CN113646538B - Method for vibration avoidance in a pump - Google Patents
Method for vibration avoidance in a pump Download PDFInfo
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- CN113646538B CN113646538B CN202080029386.2A CN202080029386A CN113646538B CN 113646538 B CN113646538 B CN 113646538B CN 202080029386 A CN202080029386 A CN 202080029386A CN 113646538 B CN113646538 B CN 113646538B
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- 238000000034 method Methods 0.000 title claims abstract description 67
- 230000010355 oscillation Effects 0.000 claims abstract description 5
- 230000008859 change Effects 0.000 claims description 21
- 238000001228 spectrum Methods 0.000 claims description 10
- 239000007787 solid Substances 0.000 claims description 8
- 239000002351 wastewater Substances 0.000 claims description 6
- 239000000463 material Substances 0.000 claims description 5
- 230000002068 genetic effect Effects 0.000 claims description 4
- 238000005457 optimization Methods 0.000 claims description 4
- 230000009466 transformation Effects 0.000 claims description 4
- 239000002699 waste material Substances 0.000 claims 1
- 230000004044 response Effects 0.000 description 20
- 238000011156 evaluation Methods 0.000 description 5
- 230000008901 benefit Effects 0.000 description 4
- 238000012544 monitoring process Methods 0.000 description 4
- 230000008569 process Effects 0.000 description 4
- 230000001419 dependent effect Effects 0.000 description 3
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- 238000010586 diagram Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000004927 fusion Effects 0.000 description 2
- 238000005086 pumping Methods 0.000 description 2
- 230000035939 shock Effects 0.000 description 2
- 230000009471 action Effects 0.000 description 1
- 230000003321 amplification Effects 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
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- 238000001514 detection method Methods 0.000 description 1
- 230000005284 excitation Effects 0.000 description 1
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- 230000006698 induction Effects 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 238000005065 mining Methods 0.000 description 1
- 238000003199 nucleic acid amplification method Methods 0.000 description 1
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- 238000011282 treatment Methods 0.000 description 1
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D15/00—Control, e.g. regulation, of pumps, pumping installations or systems
- F04D15/0066—Control, e.g. regulation, of pumps, pumping installations or systems by changing the speed, e.g. of the driving engine
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D15/00—Control, e.g. regulation, of pumps, pumping installations or systems
- F04D15/0088—Testing machines
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D29/00—Details, component parts, or accessories
- F04D29/66—Combating cavitation, whirls, noise, vibration or the like; Balancing
- F04D29/669—Combating cavitation, whirls, noise, vibration or the like; Balancing especially adapted for liquid pumps
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Control Of Non-Positive-Displacement Pumps (AREA)
- Control Of Positive-Displacement Pumps (AREA)
- Structures Of Non-Positive Displacement Pumps (AREA)
Abstract
The invention relates to a method for avoiding or reducing mechanical vibrations of a pump, in particular a centrifugal pump, during operation of the pump, wherein a frequency converter and a pump controller are provided, and wherein the pump controller detects at least one signal of a pump operating parameter and checks the signal oscillations in order to recognize the occurring mechanical vibrations of the pump, and wherein the pump rotational speed is changed by means of the frequency converter in order to reduce the recognized vibrations.
Description
Technical Field
The invention relates to a method for avoiding or reducing mechanical vibrations during operation of a pump, in particular a centrifugal pump.
Background
Mechanical vibrations in centrifugal pumps lead to increased wear and undesirable noise occurrence in operation. The cause of the vibrations may be varied. For example, externally excited vibrations due to rotation of the pump impeller or free vibrations due to the natural frequency of the built-in pump may be the cause.
Free vibration occurs particularly in solid pumps. The solid pump is a centrifugal pump for transporting a suspension of a pumping medium having a strongly abrasive solid part, such as slag, coal or ore in the mining industry. Occasionally, the pumping medium may also contain stones or other rigid elements, which during operation of the pump may generate shocks when hitting the pump structure, which shocks result in excitation of free vibrations of the pump. This effect is also increasingly present in pumps for use in the wastewater field.
There are particularly disadvantageous cases when the rotational frequency of the impeller, i.e. the set pump rotational speed, falls on or corresponds to an integer multiple of the natural frequency of the internal pump. Resonance occurs in this case, i.e. the two vibration causes amplify each other. Similarly problematic is that the set rotational frequency of the impeller coincides with the pipe resonance of the conveying system.
