noise test, energy characteristics, start-up, shutdown, steady-state operation, variable flow rate, variable blade pitch, barring gear, dynamic balance, efficiency, load rejection, etc.; used for the acquisition and storage of test data; used for the curve drawing and data storage of efficiency tests, etc. In the test module, click the menu item "File" → "Open Sensor Information File", select the calibration file with the extension "MCX", enter the HSJ data acquisition program, and double-click the item in the navigation bar to view the relevant information.

[0031] The sorting module is used to cut out the effective data corresponding to each test condition from the continuously collected waveform recording data file according to the working condition parameters, so as to prepare for further analysis and processing by the signal analysis module; it simplifies the test process, avoids the cumbersome operations such as manually recording the test conditions and test time at the test site in the prior art, ensures the continuous waveform recording method without manual intervention in the test module of the present utility model, and reduces the error probability. Click "Data Sorting" in the sorting module to enter the data sorting program. Click the menu item "System Configuration" → "Working Directory Selection", select the working directory, the system will automatically open the available data files, and then select the sorting reference channel to perform data sorting for the test conditions. In theory, any signal in the navigation bar can be used as the basis for data sorting. Generally, the active power signal is selected for the variable load test, and the rotational speed signal is selected as the sorting basis for the variable speed test. In the window of the sorting module, there are some specific operation tools to help complete the sorting task: dragging the cursor, stretching the X coordinate, stretching the XY coordinate, regional translation, refreshing the data, directly saving the sorted data, outputting the sorted data, saving the sorting record, loading the sorting record, clearing the sorting, restoring the sorting, adding sorting segments, etc.

[0032] The signal analysis module is used to analyze and process the data of each test condition after sorting to obtain the test analysis results; it supports two analysis modes: signal full cycle and non-full cycle; it adopts time domain and frequency domain analysis methods, and provides customized output functions for data list, time domain waveform diagram, frequency spectrum diagram, waveform long diagram, three-dimensional waterfall diagram, shaft center locus diagram, dynamic balance counterweight azimuth diagram, data report and the corresponding data file; it provides analysis functions such as the maximum value, minimum value, average value, peak-to-peak value, effective value, frequency, trend analysis, and correlation analysis of the signal. The signal analysis module supports two signal analysis modes: full cycle and non-full cycle (Full cycle analysis: One rotation of the unit is called a cycle. When analyzing, the selection of data is based on the key phase point. The length of the data always starts from the key phase point and ends at another key phase point, so as to ensure that the rotational speed frequency of the unit obtained by analysis is accurate. Definition of non-full cycle analysis: It is based on time as the starting point of the data. The time can be the time length at the time of sorting or the time length selected manually.) Click "File" → "Open Sorted File" in the signal analysis module to load the data to be analyzed into the window for signal analysis of relevant test data.

[0033] In summary of the above embodiments, a performance testing device for a water pump or a hydro-generator unit disclosed by the present utility model can perform multi-channel continuous parallel real-time monitoring, wave recording, performance testing and analysis on the measuring points arranged for the water pump and the hydro-generator unit; simplifies the test process, without the need for operators to intervene during wave recording, enables continuous wave recording, and then sorts the continuous wave recording data into valid data corresponding to different test conditions according to the operating condition parameters, avoiding the cumbersome operations such as manual recording of test conditions and test time in the prior art on site, and reducing the error probability; has both the test function and the online monitoring function for the water pump unit and the hydro-generator unit; is equipped with a professional comprehensive testing and analysis software; has simple and reliable wiring, is small in size and convenient to carry.

[0034] It is easy for those skilled in the art to understand that the above are only the preferred embodiments of the present utility model, and are not intended to limit the present utility model. Any modifications, equivalent replacements, and improvements made within the spirit and principle of the present utility model shall be included within the protection scope of the present utility model.

Claims

1. A performance testing device for a water pump or a hydroelectric generating unit, characterized in that, It includes a collection module and a test module, the collection module and the test module are electrically connected. The collection module includes a sensor group, a power supply unit, a signal conditioning circuit and a data acquisition card. The power supply unit, the signal conditioning circuit and the data acquisition card are encapsulated in a portable interface box. The interface box and the sensor group are connected by Phoenix terminals. After each sensor in the sensor group is connected to a Phoenix terminal on the interface box, an independent signal channel is formed; The test module includes a calibration module, a test module, a sorting module and a signal analysis module arranged in sequence from top to bottom; Among them, the calibration module includes calibration optical cables connected to each signal channel in one-to-one correspondence, and the other ends of the calibration optical cables are connected to the test module through data lines; The test module includes an on-line monitoring unit, a test unit and a test wave recording unit connected in sequence. The on-line monitoring unit is used for on-line monitoring of multiple state variables of a water pump or a hydro-generator set; The sorting module is used for cropping the wave recording data of the test wave recording unit to obtain valid test data corresponding to the test unit; The test module is used for on-line monitoring, testing and wave recording during the operation of a water pump or a hydro-generator set, and obtaining wave recording data; The sorting module is used for cropping the wave recording data of the test module to obtain valid data corresponding to the test working conditions; The signal analysis module is used for analyzing and processing the valid data.

2. The performance testing device for a water pump or a hydroelectric generating unit according to claim 1, characterized in that, The sensor group is used for capturing current signals or voltage signals corresponding to physical quantities representing a water pump or a hydro-generator set, transmitting the current signals or voltage signals to the signal conditioning circuit. The signal conditioning circuit is used for conditioning and converting the current signals or voltage signals into electrical signals within the input range of the data acquisition card. The data acquisition card is used for converting the electrical signals into digital signals and uploading them to the calibration module. The input range of the data acquisition card is ±10V, ±5V, ±2V and ±1V.

3. The performance testing device for a water pump or a hydroelectric generating unit according to claim 1, wherein, Each Phoenix terminal includes a -24V power supply, a +24V power supply, a current signal input terminal, a voltage signal input terminal and a ground terminal.

4. A performance testing device for a water pump or a hydroelectric generating unit according to claim 1, characterized in that The sensor group is a 32-channel sensor, the maximum sampling rate of the signal channel is 250K / s, and the AD resolution is 16 bits.

5. A performance testing device for a water pump or a water turbine generator set according to any one of claims 1-4, characterized in that, The calibration module is an off-line calibration module or an on-line calibration module.

6. A performance testing device for a water pump or a water turbine generator unit according to any one of claims 1-4, characterized in that, The test module includes multiple on-line monitoring units. The multiple on-line monitoring units are used for on-line monitoring of multiple state variables of a water pump or a hydro-generator set. The multiple state variables include vibration, noise, swing, flow rate, temperature, pressure, pressure pulsation, torque and rotational speed.

7. A performance testing device for a water pump or a water turbine generator set according to any one of claims 1-4, characterized in that The signal analysis module includes a time domain analysis module and a frequency domain analysis module. The time domain analysis module is used for drawing a data list, a time domain waveform diagram, a frequency spectrum diagram, a waveform length diagram, a three-dimensional waterfall diagram, an axis locus diagram, a dynamic balance counterweight azimuth diagram or a data report form for the valid data. The frequency domain analysis module is used for providing the maximum value, minimum value, average value, peak value, effective value, frequency and signal trend analysis of the signals in the signal channel.

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