往复机械故障诊断技术研究及模拟仿真系统开发
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摘要
往复机械是石油化工领域核心设备之一，其结构复杂性造成信号重叠、激励源难分解，同时振动噪声大的环境带来了很多无效信号，有效的故障信号被淹没，这些都为往复机械的故障诊断带来了巨大的困难。论文研究的往复机械故障诊断技术及故障模拟仿真系统对往复机械故障诊断和技术指导具有一定理论意义和工程应用价值。论文的主要工作如下：
1.研究角度域分析诊断方法，提出了一种基于角域结合机组工艺参数、振动状态参数的往复压缩机综合故障诊断分析方法，分解机组振动激励源。
2.对双缸双作用和一体式压缩机进行了完整的机组建模，应用计算机仿真技术，融合了机组监测方法、机组故障征兆和故障信号图谱，搭建了两者的运动原理、工作循环、动态示功图的模拟模块，完成了两类往复压缩机正常运行及32种故障的建模及模拟仿真，开发往复机械故障诊断培训软件，实现故障学习的人机交互，全面展现各类故障机理及现象。
3.将论文研究的诊断方法和模拟仿真系统在实际工程应用，指导分析出10余种机组故障，通过实际应用对其效果进行整体评价，完善了整套故障模拟仿真系统，达到了较好的精度，为专职人员提供了有效的故障诊断指导。
Reciprocating machinery is one of the core equipment inpetrochemical field, The complexity of its structure causes the acquisitionsignal overlap, it is difficult to decompose the excitation source. Whilethe vibration nosise environment brings many invaid signals, the effectivefault signal is submerged. These are big problems for reciprocatingmachinery fault diagnosis. The research of reciprocating machinery faultdiagnosis technology and fault simulation system for failure ofreciprocating machinery have theory significance and project applicationvalue. The main work of this paper is as follows:
(1) Researches the key technique of fault diagnosis based onangle-domain analysis and porposes an angle-domain analysis methodcombining process and vibration parameters for reciprocating compressorto decompose vibration excitation source.
(2) The complete unit modeling for double-cylinder, actingcompressor and one-piece compressor are completed. The analog moduleof motion principle, working cycle and dynamic damping-displacementfigure are constructed based on the fusion of monitoring method, failuresymptom and fault signal map. Modeling and analog simulation for thenormal operation and32faults of reciprocating compressor are completed.Man-machine interaction of fault learning is implemented to showvarious failure mechanism and fault phenomenon based on trainingsystem for reciprocating compressor fault diagnosis.
(3) Take the diagnostic methods and simulation systems to practicalengineering application. Guide analysis of more than10types of unitfailure. Give an overall evaluation through the practical application.Improve the fault simulation system to achieve better accuracy. Provideeffective guidance for fault diagnosis to full-time staff.
1.研究角度域分析诊断方法，提出了一种基于角域结合机组工艺参数、振动状态参数的往复压缩机综合故障诊断分析方法，分解机组振动激励源。
2.对双缸双作用和一体式压缩机进行了完整的机组建模，应用计算机仿真技术，融合了机组监测方法、机组故障征兆和故障信号图谱，搭建了两者的运动原理、工作循环、动态示功图的模拟模块，完成了两类往复压缩机正常运行及32种故障的建模及模拟仿真，开发往复机械故障诊断培训软件，实现故障学习的人机交互，全面展现各类故障机理及现象。
3.将论文研究的诊断方法和模拟仿真系统在实际工程应用，指导分析出10余种机组故障，通过实际应用对其效果进行整体评价，完善了整套故障模拟仿真系统，达到了较好的精度，为专职人员提供了有效的故障诊断指导。
Reciprocating machinery is one of the core equipment inpetrochemical field, The complexity of its structure causes the acquisitionsignal overlap, it is difficult to decompose the excitation source. Whilethe vibration nosise environment brings many invaid signals, the effectivefault signal is submerged. These are big problems for reciprocatingmachinery fault diagnosis. The research of reciprocating machinery faultdiagnosis technology and fault simulation system for failure ofreciprocating machinery have theory significance and project applicationvalue. The main work of this paper is as follows:
(1) Researches the key technique of fault diagnosis based onangle-domain analysis and porposes an angle-domain analysis methodcombining process and vibration parameters for reciprocating compressorto decompose vibration excitation source.
