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磁致伸缩位移传感器船闸系统故障分析

  故障现象

  2021年5月,在下游左岸闸门启闭过程中,其变频器一直低频(18Hz)运行,闸门运行较慢,导致左、右岸闸门运行不同步,每次开关时差近3min(正常开关门需3min,现在约需6min),严重影响船闸的运行速度。同时,左、右岸闸门运行不同步,闸门关闭到位时极易产生错位,导致闸门在涨落水过程中抖动,给船闸运行带来重大安全隐患。因此,有必要查明故障原因并予以排除,使闸门尽快恢复正常运行。

  故障分析及确认

  导致变频器在工作过程中频率不变的故障原因有两个:变频器本身故障;变频器未收到变频信号。

  为查明变频器是否有故障,首先对变频器的各项参数进行检查,并与其它三台变频器进行比较,结果未发现异常,因此变频器设置没有问题。接着,对变频器的接线进行检查,未发现线路有中断、松动、短路现象;对变频器各接线端子信号进行检测,信号正常。根据以上检查结果初步判断变频器正常。为了验证这一判断,将上下游左、右岸的变频器进行调换,左岸故障仍存在,故可以确定变频器不存在故障,导致变频器在工作过程中频率不变的原因应是变频器未收到变频信号。

  由于变频器变频触发信号来自博尔森磁致伸缩位移传感器的行程检测,因此在闸门运行过程中对传感器的输出信号进行检测,结果显示无信号输出。检查博尔森磁致伸缩位移传感器接线,未发现接线有破损、断线及短路等现象,24VDC供电电源信号正常,但无4~20mA模拟量输出。在线调阅PLC控制程序,发现在闸门运行过程中检测不到闸门开度信号,因而无法产生变频信号。查看工作站计算机上的组态画面,发现下左闸门运行中的开度模拟显示尺度不变,只在闸广]开关到位后才跳变。综上可推定博尔森磁致伸缩位移传感器存在故障。为验证这一判断, 调换下左、下右闸门油缸中的博尔森磁致伸缩传感器进行测试,下 左闸门恢复正常运行,而下右闸门出现了,上述故障现象。至此,已可确定故障由博尔森磁致伸缩位移传感器损坏引发。