Vibration measurement system suitable for vibration displacement of air compressor
By employing an independent power supply and signal isolation vibration measurement system on the air compressor, the problems of single-point failure, signal interference, and high maintenance costs of the air compressor vibration displacement monitoring system have been solved, achieving system stability and scalability, and reducing failure risks and hardware costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- 重庆朝阳气体有限公司
- Filing Date
- 2025-04-23
- Publication Date
- 2026-05-15
AI Technical Summary
Existing air compressor vibration and displacement monitoring systems suffer from high single-point failure risk, severe signal interference, high maintenance costs, and limited scalability. Furthermore, existing distributed solutions have failed to effectively address issues such as signal transmission delay and unstable power supply.
It employs multiple vibration measurement point modules, a distributed control system, and an independent power supply module, connected via eddy current probes, extension cables, and vibration transmitters to achieve independent power supply and signal isolation. Combined with a double-layer shielding structure and opto-isolation design, it ensures the stability and reliability of signal transmission.
It achieves physical isolation between power supply and signal, reduces the risk of failure and signal distortion, reduces hardware costs and maintenance expenses, improves system scalability and equipment security, and avoids unplanned downtime accidents.
Smart Images
Figure CN224247147U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of measurement and monitoring, and relates to a vibration measurement system suitable for the vibration displacement of a group air compressor. Background Technology
[0002] As a key power equipment in the industrial field, the operational stability of air compressors directly affects the continuity and safety of production systems. Vibration displacement monitoring is an important means of assessing the health status of core components such as air compressor rotors and bearings. Traditional vibration measurement systems mostly adopt a centralized architecture, such as the Bentley 3500 series monitoring system, which connects multiple vibration probes through a centrally powered multi-channel acquisition module and aggregates the signals to a unified controller for processing. Such systems have the following drawbacks:
[0003] 1. High risk of single point of failure: In a centralized power supply and signal processing architecture, if a channel fails due to external factors (such as liquid corrosion or short circuit), it may paralyze the entire system. For example, liquid seepage caused by rodent activity has damaged multiple channels, causing vibration monitoring to fail and nearly triggering an interlocking shutdown accident.
[0004] 2. Severe signal interference: When multiple measuring points share a power supply and signal cables, electromagnetic interference and grounding loop noise can easily couple to all channels through the centralized power supply line, causing vibration signal distortion. Especially in the complex electromagnetic environment of a factory, the risk of false alarms increases significantly.
[0005] 3. High maintenance costs: Centralized systems require regular replacement of multi-channel acquisition modules, resulting in high spare parts procurement costs (e.g., the unit price of the Bentley 3500 module exceeds 300,000 yuan), and maintenance requires shutdown and disassembly of the entire cabinet, affecting production efficiency.
[0006] 4. Limited scalability: Adding new measurement points requires rewiring and upgrading the centralized control module, which is time-consuming, costly, and difficult to adapt to equipment upgrade needs.
[0007] In recent years, although some distributed vibration monitoring solutions have been proposed, problems such as signal transmission delay and unstable power supply still exist. For example, some solutions use wireless transmission technology, but its anti-interference capability is insufficient, making it difficult to meet the high reliability requirements of industrial sites; other solutions, while achieving distributed power supply, have not resolved the contradiction between signal isolation and integrated processing, leading to increased system complexity. Therefore, there is an urgent need for a vibration monitoring system that balances reliability, economy, and ease of maintenance to meet the long-term stable monitoring needs of critical equipment such as air compressors. Utility Model Content
[0008] In view of this, the purpose of this utility model is to provide a vibration measurement system suitable for the vibration displacement of air compressors, and to solve the existing problems.
[0009] To achieve the above objectives, this utility model provides the following technical solution: a vibration measurement system suitable for the vibration displacement of a group air compressor, comprising:
[0010] Multiple vibration measurement point modules, distributed control system (DCS) or programmable logic controller (PLC), and independent power supply module;
[0011] Each vibration measuring point module consists of an eddy current probe, an extension cable, and a vibration transmitter connected in sequence.
