Rotating machinery equipment abnormality diagnosis device and method

Abstract

To provide an abnormality diagnosis device and method for rotating machinery equipment that is highly reliable while reducing diagnostic costs.SOLUTION: An abnormality diagnosis device 15 for rotating machinery equipment according to the present invention includes a motor 1 as a rotation drive unit that rotates, a coupling 5, a drive shaft 3, a first bearing unit 7, and a second bearing unit 9 as a transmission unit that transmits the driving force of the rotation drive unit, and an impeller 11 as a rotation driven unit that rotates by the rotation force transmitted by the transmission unit, and has vibration sensors (i) to (iv) provided on the rotation drive unit, the transmission unit and the rotation driven unit, respectively, and an abnormality diagnosis unit (17) that receives vibration data collected by the vibration sensors (i) to (iv) and diagnoses abnormalities, where the abnormality diagnosis unit 17 includes an abnormality location identification unit 19 that identifies an abnormal location of the rotating machinery equipment based on the relative relationship of each vibration data, and an abnormality cause identification unit 21 that identifies the cause of the abnormality based on the vibration data at the identified abnormal location.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an abnormality diagnosis device and method for rotating machinery equipment. [Background technology]

[0002] Conventional methods for diagnosing abnormalities in rotating machinery using vibration sensors are disclosed in, for example, Patent Documents 1 to 4. The methods disclosed in these patent documents are summarized as follows. For example, vibration sensors are installed on each of the motors, bearings, pumps, and other driven machines that make up the rotating machinery equipment to collect vibration waveform data, and vibration magnitude evaluation and frequency analysis are performed for each part.The information obtained from the analysis results is then compared for similarity with the judgment conditions of an abnormality judgment matrix that is predefined for each cause of abnormality, and the cause of the abnormality is estimated to be one with a high degree of similarity. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 63-169536 [Patent Document 2] Japanese Patent Application Laid-Open No. 2003-149043 [Patent Document 3] Japanese Patent Application Publication No. 03-099234 [Patent Document 4] Japanese Patent Application Publication No. 62-093620 Summary of the Invention [Problem to be solved by the invention]

[0004] However, conventional diagnostic logic infers the cause of an abnormality for each part based on the analysis results of each vibration sensor (part-by-part) attached to the rotating machinery equipment, and does not compare the analysis results of multiple vibration sensors attached to multiple parts to determine the overall abnormality location and cause for the equipment as a whole.

[0005] For example, in equipment where a motor rotates a blower impeller, if the impeller is unbalanced, the vibration caused by the unbalanced impeller will also affect the motor and coupling. For this reason, if a diagnosis is performed on a part-by-part basis as in the past, abnormal vibrations will be detected by all vibration sensors, and as a result, it may be automatically diagnosed that all parts are the cause of the abnormality due to imbalance.

[0006] In this case, unnecessary overhauls and irrelevant repairs and adjustments may be performed on motors and couplings that are not actually faulty. In the past, to avoid such misjudgments, a thought process was required in which a veteran diagnostician would comprehensively determine the true cause of the abnormality and the location of the abnormality based on their knowledge and experience. In other words, based on the results of automated part-by-part diagnostics, experienced diagnosticians would make a comprehensive judgment as to which part was causing the abnormality while overlooking the entire facility.

[0007] However, if the comprehensive judgment of a veteran diagnostician is required, the cost of the diagnostics will increase, and the diagnostic results may depend on the ability of the veteran diagnostician. Therefore, there has been a demand for an abnormality diagnosis device and method for rotating machinery equipment that is highly reliable while keeping diagnostic costs down.

