CN101819093A - Fault diagnosis device for spindle bearing of roadheader cutting head and use method thereof - Google Patents
Fault diagnosis device for spindle bearing of roadheader cutting head and use method thereof Download PDFInfo
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Abstract
The invention discloses a fault diagnosis device for a spindle bearing of a roadheader cutting head and a use method thereof. The device is characterized in that a central processing unit monitor is connected, via a signal conditioning circuit, with acceleration transducers which are respectively mounted at a front bearing casing and a rear bearing casing of the spindle of the roadheader cutting head. The monitor, an embedded real-time multitask operating system, comprises an original signal vibration amplitude monitor device, a signal feature extraction device and a maintenance guidance module. The use method of the device comprises the steps: vibrating signals of the front and rear bearings of the spindle are online measured to obtain wear-out failure signature spectrum of the spindle bearing, the failure signature spectrum and corresponding maintenance guidance are stored in the monitor; and signal features are extracted by online monitor signals and then compared with the spectrum to analyze diagnosis policy, and maintenance guidance advice in relation to the wear-out failure of the spindle bearing is given. On the premise of overcoming the difficulty problems of large vibration amplitude, adverse working environment and the like of the roadheader cutting head, the device identifies the wear-out failure of the spindle bearing of the roadheader cutting head reliably and is accordingly suitable for the diagnosis of mechanical faults which are widely present in the roadheader cutting head.
Description
Technical field
The invention belongs to physical construction fault diagnosis technology field, be specifically related to a kind of fault diagnosis device for spindle bearing of roadheader cutting head and using method thereof.
Background technology
At present, along with the develop rapidly of national economy, society enlarges day by day to the demand of the energy.Production safety form as the coal industry in main energy sources source allows of no optimist, and one of its reason is that coal mine machinery generally lacks necessary safety on line monitoring diagnosis system.With regard to development machine, the cutting head main shaft of accident pilosity crucial easily worn part, the especially running status of cutting head main shaft bearing are depended in its security.Homemade development machine has begun to take shape a plurality of series such as EBJ type, EL type, EBH type at present since the research and development eighties, can satisfy the needs of domestic bargh and infrastructure construction substantially.Yet present homemade development machine does not still have the online malfunction monitoring diagnostic system in crucial position, if untimely on-line monitoring and diagnosis has machine whether fault is arranged, can cause catastrophic consequence.Positive so-called " a thousand li causeway; burst " in the ant cave, if in time whether on-line monitoring and diagnosis development machine key components and parts has the position and the degree of fault, fault, evolution, the formulation maintenance policy that can in time indicate fault, maintenance provides technical support with intelligence for precognition, improve coal mine development machine overall operation security and reliability, avoid serious accident.Thereby solve defectives such as domestic development machine is not high owing to part reliability, the maintenance level is low and cause the low problem of equipment service efficiency.
At present, Mechatronic Systems monitoring running state and fault diagnosis system mainly adopt standalone monitoring diagnosis system, centralized monitoring diagnosis system, based on network online distributed monitoring diagnostic system etc., have brought into play important effect in large-scale dynamoelectric equipment and system.But these monitor control systems cost an arm and a leg, and for example: rotor of large turbo-type generator vibratory output supervising device price is up to 1,000,000 yuan.
And the industry monitoring control device of getting up as newly-developed based on the embedded system of the microprocessor ARM of Advanced RISC Machines company, be the product that computer technology, semiconductor technology and electronic technology with the advanced person combine with the concrete application of industry-by-industry, this point has just determined that it must be technology-intensive a, intensive capital, high degree of dispersion, the knowledge integrated system of constantly bringing forth new ideas.Become at present the forward position research direction of malfunction monitoring diagnostic field.But Shang Weijian has the report based on the fault diagnosis device for spindle bearing of roadheader cutting head of ARM.
Summary of the invention
The objective of the invention is to design a kind of fault diagnosis device for spindle bearing of roadheader cutting head and using method thereof, thereby can solve spindle bearing of roadheader cutting head mechanical wear troubleshooting issue efficiently, reliably.
The fault diagnosis device for spindle bearing of roadheader cutting head of the present invention's design comprises center processing unit and acceleration transducer, described center processing unit is a monitor, at cutting head of roadheader main spindle front bearing shell, rear bearing shell 1～3 acceleration transducer is installed respectively; Acceleration transducer inserts monitor through signal conditioning circuit.