[0012] The eddy current probe is installed at the monitoring position of the air compressor shaft and is electrically connected to the input end of the vibration transmitter via an extension cable;
[0013] The output of the vibration transmitter is connected to the independent input channel of the DCS or PLC via an independent signal line.
[0014] The independent power supply module provides an independent power supply for each vibration measuring point module, and the power supply lines and signal lines of each vibration measuring point module are physically isolated.
[0015] Optionally, the vibration transmitter includes an integrated signal processing unit that integrates an eddy current probe preamplifier and a signal conditioner to convert the raw vibration signal from the eddy current probe into a 4-20mA analog signal and transmit it to a DCS or PLC through the independent signal line.
[0016] Optionally, the vibration transmitter also includes a BNC buffer signal output interface, which is connected to the signal processing unit and is used to output the buffered vibration signal to an external vibration analysis device.
[0017] Optionally, the independent power supply module adopts a two-wire loop power supply structure, with the same cable providing working power to the vibration transmitter and transmitting a 4-20mA signal to the DCS or PLC.
[0018] Optionally, the independent power supply module includes redundant power supply units, and the power supply line of each vibration measuring point module is equipped with an independent overvoltage protection circuit and a filtering circuit.
[0019] Optionally, each input channel of the DCS or PLC is equipped with an isolated signal acquisition card, and electrical isolation of signal transmission between channels is achieved through opto-isolators.
[0020] Optionally, the connection interface between the extension cable and the eddy current probe and vibration transmitter adopts a double-layer shielding structure, including an inner copper braided mesh shielding layer and an outer metal armor sheath.
[0021] Optionally, the system also includes an alarm module, which is connected to the output of a DCS or PLC. When the received vibration signal exceeds a preset threshold, it triggers an audible and visual alarm and a shutdown protection signal.
[0022] Optionally, the housing of the vibration transmitter is provided with a debugging interface, which is connected to the signal processing unit via a jumper for on-site calibration of the vibration signal zero point and range.
[0023] The beneficial effects of this utility model are as follows:
[0024] 1) Independent Power Supply and Signal Isolation: Each measuring module is powered by an independent power supply and directly connected to the DCS / PLC point-to-point, achieving physical isolation between power supply and signal transmission. This completely eliminates the risk of monitoring failure caused by single-point faults (such as short circuits or external liquid corrosion) in traditional centralized systems. Practical application shows that no unplanned downtime accidents caused by vibration measurement system problems have occurred since the system was upgraded.
[0025] 2) Double-layer shielding and opto-isolation: The extension cable from the eddy current probe to the transmitter adopts a double-layer shielding structure (copper braided layer + armored sheath), combined with the opto-isolation design of the DCS / PLC channel, effectively suppressing electromagnetic interference and grounding loop noise. Test data shows that the signal distortion rate has decreased from 12% before the upgrade to below 2%, and the false alarm rate has been reduced by 90%.
[0026] 3) Modular design and two-wire power supply: The vibration transmitter integrates a preamplifier and signal conditioning functions, and is equipped with a two-wire circuit power supply (power and signal share the same cable), reducing wiring complexity and hardware costs. In actual renovation projects, hardware spare parts costs were reduced by 300,000 yuan, and annual maintenance costs were reduced by more than 50%.
[0027] 4) Threshold Alarm and Shutdown Protection: The DCS / PLC's built-in alarm module monitors vibration displacement signals in real time. When the value exceeds a preset threshold, it immediately triggers an audible and visual alarm and outputs a shutdown protection signal to prevent further damage to the equipment. After the upgrade, three potential faults were successfully intercepted, and it is estimated that direct economic losses of over 2 million yuan were avoided.
[0028] 5) Standardized Interfaces and Independent Modules: The system supports connecting external vibration analyzers via BNC buffer interfaces, facilitating in-depth data mining; adding new measuring points only requires expanding the independent measuring point module, without modifying the existing system architecture. It has already been replicated and applied to similar units, shortening the single modification cycle to less than 5 days.