[0008] The present invention is made in response to such a demand, and has as its object to provide an apparatus and method for diagnosing abnormalities in rotating machinery equipment that are highly reliable while reducing diagnostic costs. [Means for solving the problem]

[0009] (1) The abnormality diagnosis device for rotary machinery equipment according to the present invention includes a rotary drive unit that rotates, a transmission unit that transmits the driving force of the rotary drive unit, and a rotary driven unit that rotates by the rotational force transmitted by the transmission unit, a vibration sensor installed in each of the rotation drive unit, the transmission unit, and the rotation driven unit; and an abnormality diagnosis unit that receives vibration data collected by the vibration sensors and diagnoses an abnormality, The abnormality diagnosis unit is characterized by comprising an abnormality location identification unit that identifies an abnormal location in the rotating machinery equipment based on the relative relationship between the vibration data, and an abnormality cause identification unit that identifies the cause of the abnormality based on the vibration data at the identified abnormal location.

[0010] (2) In addition, in the device described in (1) above, the abnormality location identifying unit identifies the abnormality location based on the relative relationship between the velocity value and acceleration value of each of the vibration data.

[0011] (3) In addition, in the device described in (1) or (2) above, the abnormality cause identification unit is characterized in that it performs frequency analysis based on the vibration data and identifies the cause of the abnormality based on the results of the frequency analysis.

[0012] (4) A method for diagnosing an abnormality in a rotating machine equipment according to the present invention is a method for diagnosing an abnormality in a rotating machine equipment including a rotation drive unit that rotates, a transmission unit that transmits a driving force of the rotation drive unit, and a rotation driven unit that rotates by the rotation force transmitted by the transmission unit, The method is characterized by comprising an abnormality location identification process for identifying an abnormal location in the rotating machinery equipment based on the relative relationship of vibration data collected by vibration sensors installed in the rotation drive unit, the transmission unit, and the rotation driven unit, and an abnormality cause identification process for identifying the cause of the abnormality based on the vibration data at the identified abnormal location.

[0013] (5) In addition, in the device described in (4) above, the abnormality location identifying step is characterized in that the abnormality location is identified based on the relative relationship between the velocity value and acceleration value of each of the vibration data.

[0014] (6) In addition, in the device described in (4) or (5) above, the abnormality cause identification step is characterized in that a frequency analysis is performed based on the vibration data, and the abnormality cause is identified based on the result of the frequency analysis. [Effects of the Invention]

[0015] In the rotating machinery abnormality diagnosis device according to the present invention, the abnormality diagnosis unit includes an abnormality location identification unit that identifies an abnormality location in the rotating machinery based on the relative relationship of each vibration data, and an abnormality cause identification unit that identifies the cause of the abnormality based on the vibration data at the identified abnormality location, thereby enabling highly reliable abnormality diagnosis of the rotating machinery while reducing diagnostic costs. As a result, incorrect maintenance work and incorrect repair and adjustment can be prevented, optimal maintenance can be achieved, and repair costs can be reduced. [Brief explanation of the drawings]

[0016] [Figure 1] 1 is a block diagram illustrating the configuration of an abnormality diagnosis device according to a first embodiment. [Figure 2] 3 is a flowchart of an abnormality diagnosis method according to the first embodiment. [Figure 3] FIG. 2 is a diagram showing a velocity waveform detected by a vibration sensor attached at a location (iv) in FIG. 1. [Figure 4] 10 is a graph showing velocity values ​​detected by each vibration sensor. [Figure 5] FIG. 2 is a diagram showing an example of a database of the abnormality diagnosis device according to the present embodiment. [Figure 6] FIG. 10 is a diagram showing the results of frequency analysis of data obtained by a vibration sensor. [Figure 7] 10 is an explanatory diagram of a rotating machine facility that is the target of an abnormality diagnosis method according to a second embodiment and the mounting positions of vibration sensors. FIG. [Figure 8] 8 is a graph showing velocity values ​​detected by each vibration sensor in FIG. 7. [Figure 9] 8 is a diagram showing the results of frequency analysis of data obtained by vibration sensors attached at the mounting locations (ii) and (iii) in FIG. 7. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0017] [Embodiment 1] In this embodiment, as shown in Figure 1, the diagnosis target is a blower equipment 13 that includes a rotationally driven motor 1, a shaft coupling 5 that connects the rotating shaft of the motor 1 to a drive shaft 3, a first bearing portion 7 and a second bearing portion 9 that incorporate bearings that support the rotation of the drive shaft 3, and an impeller 11 that rotates with the drive shaft 3. The motor 1 corresponds to the rotary drive unit of the present invention, the coupling 5, drive shaft 3, first bearing unit 7, and second bearing unit 9 correspond to the transmission unit of the present invention, the impeller 11 corresponds to the rotary driven unit of the present invention, and the blower equipment 13 corresponds to the rotary mechanical equipment of the present invention.

