CN114167842A - Fault prediction and health management method based on vibration active control system - Google Patents
Fault prediction and health management method based on vibration active control system Download PDFInfo
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- CN114167842A CN114167842A CN202111491852.1A CN202111491852A CN114167842A CN 114167842 A CN114167842 A CN 114167842A CN 202111491852 A CN202111491852 A CN 202111491852A CN 114167842 A CN114167842 A CN 114167842A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
- G05B23/0243—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults model based detection method, e.g. first-principles knowledge model
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/20—Pc systems
- G05B2219/24—Pc safety
- G05B2219/24065—Real time diagnostics
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- Automation & Control Theory (AREA)
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Abstract
A fault prediction and health management method based on a vibration active control system determines the installation positions and the number of sensors of the vibration active control system, which are used for sensing the vibration of a controlled object; in the long-term operation of the controlled object, the vibration continuous monitoring and data processing are kept, and the controlled object operation characteristic library is established and appropriately updated according to the operation use habit, so that the fault false alarm caused by the operation is avoided; in data processing, the frequency and amplitude are abnormal; under the condition that a controlled object is suspected to have a fault, a vibration active control system is used as a test system, an actuator is used for inputting pulses, sine or other excitations which are beneficial to judging the type of the fault, and the fault caused by looseness, unbalance, incoordination and the like is diagnosed through the acquisition of a sensor and the processing of a controller; automatically adjusting the output of an actuator of the active control system for the fault which occurs, and inhibiting the vibration of the controlled object; the work is reliable.
Description
Technical Field
The invention relates to the technical field of fault prediction and health management of equipment, in particular to a fault prediction and health management method based on a vibration active control system.
Background
At present, in the military field, in order to improve the sound stealth performance of naval vessels, reduce the probability of being discovered by enemy sonar, improve the detection performance of self sonar simultaneously, it is very important to control the mechanical noise on the naval vessels, under the condition that means such as traditional vibration isolation, vibration absorption, sound insulation have been fully excavated, adopt initiative means to control the vibration to reduce acoustic radiation, become more and more important. Regardless of military use, in order to improve the comfort of surrounding personnel, improve the working precision and reliability of equipment and reduce the failure risk caused by fatigue, the application of the vibration active control technology is more and more extensive.
Prediction and Health Management (PHM) utilizes a large amount of state monitoring data and a priori knowledge to assess the state of Health of Management equipment by means of statistical algorithms or models. The PHM can predict potential faults in advance, and provides maintenance decisions by combining various equipment information, so that the visual maintenance is realized, the safety of the production process is improved, and the maintenance cost is reduced.
The complete active vibration control system comprises a vibration sensor, a controller, a power amplifier and an actuator, and the complete PHM system comprises a device characteristic sensing element such as the vibration sensor and a data processing and analyzing unit. The two systems are overlapped to a certain degree, if the two systems are independently built, time and labor are consumed, and the arrangement positions of hardware are possibly in conflict.
Disclosure of Invention
The applicant provides a fault prediction and health management method based on a vibration active control system aiming at the defects in the prior art, so that the fault prediction and health management can be realized only by adding corresponding functions on software, the cost of the whole period is saved, the system reliability is improved, the maintenance requirement is reduced, the fault diagnosis accuracy is improved, the fault can be prevented from further deterioration after the fault occurs, and the loss is reduced to the minimum.
The technical scheme adopted by the invention is as follows:
a fault prediction and health management method based on a vibration active control system comprises the following operation steps:
the method comprises the following steps: determining a vibration active control system, wherein the vibration active control system is used for sensing the installation position and the number of sensors for sensing the vibration of a controlled object;
from the angle of fault prediction and health management, judging whether a sensor used for a vibration active control system currently meets the requirements of fault prediction and health management or not by combining the fault mechanism, mode and influence of a controlled object, and performing overall arrangement and proper adjustment;
step two: in the long-term operation of the controlled object, the vibration continuous monitoring and data processing are kept, and the controlled object operation characteristic library is established and appropriately updated according to the operation use habit, so that the fault false alarm caused by the operation is avoided;
step three: in data processing, aiming at the conditions of abnormal frequency and amplitude and the like, early warning and diagnosis are carried out on potential faults by combining common fault information of equipment, and the residual service life of a controlled object is predicted aiming at the gradual change conditions of the frequency and the amplitude;
step four: under the condition that a controlled object is suspected to have a fault, a vibration active control system is used as a test system, an actuator is used for inputting pulses, sine or other excitations which are beneficial to judging the type of the fault, and the fault caused by looseness, unbalance, incoordination and the like is diagnosed through the acquisition of a sensor and the processing of a controller;
step five: for faults that have occurred, the output of the actuators of the active control system is automatically adjusted, the vibration of the controlled object is suppressed, the faults are prevented from further worsening, and conduction to other peripheral devices causes damage to the other devices.
