Computer disc software and application engineering technology high-power air compressor troubleshooting and diagnosis Xing Yanping (Shaanxi Shenmu Chemical Industry Co., Ltd., Shaanxi Yulin 719319 less equipment. In the long-term high-speed operation, high-power air compressor will inevitably occur For faults, such as resonance faults, motor bearing failures and other sudden faults, this paper deals with fault diagnosis and diagnosis of high-power air compressors: begging.

First, the characteristics of the high-power air compressor control system The control system is the rectification, filtering, and voltage regulation that is directly transmitted to each unit circuit after the system is transformed. The purpose is to reduce or eliminate the coupling interference between the power line and the ground between the various units. In addition, the system can use some means to achieve the power supply voltage monitoring function.

Because the air compressor has a lot of high-power inductive loads on site. Impact on the microcontroller system. Therefore, some anti-interference measures need to be selected during the compressor control process, and power pollution problems such as noise interference and electromagnetic interference may occur. After the analysis, this paper suggests that you can take some special measures from both hardware and software.

Realize air compressor network monitoring function. It can transmit all operating status and fault signals to the host computer. Thereby, the unattended work of the air compressor room and the regular sewage discharge of the wind pressure tank can be controlled.

Line measurement and processing of air compressor operating parameters as well as historical curve graphical display and data query at any one time. The data is displayed and printed in the form of a report.

When the motor is overloaded, it can stop the alarm in time; when the air filter is blocked, it will alarm; realize the reverse phase loss protection of the power supply.

Fault diagnosis and analysis function: The control system has a fault display function. Exhaust pressure, turntable unloading, load standby, etc. The fault can realize self-diagnosis shutdown maintenance, and the control panel can display the system exhaust temperature in real time. And the cause of the failure is displayed. When an unsafe action occurs, the alarm light flashes, the buzzer sounds, and switches to the alarm window.

After the fault is removed, the safety reset function can be implemented. At the same time, the system must have certain anti-interference ability.

Second, the air compressor system state detection hardware configuration status monitoring and fault diagnosis hardware configuration is mainly composed of on-site monitoring components, communication processors, fiber hubs, control networks, plant information networks.

The overall structure of the hardware configuration is divided into three layers. The first layer, the state monitoring layer, the monitoring signals of each unit are connected to the fiber hub through their respective communication processors, and then communicate with the MODBUS interface of the control network. The second layer, the control network layer, the DCS system collects the status monitoring data of each unit through the hub and controls the field equipment, and the engineer station or the operator station integrates fault diagnosis and prediction maintenance software, which can realize real-time analysis or timing analysis. The third layer, the factory information network, is connected to the factory backbone information network through the engineering station. The authorized computer on the backbone network can display status monitoring and install corresponding software for management personnel to analyze and use.

Third, the software for fault diagnosis and monitoring and maintenance With the rapid development of computer technology, DCS system is widely used in the automation field of various enterprises. For air compressor units, DCS system is combined with fault analysis software to support remote The diagnosis is a basic feature, which consists of subsystems such as data acquisition, online monitoring and forecasting, signal analysis, and fault diagnosis. It has the characteristics of strong management function, convenient expansion and high data transmission rate.

Fourth, the relevant theory in the signal analysis and processing system The main safety parameters affecting the stable operation of the air compressor are bearing temperature, shaft displacement, shaft vibration, phase and speed. Therefore, the following knowledge curves are used for the system.

The axis trajectory map is synthesized by the frequency of the vibration signal of the horizontal and vertical signals of the axis. The trajectory of the axis changes with the load. Firstly, it is very "one spoonful of ellipse, which indicates that the situation is normal. With the load The increase of the ellipse becomes flat. The load is re-occurring with a double frequency component. If the preload is large enough, the machine may cause excessive wear, shaft fatigue, shaft cracks and the like.

