JP2001208655A - 故障診断方法及びその装置 - Google Patents
故障診断方法及びその装置Info
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Abstract
える判定基準値を採用した故障診断装置を提供する。 【解決手段】 機械設備が発する振動速度波形を検出す
る振動検出手段1〜6と、この振動検出手段が検出した
振動速度波形をフーリエ級数に展開して周波数スペクト
ルを算出する周波数スペクトル算出手段7,8,10
と、この周波数スペクトル算出手段が算出した周波数ス
ペクトルをパワー合成して振動値Aを算出する振動値算
出手段7,8,10と、周波数スペクトルから回転数成
分とその高調波成分のスペクトルを選んでパワー合成し
て故障値Bを算出する故障値算出手段7,8,10と、
振動値Aに対する故障値Bの比(故障スペクトル比B/
A)を算出する故障スペクトル比算出手段7,8,10
と、故障スペクトル比B/Aの大きさから機械設備の故
障の程度を診断する故障診断手段7,8,10を備え
た。
Description
量が不釣り合いなアンバランス、2台の回転機械の軸心
がずれたミスアライメントや固定するためのボルトが緩
んだガタなどの構造系の故障を診断する故障診断方法及
びその装置に関する。
因となったり、あるいは極めて大きな経済的損失をもた
らす。生産現場では突発停止を避けるため予防保全が行
われている。故障回避の予防保全として運転中の機械設
備が発する音や振動を計測して、機械設備の状態を把握
する方法があり、これを状態基準保全と言う。ここで
は、振動計測を例に状態基準保全の従来技術について説
明する。
断する場合には、計測した振動の大きさが基準の値を超
えているか否かで判定する。通常、判定基準値は二種類
用意される。値の小さい判定基準値を超えると注意領域
で、運転を継続するが監視を頻繁に行う。値の大きい判
定基準値を超えると危険領域であり、直ちに運転を停止
させて修復が必要である。そして、機械設備の状態が注
意領域に達すると、平常状態から注意領域に変化した過
去の傾向を示した図表などから危険領域に達する時期を
推定して、経済効率の最も高い生産計画と保全計画を立
案して、修復を実施している。
じて回転数や消費電力(パワー)、負荷など仕様が異な
り、形状も大型・小型があり、振動の大きい機械や小さ
い機械などと種々雑多な種類の機械設備がある。故障の
有無を診断するための判定基準値は、これら機械設備に
固有のものであり、平常状態の他に故障状態の多くの事
例データを蓄積して決定される。状態基準保全の効果を
発揮させるためには、最適な判定基準値が必要である。
めに故障時の事例データが得られないとか、対象機械設
備の種類が多すぎて判定基準を決定するまでに膨大な労
力が必要であるとか、故障診断知識の豊富な保全技術者
が不在なため故障事例データが採取できないとか、種々
の理由で判定基準値を決められずに状態基準保全を採用
できない企業も多い。また、状態基準保全は保全費用を
低く押さえられ、経済的に優れた保全方法であるが、前
述のように状態基準保全を活用するためには最適な判定
基準が必要であるため、この判定基準を決められないで
状態基準保全を採用できない企業も多い。
問題点に鑑みてなされたものであり、その目的とすると
ころは、機械設備が発する振動の全エネルギーに対する
故障による振動エネルギーの占有率に注目して、仕様の
異なる多くの回転機械設備に共通に使える判定基準値を
採用した故障診断方法及びその装置を提案しようとする
ものである。
求項1に係る発明は、機械設備が発する振動波形を検出
し、得られた振動波形をフーリエ級数に展開して周波数
スペクトルを算出し、この周波数スペクトルをパワー合
成して振動値Aとし、また前記周波数スペクトルから回
転数成分とその高調波成分のスペクトルを選んでパワー