The further technical scheme is as follows:
in the first step, when the requirements of fault prediction and health management are not met, sensors are added appropriately.
In the first step, vibration monitoring is a useful means for fault prediction and health management, but the positions and the number of the mounted sensors are different from the two aspects of fault prediction and health management and from the vibration control, so that the vibration control is mainly used, the fault prediction and the health management are considered, and the mounting positions and the number of the sensors are arranged comprehensively.
And in the second step, a controlled object feature library established based on long-term monitoring and operation use habits is mainly amplitude-frequency characteristics under the condition that each working condition normally operates and corresponding amplitude-frequency characteristics when the working conditions are switched, threshold intervals are respectively set according to the long-term operation conditions, and then self-adaptive updating is carried out according to the operation characteristics of the controlled object.
In the third step, for gradual or progressive faults, the variation trend of the amplitude-frequency curve of the acquired data is observed, the trend is confirmed by comparing with the previous characteristics, an early warning is given, and for sudden faults, the amplitude or frequency is observed suddenly.
In the third step, a fault diagnosis result can be given by combining with common equipment fault information provided by a manufacturer, and the residual service life of the controlled object can be predicted according to a controlled object performance decline curve provided by the manufacturer or based on monitoring data by a machine learning or deep learning method.
In the fourth step, the theoretical basis is that when the equipment is normal and has loose, unbalanced and unpaired faults, different response curves exist under specific excitation, so that after the faults are found, the faults are further diagnosed by virtue of an active control system.
In the fifth step, after the fault occurs, the vibration of the equipment is more violent, which not only causes the deterioration of the fault of the equipment, but also causes the damage of other peripheral equipment, therefore, the vibration of the equipment is restrained by the active control system, and the loss is automatically and timely reduced until the equipment is shut down.
The invention has the following beneficial effects:
the invention has convenient operation, fully utilizes the hardware system of the vibration active system, realizes the fault prediction and the health management of the rotary and reciprocating machines, saves the installation cost and the operation and maintenance cost, increases the fault diagnosis means, reduces the fault loss and improves the fault prediction and the health management level.
The invention fully utilizes the hardware system of the vibration active control system, reduces the cost for additionally constructing the PHM system, increases the means of fault diagnosis and fault loss reduction through the organic integration of the hardware system and the PHM system, and improves the PHM level.
Firstly, determining the installation positions and the number of sensors used by a vibration active control system for sensing the vibration of a controlled object, then, from the aspects of fault prediction and health management, combining the fault mechanism, the mode and the influence of the controlled object, judging whether the sensors currently used by the vibration active control system meet the requirements of fault prediction and health management, and if not, comprehensively considering the installation positions and the number of the sensors; then, in the long-term operation of the controlled object, vibration is kept to be continuously monitored and data are processed, and the controlled object operation characteristic library is established and appropriately updated according to operation use habits and the like, so that fault false alarm caused by the operation is avoided. In addition, in the data processing, aiming at the conditions of abnormal frequency and amplitude and the like, the early warning and diagnosis are carried out on potential faults by combining with common fault information of equipment provided by manufacturers, and the residual service life of the controlled object can be predicted according to a performance degradation curve given by the manufacturers or aiming at the gradual change conditions of the frequency, the amplitude and the like by a data mining method.
In addition, when the controlled object is suspected to have a fault, the vibration active control system can be used as a test system, and faults caused by looseness, unbalance, incorrectness and the like can be diagnosed through the acquisition of a sensor and the processing of a controller by utilizing an actuator input pulse, sine or other excitation which is beneficial to judging the fault type. Finally, for the fault that has occurred, the output of the actuator of the active control system can be automatically adjusted, the vibration of the controlled object can be suppressed, the fault can be prevented from further worsening, and the conduction to other peripheral equipment can cause the damage of other equipment.
The invention aims at the rotary or reciprocating machinery needing to control vibration, fully utilizes the hardware of the vibration control system, can realize fault prediction and health management by only adding corresponding functions on software, saves the cost of the whole period, improves the reliability of the system, reduces the maintenance requirement, not only improves the fault diagnosis accuracy, but also can ensure that the fault is not further worsened after the fault occurs, and reduces the loss to the minimum.