This resonance situation is schematically shown in fig. 1. The figure shows the frequency response of a centrifugal pump built in a manner ready for operation. The natural frequency of the free vibration of the system has a frequency value f 1、f2、f3. The frequency response, i.e., the location of natural frequency f 1、f2、f3, depends on the particular pump configuration, the chosen mounting location, the materials used, and the bearings mounted. If the rotational frequency of the impeller set by means of the frequency converter is the same as one of the illustrated natural frequencies f 1、f2、f3 or alternatively an integer multiple of one of the illustrated natural frequencies f 1、f2、f3, the system is excited by the externally excited rotation of the impeller and an amplified resonance of the pump occurs. If the rotation frequency of the impeller is instead within one of the anti-resonances af 1、af2 plotted here, then the effect is minimal and no or only very little vibration occurs.
Disclosure of Invention
The inventive concept is based on the above knowledge and proposes a method which minimizes the risk of possible vibrations, in particular resonance, occurring by targeted measures during operation of the pump.
This object is achieved by the method according to the invention for avoiding or reducing mechanical vibrations of a pump during operation of the pump.
For the implementation of the method, it is decisive to use a frequency converter to change the rotational speed of the pump. However, it is irrelevant whether such a frequency converter is integrated into the pump, mounted on the pump housing or mounted separately from the pump. The same applies to a pump control for the implementation of the method, which may be an integral part of the pump, but may also be installed as a separate unit with respect to the pump, if necessary in combination with a separate frequency converter.
The solution according to the application consists in varying the rotational speed by the pump control unit during operation of the pump in the case of a pump with a frequency converter, so that the mechanical vibrations of the pump are reduced as optimally as possible. A further central aspect of the application is that the pump, in operation, independently recognizes its existing natural frequency by means of a suitable signal evaluation, so that the set pump speed can be optimally adapted on the basis of this knowledge.
The pump thus does not need information about its frequency response that has been generated in advance and stored in the pump, but instead can determine said information independently in operation. For this purpose, the pump records a signal during the operation of the pump, which signal characterizes a pump operating parameter, which is influenced by the occurring mechanical vibrations. The recorded signal is then checked by the pump for the presence of possible vibrations, in particular resonances. This vibration is then reduced by a suitable change in rotational speed.
Among the recorded signals, signal fluctuations caused by mechanical vibrations of the pump can be identified in particular. The amplitude of the identified oscillation frequency of the signal is reduced by a suitable rotational speed change. Thus, according to an advantageous embodiment of the method, the spectrum of the recorded signal is considered. Advantageously, the signal is first transformed into its frequency spectrum by means of a transformation, in particular by means of a fast fourier transformation, in order to thus identify the corresponding frequency values and the associated amplitudes of the signal oscillations that occur.
One or more motor currents of the pump drive proved to be suitable operating signals for identifying possible vibrations. The current value is always present in the frequency converter used, so that no further sensor is required. Since the mechanical vibrations of the pump system are also reflected by the magnetic induction in the motor windings of the pump drive and accordingly in the current of the motor, the motor acts like a sensor that is effective and available at any time. The mechanical vibrations of the pump system can then be recognized sufficiently precisely by means of a corresponding amperometric analysis. This possibility exists independently of the type of motor used for the electric pump drive.
As an alternative or additional operating parameter for determining the frequency response of the pump, for example, a pump pressure, in particular the final pressure of the pump, is suitable. Here, the mechanical vibration is also reflected in the signal change process (Signalverlauf). The final pressure of the pump can be determined, for example, by means of an existing pressure sensor and can be converted into its frequency spectrum by means of a signal conversion, in particular a fast fourier conversion.
However, for signal detection, a suitable sensor does not necessarily have to remain available. Alternatively, the current pump pressure can be determined computationally, for example, by means of an operating point estimation. A possible method for this is disclosed in DE102018200651, the contents of which are fully included here.
According to one possible embodiment, the method can be implemented iteratively with a varying pump speed, for example, in order to identify a pump speed at which the amplitude of the identified vibrations becomes as minimal as possible. Thus, the pump again analyzes the spectrum of the repeatedly recorded signal after the speed change has been made and checks whether the speed change has resulted in a corresponding reduction in amplitude.
Iterative implementations of method steps may provide arbitrary or random or controlled rotational speed variations. The change in rotational speed between two iterations is reversed if the amplitude increases, for example, and is otherwise maintained. It is also conceivable to drive (abfahren) completely through the defined speed range and then to set the speed with the smallest amplitude for the pump operation.