合成して故障値Bとし、振動値Aに対する故障値Bの比
(故障スペクトル比B/A)を算出し、この故障スペク
トル比B/Aの大きさから機械設備の故障の程度を診断
するものである。
故障診断方法において、前記周波数スペクトルに0(ゼ
ロ)Hzを基点にして複数の窓を等間隔に並べた高調波
窓を、窓の等間隔を崩さず同時に伸張させて重ね、それ
ぞれの窓に一致した周波数スペクトルを合成し、得られ
た周波数スペクトルの合成値の最大値を故障値Bとする
ものである。
振動波形を検出する振動検出手段と、この振動検出手段
が検出した振動波形をフーリエ級数に展開して周波数ス
ペクトルを算出する周波数スペクトル算出手段と、この
周波数スペクトル算出手段が算出した周波数スペクトル
をパワー合成して振動値Aを算出する振動値算出手段
と、前記周波数スペクトルから回転数成分とその高調波
成分のスペクトルを選んでパワー合成して故障値Bを算
出する故障値算出手段と、振動値Aに対する故障値Bの
比(故障スペクトル比B/A)を算出する故障スペクト
ル比算出手段と、前記故障スペクトル比B/Aの大きさ
から機械設備の故障の程度を診断する故障診断手段を備
えたものである。
故障診断装置において、前記故障値算出手段は、前記周
波数スペクトルに0(ゼロ)Hzを基点にして複数の窓
を等間隔に並べた高調波窓を、窓の等間隔を崩さず同時
に伸張させて重ね、それぞれの窓に一致した周波数スペ
クトルを合成し、得られた周波数スペクトルの合成値の
最大値を故障値Bとするものである。
図面に基づいて説明する。ここで、図1は回転機械のア
ンバランス時に軸受けに生じる振動速度波形の周波数ス
ペクトル図、図2は回転機械のミスアライメント時に軸
受けに生じる振動速度波形の周波数スペクトル図、図3
は回転機械の平常時に軸受けに生じる振動速度波形の周
波数スペクトル図、図4は伸張式高調波窓の構造説明
図、図5は高調波合成処理の動作原理の説明図、図6は
本発明に係る故障診断装置の構成図である。
イメント、軸曲がり、緩み、クラック、ガタなどの構造
系の故障を診断することを目的とし、機械設備が発する
振動が必ずしも故障や異常によるものだけではないこと
に着目して、故障や異常状態が進行するに従って機械設
備が発する振動の全エネルギーに対する故障によるエネ
ルギー成分の占有率が高くなることを基本原理としてい
る。
大きさの情報を直接利用せずに、振動の全エネルギーに
対する故障によるエネルギーの比で判定を行っているの
で、機械の回転数や消費電力、負荷、構造の規模などの
仕様に影響されずに故障診断を行うことができる。
械が発する振動を計測し、得られた振動波形をFFT
(高速フーリエ変換)処理して周波数スペクトルsiを
求める。求めた周波数スペクトルsiの例として、回転
機械のアンバランス状態の機械振動の周波数スペクトル
を図1に、回転機械のミスアライメント状態の機械振動
の周波数スペクトルを図2に示す。
iを、次式(1)に示すように、パワー合成してオーバ
ーオールの値Sを算出し、振動値A(=S1/2)とす
る。ただし、図1及び図2では、機械設備が発する0H
z〜200Hzの周波数範囲の振動について、S及び振
動値Aを求める。
ペクトルを故障値Bとするが、アンバランスやミスアラ
イメント、あるいはガタなどの構造系の故障は、主軸の
回転数とその高調波成分のスペクトルを発生することが
物理的に判明している。従って、故障値Bは回転数の周
波数成分とその整数倍の周波数成分を合成すればよいこ
とになるが、そのためには回転計を具備する必要があ
り、回転計を具備することは計測が極めて利便性を欠く
ことになる。
故障診断方法とした。先ず、図1に示すアンバランス状
態の周波数スペクトルでは、駆動モータの電力(パワー)
が異なっても、回転数が異なっても、回転数成分の周波
数スペクトルが最も大きな値となっている。このような
