Real-time monitoring system for vibration isolation efficiency, attenuation change and service life of pipeline damper

Abstract

The utility model discloses a real-time monitoring system for vibration isolation efficiency, attenuation change and service life of a pipeline shock absorber, which comprises a load sensor used for monitoring load change borne by the shock absorber in real time; the displacement sensor is used for monitoring the deformation quantity of the shock absorber in real time; the data processing unit is connected with the load sensor and the displacement sensor and used for processing data of the load sensor and the displacement sensor; the data processing unit is further connected with an early warning unit, a display unit and a power supply unit, the early warning unit is used for warning, the display unit is used for displaying monitoring data, and the power supply unit is used for providing a working power supply. According to the utility model, the vibration isolation efficiency, the attenuation trend and the residual life of the pipeline damper are monitored in real time by collecting load and displacement data, so that an early warning function is realized.

Description

A real-time monitoring system for the vibration isolation efficiency, attenuation changes, and service life of pipeline vibration dampers. Technical Field

[0001] This utility model relates to the field of equipment monitoring technology, and in particular to a real-time monitoring system for the vibration isolation efficiency, attenuation changes and service life of a pipeline vibration damper. Background Technology

[0002] In precision industrial environments (such as semiconductor manufacturing plants), precision equipment has increasingly stringent requirements for micro-vibration. In practical applications, when the flow velocity of various gas pipelines is greater than 12.7 m / s, the support design must also consider the vibration reduction design of the pipeline. Seat-type and hanging-type vibration dampers are often used to isolate the vibration of the pipeline. However, due to the narrow environment of some factories, it is very difficult and risky to change the pipeline support and vibration damper. The pipeline vibration has a significant impact on the stability of the equipment. Traditional methods rely on one-time micro-vibration test to evaluate the performance of the vibration damper, but there are the following problems: (1) Cannot monitor in real time: After the vibration damper is installed, it is impossible to dynamically track whether the vibration isolation efficiency matches the design value; (2) Lack of long-term trend analysis: The curve of the vibration isolation efficiency decaying over time and the life prediction are missing; (3) Lagging maintenance: Relying on manual troubleshooting leads to production interruption and high costs.

[0003] Therefore, there is currently no system in the technology that can monitor the performance of vibration dampers in real time and predict their lifespan using multi-dimensional sensor data. Summary of the Invention

[0004] To address the shortcomings of existing technologies, the purpose of this utility model is to provide a real-time monitoring system for the vibration isolation efficiency, attenuation changes, and service life of pipeline vibration dampers. By collecting load and displacement data, the system monitors the vibration isolation efficiency, attenuation trend, and remaining service life of pipeline vibration dampers in real time, thereby achieving an early warning function.

[0005] To achieve the above objectives, the technical solution adopted by this utility model is as follows: a real-time monitoring system for the vibration isolation efficiency, attenuation change, and service life of a pipeline vibration damper, comprising:

[0006] Load sensors are used to monitor changes in the load on the vibration damper in real time.

[0007] Displacement sensors are used to monitor the deformation of the vibration damper in real time;

[0008] The data processing unit is connected to the load sensor and displacement sensor and is used to process the data from the load sensor and displacement sensor.

[0009] The data processing unit is also connected to an early warning unit, a display unit, and a power supply unit. The early warning unit is used for warning purposes, the display unit is used for displaying monitoring data, and the power supply unit is used for providing operating power.

[0010] As a preferred embodiment, the load sensor and the displacement sensor are integrated and packaged in the same housing.

[0011] As a preferred embodiment, the load sensor is a strain gauge load sensor.

[0012] As a preferred embodiment, the displacement sensor is a magnetostrictive displacement sensor.

[0013] As a preferred embodiment, the data processing unit includes a data processing module and a data acquisition module and a storage module connected to the data processing module.

[0014] As a preferred embodiment, the early warning unit includes an audible and visual alarm or a wired / wireless transmission unit, which is connected to a terminal.

[0015] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0016] (1) Real-time dynamic detection: replaces traditional single test to achieve continuous tracking of vibration damper performance;

[0017] (2) Dual data source verification: Load and displacement data complement each other to improve monitoring accuracy;

[0018] (3) Predictive maintenance: Predict lifespan using attenuation models to reduce the risk of sudden failures;

[0019] (4) Wide compatibility: Adaptable to various industrial scenarios, reducing the impact of micro-vibrations on precision equipment. Attached Figure Description

[0020] Figure 1 is a system block diagram of this utility model;

[0021] The attached diagram lists the following components: Load sensor 1, Displacement sensor 2, Data processing unit 3, Early warning unit 4, Display unit 5, Power supply unit 6, Data processing module 7, Data acquisition module 8, Storage module 9, Timer 10, Audible and visual alarm 11, Wired / wireless transmission unit 12, Terminal 13. Detailed Implementation

[0022] The present invention will be further described below with reference to specific embodiments. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and should not be used to limit the protection scope of the present invention.

