大离心泵状态监测及故障诊断仪的研究
摘要
在船舶系统中,大离心泵、发电机组、减速齿轮箱、风机等这类旋转机械设备运行时都会产生振动,而振动过大是机组破坏的重要原因之一,一旦这些机组因振动过大而产生故障,必定会影响船只的正常航行安全。所以为了保证设备机组的有效运行,必须针对这些设备配置状态监测与报警系统。设备运行时,振动参数能比其他的状态参数更直接、快速和准确地反映机组的运行状态,因此目前大多采用振动参数作为机组状态监测和运行状态趋势预测依据。但在正常使用状况下,随着设备的老化,机组振动烈度必然呈上升趋势。因此,当这些设备使用一定年限后,尽管依然能够正常工作,但其振动烈度往往会超过报警预设值,导致设备频繁报警,给现场操作人员工作带来很大不便。特别的,目前在船舶系统中,还存在着数量巨大的老旧设备甚至是超期服役设备。相比新设备,老旧设备在运行过程中存在着更大的安全隐患。但出于成本方面的考虑,对于这些依然能够正常工作老旧设备甚至是超期服役设备又不能盲目淘汰。
针对这种情况,利用现代计算机技术,本文设计出了一款可用于船用大离心泵在线监测的装置。该装置利用以单片机为基础的嵌入式计算机系统对监测对象实施在线不间断监测,定时保存采集数据,并通过上位机软件对所记录数据进行辅助分析。在硬件上以C8051F340单片机为核心控制芯片,通过传感器采集信号,以U盘为存储介质保存所采集数据结果。在软件上,通过C语言对单片机编程,实现下位机系统的各项功能。上位机编程软件选用VC++6.0,利用VC++6.0良好的图像处理能力,对保存的数据进行可视化处理,给出具有良好可视性的图文并茂的数据结果。
论文以某船超期服役的大离心泵为具体监测对象,阐述了大离心泵状态监测及故障诊断装置的设计原理、软硬件实现、实施流程以及大离心泵振动超标的现场报警处理过程。通过对大量监测数据的分析,得出了关于该大离心泵故障分析标准的相关结论,并得在一次评审会上得到相关专家的一致认可。
In ship system,when the rotating machinery equipment such as large centrifugal pumps, generating units,speed gear box and big fans works,vibrations must be generated.If the vibrations are too large,the equipment may be destroyed,this may be a threaten to the ship's sailing.So,in order to make the equipments work effective,the condition monitoring and alarming device is necessary.When the rotating machinery equipment works,compare with other parameters,vibration parameters can be a more direct,rapid and accurate reflection of the operational status of equipments.So,usually,we choose the vibration parameters as the base of the rotating machinery equipments' condition monitoring and running trend forecast. However,in normal use conditions,with aging equipments,their vibration intensity is often beyond the default alarm value which makes the equipment alarm too frequently.Specially, now in the ship system,there are a lot of old even extended active duty equipments.Compare whit the new equipment,there is a greater security risk when use the old equipment.But, consider of the cost,we can't eliminate them blindly.
Aim at this situation,use of modern computer technology,this article designs a device which can be used in large centrifugal pump's online monitoring.The device uses embedded computer system which basis on MCU gives an online monitoring continuously and save data on time,the data will be analyzed by a computer.In hardware,the device uses the MCU C8051F340 as the core control chip,gets signal through sensors,saves data by USB disks.In software,uses C language to program the MCU,while the computer will be programmed by VC++6.0,using VC++6.0's good image processing capability,gives the saved data a visualization deal,then the finally results will be gave.
The article uses a ship's large centrifugal pump which is in extended active duty as specific monitoring object,explains the large centrifugal pump condition monitoring and fault diagnosis device's design principle,software and hardware's implement and the large centrifugal pump's alarming process.Through the analysis of large amounts of data,we get the result of the large centrifugal pump's fault diagnosis standard which was recognized by the experts in an accreditation council.