(2) The complete unit modeling for double-cylinder, actingcompressor and one-piece compressor are completed. The analog moduleof motion principle, working cycle and dynamic damping-displacementfigure are constructed based on the fusion of monitoring method, failuresymptom and fault signal map. Modeling and analog simulation for thenormal operation and32faults of reciprocating compressor are completed.Man-machine interaction of fault learning is implemented to showvarious failure mechanism and fault phenomenon based on trainingsystem for reciprocating compressor fault diagnosis.
(3) Take the diagnostic methods and simulation systems to practicalengineering application. Guide analysis of more than10types of unitfailure. Give an overall evaluation through the practical application.Improve the fault simulation system to achieve better accuracy. Provideeffective guidance for fault diagnosis to full-time staff.
引文
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[24] S. Ebersbach,Z. Peng. Expert system development for vibration analysis in machinecondition monitoring[J]. Expert Systems with Applications,2008,34(1):291-299
[25]盛兆顺,尹琦岭.设备状态监测与故障诊断技术及应用[M].北京：化学工业出版社,2002
[26]朝霞,曹艳白,伍钦.用FlashMX2004开发离心泵实验仿真课[J].计算机与应用化学,2007.8,24（8）,1127
[27]王继英.基于SolidWorks软件的虚拟样机技术及其应用[J].同煤科技,2007.6
[28]张晓华.系统建模与仿真[M].北京:清华大学出版社,2006
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[30] Shanxiang Xu, Qiang Jiang. Expert Knowledge-Based Online Fault Diagnostic Systemfor Reciprocating Compressor. ICTCC,1993
[31]李国华,张永忠.机械故障诊断[M].北京：化学工业出版社,1998
[32]刘世元,杜润生,杨叔子.柴油机缸盖振动信号的小波分解与诊断方法研究[J].振动工程学报,2000(13):577-583
[33]程香平,丁雪兴,刘海亮，张鹏高.小波分析在往复压缩机故障诊断中的应用[J].压缩机技术.2007(6):19-21
[34]姜耀华,邓军,王斌,王静.瞬时转速在柴油机故障检测中的应用[J].航海工程.2007(8):66-67
[35]虞和济.设备故障诊断工程[M].北京:冶金工业出版社,2001
[36]丰田利夫.设备现场诊断的开展方法[M].北京:机械工业出版社,1985
[37]陈杰.传感器与检测技术[M].北京:高等教育出版社，2002
[38]王化祥.传感器原理及应用[M].天津:天津大学出版社,1991
[39]雷继饶,何世惠,王家琛.工程信号处理技术[M].重庆：重庆大学出版社,1990
[40]何渝.计算机常用数值算法与程序（C++版）[M].北京:人民邮电出版社,2003
[2]刘卫华,郁永章.往复压缩机故障诊断方法的研究[J].压缩机技术,2001（1）.
