Study On Methods Of Hydrocyclone Operating Condition Monitoring And Fault Diagnosis

In recent years,the proposal of intelligent manufacturing 2025 in China has put forward strict requirements for the process of intellectualization in the whole industry.It is imperative for the equipment of the coal preparation plant to be intelligent.Real-time fault detection and diagnosis of important equipment in coal preparation plant is an important step to promote the intelligent process of coal preparation plant.Therefore,how to monitor the operating state of the hydrocyclone has become an important issue in the coal preparation plant.In addition,how to monitor and diagnose the fault of the hydrocyclone has become an important issue.Traditional hydrocyclone fault monitoring relies entirely on manual inspections,which failed to timely forecast and deal with faults,and resulting in greater economic losses.In this paper,vibration signal is used as the research object to explore the influence of hydrocyclone fault state on the characteristic value of vibration signal,and build a fault monitoring and diagnosis system of hydrocyclone.In this paper,the relationship between the fault state of hydrocyclone and the characteristic value of vibration signal is explored by the way of vibration acceleration sensor collecting the vibration signal of hydrocyclone fault state.The vibration signal data directly determines the accuracy of the fault characteristic value analysis of the hydrocyclone.The vibration signal of the hydrocyclone is collected in the field and the performance parameters,the sensor range and sensitivity of the optimal collection point of the integrated time acceleration sensor signal are determined through the analysis and test.In order to obtain the best test conditions and reduce the systematic error,a hydrocyclone experimental platform was built,the hydrocyclone fault vibration signal data was collected and the optimal noise reduction function was determined.The vibration signal is collected by the vibration acceleration sensor in the normal state,blocked state and spillover state of the hydrocyclone.The time-frequency domain analysis is performed to determine the frequency characteristic value of the hydrocyclone jamming fault.The experimental results show that the frequency characteristic value of the hydrocyclone plugging fault is between 16 and 17 Hz.In order to explore the influence of feed properties on the vibration signal of hydrocyclone,a single factor test was designed to investigate the influence of feed flow and feed concentration on the dimensional index and dimensionless index of hydraulic cyclone vibration acceleration.The experimental results show that the influence of the feed flow rate on the characteristic value of the hydrocyclone vibration signal is greater than the influence of the feed concentration,and the larger the feed flow rate,the larger the standard deviation of the hydraulic cyclone vibration acceleration.The wear fault at the bottom of the hydrocyclone is also one of the faults that occur at a higher frequency.The factors that need to be considered for the simulation of wear faults are material,thickness,and wear surface condition.When investigating the relationship between the characteristics of the vibration signal and the degree of wear,five different thickness bottom openings of the ABS material were selected,based on the principle of the control variable,and each underflow port was pretreated on the experimental platform for one hour before the wear fault signal was collected.In order to investigate the influence of wear fault on the vibration signal of hydrocyclone,a single factor test was designed to collect the vibration acceleration signals of each thickness of the bottom flow port.In addition,the time-frequency domain analysis and the statistical calculation and analysis of the eigenvalues were carried out.The experimental results show that the wear fault can be warned by the rms value.A single factor test was designed to investigate the influence of the clogging fault on the vibration acceleration of the hydrocyclone under wear.The rms value of the acceleration under each degree of wear is slightly reduced after the clogging occurs.Therefore,the frequency characteristic value of the clogging needs to be utilized.The hydrocyclone faults can be monitor and warn simultaneously though the graph of frequency characteristic values and rms value.Using the LabVIEW programming environment,Matlab hybrid programming technology,and filter processing technology,the fault monitoring and diagnosis system of flow cyclone was built,which made the realization of the real-time monitoring and analysis of time-frequency domain.In addition,various eigenvalues of hydrocyclone fault can be monitorred,offline analysis of fault data and fault warning can be reached.