针对这种情况,利用现代计算机技术,本文设计出了一款可用于船用大离心泵在线监测的装置。该装置利用以单片机为基础的嵌入式计算机系统对监测对象实施在线不间断监测,定时保存采集数据,并通过上位机软件对所记录数据进行辅助分析。在硬件上以C8051F340单片机为核心控制芯片,通过传感器采集信号,以U盘为存储介质保存所采集数据结果。在软件上,通过C语言对单片机编程,实现下位机系统的各项功能。上位机编程软件选用VC++6.0,利用VC++6.0良好的图像处理能力,对保存的数据进行可视化处理,给出具有良好可视性的图文并茂的数据结果。
论文以某船超期服役的大离心泵为具体监测对象,阐述了大离心泵状态监测及故障诊断装置的设计原理、软硬件实现、实施流程以及大离心泵振动超标的现场报警处理过程。通过对大量监测数据的分析,得出了关于该大离心泵故障分析标准的相关结论,并得在一次评审会上得到相关专家的一致认可。
In ship system,when the rotating machinery equipment such as large centrifugal pumps, generating units,speed gear box and big fans works,vibrations must be generated.If the vibrations are too large,the equipment may be destroyed,this may be a threaten to the ship's sailing.So,in order to make the equipments work effective,the condition monitoring and alarming device is necessary.When the rotating machinery equipment works,compare with other parameters,vibration parameters can be a more direct,rapid and accurate reflection of the operational status of equipments.So,usually,we choose the vibration parameters as the base of the rotating machinery equipments' condition monitoring and running trend forecast. However,in normal use conditions,with aging equipments,their vibration intensity is often beyond the default alarm value which makes the equipment alarm too frequently.Specially, now in the ship system,there are a lot of old even extended active duty equipments.Compare whit the new equipment,there is a greater security risk when use the old equipment.But, consider of the cost,we can't eliminate them blindly.
Aim at this situation,use of modern computer technology,this article designs a device which can be used in large centrifugal pump's online monitoring.The device uses embedded computer system which basis on MCU gives an online monitoring continuously and save data on time,the data will be analyzed by a computer.In hardware,the device uses the MCU C8051F340 as the core control chip,gets signal through sensors,saves data by USB disks.In software,uses C language to program the MCU,while the computer will be programmed by VC++6.0,using VC++6.0's good image processing capability,gives the saved data a visualization deal,then the finally results will be gave.
The article uses a ship's large centrifugal pump which is in extended active duty as specific monitoring object,explains the large centrifugal pump condition monitoring and fault diagnosis device's design principle,software and hardware's implement and the large centrifugal pump's alarming process.Through the analysis of large amounts of data,we get the result of the large centrifugal pump's fault diagnosis standard which was recognized by the experts in an accreditation council.
引文
[1]朱德恒.电气设备状态监测及故障诊断技术[M].北京:中国电力出版社,2009.3.
[2]易良蕖.简易振动诊断现场实用技术[M].北京:机械工业出版社,2003.
[3]王飞.基于LabVIEW的船舶机械振动监测系统设计[J].中外船舶科技,2008,4:28-31.
[4]LainBate,SteveLiu.Real-Time Embedded systems.Computing&programming,1999,(12);34-37
[5]Keweenaw Research Center,DEVELOPMENTAND ANALYSIS OF TIME VARIANT DISCRETE FOURIER TRANSFORM ORDER TRACKING,Mechanical Systems and Signal Processing,2003,17(6)
[6]J.Geiger.MaehineryVibrationMonitoringSensors[M].SensorTeehnologyHandbook,2005:285-306.
[7]C.Aszkler.Aeeeleration,ShoekandVibrationSensors[M].SensorTeehnologyHandbook,2005:137.
[8]黄继昌,徐巧鱼,张海贵等.传感器工作原理及应用实例[J].北京:人民邮电出版社,1998:18-21.
[9]冯子成.基于单片机的无纸记录仪研发[D].重庆:重庆大学,2008.
[10]Song Zhu-Mei,Li Di.Modeling method for embedded equipment control system.Source:Journal of South China University of Technology(Natural Science),v 33(10):p29-33,2005.10
[11]李吉祥.基于嵌入式系统的无纸记录仪的研制[D].黑龙江:哈尔滨理工大学,2008.
[12]龚运新,罗惠敏,彭建军等.单片机接口C语言开发技术[M].北京:清华大学出版社,2009.
[13]罗勇.C语言程序设计[M].北京:中国电力出版社,2009.