[0029] Other advantages, objectives, and features of this invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination and study, or may be learned from practice of this invention. The objectives and other advantages of this invention can be realized and obtained through the following description. Attached Figure Description
[0030] To make the objectives, technical solutions, and advantages of this utility model clearer, the preferred embodiments of this utility model will be described in detail below with reference to the accompanying drawings, wherein:
[0031] Figure 1 This is a schematic diagram of the overall system of this utility model.
[0032] Attached reference numerals: 1. Air compressor shaft; 2. Eddy current probe; 3. Extension cable; 4. Vibration transmitter; 41. Information processing unit; 42. Debugging interface; 43. BNC interface; 5. Signal processing unit; 6. Independent power supply module; 7. DCS or PLC; 8. Alarm module. Detailed Implementation
[0033] The following specific examples illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification. This utility model can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this utility model. It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of this utility model. Unless otherwise specified, the following embodiments and features can be combined with each other.
[0034] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual pictures. They should not be construed as limiting the present invention. To better illustrate the embodiments of the present invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual product dimensions. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.
[0035] In the accompanying drawings of this utility model, the same or similar reference numerals correspond to the same or similar components. In the description of this utility model, it should be understood that if terms such as "upper," "lower," "left," "right," "front," and "rear" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting this utility model. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.
[0036] Please see Figure 1 This is a vibration measurement system suitable for the vibration displacement of air compressors, specifically:
[0037] Example 1,
[0038] This embodiment uses a single-point basic configuration. The system structure and installation steps are as follows:
[0039] 1. Installation of measuring point module
[0040] At the vibration monitoring position of the air compressor shaft 1 (such as near the bearing housing), the mounting bracket assembly is fixed by bolts, the eddy current probe 2 is fixed to the base by an adjustable clamp, and anti-vibration pads are added to reduce mechanical vibration interference.
[0041] Eddy current probe 2 is connected to the input end of vibration transmitter 4 via double-shielded extension cable 3 (inner copper braided mesh shielding layer + outer metal armor sheath) to ensure electromagnetic isolation of the signal transmission path.
[0042] 2. Vibration transmitter configuration
[0043] The vibration transmitter 4 integrates a signal processing unit 41 (preamplifier + signal conditioner) to convert the original vibration signal of the eddy current probe 2 into a 4-20mA analog signal.
[0044] Zero point and range are calibrated on-site via debugging interface 42 (jumped to signal processing unit 41) to ensure signal accuracy error ≤1%.
[0045] The BNC interface 43 connects to a portable vibration analyzer for offline acquisition of buffered signals.
[0046] 3. Power supply and signal transmission
[0047] The independent power supply module 6 adopts a two-wire circuit power supply structure, which provides 24V DC power to the vibration transmitter 4 through the same cable and transmits 4-20mA signals back to the isolated acquisition channel of DCS / PLC7.
[0048] The power supply module 6 is equipped with an overvoltage protection circuit and a filtering circuit to prevent power fluctuations from affecting signal stability.
[0049] 4. Alarm and protection linkage
[0050] The alarm module 8 of the DCS / PLC7 has a preset vibration displacement threshold (such as ±50μm). When the signal exceeds the limit, it triggers an audible and visual alarm and outputs a shutdown protection signal to the air compressor control system to prevent further damage to the equipment.
[0051] Operational results: After the modification of the No. 3 air compressor in a chemical plant, the single-point measurement system ran continuously for 6 months without failure, and the false alarm rate dropped from 12% to 1.5%. It successfully avoided an unplanned shutdown caused by bearing wear and saved direct losses of 800,000 yuan.
[0052] Example 2,
[0053] In this implementation, a multi-measurement point extended configuration is adopted. The system structure and installation steps are as follows:
[0054] 1. Multi-point deployment
[0055] Three measuring point modules are set at the front, middle and rear ends of the air compressor shaft 1.
[0056] The eddy current probe 2 at each measuring point is connected to the corresponding vibration transmitter 4 via an independent extension cable 3, and the power supply and signal lines of each transmitter 4 are completely physically isolated.
[0057] 2. Redundant power supply design
[0058] The independent power supply module 6 contains 3 redundant power supply units. Each power supply unit independently supplies power to the corresponding measurement point. If any unit fails, it automatically switches to the backup power supply to ensure continuous operation of the system.