Instead, suitable methods and algorithms are used to identify local or global amplitude minima with the associated rotational speed. It is conceivable to use a space halving method and/or an optimization method, such as an active set method and/or newton method, in order to determine the appropriate rotational speed that results in the minimum amplitude value as quickly as possible. Genetic algorithms are also conceivable which, although relatively slow, nevertheless enable the identification of a global minimum of the frequency response for this purpose.
The setting of the rotational speed or its variation during the method iteration is also dependent on which operating conditions are predefined, for example, by the pump operator. For example, it is conceivable for the pump operator to specify a constant pump speed or only a small tolerance range for speed changes. During the iteration of the method, the rotational speed change is then only carried out within a previously defined tolerance range. In this case, an iterative method implementation is generally sufficient in which all or at least a part of the permitted rotational speeds is operated in order to determine a corresponding amplitude minimum for the range.
If, however, the operator does not specify the permissible rotational speed range, i.e. can instead make full use of the complete technically possible rotational speed range of the pump, it is expedient if the method uses one of the above-mentioned methods for determining the suitable rotational speed.
However, according to a further advantageous embodiment of the invention, the method can be used not only for reducing the vibrations that occur, but the determination of the frequency response according to the invention is equally suitable for pump monitoring, for example, in order to be able to detect early wear or possible damage on the pump mechanism. As already explained in detail above, a core aspect of the invention is to determine the frequency response of the pump. The frequency response is primarily dependent on the pump construction, its mounting location, the materials used, and the bearing components installed. A change in one of these factors, for example due to wear or material damage, results in a change in the frequency response of the pump. The pump thus preferably stores the determined frequency response and monitors the frequency response by continuously repeated measurements of the frequency shift of the identified deterministic frequency. If such a frequency deviation is recognized, this is an indication of wear phenomena or pump damage. The pump may then generate a corresponding warning message or take appropriate action.
Wear and damage can furthermore be distinguished by further checking the frequency variation. Typically wear results in a slow change in the frequency response, while pump damage, such as bearing damage or impeller breakage, results in a sudden change in the frequency response. The pump thus takes into account the time component of the detected change in its evaluation in order to distinguish between wear and damage. Varying degrees may also be included.
In addition to the method according to the invention, the invention furthermore relates to a pump, preferably a centrifugal pump, particularly preferably a wastewater pump or a solid pump or a supply pump, having an internal or external frequency converter and an internal or external pump controller for carrying out the method according to the invention. Accordingly, such a pump is characterized by the same advantages and properties as have been explained in detail above with the aid of the method according to the invention. For this reason, duplicate descriptions are omitted.
Furthermore, the use of a pump, in particular a centrifugal pump, as a waste water pump, a solid pump or a supply pump according to the application is proposed by the application. The minimization of the mechanical vibrations that occur according to the application is particularly important in the case of waste water pumps or solid pumps, so that the use of the method according to the application in this type of pump brings about far-reaching advantages.
Drawings
Further advantages and features of the invention will be explained in more detail later on by means of the embodiments shown in the drawings.
Figure 1 shows a possible frequency response of a centrifugal pump installed and ready to operate,
FIG. 2 is a time chart showing a periodic signal, and
Fig. 3 shows the calculated spectrum of the time signal from fig. 2.
Detailed Description
The application relates to a method for the targeted avoidance of undesired vibration amplification in the event of resonance by means of a frequency converter during operation of a pump, in particular a solid-state pump, waste water pump or other supply pump. The targeted avoidance of these resonances is based on the fact that these resonances must first be detected by the pump controller, but that no special sensors, such as acceleration sensors, have to be added to the pump as much as possible. However, there is nothing to prevent or to equip the pump with additional sensors, for example acceleration sensors, whereby the accuracy of the method can be increased if necessary.
Since the mechanical vibrations are a result of the interaction of the constructional structure with the motor forces, these mechanical vibrations can also be recognized as a superposition of the drive currents of the pump drive. Since the intensity of each superimposed vibration is of interest here, the evaluation of the motor current is performed by analyzing the spectrum of the recorded motor signal, which is obtained by the pump controller by performing a Fast Fourier Transform (FFT).
This processing may be briefly elucidated on the basis of the diagrams of fig. 2, 3. Fig. 2 shows a time diagram of a recorded signal, which is generated here for simplicity by superposition of three sinusoidal signals with different frequencies. By applying an FFT, the time signal can now be decomposed into its harmonic components and a frequency magnitude spectrum is obtained, which is shown in fig. 3, from which the individual frequencies of the sinusoidal signal can be read out as expected.