Detailed Description
The following describes specific embodiments of the present invention.
The fault prediction and health management method based on the vibration active control system comprises the following operation steps:
the method comprises the following steps: determining a vibration active control system, wherein the vibration active control system is used for sensing the installation position and the number of sensors for sensing the vibration of a controlled object;
from the angle of fault prediction and health management, judging whether a sensor used for a vibration active control system currently meets the requirements of fault prediction and health management or not by combining the fault mechanism, mode and influence of a controlled object, and performing overall arrangement and proper adjustment;
step two: in the long-term operation of the controlled object, the vibration continuous monitoring and data processing are kept, and the controlled object operation characteristic library is established and appropriately updated according to the operation use habit, so that the fault false alarm caused by the operation is avoided;
step three: in data processing, aiming at the conditions of abnormal frequency and amplitude and the like, early warning and diagnosis are carried out on potential faults by combining common fault information of equipment, and the residual service life of a controlled object is predicted aiming at the gradual change conditions of the frequency and the amplitude;
step four: under the condition that a controlled object is suspected to have a fault, a vibration active control system is used as a test system, an actuator is used for inputting pulses, sine or other excitations which are beneficial to judging the type of the fault, and the fault caused by looseness, unbalance, incoordination and the like is diagnosed through the acquisition of a sensor and the processing of a controller;
step five: for faults that have occurred, the output of the actuators of the active control system is automatically adjusted, the vibration of the controlled object is suppressed, the faults are prevented from further worsening, and conduction to other peripheral devices causes damage to the other devices.
In the first step, when the requirements of fault prediction and health management are not met, sensors are added appropriately.
In the first step, vibration monitoring is a useful means for fault prediction and health management in this embodiment, but the positions and the number of the sensors are inevitably different from the two aspects of fault prediction and health management and from the vibration control, so that the vibration control is mainly used, the fault prediction and the health management are considered, and the installation positions and the number of the sensors are arranged in a general way.
And in the second step, a controlled object feature library established based on long-term monitoring and operation use habits is mainly amplitude-frequency characteristics under the condition that each working condition normally operates and corresponding amplitude-frequency characteristics when the working conditions are switched, threshold intervals are respectively set according to the long-term operation conditions, and then self-adaptive updating is carried out according to the operation characteristics of the controlled object.
In the third step, for gradual or progressive faults, the variation trend of the amplitude-frequency curve of the acquired data is observed, the trend is confirmed by comparing with the previous characteristics, an early warning is given, and for sudden faults, the amplitude or frequency is observed suddenly.
In the third step, a fault diagnosis result can be given by combining with common equipment fault information provided by a manufacturer, and the residual service life of the controlled object can be predicted according to a controlled object performance decline curve provided by the manufacturer or based on monitoring data by a machine learning or deep learning method.
In the fourth step, the theoretical basis is that when the equipment is normal and has loose, unbalanced and unpaired faults, different response curves exist under specific excitation, so that after the faults are found, the faults are further diagnosed by virtue of an active control system.
In the fifth step, after the fault occurs, the vibration of the equipment is more violent, which not only causes the deterioration of the fault of the equipment, but also causes the damage of other peripheral equipment, therefore, the vibration of the equipment is restrained by the active control system, and the loss is automatically and timely reduced until the equipment is shut down.
The specific operation flow and functions of the invention are as follows:
the method comprises the following steps: determining the installation positions and the number of sensors used by a vibration active control system for sensing the vibration of a controlled object; from the aspects of fault prediction and health management, the fault mechanism, the mode and the influence of a controlled object are combined, whether the sensor used for the vibration active control system currently meets the requirements of fault prediction and health management is judged, and if the sensor does not meet the requirements, the sensor can be added appropriately.
Step two: in the long-term operation of the controlled object, the vibration is kept to be continuously monitored and data are processed, and the controlled object operation characteristic library is established and appropriately updated according to operation use habits and the like, so that fault false alarm caused by the operation is avoided.
Step three: in the data processing, aiming at the conditions of abnormal frequency and amplitude and the like, the potential fault is early warned and diagnosed by combining common fault information of equipment provided by a manufacturer or mining data. And for the slowly changing conditions of frequency, amplitude and the like, the residual service life of the controlled object is predicted by combining a performance degradation curve or mining data.
Step four: under the condition that the controlled object is suspected to have a fault, the vibration active control system can be used as a test system, and the faults caused by looseness, unbalance, incorrectness and the like can be diagnosed by utilizing certain excitation input by an actuator, acquisition of a sensor and processing of a controller.