[0023] Example:

[0024] As shown in Figure 1, a monitoring system for implementing the real-time monitoring method includes...

[0025] Load sensor 1 is used to monitor the load changes borne by the vibration damper in real time;

[0026] Displacement sensor 2 is used to monitor the deformation of the vibration damper in real time;

[0027] Data processing unit 3 is connected to load sensor 1 and displacement sensor 2 and is used to process the data from load sensor 1 and displacement sensor 2.

[0028] The data processing unit 3 is also connected to an early warning unit 4, a display unit 5, and a power supply unit 6. The early warning unit 4 is used for warning purposes, the display unit 5 is used for displaying monitoring data, and the power supply unit 6 is used for providing operating power.

[0029] Preferably, the load sensor 1 and the displacement sensor 2 are integrated and packaged in the same housing.

[0030] Specifically, an integrated design is adopted, with two sensors sharing a protective housing and internally isolated wiring. In actual implementation, Rittal standard sensor housings can be used.

[0031] More preferably, the load sensor 1 is a strain gauge load sensor.

[0032] Specifically, the strain gauge load cell used in practical applications is model HBM U9C / 5T.

[0033] More preferably, the displacement sensor 2 is a magnetostrictive displacement sensor.

[0034] Specifically, in practical applications, the magnetostrictive displacement sensor used is the Balluff BMF003K.

[0035] Preferably, the data processing unit 3 includes a data processing module 7 and a data acquisition module 8 and a storage module 9 connected to the data processing module 7.

[0036] Specifically, in practical applications, the data processing module 7 uses an STM32F407 series microcontroller. The timer 10 of the microcontroller captures the pulse of the signal from the magnetostrictive displacement sensor. The data acquisition module 8 is an A / D converter, which acquires and converts the signal from the strain gauge load sensor. The A / D converter can be a TI ADS1220.

[0037] More specifically, the storage module 9 is used to store the collected data and the data processed by the data processing module 7.

[0038] Preferably, the early warning unit 4 includes an audible and visual alarm 11 or a wired / wireless transmission unit 12, which is connected to the terminal 13.

[0039] Specifically, in practical applications, the sound and light alarm 11 can be a sound alarm TDK PS1240P02 piezoelectric buzzer or a light alarm OSRAM SFH4715AS red LED.

[0040] More specifically, it can also be connected to the terminal 13 for early warning via the wired / wireless transmission unit 12, wherein the wireless transmission unit can be a SIM7080G 4G module from SIMCom.

[0041] In practical use, this embodiment also discloses a monitoring method based on the real-time monitoring system, including the following steps:

[0042] (1) Install composite sensors on the vibration damper and collect load data and displacement data synchronously through the composite sensors;

[0043] (2) Initialization of design parameters: Input the damper elastic coefficient s, rated load G1, and equipment speed n, and calculate the initial vibration isolation efficiency T. e初始 ;

[0044] (3) Calculate the real-time vibration isolation efficiency T using the collected load data. e荷载 and the initial vibration isolation efficiency parameter T e初始 contrast;

[0045] (4) Calculate the real-time vibration isolation efficiency T using the collected displacement data. e位移 and the initial vibration isolation efficiency parameter T e初始 contrast;

[0046] (5) Vibration isolation efficiency T obtained through load monitoring e荷载 Vibration isolation efficiency T obtained from displacement monitoring e位移 Perform cross-validation to generate the vibration isolation efficiency T. e - Decay curve over time t;

[0047] (6) Set the vibration isolation efficiency T e The threshold is used to predict the remaining lifetime L based on the fitted slope k of the decay curve, and maintenance is notified in advance.

[0048] Preferably, in step (1), the composite sensor integrates and packages a magnetostrictive displacement sensor and a strain gauge load sensor. The magnetostrictive displacement sensor outputs a displacement pulse signal to obtain the measured displacement value δ. 1位移 The strain gauge load sensor outputs a load electrical signal to obtain the real-time load value G. 1实测 .

[0049] Specifically, by integrating a magnetostrictive displacement sensor and a strain gauge load sensor into the same housing, dual-mode data synchronous acquisition is achieved. The magnetostrictive displacement sensor outputs a displacement pulse signal by detecting the absolute position of the magnetic ring, while the strain gauge load sensor outputs a load electrical signal through a resistance strain gauge.

