燃?xì)獍l(fā)電機(jī)組作為能源領(lǐng)域?qū)崿F(xiàn)能量高效轉(zhuǎn)換的關(guān)鍵設(shè)備，在長(zhǎng)時(shí)間不間斷運(yùn)行過(guò)程中，不可避免地會(huì)遭遇一系列復(fù)雜的技術(shù)問(wèn)題，這些問(wèn)題涵蓋機(jī)械、電氣、控制系統(tǒng)以及燃?xì)庀到y(tǒng)等多個(gè)重要方面，以下將進(jìn)行全面且深入的解析。

As a key equipment for achieving efficient energy conversion in the energy field, gas generator sets inevitably encounter a series of complex technical problems during long-term uninterrupted operation. These problems cover multiple important aspects such as mechanical, electrical, control systems, and gas systems. The following will provide a comprehensive and in-depth analysis.

在機(jī)械系統(tǒng)故障層面，發(fā)動(dòng)機(jī)異常振動(dòng)是較為突出的問(wèn)題之一。其產(chǎn)生的根源主要涉及曲軸不平衡，當(dāng)曲軸因制造缺陷或長(zhǎng)期使用出現(xiàn)質(zhì)量分布不均時(shí)，在高速運(yùn)轉(zhuǎn)下便會(huì)引發(fā)振動(dòng)；軸承磨損也是重要原因，長(zhǎng)期的摩擦使得軸承間隙增大，無(wú)法有效支撐曲軸運(yùn)轉(zhuǎn)，從而產(chǎn)生振動(dòng)；飛輪松動(dòng)會(huì)破壞整體轉(zhuǎn)動(dòng)的穩(wěn)定性，進(jìn)而導(dǎo)致振動(dòng)；基礎(chǔ)固定不牢，地腳螺栓松動(dòng)或基礎(chǔ)結(jié)構(gòu)設(shè)計(jì)不合理，無(wú)法為發(fā)動(dòng)機(jī)提供穩(wěn)固支撐，同樣會(huì)引發(fā)振動(dòng)。針對(duì)這些問(wèn)題，有效的解決方案包括使用激光對(duì)中儀對(duì)曲軸同心度進(jìn)行精準(zhǔn)校正，將偏差嚴(yán)格控制在≤0.05mm 的范圍內(nèi)，以確保曲軸運(yùn)轉(zhuǎn)平穩(wěn)；選用 SKF、FAG 等高品質(zhì)品牌軸承，并且建議在運(yùn)行 8000 小時(shí)后進(jìn)行強(qiáng)制更換，保證軸承的可靠性；采用扭矩扳手按照廠(chǎng)家規(guī)定的扭矩值緊固地腳螺栓，增強(qiáng)基礎(chǔ)的穩(wěn)固性。而缸體過(guò)熱（溫度＞95℃）同樣是機(jī)械系統(tǒng)常見(jiàn)故障，其原因主要有冷卻系統(tǒng)故障，當(dāng)水泵效率下降超過(guò) 15% 時(shí)，冷卻液循環(huán)不暢，無(wú)法及時(shí)帶走熱量；缸套結(jié)垢，若水垢厚度超過(guò) 0.5mm，會(huì)嚴(yán)重影響熱傳導(dǎo)效率；潤(rùn)滑油路堵塞，導(dǎo)致潤(rùn)滑不良，部件摩擦產(chǎn)生大量熱量。對(duì)應(yīng)的解決措施為使用高壓水槍配合專(zhuān)用清洗劑對(duì)散熱器進(jìn)行徹底清洗，恢復(fù)其散熱性能；選用濃度在 40%-60% 的乙二醇基冷卻液，保證冷卻效果；安裝在線(xiàn)油壓監(jiān)測(cè)系統(tǒng)，將預(yù)警值設(shè)定為＜2bar，以便及時(shí)發(fā)現(xiàn)潤(rùn)滑油路異常。

At the level of mechanical system failures, abnormal engine vibration is one of the more prominent issues. The root cause of its occurrence mainly involves the imbalance of the crankshaft. When the crankshaft has uneven mass distribution due to manufacturing defects or long-term use, it will cause vibration during high-speed operation; Bearing wear is also an important cause. Long term friction increases the clearance between bearings, which cannot effectively support the operation of the crankshaft, resulting in vibration; Loose flywheels can disrupt the overall stability of rotation, leading to vibration; Poor foundation fixation, loose anchor bolts or unreasonable foundation structure design, which cannot provide stable support for the engine, can also cause vibration. Effective solutions to these issues include using a laser alignment instrument to accurately correct the concentricity of the crankshaft, strictly controlling the deviation within a range of ≤ 0.05mm to ensure smooth operation of the crankshaft; Select high-quality brand bearings such as SKF and FAG, and it is recommended to replace them forcibly after 8000 hours of operation to ensure the reliability of the bearings; Use a torque wrench to tighten the anchor bolts according to the manufacturer's specified torque value, enhancing the stability of the foundation. Overheating of the cylinder body (temperature>95 ℃) is also a common fault in mechanical systems, mainly caused by cooling system failures. When the efficiency of the water pump decreases by more than 15%, the circulation of coolant is not smooth, and heat cannot be taken away in a timely manner; If the thickness of the scale on the cylinder liner exceeds 0.5mm, it will seriously affect the thermal conductivity efficiency; The blockage of the lubrication oil circuit leads to poor lubrication and generates a large amount of heat due to component friction. The corresponding solution is to thoroughly clean the radiator with a high-pressure water gun and a specialized cleaning agent to restore its heat dissipation performance; Select ethylene glycol based coolant with a concentration of 40% -60% to ensure cooling effect; Install an online oil pressure monitoring system and set the warning value to<2 bar to promptly detect any abnormalities in the lubrication system.