In the polar plot, the two components of the magnitude and phase of the vector are shown in polar form in a graph, while in the Bode plot, the magnitude and phase are indicated on the Y-axis of the two XY plots, respectively. The X-axis is represented by the rotational speed. Any of the above graphic formats can be used to easily identify a certain characteristic. The polar coordinate map and the Bode diagram can be used to distinguish the resonance speed, the friction due to the friction and the shaft crack.

U) requires the system to implement an air compressor and automatic linkage control related to the cooling and pneumatic system valves, so that the installation program can start or stop the operation of controlling the air compressor, and the ultimate goal is to improve the operational accuracy and safety of the system. Sex.

(2) The control system has two control modes, manual and remote. The air compressor's ground control system can display and record all the operations or faults of the air compressor system, and finally generate operational reports, which can be printed at any time.

(3) On-line measurement and processing of air compressor operating parameters historical curve graphic display and data query at any time. The data is displayed and printed in the form of a report.

(4) When the motor is overloaded, it can stop the alarm in time; when the air filter is blocked, it will alarm; realize the reverse phase loss protection of the power supply.

The system consists of pressure and temperature detection sensors, PLC control cabinets, analog input modules, digital output modules, Ethernet modules and other components. The whole system is divided into three layers, namely the on-site measurement control layer, the central management layer and the remote monitoring layer. The central management layer and the remote monitoring layer system are controlled in the same computer, which can effectively reduce the hardware requirements.

U) Exhaust pressure sensor: The exhaust pressure sensor is installed on the connecting pipe of the pressure regulating valve and the exhaust pipe, and is realized by adding a tee through the connecting pipe. The sensor is used to monitor the exhaust pressure and send the monitoring data to the PLC control cabinet. Finally, the data is analyzed by the PLC to realize the loading and unloading of the pressure.

Engineering technology computer CD software and application (2) Lubrication pressure sensor: installed at the end of the oil return pipe of the machine head, the pressure signal is in the same position as the existing analog pressure gauge, and is realized by adding a three-way. It is used to monitor the lubrication status of the compressor and control the start and stop of the compressor in real time through the PLC control cabinet.

(3) Detection sensor: The on-site measurement control layer is composed of various measurement modules and sensors, transmitters and actuators. It is the measurement component and actuator part of the front part of the control system, mainly completing the collection, processing and control of field data; The central management layer and the remote monitoring layer are composed of monitoring hosts. It communicates with the field control layer through the field control bus to dynamically monitor the running status of the field devices and the collection of test data, and sends control commands to the field devices to control system operation and pass Ethernet. Communicate with other systems using the TCP/IP protocol and transmit detection information of field devices.

The 25D03 EEPROM is an extension of the data memory.

As for the remote monitoring layer equipment, it can be selected according to the company's situation.

U) Check the filter of the air compressor. If the air filter in the filter is found to be damaged, defective or dirty, it should be replaced in time; check the air compressor intake pipe for kinks or deformation, the purpose is to Ensure that the intake duct has the minimum required inner ring diameter.

(2) Check if the return pipe has excessive bending, kinking and obstacles. It is recommended that the minimum return line has an inner diameter of 12 mm. In addition, the return line must always be lowered from the air compressor into the engine crankcase.

(3) Check and measure the wear and damage of the air compressor cylinder liner and piston ring and the assembly condition. If the wear is serious, it should be replaced.

Eight, high power air compressor fault troubleshooting and diagnosis example 1, cut off the power of the control loop and module, bypass module, remove the control loop wire from the module Ml and M2 terminals, connect a jumper on the control loop wire, so that The "control loop" of the module is bypassed. (Note: the internal motor protection module of the air compressor is now bypassed. This method can only be used for the transient test of the module.) The power supply to the control loop and the module is re-enabled. Air compressor. If the air compressor does not operate when the module is bypassed, the fault is not in the control system and the module. If the air compressor is running when the module is bypassed and the module is not connected when it is reconnected, then the control loop in the module The relay is open. It is now necessary to test the thermistor chain to determine if the module control loop relay is disconnected due to excessive internal temperature or component failure.