[0050] Furthermore, since the magnetostrictive displacement sensor and strain gauge load sensor used are both existing components in the prior art, they will not be described in detail here.

[0051] Preferably, in step (2), the initial vibration isolation efficiency T is calculated. e初始 The steps are as follows: First, calculate the spring compression: δ1 = G1 / s, where δ1 is the spring compression, G1 is the rated load, and s is the damper's elastic coefficient; then calculate the natural frequency: Where f n Let 15.76 be the natural frequency, δ1 be a fixed coefficient, and δ1 be the spring compression. Then calculate the equipment frequency: f = n / 60, where f is the equipment frequency and n is the equipment rotational speed. Finally, calculate the vibration isolation efficiency: T e =1-|1 / (1-(f / f) n ) 2 )|, where T e The vibration isolation efficiency is given by f, where f is the equipment frequency. n It is the natural frequency.

[0052] Specifically, the initial vibration isolation efficiency parameter T is calculated based on the design specifications of the vibration damper, through design parameter initialization. e初始 The theoretical value of the vibration damper is obtained to verify whether the actual installation meets expectations, thereby troubleshooting installation or composite sensor problems. The theoretical value can be used as a reference for the initial calibration of composite sensors. For example, the deformation δ1 monitored by the magnetostrictive displacement sensor should be consistent with the theoretical spring compression δ1, while the reading of the strain gauge load cell should match G1 = operating weight * 1.2.

[0053] More specifically, the measured displacement δ using a magnetostrictive displacement sensor 1位移 Inverse load G1 = δ 1位移 ×s, and thus compare it with the theoretical load. If the deviation between the theoretical value and the actual value is large, the magnetostrictive displacement sensor calibration or fault alarm is triggered.

[0054] More specifically, the measured load G is obtained through a strain gauge load cell. 1实测 Calculate the downforce δ 1荷载 =G 1实测 / s, where δ 1荷载The measured spring compression is G1, the measured load, and s, the damper's elastic coefficient. This is compared with the theoretical compression. If the theoretical value deviates significantly from the actual value, the strain gauge load sensor calibration or fault alarm is triggered.

[0055] More specifically, the spring constant s may change after long-term use, which can be corrected in reverse using theoretical formulas:

[0056] Furthermore, the fixed coefficient of 15.76 is a standard conversion value in vibration engineering, widely used in the calculation of the natural frequency of spring vibration dampers. Refer to the Mechanical Vibration Handbook or ISO standards; it will not be elaborated on here.

[0057] Preferably, in step (3), the real-time vibration isolation efficiency T e荷载 The real-time load value G is calculated using a strain gauge load cell and obtained through the following steps. 1实测 First, calculate the spring compression: δ 1荷载 =G 1实测 / s, where δ 1荷载 To measure the spring compression, G 1荷载 The measured load is given, and s is the elastic coefficient of the vibration damper; then the natural frequency is calculated. Where f n荷载 The natural frequency is 15.76, which is a fixed coefficient, and δ is... 1荷载 The spring compression is given; then the equipment frequency is calculated: f = n / 60, where f is the equipment frequency and n is the equipment rotational speed; finally, the frequency ratio is calculated: Where u 荷载 The frequency ratio is f, where f is the device frequency. n荷载 Given the natural frequency; then calculate the vibrational conductivity: Where T r荷载 u is the vibrational conductivity. 荷载 The frequency ratio is used; finally, the vibration isolation efficiency is calculated: T e荷载 =1-T r荷载 T e荷载 To measure the vibration isolation efficiency, T r荷载 It represents the vibration conductivity.

[0058] Specifically, the load value reflects the actual force on the vibration damper. The deformation is derived through mechanical relationships, and then the vibration isolation efficiency is calculated. In this embodiment, the stress change is directly measured by a strain gauge load sensor, which has high sensitivity.

[0059] In actual use, calculations are performed using multiple sets of comparative data, as detailed in Table 1:

[0060] Table 1

[0061]

[0062] Preferably, in step (4), the real-time vibration isolation efficiency T e位移 The displacement value δ, obtained by acquiring the measured displacement value using a magnetostrictive displacement sensor, is calculated through the following steps. 1位移 First, calculate the natural frequency. Where f n位移 The natural frequency is 15.76, which is a fixed coefficient, and δ is... 1位移 The spring compression is given; then the equipment frequency is calculated: f = n / 60, where f is the equipment frequency and n is the equipment rotational speed; finally, the frequency ratio is calculated: Where u 位移 The frequency ratio is f, where f is the device frequency. n位移 Given the natural frequency; then calculate the vibrational conductivity: Where T r位移 u is the vibrational conductivity. 位移 The frequency ratio is used; finally, the vibration isolation efficiency is calculated: T e位移 =1-T r位移 T e位移 To measure the vibration isolation efficiency, T r位移 It represents the vibration conductivity.