Due to the FFT of the motor current, the pump can thus recognize the mechanical vibrations reflected in the recorded motor current. In a subsequent step, the pump or pump controller then attempts to set the pump speed such that the resulting rotational frequency of the impeller does not fall above the natural frequency of the pump or a multiple of such natural frequency. For this purpose, the rotational speed is first changed and in a further step, in the event of a change in rotational speed, a spectral analysis of the currently recorded motor current is carried out again. If the amplitude of the current oscillations that occur has become smaller, this is an indication that the mechanical vibrations can be successfully reduced by a change in the rotational speed. The method is now performed iteratively in order to achieve as small an amplitude value as possible of the fluctuations occurring in the current signal. Finding the ideal rotational speed can in principle be performed according to two scenarios:
Scenario 1-the required rotational frequency is subject to fixed requirements.
According to scenario 1, the rotation frequency may only have a certain value. This may have energy-dependent reasons or use purposes requiring a determined (fixed) rotational speed. In this case, the pump operator defines a tolerance value in the pump controller, which may deviate the rotational frequency by a maximum of, for example, ±3Hz. The pump controller then changes the rotational speed within the allowable tolerance range and iteratively finds the rotational speed at which the vibration amplitude is minimal. Often, a small change is sufficient here to leave the natural frequency of the system and thus minimize the occurrence of mechanical vibrations.
Scenario 2-there is no special requirement for rotation frequency.
The pump controller may vary the pump speed at will if there is no process requirement for the rotational frequency. This enables a targeted search for an antiresonance and setting of the final operating speed of the pump to this antiresonance. The simplest approach for determining the appropriate rotational speed (antiresonance) from the available rotational speed range (and thus the one with the lowest memory and process requirements) is based on the dichotomy. Mathematical optimization methods such as "active set method" or "newton method" are faster and more efficient. The global optimum can also be reliably determined by means of genetic algorithms.
Alternatively or additionally to the motor current, a signal of the final pressure of the pump can also be checked, wherein, similarly to the motor current, the frequency spectrum is also analyzed here by means of a fast fourier transformation and evaluated as a function of the corresponding resonance frequency. The final pressure may be calculated, for example, using a pressure sensor of the pump or by means of an operating point estimation.
To improve the signal quality, the two signals (final pressure and motor current) can also be combined by means of sensor data fusion. If this is not possible, the current and pressure signals may also be evaluated separately. For sensor fusion, the individual signal values can be evaluated, for example, as shown above, and then combined by means of weighting. It is also conceivable to define a frequency range in which the individual results of the individually evaluated signals are weighted differently. For example, the result of the evaluation of the motor current in the frequency range between 10Hz and 200Hz is used, while the result of the final pressure evaluation at a higher frequency is considered.
A particular advantage of the method described here is that the pump itself can find its natural frequency and thus does not require mathematical process models that would have to be developed in a complex manner. The main application of the method described herein is to avoid or reduce vibrations in order to reduce wear and noise during pump operation. Furthermore, the method may also contribute to wear and damage monitoring and alert the user when damaged.
Wear monitoring
In the described method, the frequency response of the built-in pump is permanently monitored. However, as mentioned above, the frequency response depends on the pump construction, mounting location, material and bearings. Thus, the change in the frequency response is in any case an indication that one or more of these variables has changed, for example due to wear. This information can then be used for wear monitoring, for example also in combination with the solution from DE 102018200651, which is explicitly referred to here. The combination of these two treatments enables a more accurate assessment of wear conditions.
Warning of damage
Unlike wear, which results in very slow changes in the frequency response, pump damage will suddenly and significantly change the frequency response. The damage may be bearing or impeller breakage, among many other damage. Due to the rapid change in frequency response, the pump controller can reliably separate wear and damage and can output a warning to the operator in the event of damage.
Claims (18)
1. Method for avoiding or reducing mechanical vibrations of a pump during operation of the pump, wherein a frequency converter and a pump controller are provided, and the pump controller detects at least one signal of a pump operating parameter and checks the signal oscillations in order to recognize the occurring mechanical vibrations of the pump, and in order to reduce the recognized vibrations, the pump rotational speed is changed by means of the frequency converter, and the method is iteratively carried out with a changing pump rotational speed in order to recognize the pump rotational speed, in which case the amplitude of the recognized mechanical vibrations in the frequency-amplitude spectrum is minimal.