Step five: the output of the actuator of the active control system can be automatically adjusted for the fault, the vibration of the controlled object can be restrained, the fault can be prevented from further worsening, and the conduction to other peripheral equipment can cause the damage of other equipment.
The invention aims at the rotary or reciprocating machinery needing to control vibration, fully utilizes the hardware of the vibration control system, can realize fault prediction and health management by only adding corresponding functions on software, saves the cost of the whole period, improves the reliability of the system, reduces the maintenance requirement, not only improves the fault diagnosis accuracy, but also can ensure that the fault is not further worsened after the fault occurs, and reduces the loss to the minimum.
The above description is intended to be illustrative and not restrictive, and the scope of the invention is defined by the appended claims, which may be modified in any manner within the scope of the invention.
Claims (8)
1. A fault prediction and health management method based on a vibration active control system is characterized in that: the method comprises the following operation steps:
the method comprises the following steps: determining a vibration active control system, wherein the vibration active control system is used for sensing the installation position and the number of sensors for sensing the vibration of a controlled object;
from the angle of fault prediction and health management, judging whether a sensor used for a vibration active control system currently meets the requirements of fault prediction and health management or not by combining the fault mechanism, mode and influence of a controlled object, and performing overall arrangement and proper adjustment;
step two: in the long-term operation of the controlled object, the vibration continuous monitoring and data processing are kept, and the controlled object operation characteristic library is established and appropriately updated according to the operation use habit, so that the fault false alarm caused by the operation is avoided;
step three: in data processing, aiming at the abnormal conditions of frequency and amplitude, the early warning and diagnosis are carried out on potential faults by combining common fault information of equipment, and the prediction is carried out on the residual service life of a controlled object aiming at the slowly changing conditions of frequency and amplitude;
step four: under the condition that a controlled object is suspected to have a fault, a vibration active control system is used as a test system, an actuator is used for inputting pulses, sine or other excitations which are beneficial to judging the type of the fault, and the fault caused by looseness, unbalance and misalignment is diagnosed through the acquisition of a sensor and the processing of a controller;
step five: for faults that have occurred, the output of the actuators of the active control system is automatically adjusted, the vibration of the controlled object is suppressed, the faults are prevented from further worsening, and conduction to other peripheral devices causes damage to the other devices.
2. The vibration active control system based failure prediction and health management method of claim 1, wherein: in the first step, when the requirements of fault prediction and health management are not met, sensors are added appropriately.
3. The vibration active control system based failure prediction and health management method of claim 1, wherein: in the first step, vibration monitoring is a useful means for fault prediction and health management, but the positions and the number of the mounted sensors are different from the two aspects of fault prediction and health management and from the vibration control, so that the vibration control is mainly used, the fault prediction and the health management are considered, and the mounting positions and the number of the sensors are arranged comprehensively.
4. The vibration active control system based failure prediction and health management method of claim 1, wherein: and in the second step, a controlled object feature library established based on long-term monitoring and operation use habits is mainly amplitude-frequency characteristics under the condition that each working condition normally operates and corresponding amplitude-frequency characteristics when the working conditions are switched, threshold intervals are respectively set according to the long-term operation conditions, and then self-adaptive updating is carried out according to the operation characteristics of the controlled object.
5. The vibration active control system based failure prediction and health management method of claim 1, wherein: in the third step, for gradual or progressive faults, the variation trend of the amplitude-frequency curve of the acquired data is observed, the trend is confirmed by comparing with the previous characteristics, an early warning is given, and for sudden faults, the amplitude or frequency is observed suddenly.
6. The vibration active control system based failure prediction and health management method of claim 1, wherein: in the third step, a fault diagnosis result can be given by combining with common equipment fault information provided by a manufacturer, and the residual service life of the controlled object can be predicted according to a controlled object performance decline curve provided by the manufacturer or based on monitoring data by a machine learning or deep learning method.
7. The vibration active control system based failure prediction and health management method of claim 1, wherein: in the fourth step, the theoretical basis is that when the equipment is normal and has loose, unbalanced and misaligned faults, different response curves exist under specific excitation, so that after the faults are found, the faults are further diagnosed by virtue of an active control system.
8. The vibration active control system based failure prediction and health management method of claim 1, wherein: in the fifth step, after the fault occurs, the vibration of the equipment is more violent, which not only causes the deterioration of the fault of the equipment, but also causes the damage of other peripheral equipment, therefore, the vibration of the equipment is restrained by the active control system, and the loss is automatically and timely reduced until the equipment is shut down.
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