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Decanter Centrifuge Real-time monitoring and fault self-healing system
Ma Bo Ma Japanese Red 2 1 1 Jin-Ji Jiang Zhinong 1
Abstract: centrifuge unit during operation prone to vibration, excessive torque characteristics such as failure to develop a set of real-time condition monitoring and fault self-healing as one of the self-healing control system, while long-term stable operation units provide reliable protection. This paper introduces the overall system structure and function, and equipment failure self-healing system of regulation.
Keywords: fault self-healing; real-time monitoring; centrifuge
CLC number: TH17 Horizontal spiral centrifuge is a complex, high-speed rotating machinery, as a continuous operation, large capacity, etc., the actual use, under harsh conditions, their reliability unsatisfactory, frequently showed failure to use a short cycle. For large-scale chemical production, stop loss is enormous. Currently, most enterprises are still in use after the maintenance of petrochemical and periodic maintenance of the system, not only to reduce production time and increased maintenance costs, and easy to stop the process at the beginning of a new fault occurs and even accidents [13].
Complex system in the process, the introduction of equipment to fault prevention and self-healing as the goal of self-regulation mechanism, breaking the traditional "professional barriers", running through the active control equipment to eliminate the reasons for failure of the initial , the fault elimination in the bud, can improve equipment reliability, long-term operation to ensure their safety. Therefore, the research and development set of real-time monitoring and fault self-healing for the whole control system and self-healing when in fact transformed into industrial applications, both for theoretical research, or actual production, are extremely important [45].
1 overall system design The system includes real-time monitoring, fault self-recovery and data collection of three subsystems. The system uses Server / Client 2 structure Server End of data acquisition and data Storage Work, the client is running real-time monitoring and fault self-healing subsystem.
Real-time monitoring part is the part Decanter centrifuge process parameters and condition monitoring parameters analyzed. Through the vibration spectrum analysis, any time trend analysis and other means to ensure the safety Decanters and stable operation, to detect possible failures centrifuge provides protection [1,3,6]. Fault self-recovery subsystem is to analyze the collected signal to determine the possibility of failure and take appropriate measures to eliminate potential failure. According to the system's functional requirements, the overall layout of measurement points chart in Figure 1 and Figure 2.
2 real-time monitoring and data acquisition subsystem design
Real-time monitoring subsystem primarily on the centrifuge feed side and the discharge end bearing vibration monitoring, the feed end of the centrifuge and the discharge end bearing temperature, torque and current on-line monitoring, to ensure that the unit run in the best condition. Install it on any host within the LAN, it makes analysis station, installed in the data acquisition workstation, then it can independently monitor the station's stand-alone work. That Software Front panel button functions with the image of choice, really simple and flexible, and reliable operation. Include the following.
1) On-line monitoring. The part of the function is to make the system at any time to dynamically display the status of all test points for easy monitoring to bar graph form that can intuitively understand the bearing vibration signal is exceeded, if a measuring point over the set of "yellow "or" red light "limit, the system immediately into the alarm state, the operator can grasp the equipment running.
2) On-line data analysis. Data analysis provides a powerful digital signal analysis. Including time-domain analysis, frequency domain analysis (mechanical vibration amplitude spectrum, power spectrum, with a window function selection, spectral average, coordinate selection function), envelope spectrum analysis, cepstrum analysis. Users in the data analysis process, if this group of waveform data that have some features characteristic waveform data can be stored online.
3) trend analysis. Trend analysis is to determine an important means of equipment operating conditions. By selecting the unit, measuring point, the time interval to obtain the measuring points in the operating conditions in this period, the trend of the system is divided into time, day, week, month, year trend.
4) historical wave data analysis. Can query the alarm data, historical data and characteristics of working conditions waveform data, and associated data analysis.
5) fine spectral analysis [6]. Fine spectral analysis with specific Decanters vibration characteristics of film, for the design. Beat frequency oscillator is composed of two similar but not a whole multiple of the harmonic oscillation superimposed formed. Because the collected vibration and internal and external drum beat frequency information, we need a long sampling period. In this case, by detailed spectral analysis to the outside can see the vibration frequency of the drum. Figure 3 for detailed spectral analysis and spectrum analysis of general comparison. Can be seen from the chart: The chart can not tell the general spectrum inside and outside the rotating hub of the frequency spectrum in the refinement can clearly identify the frequency of internal and external transfer hub.
Data acquisition subsystem for real-time acquisition unit vibration, bearing temperature, pressure, torque and current of the signal, and complete the necessary signal processing, transmission and storing and so on. These signals directly reflect the unit's operating state, the signal transmission through the Ethernet to the real-time monitoring and fault prevention subsystem. On the server side storage trends and historical data to Decanter failure, maintenance and performance analysis has a very important value.
3 Design of fault self-healing subsystem
3 1 fault self-recovery control theory
Equipment and, like living organisms, in fact, there are many interrelated and interacting each (element) consisting of complex systems, it also is a certain organization (ordering), diversity of (complex) in a certain stable state, and through interaction between the various systems and interaction, to achieve life processes in order to maintain the body's stability. Once the failure of the body (sick), then time must be the body of a local system (subsystem) deviated from its steady state, that it's orderly, organization, complexity and diversity of some degree of change occurring .
Addition to the sudden failure of a handful of other, most of the production is a process failure is gradual. Produce the ultimate reason for failure is sometimes the equipment overall equipment parts, components and environmental interaction. Information can reveal the machine and biological interactions
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