場合は、最大スペクトルを故障値Bとしても大きな誤差
とはならない。
周波数スペクトルでは、必ずしも回転周波数成分が突出
したスペクトルとはならず、第2高調波や第3高調波な
どの高調波成分も顕著に現れている。このような高調波
成分も故障が原因で発生しており、故障値Bはこれら高
調波を合成する必要がある。
手法は、図4に示すような伸張式高調波窓を想定する。
図4における太線は高調波窓W1,…Wmであり、高調波
窓W 1,…Wmは1周波数分だけの幅を持っている。高調
波窓W1,…Wmは等間隔にm本並んでいる。左端はDC
(0Hz)箇所に固定されており、右側の第m高調波窓
Wmを右に移動して広げると、DCと第m高調波窓Wmの
間隔は広がるが、その間にある夫々の高調波窓W1,…
Wm-1の間隔も等間隔で広がることを想定している。な
お、図4では、m=6としている。
態の周波数スペクトルに重ね合わせて高調波合成処理を
している例を、図5に図示する。伸張式高調波窓の間隔
が狭い状態から、第m高調波窓Wmを1周波数毎に高い
周波数(右)の方へ徐々に広げる。その都度、次式
(2)に示すように、夫々の高調波窓W1,…Wmに重ね
合った周波数スペクトルsfhのパワーを合成して、第1
周波数f1の成分Bf1(=Sf1 1/2)とする。なお、図5
においても、m=6としている。
数を表し、sfhは周波数fhの周波数スペクトルを表
す。
の最高周波数になるまで、第m高調波窓Wmを移動して
得られた高調波合成値Bf1を求める。図5(a)(90
kW、2600rpm、ブロア)に示すミスアライメン
ト状態の周波数スペクトルから高調波合成値Bf1を求め
て図示すると、図5(b)に示すような周波数スペクト
ルに変換される。
主軸回転数の43.3Hzは小さいが、第4高調波の1
73.3Hzが最大で、次に第3高調波の130Hzが
大きい。図5(b)に示す周波数スペクトルでは、これ
ら第4高調波と第3高調波のゴーストスペクトルも現れ
るが、第1次周波数の43.3Hzは高調波成分が合成
された値を示している。図5(b)で最大を示す周波数
スペクトルは、故障によって発生する主軸回転数成分の
周波数スペクトルであり、故障値Bである。
を、図1に示すアンバランス状態の周波数スペクトルに
適用しても主軸回転数成分の周波数スペクトルは変更さ
れることがないので、伸張式高調波窓による高調波合成
処理は、全ての周波数スペクトルに適用できる。
(=B/A)を求める。この比Rを故障スペクトル比と
呼ぶ。得られた故障スペクトル比Rに対して判定基準を
定め故障の診断を行う。例えば、実際に稼動している多
くの機械設備の平常稼動事例と故障事例を基に、R≧
0.9の場合は故障、R≧0.8の場合は注意、R<
0.8の場合は平常と判定基準を定めた。
らない相対値であるので、この判定基準は機械設備の電
力や回転数に依存せずに適用できる。
の周波数スペクトルの例を示す図1(a)〜図1(d)
について、振動数スペクトルから故障スペクトル比Rを
算出して故障の診断を行う。
rpm、ブロワ)について、全周波数スペクトルを合成
した振動値Aが0.186であり、伸張式高調波窓を適
用してえられた高調波合成値の最大値、すなわち故障値
Bが0.182である。従って、故障スペクトル比Rは
0.98となり、0.9を超えているので「故障」と診
断する。
00rpm、ブロワ)について、振動値Aが0.239
で、故障値Bが0.239である。従って、故障スペク
トル比Rが1.00であるから、「故障」と診断する。
図1(c)(1750rpm、モータ)について、振動
値Aが0.624で、故障値Bが0.618である。従
って、故障スペクトル比Rが0.99であるから、「故
障」と診断する。図1(d)(3000rpm、遠心分
離機)について、振動値Aが0.306で、故障値Bが
0.300である。従って、故障スペクトル比Rが0.