[14]Stanley B Lippman,josee Lajoie.C++Primer[M].北京:中国电力出版社,2005,6
[15]谢凤英,赵丹培.Visual C++数字图像处理[M].北京:电子工业出版社,2008.
[16]徐睿.高频开关电源直流系统[D].济南:山东大学,2008.
[17]B.W.Will Jams.Power Electronics Devices Drives and Application.Macmillan EducationLtd,1997.
[18]张秀澹.开关电源的发展动向[J].石家庄:半导体技术,1993,2:29-31.
[19]康华光,陈大钦.电子技术基础模拟部分(第四版).北京:高等教育出版社,1999.
[20]马新群,马传添.发展中的中小功率UPS技术[J].电子技术,1993,12:14-15.
[21]杨军,周凡.高效率嵌入式程序开发[J].电子设计应用,2006,11:106-108.
[22]Wick,Carl E.Teaching embedded computer systems with a Windows-based simulator[J].IEEE,1996,6:242-245
[23]黄磊.单片机和嵌入式系统开发平台化的研究[D].江苏:南京航空航天大学,2004.
[24]周毓林,宁杨,陆桂强等.Windows CE.net内核定制及应用开发[M].北京:电子工业出版社,2005,2.
[25]柴钰.单片机原理及应用[M].西安:西安电子科技大学出版社,2009.
[26]潘琢金.C8051F340/1/2/3/4/5/6/7全速USB FLASH微控制器数手册.沈阳:沈阳工业大学,2006.
[27]付汝揖.汽轮发电机组振动标准的研究[J].东方电气评论,1991,5(3):168-169.
[28]王吉兴.机械振动案例分析[J].机械,2008(S1):107-108.
[29]张志勇,辛长宇,朱玉龙等.Pt100温度传感器非线性的补偿方法与电路实现[J].电子器 件,2007,6:2189-2191.
[30]才智等.PT100铂热电阻温度测量系统的设计[J].现代电子技术,2008,20:172-175.
[31]蔡彬彬,包亚萍,陶卉等.基于铂热电阻PT100的USB测温仪的设计[J]北京:微计算机信息2008,10:186-188.
[32]李芸婷,万振凯.PT100温度传感器数据实时采集系统[J].仪器仪表用户,2007,5:25-26.
[33]Paul Rako.用模拟开关实现信号复用[J].电子设计技术,2008,9:72-78.
[34]张银海.基于CH375的USB移动存储接口设计[J].电子元器件应用,2008,10:22-24.
[35]作者不详.CH375技术资料,南京沁恒公司.
[36]张晞,王德银,张晨.MSP430系列单片机实用C语言程序设计.北京:北京航天航空大学出版社,2000.
[37]王晨光,孙运强.串行时钟芯片DS1302在温度测量记录仪表中的应用[J].电子测试2008,12:65-70.
[38]黄河,郭纪林.单片机原理应用[M].大连:大连理工大学出版社.
[39]范立南.基于Keil C51的软件看门狗系统设计[J]西安:计算机技术与发展.2009:154-157.
[40]Intel MIC-51 Fimily of single chip Microcomputers user's Manual.1981.
[41]Todd D.Morton.Embedded Microcontrollers.北京:科学出版社,2003.8.
[42]杨长虹.C语言程序中清除键盘缓冲区的方法[J].益阳职业技术学院学报,2006,4:50.
[43]张利平.机组振动的危害、振动的标准及原因分析.科技与经济,2006,15:83.
[2]易良蕖.简易振动诊断现场实用技术[M].北京:机械工业出版社,2003.
[3]王飞.基于LabVIEW的船舶机械振动监测系统设计[J].中外船舶科技,2008,4:28-31.
[4]LainBate,SteveLiu.Real-Time Embedded systems.Computing&programming,1999,(12);34-37
[5]Keweenaw Research Center,DEVELOPMENTAND ANALYSIS OF TIME VARIANT DISCRETE FOURIER TRANSFORM ORDER TRACKING,Mechanical Systems and Signal Processing,2003,17(6)
[6]J.Geiger.MaehineryVibrationMonitoringSensors[M].SensorTeehnologyHandbook,2005:285-306.
[7]C.Aszkler.Aeeeleration,ShoekandVibrationSensors[M].SensorTeehnologyHandbook,2005:137.