[0018] The abnormality diagnosis device 15 of this embodiment, which is intended to diagnose the above-mentioned blower equipment 13, has, as shown in Figure 1, vibration sensors (i) and (ii) installed on the motor 1, vibration sensor (iii) installed on the first bearing section 7, which is one of the two bearing sections and is closer to the shaft coupling 5, and vibration sensor (iv) installed on the second bearing section 9, which is closer to the impeller 11, and an abnormality diagnosis unit 17 that inputs vibration data acquired by these vibration sensors (i) to (iv) and diagnoses abnormalities. The abnormality diagnosis unit 17 includes an abnormality location identification unit 19 that identifies an abnormal location in the blower equipment 13 based on the relative relationship between each piece of vibration data, and an abnormality cause identification unit 21 that identifies the cause of the abnormality based on the vibration data at the identified abnormal location.

[0019] The abnormality location identifying unit 19 of the first embodiment identifies an abnormality location based on the relative relationship between the velocity value and acceleration value of each vibration data. Furthermore, the abnormality cause identifying unit 21 of the first embodiment performs frequency analysis based on the vibration data and identifies the cause of the abnormality based on the results of the frequency analysis.

[0020] Next, an abnormality diagnosis method using the abnormality diagnosis device 15 shown in FIG. 1 will be described with reference to FIG. 1 and FIGS. The abnormal part identifying unit 19 acquires vibration data from the vibration sensors (i) to (iv) and acquires velocity values ​​(velocity waveforms) (S1). The velocity waveform obtained from vibration sensor (iv) is shown in Fig. 3. As shown in Fig. 3, it can be seen that vibration of 6.0 mm / s occurs at the location of vibration sensor (iv) every 20 ms. A graph of each velocity value caused by vibration of vibration sensors (i) to (iv) is shown in Figure 4. Table 1 also shows each velocity value and the individual judgment results based on these.

[0021] [Table 1]

[0022] When the speed values ​​are viewed individually, it is determined that there is a need for caution or an abnormality in the location where vibration sensors (iv), (iii), and (i) with a speed value exceeding 3.0 are installed. Since conventional diagnostic logic performs an individual judgment for each part, the diagnostic results indicate that there is an imbalance abnormality in both the unbalance of motor 1 and the unbalance of the fan, as shown in Table 1.

[0023] In contrast to this, in this embodiment, the abnormality point identifying unit 19 compares the velocity values ​​of the vibration sensors (i) to (iv) (S2). The relative relationship between the velocity values ​​is (iv)>(iii)>(i)>(ii), as shown in Table 1 and FIG. The abnormal part identifying unit 19 refers to the database 22 that stores the relationship between the relative relationship of the speed values ​​and the abnormal part, and identifies that the abnormal part is in the impeller 11 (S5).

[0024] An example of the database 22 will now be described with reference to FIG. As shown in FIG. 5, the database 22 stores data on the magnitude distribution of velocity values, the magnitude distribution of acceleration values, the velocity frequency components of abnormal locations, and the acceleration frequency components of abnormal locations, in association with the names of abnormality causes.

[0025] In the case of the fan equipment 13 shown in Fig. 1, possible locations where an abnormality may occur include the impeller 11, the shaft coupling 5, the motor 1, the first bearing 7, and the second bearing 9. The cause of an abnormality in the impeller 11 and the motor 1 is imbalance, and the cause of an abnormality in the shaft coupling 5 is misalignment. The cause of an abnormality in the first bearing 7 and the second bearing 9 is damage (for example, wear or deformation of the balls in the ball bearing). Below, we will explain the characteristics of the velocity value magnitude distribution, acceleration value magnitude distribution, velocity frequency components of the abnormal part, and acceleration frequency components of the abnormal part for each abnormality location and abnormality cause, for both normal and abnormal conditions.