99であるから、「故障」と診断する。
状態の周波数スペクトルの例を示す図2(a)〜図2
(d)について、振動数スペクトルから故障スペクトル
比Rを算出して故障の診断を行う。
pm、ブロワ)について、全周波数スペクトルを合成し
た振動値Aが0.213であり、伸張式高調波窓を適用
してえられた高調波合成値の最大値、すなわち故障値B
が0.212である。従って、故障スペクトル比Rは
1.00となり、0.9を超えているので「故障」と診
断する。
00rpm、ブロワ)について、振動値Aが0.055
で、故障値Bが0.053である。従って、故障スペク
トル比Rが0.96であるから、「故障」と診断する。
図2(c)(11kW、3600rpm、ブロワ)につ
いて、振動値Aが0.717で、故障値Bが0.689
である。従って、故障スペクトル比Rが0.96である
から、「故障」と診断する。図2(d)(5.5kW、
3600rpm、遠心ポンプ)について、振動値Aが
0.301で、故障値Bが0.297である。従って、
故障スペクトル比Rが0.99であるから、「故障」と
診断する。
スペクトルの例を示す図3(a)〜図3(d)につい
て、振動数スペクトルから故障スペクトル比Rを算出し
て故障の診断を行う。
0rpm、ブロワ)について、全周波数スペクトルを合
成した振動値Aが0.058であり、伸張式高調波窓を
適用してえられた高調波合成値の最大値、すなわち故障
値Bが0.035である。従って、故障スペクトル比R
は0.60となり、0.8未満であるので「平常」と診
断する。
rpm、増速機)について、振動値Aが0.211で、
故障値Bが0.141である。従って、故障スペクトル
比Rが0.67であるから、「平常」と診断する。図3
(c)(11kW、1800rpm、モータ)につい
て、振動値Aが0.071で、故障値Bが0.057で
ある。従って、故障スペクトル比Rが0.79であるか
ら、「平常」と診断する。図3(d)(18.5kW、
3500rpm、遠心ポンプ)について、振動値Aが
0.060で、故障値Bが0.040である。従って、
故障スペクトル比Rが0.67であるから、「平常」と
診断する。
に示すように、機械の発する振動加速度を検出する圧電
式の振動センサ1と、10Hz以上の振動数成分を通過
させるフィルタ2と、増幅器3と、振動加速度を振動速
度に変換する積分器4と、200Hz以下の振動数成分
を通過させるフィルタ5と、12ビットのA/D変換器
6と、コントロールプログラムと演算処理プログラムを
格納するメモリ(ROM)7と、A/D変換されたデー
タや判定結果などを格納するメモリ(RAM)8と、診
断開始などの指示を入力するスイッチ類9と、演算処理
とデータの入出力処理を行うCPU10と、判定結果を
表示する液晶表示器11などを備えてなる。
器3と積分器4とフィルタ5とA/D変換器6により、
機械設備が発する振動速度波形を検出する振動検出手段
が構成される。
より、振動速度波形をフーリエ級数に展開して周波数ス
ペクトルを算出する周波数スペクトル算出手段、周波数
スペクトルをパワー合成して振動値Aを算出する振動値
算出手段、周波数スペクトルから回転数成分とその高調
波成分のスペクトルを選んでパワー合成して故障値Bを
算出する故障値算出手段、振動値Aに対する故障値Bの
比(B/A)を算出する故障スペクトル比算出手段、B
/Aの大きさから機械設備の故障の程度を診断する故障
診断手段が夫々構成される。
作について説明する。先ず、振動センサ1が検出する機
械設備の振動加速度を、フィルタ2、増幅器3、積分器
4、フィルタ5を通すことにより、機械設備が発する1
0Hz〜200Hzの周波数範囲の振動速度を求める。
6でA/D変換してからCPU10により、2ms毎に
512個の時系列データxiとしてRAM8に記憶させ
る。
ータの入出力処理を行う。時系列データxiをハニング
窓で重み付けをしてフーリエ変換をし、DC(0Hz)
〜200Hzまで1Hz毎に、200本のパワースペク
トルsi 2を求める。
0Hzまでのパワースペクトルの合成値Sを算出し、振
動値A(=S1/2)を求める。
高調波窓で高調波合成処理をする。第6高調波を60H
zから1200Hzまで1Hzずつ増やしf6とする。
この時の第1次周波数f1は、f1=int(f6/6)
とする。第1次周波数f1のパワースペクトルは、sf1 2
である。
sf2 2、…、sf6 2となり、次式(4)から第1次周波数