2. The method of claim 1, wherein the pump is a centrifugal pump.
3. The method according to claim 1, characterized in that the spectrum of the detected signal is calculated by fast fourier transformation.
4. A method according to any of the preceding claims, characterized in that at least one of the examined signals corresponds to the motor current of the pump drive.
5. A method according to any one of claims 1 to 3, characterized in that at least one of the examined signals corresponds to the hydraulic final pressure of the pump.
6. The method according to claim 5, wherein the final pressure is determined sensorily by means of a pressure sensor and/or by estimating the operating point of the pump.
7. The method of claim 1, wherein the pump speed is varied within a definable tolerance range.
8. A method according to any one of claims 1 to 3, characterized in that the method is iteratively performed at an arbitrarily varying rotational speed in order to identify at least one anti-resonance of a pump and to operate the pump in said anti-resonance.
9. Method according to claim 7, characterized in that the rotational speed is changed by means of a halving method and/or an optimization method and/or by means of a genetic algorithm.
10. Method according to claim 9, characterized in that the rotational speed is varied by means of active set method and/or newton method.
11. Method according to claim 8, characterized in that the rotational speed is changed by means of a halving method and/or an optimization method and/or by means of a genetic algorithm.
12. Method according to claim 11, characterized in that the rotational speed is varied by means of active set method and/or newton method.
13. A method according to any one of claims 1 to 3, characterized in that the frequency of the identified resonance is stored and the method is repeatedly carried out in order to recognize the frequency change of the identified resonance.
14. The method according to claim 13, characterized in that the pump is able to determine material wear of the pump and/or damage on the pump structure by means of the detected frequency change.
15. A pump device having a frequency converter and a pump controller configured to implement the method of any one of the preceding claims.
16. Pump apparatus according to claim 15, wherein the pump apparatus is in the form of a centrifugal pump arrangement.
17. Pump apparatus according to claim 15, wherein the pump apparatus is a waste or solids pump or a supply pump.
18. Use of the pump device according to claim 15 as a waste water pump or a solid pump or a supply pump.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE102019002826.0 | 2019-04-18 | ||
| DE102019002826.0A DE102019002826A1 (en) | 2019-04-18 | 2019-04-18 | Process for avoiding vibrations in pumps |
| PCT/EP2020/060432 WO2020212330A1 (en) | 2019-04-18 | 2020-04-14 | Method for preventing vibration in pumps |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN113646538A CN113646538A (en) | 2021-11-12 |
| CN113646538B true CN113646538B (en) | 2025-04-08 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202080029386.2A Active CN113646538B (en) | 2019-04-18 | 2020-04-14 | Method for vibration avoidance in a pump |
Country Status (6)
| Country | Link |
|---|---|
| US (1) | US20220186749A1 (en) |
| EP (1) | EP3956567A1 (en) |
| JP (1) | JP7583742B2 (en) |
| CN (1) | CN113646538B (en) |
| DE (1) | DE102019002826A1 (en) |
| WO (1) | WO2020212330A1 (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| TWI773107B (en) * | 2021-01-29 | 2022-08-01 | 復盛股份有限公司 | Surge detection method and compression device |
| DE102021206777A1 (en) | 2021-06-29 | 2022-12-29 | Rolls-Royce Solutions GmbH | Control device for controlling the operation of a turbomachine, turbomachine arrangement with such a control device, internal combustion engine with such a turbomachine arrangement, and method for operating a turbomachine |
| CN115929608B (en) * | 2022-10-12 | 2024-07-26 | 中国船舶重工集团公司第七一九研究所 | Variable-frequency speed regulation control method for reducing vibration noise of ship pump set |
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| DE10334817A1 (en) * | 2003-07-30 | 2005-03-10 | Bosch Rexroth Ag | Pump failure detection unit uses Fourier analysis of pressure sensor measurement to determine if characteristic frequency exceeds reference amplitude |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2020212330A1 (en) | 2020-10-22 |
| JP2022529976A (en) | 2022-06-27 |
| BR112021019522A2 (en) | 2021-12-07 |
| EP3956567A1 (en) | 2022-02-23 |
| JP7583742B2 (en) | 2024-11-14 |
| DE102019002826A1 (en) | 2020-10-22 |
| US20220186749A1 (en) | 2022-06-16 |
| CN113646538A (en) | 2021-11-12 |
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