[0026] <Normal time> As shown in FIG. 5, under normal conditions, the velocity and acceleration values ​​of each part are small and are approximately the same in magnitude.

[0027] <Impeller imbalance> Unbalance refers to a state in which the mass distribution of the rotor is uneven due to factors such as wear or deformation occurring in parts of the rotor, adhesion of foreign matter, etc. When the rotor rotates in this unbalanced state, centrifugal force is generated in the uneven parts, and this centrifugal force causes the impeller 11 and shaft to whirl, resulting in abnormal vibrations such as vibrations. The whirling vibration is propagated to other parts via the rotating shaft connected to the rotor having the uneven part, but the abnormal vibration is greatest in the part having the uneven part.

[0028] If an imbalance occurs in the impeller 11, the speed value will be maximum at the vibration sensor (iv) closest to the impeller 11 where the imbalance occurred. However, since this abnormal vibration is transmitted to other parts, vibration sensors (iii) to (i) will also observe vibrations that are greater than normal. The relative relationship of the magnitude of the velocity values ​​is (iv)>(iii)>(ii)>(i). In Table 1 and Figure 4, the speed value of (i) is greater than that of (ii), but this is because the vibration is amplified due to the fact that the structure of motor 1 makes part (i) prone to swing freely. In other words, if an imbalance occurs in impeller 11 in the case of Figure 1, it is expected that the order will be (iv) > (iii) > (ii) > (i) or (iv) > (iii) > (i) > (ii). In the database 22 of FIG. 5, the order (iv)>(iii)>(i)>(ii) is omitted.

[0029] In the case of imbalance, the acceleration values ​​are not affected, and the acceleration values ​​are small and almost the same as normal values ​​for the four vibration sensors (i) to (iv).

[0030] In the case of impeller imbalance, when the vibration data of the vibration sensor (iv) is frequency analyzed, the speed value becomes large at the rotation frequency (fr) of the impeller 11 .

[0031] <Shaft coupling misalignment> When misalignment occurs in the shaft coupling 5, vibration increases at the locations of the two vibration sensors (ii) and (iii) that sandwich the shaft coupling 5, and the velocity values ​​of the vibration sensors (ii) and (iii) increase. Since the abnormality is at the shaft coupling 5, the velocity values ​​of the vibration sensors (ii) and (iii) on both sides of the shaft coupling 5 are almost the same.

[0032] In the case of misalignment, the acceleration values ​​are not affected, so the acceleration values ​​are small and almost the same as normal values ​​for the four vibration sensors (i) to (iv).

[0033] In the case of misalignment of the shaft coupling, the speed value becomes large at the rotational frequency (fr) and at high frequencies twice or more of that frequency.

[0034] <Motor unbalance> If an imbalance occurs in the rotating shaft of motor 1 for some reason, the velocity value of vibration sensor (i), which is installed in a part of motor 1 that is likely to swing freely due to its structure, will be larger than the velocity value of vibration sensor (ii).

[0035] In the case of motor unbalance, the acceleration value is not affected, so the acceleration values ​​of the four vibration sensors (i) to (iv) are small and almost the same as normal values.

[0036] In the case of motor imbalance, when the vibration data of the vibration sensor (i) is frequency analyzed, the speed value becomes large at the rotation frequency (fr) of the impeller 11 .

[0037] <Blower bearing damage (part (iii))> If the first bearing 7, which is equipped with the vibration sensor (iii), is damaged, high-frequency vibrations will occur at that location. In this case, there will be no change in the speed value, and the speed values ​​of the four vibration sensors (i) to (iv) will be small and almost the same as normal values. On the other hand, the acceleration value of the vibration sensor (iii) is significantly larger. In this case, frequency analysis reveals that frequency components due to flaws or the like in the first bearing portion 7 become large, and frequency components at least twice as large as the flaws also appear.