f1の高調波合成値Bf1を算出する。
なるまで、第6高調波の周波数を1Hzずつ増やす度に
第1次周波数f1の高調波合成値Bf1を算出する。得ら
れた10Hzから200Hzまでの高調波合成値Biの
なかで最大値を故障値Bとする。
クトル比R(=B/A)を求め、R≧0.9の場合は故
障、R≧0.8の場合は注意、R<0.8の場合は平常
と診断し、液晶表示器11に「故障」、「注意」、「平
常」のいずれかを表示する。
は、本発明を振動計測に基づいた故障診断方法及びその
装置に適用する場合について述べたが、本発明はこれに
限らず、アンバランスやミスアライメントなどの機械の
構造系故障により発生する振動と同時に発生する音圧や
音響放射(AE:アコーステックエミッション)、回転
軸の歪波形など種々の計測信号に基づいた故障診断方法
及びその装置に適用することができる。
によれば、機械設備が発する振動波形から求めた周波数
スペクトルをパワー合成した振動値Aと、回転数成分と
その高調波成分の周波数スペクトルをパワー合成した故
障値Bを算出し、振動値Aと故障値Bの比(故障スペク
トル比B/A)に対する判定基準値を一つだけ決定する
ことで、仕様の異なる多くの回転機械を対象にした確度
の高い故障診断ができる。
波窓による高調波合成処理手法を用いて回転数成分とそ
の高調波成分の周波数スペクトルをパワー合成するた
め、回転計を必要とせずに容易に高調波成分を合成する
ことができ、回転機械を対象にした確度の高い故障診断
ができる。
発する振動波形から求めた周波数スペクトルをパワー合
成した振動値Aと、回転数成分とその高調波成分の周波
数スペクトルをパワー合成した故障値Bを算出し、振動
値Aと故障値Bの比(故障スペクトル比B/A)に対す
る判定基準値を一つだけ決定することで、仕様の異なる
多くの回転機械を対象にした確度の高い故障診断装置を
実現できる。
波窓による高調波合成処理手法を用いて回転数成分とそ
の高調波成分の周波数スペクトルをパワー合成するた
め、回転計を必要とせずに容易に高調波成分を合成する
ことができ、回転機械を対象にした確度の高い故障診断
装置を実現できる。
動速度波形の周波数スペクトル図
る振動速度波形の周波数スペクトル図
形の周波数スペクトル図
積分器、6…A/D変換器、7…メモリ(ROM)、8
…メモリ(RAM)、9…スイッチ類、10…CPU、
11…液晶表示器。
Claims (4)
- 【請求項1】 機械設備が発する振動波形を検出し、得
られた振動波形をフーリエ級数に展開して周波数スペク
トルを算出し、この周波数スペクトルをパワー合成して
振動値Aとし、また前記周波数スペクトルから回転数成
分とその高調波成分のスペクトルを選んでパワー合成し
て故障値Bとし、振動値Aに対する故障値Bの比(故障
スペクトル比B/A)を算出し、この故障スペクトル比
B/Aの大きさから機械設備の故障の程度を診断するこ
とを特徴とする故障診断方法。 - 【請求項2】 前記周波数スペクトルに0(ゼロ)Hz
を基点にして複数の窓を等間隔に並べた高調波窓を、窓
の等間隔を崩さず同時に伸張させて重ね、それぞれの窓
に一致した周波数スペクトルを合成し、得られた周波数
スペクトルの合成値の最大値を故障値Bとする請求項1
に記載の故障診断方法。 - 【請求項3】 機械設備が発する振動波形を検出する振
動検出手段と、この振動検出手段が検出した振動波形を
フーリエ級数に展開して周波数スペクトルを算出する周
波数スペクトル算出手段と、この周波数スペクトル算出
手段が算出した周波数スペクトルをパワー合成して振動
値Aを算出する振動値算出手段と、前記周波数スペクト
ルから回転数成分とその高調波成分のスペクトルを選ん
でパワー合成して故障値Bを算出する故障値算出手段
と、振動値Aに対する故障値Bの比(故障スペクトル比
B/A)を算出する故障スペクトル比算出手段と、前記
故障スペクトル比B/Aの大きさから機械設備の故障の
程度を診断する故障診断手段を備えたことを特徴とする
故障診断装置。 - 【請求項4】 前記故障値算出手段は、前記周波数スペ
クトルに0(ゼロ)Hzを基点にして複数の窓を等間隔
に並べた高調波窓を、窓の等間隔を崩さず同時に伸張さ
せて重ね、それぞれの窓に一致した周波数スペクトルを
合成し、得られた周波数スペクトルの合成値の最大値を
故障値Bとする請求項3に記載の故障診断装置。
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