電氣系統(tǒng)故障方面，輸出電壓波動(dòng)（±10%）是常見(jiàn)問(wèn)題。AVR 調(diào)節(jié)器響應(yīng)延遲（＞50ms），在負(fù)載變化時(shí)無(wú)法及時(shí)調(diào)整勵(lì)磁電流，導(dǎo)致電壓波動(dòng)；轉(zhuǎn)子繞組匝間短路，使得繞組阻抗變化超過(guò) 15%，影響發(fā)電性能；負(fù)載突變，當(dāng)負(fù)載變化超過(guò) 30% 額定負(fù)荷時(shí)，超出了發(fā)電機(jī)的調(diào)節(jié)能力，也會(huì)造成電壓波動(dòng)。解決這些問(wèn)題需要升級(jí)數(shù)字式 AVR，將響應(yīng)時(shí)間縮短至＜20ms，提高調(diào)節(jié)靈敏度；采用 Megger 對(duì)轉(zhuǎn)子絕緣進(jìn)行測(cè)試，若阻值＜1MΩ 則需及時(shí)檢修，避免短路故障擴(kuò)大；加裝負(fù)載緩沖裝置，減小負(fù)載突變對(duì)電壓的影響。

In terms of electrical system faults, output voltage fluctuations (± 10%) are a common problem. AVR regulator response delay (>50ms), unable to adjust excitation current in a timely manner when load changes, resulting in voltage fluctuations; Short circuit between turns in the rotor winding causes a change in winding impedance exceeding 15%, affecting power generation performance; Load mutation, when the load changes by more than 30% of the rated load, exceeds the regulating capacity of the generator and can also cause voltage fluctuations. To solve these problems, it is necessary to upgrade the digital AVR, shorten the response time to<20ms, and improve the adjustment sensitivity; Use Megger to test the rotor insulation. If the resistance value is less than 1M Ω, timely maintenance is required to avoid the expansion of short circuit faults; Install load buffering devices to reduce the impact of sudden load changes on voltage.

控制系統(tǒng)故障中，PLC 誤動(dòng)作較為常見(jiàn)。EMI 干擾，當(dāng)場(chǎng)強(qiáng)＞10V/m 時(shí)，會(huì)對(duì) PLC 的正常運(yùn)行產(chǎn)生干擾；程序死循環(huán)，導(dǎo)致掃描周期超過(guò) 200ms，影響系統(tǒng)響應(yīng)；通訊中斷，誤碼率＞10?? 時(shí)，數(shù)據(jù)傳輸不準(zhǔn)確。改進(jìn)措施包括實(shí)施三級(jí)屏蔽，對(duì)信號(hào)線(xiàn)、柜體以及接地進(jìn)行全面屏蔽，減少電磁干擾；優(yōu)化 PLC 程序，增加看門(mén)狗功能，防止程序死循環(huán)；改用光纖通訊，將衰減控制在＜0.5dB/km，提高通訊的穩(wěn)定性和準(zhǔn)確性。燃?xì)忾y組故障也是控制系統(tǒng)的常見(jiàn)問(wèn)題，伺服電機(jī)過(guò)載，當(dāng)電流超過(guò)額定值 120% 時(shí)，會(huì)影響燃?xì)忾y的正常調(diào)節(jié)；位置傳感器漂移，偏差超過(guò) ±1% FS，導(dǎo)致燃?xì)饬髁靠刂撇粶?zhǔn)確。針對(duì)這些問(wèn)題，可通過(guò)加裝力矩限制器，保護(hù)伺服電機(jī)；采用非接觸式磁編碼器，其分辨率達(dá) 0.1°，提高位置檢測(cè)的精度。

PLC misoperation is more common in control system failures. EMI interference, when the field strength is greater than 10V/m, will interfere with the normal operation of PLC; Program dead loop, resulting in a scanning cycle exceeding 200ms, affecting system response; Communication interruption, error rate>10?? At that time, the data transmission was inaccurate. Improvement measures include implementing three-level shielding, comprehensively shielding signal lines, cabinets, and grounding to reduce electromagnetic interference; Optimize PLC program, add watchdog function to prevent program dead loop; Switch to fiber optic communication and control attenuation to<0.5dB/km to improve communication stability and accuracy. Gas valve group failure is also a common problem in control systems. When the servo motor is overloaded and the current exceeds 120% of the rated value, it will affect the normal adjustment of the gas valve; The position sensor drifts with a deviation exceeding ± 1% FS, resulting in inaccurate gas flow control. To address these issues, torque limiters can be installed to protect servo motors; Adopting a non-contact magnetic encoder with a resolution of 0.1 °, it improves the accuracy of position detection.

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