[0038] The above is an overview of the database 22. As described above, the abnormal part identifying unit 19 refers to the database 22 regarding the relationship between the relative relationship of the vibration velocity values ​​and the abnormal part, and identifies that the abnormal part is in the impeller 11 because the magnitude and distribution of the velocity values ​​shown in FIG. 4 are similar to those of the impeller imbalance stored in the database 22 (S5).

[0039] When it is determined that the abnormality is in the impeller 11, the abnormality cause identification unit 21 performs frequency analysis of the identified location, i.e., the vibration data acquired by the vibration sensor (iv) (S7). The vibration waveform (speed spectrum) resulting from the frequency analysis is shown in FIG. Here, the rotation speed of the impeller 11 is 2963 rpm, so the rotation frequency (fr) is 2963 / 60=49.4 Hz, and the rotation period is 1 / 49.4=0.02 s (20 ms). The frequency analysis results show that the vibration waveform is a one-rotation cycle vibration, and that the rotational frequency component of 49.4 Hz (fr component) is dominant. This indicates that the cause of the abnormality is an imbalance.

[0040] In this regard, as mentioned above, when vibration sensors (i) to (iv) are individually judged, it is judged that there is an imbalance in both motor 1 and impeller 11, as shown in Table 1, whereas in this embodiment, it is correctly judged that the cause of the abnormality is the imbalance in impeller 11, not motor 1. This will prevent the problem from being mistakenly diagnosed as an imbalance on the motor 1 side, and abnormal vibrations will be resolved by performing maintenance on the blower side.

[0041] [Embodiment 2] Next, an example of abnormality diagnosis of pump equipment 25 including a motor 1, a coupling 5, a bearing 23, and a pump body 24 will be described, as shown in Fig. 7. Note that the same reference numerals are used in Fig. 7 to designate parts corresponding to those in Fig. 1. The bearing portion 23 is integrated with the pump body 24, and the vibration sensors are provided at four locations (i) to (iv) as shown in FIG. This example shows a case where misalignment (deviation from the center) occurs in the shaft coupling 5. A graph of the velocity values ​​caused by the vibrations of the vibration sensors (i) to (iv) is shown in Figure 8. Table 2 also shows the velocity values ​​and the individual judgment results based on these.

[0042] [Table 2]

[0043] As shown in Figure 8, the velocity value of vibration sensor (iii) is outstanding, so if an individual judgment is made, it will be determined that there is a misalignment in the coupling 5 or that there is rattle due to wear in the bearing 23, as shown in Table 2. This is because the vibration characteristics when there is rattle in the bearing 23 are similar to the vibration characteristics when there is misalignment in the shaft coupling 5. In other words, if an individual judgment is made, it will not be possible to determine whether the abnormality is in the shaft coupling 5 or the bearing 23, so both will have to be addressed. To correct the backlash in the bearing portion 23, the pump must be disassembled and serviced, and to correct the misalignment of the shaft coupling 5, a centering adjustment must be performed. Therefore, even if there is an abnormality in the shaft coupling 5 as in this example and there is no abnormality in the bearing portion 23, it is necessary to disassemble and repair the pump, which is unnecessary.

[0044] In the case of misalignment of the shaft coupling 5, the source of vibration is the shaft coupling 5, so the vibration of the vibration sensors (ii) and (iii) on both sides of the shaft coupling 5 generally increases. In this regard, Fig. 8 shows that the vibration of the vibration sensors (ii) and (iii) increases. Furthermore, because the movement of the shaft coupling 5 itself becomes a vibration waveform, the vibration waveforms of the vibration sensors (ii) and (iii) that sandwich the shaft coupling 5 become similar. As a result, when a frequency analysis is performed, it is found that the frequency spectrum components of parts (ii) and (iii) become similar when there is a misalignment abnormality, as shown in Figure 9. When misalignment occurs, the rotational frequency component fr and its harmonic components that are more than twice as high appear.

