加氢站压缩机无损监测方法与故障诊断系统

Frequent failures of hydrogen compressors bring high maintenance costs as well as plenty of time and labor expenditure to the hydrogen refueling station. In order to reduce unplanned downtime and avoid catastrophic accidents, real-time condition monitoring and fault diagnosis become the inevitable direction of the development of hydrogen safety systems. A fault diagnosis method for diaphragm compressors based on the oil-pressure “concomitant” relationship is presented. The failure mechanism of diaphragm rupture due to the breakdown of this relationship is revealed as well：excessive oil-pressure differential can drive the diaphragm to hit and cling to the cylinder wall, placing the diaphragm in a state of peak stress and adding additional stress, which can cause scratches and cracks on the surface of the diaphragm within a short period. Additionally, six typical oil pressure waveforms are proposed to enable the classification and identification of faults and fault levels based on Euclidean distances. To meet the safety requirements for non-destructive condition monitoring in hydrogen application scenarios, a non-intrusive condition monitoring method and system based on measuring piston rod strain and Bluetooth wireless transmission technology is proposed. The feasibility of the method is verified by comparing with the measurement results of the pressure sensor and the fault diagnosis cases of oil spill valve spool wear and piston ring wear in practical applications. The proposed system can safely monitor the operating status and performance of the compressor and identify the faults accurately, which brings a promising development prospect for the application and popularization of compressor monitoring and diagnostic technology in the hydrogen refueling station.