Piston Compressor Seal Life Prediction Using Vibration Simulation
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Solution Overview
Problem
Existing methods for monitoring the wear and predicting the remaining service life of piston compressor sealing arrangements are inadequate, as they do not provide real-time transmission of wear levels or accurate predictions, leading to unnecessary replacements and increased costs.
Innovation Solution
A method using vibration data simulation to predict the remaining service life of piston compressor sealing arrangements, employing a time-dependent Ginzburg-Landau model to analyze vibration patterns and simulate leakage, without requiring additional sensors, and transmitting results remotely for real-time monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are installed on each compressor unit to measure leakage, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses vibration as an intermediary parameter to indirectly measure sealing arrangement condition and predict remaining service life, avoiding the need for direct leakage sensors on each compressor unit
Solution Approach 2:
The patent replaces mechanical/direct measurement approaches with simulation-based prediction using vibration data and the time-dependent Ginzburg-Landau model, eliminating the need for additional leakage measurement sensors
2Reliability
If preventive maintenance is performed based on traditional methods, then reliability is improved, but loss of time and productivity increase due to unnecessary replacements
Solution Approach 1:
The patent performs preliminary simulation and prediction of remaining service life before actual failure occurs, allowing maintenance to be scheduled precisely when needed rather than replacing parts prematurely
Solution Approach 2:
The patent changes the maintenance approach from fixed schedules to condition-based prediction using vibration parameters and simulation models, enabling maintenance only when the sealing arrangement actually requires it
3Measurement precision
If traditional monitoring methods are used, then ease of operation is maintained, but measurement precision and prediction accuracy deteriorate
Solution Approach 1:
The system uses existing vibration data from the compressor's normal operation to self-diagnose sealing arrangement condition, eliminating the need for separate monitoring equipment or complex manual inspection procedures
Data Source
Figure 1
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Figure 4a~4b
AI summary
The invention relates to a computer-implemented method for predicting the remaining useful life of a seal arrangement (10) of a piston compressor (11), wherein the method comprises the following steps: a) providing vibration data (1a) or, calculable therefrom, features (1b) of the reciprocating part (12) of the piston compressor (11); b) creating an input matrix (3) from the vibration data (1a) or the features (1b) calculable therefrom; c) carrying out a simulation comprising a plurality of simulation steps with the application of a model (4) to the input matrix (3), said model enabling the fault propagation in a self-contained system to be described, wherein each simulation step yields an output matrix (5), and wherein the output matrix (5) of the n-th simulation step is used as the input matrix (3') of the n+1-th simulation step; f) selecting exactly one characteristic variable (6c) from the values of the output matrices (5, 5'); g) ascertaining the number of simulation steps which need to be carried out until the selected characteristic variable (6c) falls below a predefined threshold value (8a) of close to zero, and outputting this number in a time unit as the result (9) of the simulation carried out; h) repeating method steps a) to g) at regular discrete time intervals in order to obtain a plurality of simulation results (9, 9'); and i) fitting a curve to the simulation results (9, 9') obtained, and calculating the point in time (7) at which the curve intersects a predefined lower limit (8c), wherein the calculated point of intersection is regarded as an indicator of the occurrence of a malfunction and the predicted end of the useful life of the seal arrangement (10).