面向泥泵封水系统的压力传感器可解释性故障诊断及健康状态评估
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1.武汉理工大学三亚科教创新园三亚572000; 2.武汉理工大学船海与能源动力工程学院武汉430063; 3.中交广州航道局有限公司广州510220; 4.武汉理工大学交通与物流工程学院武汉430063

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TH868TH311

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国家自然科学基金(52071240)项目资助


Towards explainable fault diagnosis and health state assessment of pressure sensors in mud pump sealing water system
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1.Sanya Science and Education Innovation Park, Wuhan University of Technology, Sanya 572000, China; 2.School of Naval Architecture, Ocean and Energy Power Engineering, Wuhan University of Technology, Wuhan 430063, China; 3.CCCC Guangzhou Dredging Co., Ltd, Guangzhou 510220, China; 4.School of Transportation and Logistics Engineering, Wuhan University of Technology, Wuhan 430063, China

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    摘要:

    针对疏浚船舶泥泵封水系统中压力传感器性能衰退和失效的问题,构建了一种融合封水泵水力物理规律与数据驱动的可解释性故障诊断与健康评估框架。首先依据封水泵水力特性构建封水压力物理模型,用以推导泵出口位置的封水压力,并将该理论压力作为独立于传感器健康状态的物理真实参照;考虑到设备在长期运行中存在非线性劣化与参数偏移,进一步引入动态优化的幂指数拟合系数,以提升该物理模型在不同工况下的适应性与精度;构建融合物理信息约束的多尺度卷积-Transformer注意力融合网络,通过分段动态损失权重调度实现物理一致性与数据拟合精度的协同优化,从而显著提升封水压力预测的准确性与复杂工况下的泛化能力。基于理论压力、模型预测压力与传感器实测压力之间的残差变化构建阈值判别机制,实现对瞬时性、间歇性与永久性故障的可解释识别;同时提出多参数融合的可靠度计算方法,用于量化压力传感器从健康、初期异常、加速劣化至功能失效的全寿命退化轨迹,可靠度曲线能够准确呈现“平缓—加速—骤降”的退化演化特征。基于实船运行数据的仿真结果表明,所提方法在预测精度、稳定性及收敛性方面均优于对比模型,R2高达0.952 7,并能在健康阶段识别短时异常,实现对压力传感器的高可信度故障诊断与智能运维支撑。

    Abstract:

    To address the degradation and failure of pressure sensors in the sealing water system of dredger mud pumps, an interpretable fault diagnosis and health assessment framework that integrates hydraulic physical principles of sealing pumps with data-driven modeling is established. Firstly, a physical model of sealing water pressure is constructed based on the hydraulic characteristics of the sealing water pump to derive the sealing water pressure at the pump outlet, which serves as a physically groundedreference reference independent of the sensor health state. Considering the nonlinear degradation and parameter drift of the equipment during long-term operation, dynamically optimized power-law fitting coefficients are further introduced to improve the adaptability and accuracy of the physical model under different operating conditions. A multi-scale convolution-Transformer attention fusion network incorporating physical information constraints is developed, where a piecewise dynamic loss-weight scheduling strategy is introduced to achieve synergistic optimization between physical consistency and data-driven fitting accuracy, thereby significantly enhancing sealing-water-pressure prediction accuracy and improving generalization capability under complex operating conditions. Based on the residual variations among the theoretical pressure, the model-predicted pressure, and the sensor-measured pressure, a threshold-based discrimination mechanism is established to realize explainable identification of transient, intermittent, and permanent faults. Meanwhile, a multi-parameter fusion reliability calculation method is proposed to quantify the full-life degradation trajectory of the pressure sensor from a healthy state to initial abnormality, accelerated deterioration, and functional failure, from healthy state, initial abnormality, accelerated deterioration to functional failure and the reliability curve can accurately present the degradation evolution characteristic of "slow-accelerated-sharp decline″. Simulation results based on real vessel operation data show that the proposed method outperforms the comparison models in prediction accuracy, stability, and convergence, with R2 up to 0.952 7, and can identify short-term anomalies in the healthy stage, realizing high-confidence fault diagnosis and intelligent maintenance support for pressure sensors.

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龙哲诚,张鹏,陈容钦,危卫,范世东.面向泥泵封水系统的压力传感器可解释性故障诊断及健康状态评估[J].仪器仪表学报,2025,46(12):343-356

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  • 在线发布日期: 2026-03-02
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