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Diesel generator intelligent cloud controller fault diagnosis

2016-11-30 11:27      Click:

Diesel generator intelligent cloud controller fault diagnosis


Intelligent cloud controller is set up on the Internet of things technology is a new type of generating set controller, it can be on the terminal equipment such as mobile phone or computer to realize remote monitoring and control, fault diagnosis, failure prevention, health examination, early operation data records, and other functions, is a good choice for some unmanned intelligent, automated demand situation, but also both reduce customer maintenance cost, improve the reliability of the unit.It USES a new type of cloud controller as the master control system, main control system of the past is different, can be unlimited network, no geographical boundaries, in any place and under the condition of generator can be connected to the cloud server and a user terminal.

Traditional fault diagnosis methods

In traditional diesel generating sets fault is usually the cause of various factors, the different faults show different phenomenon, troubleshooting, you must first find out the fault reason, in practice by see, hear, touch, smell, feeling, to find the abnormal performance of diesel engine, to discover and solve problems, to eliminate the fault.

Determine the general principles of the diesel engine fault are: combining structure, contact principle, make clear phenomenon, combined with the actual, simple to the complex, situated in, press section, find the reason.

In the long-term production practice, people groping summed up "a see, two, three, four smell" of a set of inspection method, through the instrumentation and the feeling of the human organs, to observe and judge the operation of diesel engine.

Abnormal operation

After long-term operation of diesel engine, malfunctioned, often encounter the following several kinds of phenomena.

When running sound abnormal diesel engine operating at a normal beat, put guns, boasting sound, friction of the exhaust noise, cyclical, etc.

Abnormal operation work is not easy to start, there was a violent vibration of diesel engine, the fixed load, speed is not stable, etc.

Appearance of abnormal diesel engine exhaust pipe white smoke, black smoke and blue smoke, each system in the oil, water, air, etc.

Abnormal oil temperature or temperature cooling water temperature is too high, bearing temperature, etc

Abnormal operation of the diesel engine, smell stink, focal flavour, taste such as cigarette smoke

Diesel generator set to run into, found that the abnormal phenomenon, must make a careful investigation, according to the fault phenomena, analysis to determine the region and the reasons of failure.Sometimes a fault may have several kinds of abnormal phenomenon, such as the high pressure oil pump after wear, as well as performance start the difficulty, also can show the output power is insufficient, can also be the phenomenon such as low speed performance is not stable.Sometimes a kind of abnormal phenomenon, there are several kinds of failure.Diesel engine run time appear abnormal phenomenon, therefore, must find out the reasons of abnormal phenomenon seriously, this requires that we are good at analysis, reasoning, judgment, grasp the essence through the phenomena, and find out the cause of the failure parts, troubleshooting.

Check the method

Discriminant according to abnormal sound fault parts of the heart to turn over with a screwdriver or one and a half meters long end with sharpened fine iron bar, for needle judgment ", the "end of ear, on the other side hit the check parts surface, can be more clearly to monitor the abnormal noise produced by the site, the size and nature of noise.Different parts of the sound is often different.Such as main bearing clearance is too large a rushing sound is depressing, valve and piston impact sound is ringing, if loose flywheel keyway with a "Gong Gong!"Loud crash and, therefore, according to the different sound, to judge the fault location.

Judged by local law to stop after failure analysis, if the suspected fault is caused by a cylinder, can stop the cylinder work, observe whether failure phenomenon is disappear, to determine the cause of the problem and the location.Diesel smoke, for example, analysis of a cylinder nozzle spray hole blockage, to stop the oil supply, the cylinder disappear if the black smoke, right.

Using comparison method to judge according to the fault analysis, fault may be due to a suspected one zero, parts, the parts (or components) can be replaced a new parts, and switched on a diesel engine working condition before and after the change, so as to find out the cause of the problem.

According to the analysis of use heuristics to determine whether the cause of the problem is difficult to determine, can change the local state within the scope of the technology, observation is influential diesel engine performance, in order to distinguish the cause of the failure.Couldn't send the provisions of the diesel engine power, for example, suspect a compression stroke cylinder pressure is insufficient, is caused by untight seal cylinder and piston clearance is bigger, at this time will be open to inject a small amount of oil cylinder, cylinder head to improve sealing, and pack good cylinder head again, boot if test pressure, the output power increases, the analysis is correct.

After long time use of diesel generator set, a lot of the failure phenomenon, a lot of the time are manufacturers according to their own experience to determine the initial fault reasons, a lot of time is called after-sales personnel door-to-door service, not only time consuming, and low efficiency.

Intelligent cloud generator controller its modelling is novel, simple, small volume, quick installation, good dielectric performance, protection and reliable operation and safety performance, can be realized on the terminal equipment such as mobile phone or computer remote monitoring and control, fault diagnosis, failure prevention, health examination, early operation data records, and other functions, is a good choice for some unmanned intelligent, automation needs.


Intelligent technology diagnosis

The remote monitoring and control

No matter anywhere in the world, as long as there is network, can use mobile phone or PC computer remote monitoring the operation of the generator set data, control the operation of generating set

In addition to basic information monitoring unit, but also can monitor the excitation voltage, electric adjustable output voltage, bearing temperature, winding temperature, etc.A more comprehensive monitoring for accurately check the health status of the unit

Mobile terminal remote monitoring

USES the camera embedded technology, can clearly see the cloud generator in remote site environment, avoid accidental operation risk events

Generator running state of real-time dynamic data display, clear understanding of the current generator running state.

Each detail data real-time display engine, engine real-time running is normal

Real-time display various detailed data generator, to understand whether the parameters of the generator in the normal range.


Improve reliability - health monitoring unit

Health check report every Monday

Through powerful intelligent data fetching patent technology, grab the motor starting before and after the battery voltage, no-load voltage and speed for 10 seconds, excitation voltage, the electric adjustable output voltage, bearing temperature, etc, the automatic analysis of the data and generate a health check report every week, realize the health examination and early failure prevention, allows users to make maintenance, according to health guarantee the stable operation of the unit, prolong the life of generator set.

Quickly solve the problem of fault - black patent technology

Unit fails, the manufacturer directly through the cloud server for 18 seconds of black, technical personnel analysis data, remote fault diagnosis, reduced to between manufacturer and user

After sales services to the value

A province again - to reduce the user cost

Save the unit inspection fee

Through self health examination, each unit can save at least 5000 yuan of above inspection fee each year.Don't need to please the teacher to do routine check.

Avoid excessive maintenance unit:

Need maintenance unit is in failure, through the fault diagnosis, do it "knows", avoid excessive maintenance.

Reduce the indirect economic loss:

Unit failure, through the remote fault diagnosis, quickly solve the problem of fault, reduce the indirect economic loss caused by failure.

Implementation secondary accessories sales - maintenance reminder

Through health examination, found that users early failure of the unit in time, to remind the user to do maintenance.It is recommended to use original parts, the realization of the secondary parts and service sales.

Through the part life cycle management, timely remind consumer to do maintenance.It is recommended to use original parts, the realization of the secondary parts and service sales.

Lowering the cost of after-sales service to improve after-sales service

Reduce the cost of after-sales service

Patent of remote fault diagnosis technology is adopted to avoid excessive travel services and the problem caused by user error operation or improper operation and business, and even can with the help of the user, directly remote solve some fault.

Improve the quality of after-sales service

Unit failure, through the remote fault diagnosis, quickly find the cause of the problem, and inform the recent maintenance (maintenance workers to repair, fast and accurate fault solution.

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