2. Check the thermistor chain of the air compressor, cut off the power supply of the control circuit and the module, remove the sensor leads from the S1 and S2 on the module, and measure the resistance value of the thermistor chain through the sensor lead with the resistance meter. (Warning: Use a resistor with a maximum voltage of 9V to check the sensor chain. The sensor chain is sensitive and susceptible to damage; you should not attempt to check the continuity of the sensor with any non-resistive tool. Applying any external voltage to the sensor chain can cause Damaged so that the air compressor needs to be replaced.

3, according to the following figures to diagnose the resistance reading: -150225n normal operating range -: i: 275n air compressor overheating, it takes time to cool it -on sensor circuit short circuit, replace air compressor -on sensor circuit short circuit, replace air pressure machine. If the resistance reading is not normal, unplug the sensor connector on the air compressor and measure the resistance of the sensor terminal. It can be determined that the abnormal reading is due to the connector failure and the motor protection module is a thermistor.

4. After the initial start or any module trip, the resistance of the sensor chain must be lower than the module reset point before the module loop is closed. The reset value is 2250-30000. If the resistance of the sensor chain is less than 225n, and the air compressor cannot operate when the control loop is bypassed, the solid state module is broken and should be replaced. The voltage should be cut between tests to avoid short circuits and accidental arcing of the contacts. Whenever the fuse is disconnected or the circuit breaker trips, the module function should be checked to ensure that the contacts of the mold motor protection module are not bonded.

(2) The occurrence of interference fringes soon after the use of a new machine, irregular and full-screen interference fringes appear on the monitor from time to time, seriously affecting the diagnosis. This phenomenon is irregular, sometimes it starts up, sometimes it happens every few days.

Since the high-power inductive load of the air compressor is relatively large, it will cause a series of problems such as power supply pollution (overvoltage, undervoltage, spike voltage), noise interference, and electromagnetic interference. Especially in the case of frequent use of the inverter, this situation will have a certain impact on the microcontroller system. Therefore, in the process of compressor control, some anti-interference measures need to be selected, and certain measures can be taken from both hardware and software.

Hardware measures: It is recommended that the system be powered by discrete power. Since the whole system is not uniformly transformerd, filtered, and stabilized, it can be supplied to each unit circuit, but is directly sent to each unit circuit for rectification, filtering, and voltage regulation after voltage transformation. In this way, the coupling interference between the power line and the ground line between the units can be eliminated very effectively, which increases the power supply quality and increases the heat dissipation area. At the same time, an electronic dog can be used to realize the power supply voltage monitoring function. The reset signal of the IMP850 is high level, the reset threshold voltage is 4.38V, the transient amplitude is 100MV transient and the duration is 20ms transient. Causes a wrong reset.

Software measures: Write the necessary exception handling procedures and system self-diagnostics. For example, the power-on flag can be set in the EEPROM to distinguish whether the system is a power-on reset (cold start) or a fault reset (hot start). If the system is a fault reset, then the production process should be rewritten from the point of failure to execute the exception handler to restore the state before the fault. Regarding data redundancy protection and error correction in EEPROM, the program uses a triple redundant coding error correction scheme. Engineering practice has shown that interference only causes individual data in the EEPROM to be lost and does not return to the entire EEPROM area. Through the comparison and verification of three data, at least two data are the same to be able to save the data content.

Air compressor unit operation status monitoring, fault diagnosis system is the most typical mechatronics high-tech product in mechanized operation today. Its function is not only to display the parameters of the air compressor, but also to make the interlock control system stable and reliable. What's more important is that it can carry out electromechanical predictive maintenance work through the information provided by the fault diagnosis system, which greatly reduces the overhaul workload and reduces the consumption of manpower and material resources. The economic benefits are very significant. According to relevant research statistics, this is used. After the system, the failure rate of machinery in China's electromechanical industry is reduced by 75..., and the maintenance cost is reduced by 2550... Because the failure rate of air compressor units is relatively high, it is very necessary to adopt this system, and the traditional equipment maintenance method is changed. It is the direction of future development of large-scale units entering the state of predictive maintenance based on condition monitoring.

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