[3]邱荣华.往复机械故障监测与故障诊断方法研究[D].西安:西安建筑科技大学,2006
[4]王发辉,刘秀芳,程艳霞.往复压缩机故障诊断研究现状及展望[J].压缩机技术.2007,(2):45-48
[5]金涛,童水光.往复式压缩机故障监测与诊断技术[J].流体机械,1999(11)
[6]吴军超.往复活塞式压缩机常见故障的分析[J].化工装备技术,2007，28（4）,65
[7]张琳,朱瑞松,尤匡一,尤侯平，王正洪.往复压缩机监测与诊断技术研究现状及展望[J].化工进展,2004,23（10）,1099
[8]王广兵.往复活塞式压缩机特性参数的确定[J].化工设备与管道,2005,3,44
[9] Gaopin Lin, Danqing Wu, et al. Indentification of Compressor Cylinder Pressure By UsingCylinder-Head Vibration Signals. IC-TCC,1993
[10]程艳霞,铁占续,孙付伟,王发辉.往复压缩机故障诊断方法研究综述[J].仪器仪表用户,2006.5
[11]唐静.往复压缩机故障诊断方法综述[J].理论与实践，2006,1,44
[12]韩丹,丁惠萍.往复式压缩机常见故障原因分析及对策[J].贵州化工,2008.2,33（1）,55
[13]龚小刚.计算机仿真技术及其应用[J].信息科学,2007
[14]赵俊龙,张志新等.往复式压缩机气缸压力模拟曲线提取[J].振动、测试与诊断,2009.3,29（1）,79
[15]王丽，刘振全，胡淞城.动态气体力对往复式压缩机气阀运动规律影响的研究[J].甘肃科技,2009.2,25(3),55
[16]周建强,吴健,张庆功.往复式空气压缩机的故障分析及对策[J].煤矿机械，2007.1,28（1）,185
[17]齐一芳.往复式压缩机振动机理及管道仿真设计[J].设计与计算,2007.7,9,43
[18]徐敏等.设备故障诊断手册—机械设备状态监测和故障诊断[M].西安交通大学出版社,1998
[19] Amin Almasi. Advanced technologies in reciprocating compressor with respect toperformance and reliability [C].5th International Advanced Technologies Symposium,2009.1684–1687
[20]廖伯瑜.机械故障诊断基础[M].北京:冶金工业出版社,1995
[21]段礼祥,张来斌,王朝晖.往复机械故障诊断的现代方法及展望[J]石油机械,2004.32(11):66-69
[22] Steven M. Scbultbeis. Vibration analysis of reciprocating compressor [J]. Machinerymessages,1996.7-8
[23]齐伟敏.往复式压缩机热力故障判断方法[J].机电设备,2002(5):32-34
[24] S. Ebersbach,Z. Peng. Expert system development for vibration analysis in machinecondition monitoring[J]. Expert Systems with Applications,2008,34(1):291-299
[25]盛兆顺,尹琦岭.设备状态监测与故障诊断技术及应用[M].北京：化学工业出版社,2002
[26]朝霞,曹艳白,伍钦.用FlashMX2004开发离心泵实验仿真课[J].计算机与应用化学,2007.8,24（8）,1127
[27]王继英.基于SolidWorks软件的虚拟样机技术及其应用[J].同煤科技,2007.6
[28]张晓华.系统建模与仿真[M].北京:清华大学出版社,2006
[29]孙彪,陈利学.计算机仿真技术在石油工业中的应用[J].西南石油学院学报,1997,19(1):88-92
[30] Shanxiang Xu, Qiang Jiang. Expert Knowledge-Based Online Fault Diagnostic Systemfor Reciprocating Compressor. ICTCC,1993
[31]李国华,张永忠.机械故障诊断[M].北京：化学工业出版社,1998
[32]刘世元,杜润生,杨叔子.柴油机缸盖振动信号的小波分解与诊断方法研究[J].振动工程学报,2000(13):577-583
[33]程香平,丁雪兴,刘海亮，张鹏高.小波分析在往复压缩机故障诊断中的应用[J].压缩机技术.2007(6):19-21
[34]姜耀华,邓军,王斌,王静.瞬时转速在柴油机故障检测中的应用[J].航海工程.2007(8):66-67
[35]虞和济.设备故障诊断工程[M].北京:冶金工业出版社,2001
[36]丰田利夫.设备现场诊断的开展方法[M].北京:机械工业出版社,1985
[37]陈杰.传感器与检测技术[M].北京:高等教育出版社，2002
[38]王化祥.传感器原理及应用[M].天津:天津大学出版社,1991
[39]雷继饶,何世惠,王家琛.工程信号处理技术[M].重庆：重庆大学出版社,1990
[40]何渝.计算机常用数值算法与程序（C++版）[M].北京:人民邮电出版社,2003