[0059] 3. DCS / PLC multi-channel access
[0060] The DCS / PLC7 is configured with three isolated acquisition channels. Each channel is equipped with an opto-isolator to eliminate crosstalk between channels, and the signal acquisition delay is ≤1ms.
[0061] Alarm module 8 triggers an alarm based on weighted analysis of signals from multiple measurement points (such as a 3-out-of-2 logic), reducing the probability of false alarms.
[0062] 4. Debugging and Data Analysis
[0063] The range of multiple measuring points is simultaneously calibrated through the debugging interface 42 of each vibration transmitter 4 to ensure data consistency.
[0064] The BNC interface 43 connects to a distributed vibration analysis network, uploading data to a cloud platform in real time for trend prediction.
[0065] Operational Results: After the multi-point modification of the No. 5 air compressor in a steel plant, the system expansion cycle was only 3 days, and the annual maintenance cost was reduced by 60%. Through multi-point collaborative analysis, a slight gearbox imbalance was predicted 2 weeks in advance, avoiding potential downtime losses of 1.5 million yuan.
[0066] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of this utility model and are not intended to limit it. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solution of this utility model without departing from the spirit and scope of this technical solution, and all such modifications or substitutions should be covered within the scope of the claims of this utility model.
Claims
1. A vibration measurement system suitable for the vibration displacement of a group air compressor, characterized in that: include: Multiple vibration measurement point modules, distributed control system (DCS) or programmable logic controller (PLC), and independent power supply module; Each vibration measuring point module consists of an eddy current probe, an extension cable, and a vibration transmitter connected in sequence. The eddy current probe is installed at the monitoring position of the air compressor shaft and is electrically connected to the input end of the vibration transmitter via an extension cable; The output of the vibration transmitter is connected to the independent input channel of the DCS or PLC via an independent signal line. The independent power supply module provides an independent power supply for each vibration measuring point module, and the power supply lines and signal lines of each vibration measuring point module are physically isolated.
2. The vibration measurement system for the vibration displacement of a group air compressor according to claim 1, characterized in that: The vibration transmitter includes an integrated signal processing unit, which integrates an eddy current probe preamplifier and a signal conditioner to convert the raw vibration signal from the eddy current probe into a 4-20mA analog signal and transmit it to a DCS or PLC through the independent signal line.
3. The vibration measurement system for a group air compressor according to claim 1, characterized in that: The vibration transmitter also includes a BNC buffer signal output interface, which is connected to the signal processing unit and is used to output the buffered vibration signal to an external vibration analysis device.
4. A vibration measurement system for the vibration displacement of a group air compressor according to claim 1, characterized in that: The independent power supply module adopts a two-wire circuit power supply structure. The same cable provides working power to the vibration transmitter and transmits a 4-20mA signal to the DCS or PLC.
5. A vibration measurement system for the vibration displacement of a group air compressor according to claim 1, characterized in that: The independent power supply module includes redundant power supply units, and the power supply line of each vibration measuring point module is equipped with an independent overvoltage protection circuit and a filtering circuit.
6. A vibration measurement system for the vibration displacement of a group air compressor according to claim 1, characterized in that: Each input channel of the DCS or PLC is equipped with an isolated signal acquisition card, and electrical isolation of signal transmission between channels is achieved through opto-isolators.
7. A vibration measurement system for the vibration displacement of a group air compressor according to claim 1, characterized in that: The connection interface between the extension cable and the eddy current probe and vibration transmitter adopts a double-layer shielding structure, including an inner copper braided mesh shielding layer and an outer metal armor sheath.
8. A vibration measurement system for the vibration displacement of a group air compressor according to claim 1, characterized in that: The system also includes an alarm module, which is connected to the output of a DCS or PLC. When the received vibration signal exceeds a preset threshold, it triggers an audible and visual alarm and a shutdown protection signal.
9. A vibration measurement system for the vibration displacement of a group air compressor according to claim 1, characterized in that: The housing of the vibration transmitter is equipped with a debugging interface, which is connected to the signal processing unit via a jumper for on-site calibration of the vibration signal zero point and range.