[8]黄继昌,徐巧鱼,张海贵等.传感器工作原理及应用实例[J].北京:人民邮电出版社,1998:18-21.
[9]冯子成.基于单片机的无纸记录仪研发[D].重庆:重庆大学,2008.
[10]Song Zhu-Mei,Li Di.Modeling method for embedded equipment control system.Source:Journal of South China University of Technology(Natural Science),v 33(10):p29-33,2005.10
[11]李吉祥.基于嵌入式系统的无纸记录仪的研制[D].黑龙江:哈尔滨理工大学,2008.
[12]龚运新,罗惠敏,彭建军等.单片机接口C语言开发技术[M].北京:清华大学出版社,2009.
[13]罗勇.C语言程序设计[M].北京:中国电力出版社,2009.
[14]Stanley B Lippman,josee Lajoie.C++Primer[M].北京:中国电力出版社,2005,6
[15]谢凤英,赵丹培.Visual C++数字图像处理[M].北京:电子工业出版社,2008.
[16]徐睿.高频开关电源直流系统[D].济南:山东大学,2008.
[17]B.W.Will Jams.Power Electronics Devices Drives and Application.Macmillan EducationLtd,1997.
[18]张秀澹.开关电源的发展动向[J].石家庄:半导体技术,1993,2:29-31.
[19]康华光,陈大钦.电子技术基础模拟部分(第四版).北京:高等教育出版社,1999.
[20]马新群,马传添.发展中的中小功率UPS技术[J].电子技术,1993,12:14-15.
[21]杨军,周凡.高效率嵌入式程序开发[J].电子设计应用,2006,11:106-108.
[22]Wick,Carl E.Teaching embedded computer systems with a Windows-based simulator[J].IEEE,1996,6:242-245
[23]黄磊.单片机和嵌入式系统开发平台化的研究[D].江苏:南京航空航天大学,2004.
[24]周毓林,宁杨,陆桂强等.Windows CE.net内核定制及应用开发[M].北京:电子工业出版社,2005,2.
[25]柴钰.单片机原理及应用[M].西安:西安电子科技大学出版社,2009.
[26]潘琢金.C8051F340/1/2/3/4/5/6/7全速USB FLASH微控制器数手册.沈阳:沈阳工业大学,2006.
[27]付汝揖.汽轮发电机组振动标准的研究[J].东方电气评论,1991,5(3):168-169.
[28]王吉兴.机械振动案例分析[J].机械,2008(S1):107-108.
[29]张志勇,辛长宇,朱玉龙等.Pt100温度传感器非线性的补偿方法与电路实现[J].电子器 件,2007,6:2189-2191.
[30]才智等.PT100铂热电阻温度测量系统的设计[J].现代电子技术,2008,20:172-175.
[31]蔡彬彬,包亚萍,陶卉等.基于铂热电阻PT100的USB测温仪的设计[J]北京:微计算机信息2008,10:186-188.
[32]李芸婷,万振凯.PT100温度传感器数据实时采集系统[J].仪器仪表用户,2007,5:25-26.
[33]Paul Rako.用模拟开关实现信号复用[J].电子设计技术,2008,9:72-78.
[34]张银海.基于CH375的USB移动存储接口设计[J].电子元器件应用,2008,10:22-24.
[35]作者不详.CH375技术资料,南京沁恒公司.
[36]张晞,王德银,张晨.MSP430系列单片机实用C语言程序设计.北京:北京航天航空大学出版社,2000.
[37]王晨光,孙运强.串行时钟芯片DS1302在温度测量记录仪表中的应用[J].电子测试2008,12:65-70.
[38]黄河,郭纪林.单片机原理应用[M].大连:大连理工大学出版社.
[39]范立南.基于Keil C51的软件看门狗系统设计[J]西安:计算机技术与发展.2009:154-157.
[40]Intel MIC-51 Fimily of single chip Microcomputers user's Manual.1981.
[41]Todd D.Morton.Embedded Microcontrollers.北京:科学出版社,2003.8.
[42]杨长虹.C语言程序中清除键盘缓冲区的方法[J].益阳职业技术学院学报,2006,4:50.
[43]张利平.机组振动的危害、振动的标准及原因分析.科技与经济,2006,15:83.