[0063] Specifically, the displacement value directly reflects the degree of deformation of the vibration damper. The natural frequency is derived from the deformation, and then the vibration isolation efficiency is calculated. In this embodiment, a magnetostrictive displacement sensor is used for non-contact measurement, which is resistant to pollution and high pressure.

[0064] In actual use, calculations are performed using multiple sets of comparative data, as detailed in Table 2:

[0065] Table 2

[0066]

[0067] Preferably, the cross-validation in step (5) satisfies |T e位移 -T e荷载 When |≤ the set value, output the final vibration isolation efficiency. Where T e For the final output vibration isolation efficiency, T e位移 To measure the vibration isolation efficiency, T e荷载 To measure the vibration isolation efficiency; otherwise, trigger the composite sensor calibration process.

[0068] Specifically, in this embodiment, the setpoint is set to 5% during actual monitoring, that is, when |T e位移 -T e荷载 When |≤5%, the verification is successful, and the final vibration isolation efficiency T is output. e When |T e位移 -T e荷载If the percentage is greater than 5%, the verification fails, directly triggering composite sensor calibration or troubleshooting.

[0069] Preferably, the remaining lifetime prediction formula in step (6) is: Where L is the remaining lifetime, T e初始 T is the initial vibration isolation efficiency parameter in step (2). e阈值 Set the vibration isolation efficiency T in step (6) e The threshold value, k is the vibration isolation efficiency T e - The slope of the fitted decay curve at time t.

[0070] More preferably, the formula for calculating the slope of the attenuation curve is: k = ΔT e / Δt, where k is the fitted slope, and T e The output represents the final vibration isolation efficiency, and t represents time.

[0071] Preferably, the advance maintenance notification in step (6) includes setting up terminal push notifications, triggering audible and visual alarms, and initiating maintenance work orders for multi-level early warning.

[0072] Specifically, in this embodiment, T is actually used in practice. e阈值 The preset lifespan warning threshold is 80%. 阈值 =30 days, when T e When <85%, a notification is pushed to the terminal; when T e When the remaining lifespan is less than 80%, an audible and visual alarm is triggered. When the remaining lifespan L is less than or equal to 30 days, a maintenance work order is initiated, thereby achieving a closed loop of monitoring, analysis, and decision-making.

[0073] In summary, this invention achieves simultaneous acquisition of load and displacement data in two modes through the integrated design of a magnetostrictive displacement sensor and a strain gauge load sensor. Based on the independent and cross-validation of vibration isolation efficiency through dual paths, it generates a vibration isolation efficiency-time decay curve and fits the remaining lifespan, and provides multi-level early warning. This solves the problems of low data reliability and lack of lifespan prediction in traditional monitoring and can be widely applied to industrial vibration reduction systems.

[0074] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present utility model, and these improvements and modifications should also be considered within the protection scope of the present utility model.

Claims

1. A real-time monitoring system for the vibration isolation efficiency, attenuation change, and service life of a pipeline vibration damper, characterized in that, include: Load sensors are used to monitor changes in the load on the vibration damper in real time; displacement sensors are used to monitor the deformation of the vibration damper in real time. The data processing unit is connected to the load sensor and the displacement sensor to process the data from the load sensor and the displacement sensor. The data processing unit is also connected to an early warning unit, a display unit, and a power supply unit. The early warning unit is used for warning purposes, the display unit is used to display monitoring data, and the power supply unit is used to provide operating power.

2. The real-time monitoring system for the vibration isolation efficiency, attenuation change, and service life of a pipeline vibration damper according to claim 1, characterized in that: The load sensor and displacement sensor are integrated and packaged in the same housing.

3. The real-time monitoring system for the vibration isolation efficiency, attenuation change, and service life of a pipeline vibration damper according to claim 1, characterized in that: The load sensor is a strain gauge load sensor.

4. The real-time monitoring system for the vibration isolation efficiency, attenuation change, and service life of a pipeline vibration damper according to claim 1, characterized in that: The displacement sensor is a magnetostrictive displacement sensor.

5. The real-time monitoring system for the vibration isolation efficiency, attenuation change, and service life of a pipeline vibration damper according to claim 1, characterized in that: The data processing unit includes a data processing module and a data acquisition module and a storage module connected to the data processing module.

6. The real-time monitoring system for the vibration isolation efficiency, attenuation change, and service life of a pipeline vibration damper according to claim 1, characterized in that: The early warning unit includes an audible and visual alarm or a wired / wireless transmission unit, which is connected to the terminal.

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