[0045] In this second embodiment, the abnormality location identifying unit 19 refers to a database 22 that stores the relationship between the relative relationships of the speed values ​​and the abnormality locations, and identifies that the abnormality location is in the shaft coupling 5 or the bearing unit 23 based on the magnitude and distribution of the speed values. Then, since the frequency components of the vibration sensors (ii) and (iii) are similar, the abnormality cause identification unit 21 identifies the cause of the abnormality as not being due to wear and play in the bearing portion 23, but due to misalignment of the shaft coupling 5. This prevents the problem from being mistakenly diagnosed as play in the bearing portion 23, and prevents the pump from being overhauled for repair by mistake.

[0046] As described above in the first and second embodiments, the present invention enables highly reliable abnormality diagnosis of rotating machinery equipment while suppressing diagnostic costs. As a result, it is possible to prevent erroneous maintenance work and erroneous repair and adjustment, realize optimal maintenance, and reduce repair costs. In addition, when the abnormal location and the cause of the abnormality are identified, the abnormal location and the cause of the abnormality may be displayed on the display unit 27 such as a monitor, and further, an appropriate countermeasure (guidance statement) in that case may be automatically output (to the monitor or on paper). [Explanation of symbols]

[0047] 1 motor 3 drive shaft 5 Shaft coupling 7 First bearing part 9 Second bearing part 11 Impeller 13 Blower equipment 15 Abnormality diagnosis device 17 Abnormality diagnosis section 19 Abnormality location identification section 21 Abnormality cause identification section 22 Databases 23 Bearing section 24 Pump body 25 Pumping equipment 27 Display section (i) to (iv) Vibration sensor, measurement area

Claims

1. An abnormality diagnosis device for a rotating machine equipment including a rotation drive unit that rotates, a transmission unit that transmits a driving force of the rotation drive unit, and a rotation driven unit that rotates by the rotation force transmitted by the transmission unit, a vibration sensor provided in each of the rotation drive unit, the transmission unit, and the rotation driven unit; and an abnormality diagnosis unit that receives vibration data collected by the vibration sensors and diagnoses an abnormality, The abnormality diagnosis device for rotating machinery equipment is characterized in that the abnormality diagnosis unit includes an abnormality point identification unit that identifies an abnormal point of the rotating machinery equipment based on the relative relationship of each of the vibration data, and an abnormality cause identification unit that identifies a cause of the abnormality based on the vibration data at the identified abnormal point.

2. 2. The abnormality diagnosis device for rotating machinery equipment according to claim 1, wherein the abnormality location identifying unit identifies the abnormality location based on a relative relationship between a velocity value and an acceleration value of each of the vibration data.

3. 3. The abnormality diagnosis device for rotating machinery equipment according to claim 1, wherein the abnormality cause identification unit performs a frequency analysis based on the vibration data and identifies the cause of the abnormality based on a result of the frequency analysis.

4. A method for diagnosing an abnormality in a rotating machine including a rotation drive unit that rotates, a transmission unit that transmits a driving force of the rotation drive unit, and a rotation driven unit that rotates by the rotation force transmitted by the transmission unit, comprising: an abnormality diagnosis method for rotating machinery equipment, comprising: an abnormality location identification process for identifying an abnormal location of the rotating machinery equipment based on a relative relationship between vibration data collected by vibration sensors installed in the rotation drive unit, the transmission unit, and the rotation driven unit; and an abnormality cause identification process for identifying a cause of the abnormality based on the vibration data at the identified abnormal location.

5. 5. The method for diagnosing an abnormality in a rotating machine facility according to claim 4, wherein the abnormality location identifying step identifies the abnormality location based on a relative relationship between a velocity value and an acceleration value of each of the vibration data.

6. 6. The method for diagnosing an anomaly in a rotating machine facility according to claim 4, wherein the step of identifying the cause of the anomaly comprises performing a frequency analysis based on the vibration data and identifying the cause of the anomaly based on a result of the frequency analysis.

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