Monitor is an embedded real-time multi-task operating system, comprises that original signal module, characteristic extracting module and maintenance instruct module.The original signal module contains the live signal receiving element of acceleration transducer, the peak-to-peak value storage unit and the vibration values comparing unit of each monitoring position spindle vibration of development machine; Characteristic extracting module contains time domain index analytic unit, fast fourier transform (English Fast Fourier Transform is called for short FFT) analytic unit, typical fault frequency spectrum storage unit and frequency spectrum The matching analysis unit; Maintenance instructs module to contain the maintenance suggestion storage unit of fault signature correspondence, the instruction analysis decision unit of maintenance.The original signal module receives the signal of acceleration transducer in real time, extract the peak-to-peak value of each monitoring position spindle vibration of development machine, compare with the storage data, because of out of order vibration equipment peak-to-peak value will inevitably be in higher level for a long time, tentatively judged whether fault in view of the above, on-line monitoring development machine running status; Characteristic extracting module is carried out the rumble spectrum that time domain index, fast fourier transform analysis obtain each current monitoring point to the data of original signal module, extract signal characteristic, compare with the spindle bearing of roadheader cutting head wear-out failure characteristic frequency spectrum of storage, analyze according to match condition, judge the development machine running status; The main shaft bearing wear-out failure feature of module by the analyzing and diagnosing of characteristic extracting module instructed in maintenance, makes a strategic decision by the maintenance suggestion of the fault signature correspondence of its storage, provides the instruction of maintenance.
Display is used to accept and show detection information and the repair message that monitoring device is sent here.
Monitor is connected to display, is used to accept and show development machine running status detection information and the repair message that each module of monitor is sent here.
The embedded real-time multi-task operating system of described monitor is the senior risc microcontroller embedded system of Advanced RISC Machines company, i.e. ARM embedded system.
Described acceleration transducer is explosion-proof acceleration transducer, the abominable working environment of, high humidity big at the dust foremost of mine to adapt to, the high development machine of gas density.This sensor is the piezoelectric vibration survey sensor of a kind of built-in piezoelectricity integrated circuit (IEPE circuit).
Described vibration signal modulate circuit comprises every straight bandwidth-limited circuit, gain adjustment circuit, D/A converting circuit and anti-aliasing filter circuit.Signal of sensor is made up of the AC and DC signal, in vibration analysis, an of ac at vibration signal is in addition when numerical integration is handled, even small DC quantity all can cause very big error, modulate circuit will have good in straight effect.
Sensor signal insert the vibration signal modulate circuit every straight bandwidth-limited circuit, insert monitor through gain adjustment circuit, D/A converting circuit and anti-aliasing filter circuit.
When carrying out spectrum analysis, because sample sequence is limited, the frequency span of analysis in order to prevent aliasing, also comprises in the modulate circuit being series at the anti-aliasing filter circuit between gain adjustment circuit, the D/A converting circuit within the specific limits in addition.
The using method of this fault diagnosis device for spindle bearing of roadheader cutting head comprises the steps:
I, by test, obtain spindle bearing of roadheader cutting head wear-out failure characteristic frequency spectrum, it is stored in the monitor, and, works out corresponding maintenance instruction at different main shaft bearing state of wear, also be stored in the monitor;
II, monitor the main shaft and the bearing vibration signal thereof of acquisition in real time by sensor, the original signal module of monitor is extracted the peak-to-peak value of each monitoring position spindle vibration of development machine according to the live signal of acceleration transducer, on-line monitoring development machine running status, out of order vibration equipment peak-to-peak value will inevitably be in higher level for a long time, has tentatively judged whether fault in view of the above; Characteristic extracting module is carried out the frequency spectrum that time domain index, fast Fourier transform (FFT) analysis obtain current vibration signal to the data of original signal module, extract signal characteristic, compare with the spindle bearing of roadheader cutting head wear-out failure characteristic frequency spectrum of storage, according to match condition, analyze, judge the development machine running status; Analyzing and diagnosing main shaft bearing wear-out failure and the order of severity thereof of module by characteristic extracting module instructed in maintenance, makes a strategic decision, and provides the instruction of maintenance.
The advantage of fault diagnosis device for spindle bearing of roadheader cutting head of the present invention and using method thereof is:
1) monitor has adopted the embedded system based on ARM, aboundresources, good stability in its hardware integrated level height, the sheet; The ARM embedded system is the monitoring of working condition system of newly-developed, computer technology, semiconductor technology and electronic technology with the advanced person combine with the concrete application of industry-by-industry, the knowledge integrated system of become technology-intensive, intensive capital, high degree of dispersion, constantly bringing forth new ideas has characteristics such as low-power consumption, volume are little, integrated level height; And this embedded system is integrated in chip internal with many being finished by integrated circuit board of tasks in the universal cpu, and the total system design is tending towards miniaturization.Its software solidification rather than is stored in the carriers such as disk in memory chip, has improved execution speed and system reliability;
2) diagnosis of cutting head of roadheader mechanical fault is patrolled and examined and on-line monitoring under the abominable working environment of adaptation development end, and the result has effectively avoided the sudden accident generation accurately and reliably;
3) structure is light and handy, and cheap, can directly be installed on the development machine operation room, unites use with electrical equipment and hydraulic fault diagnostic system, improves coal mine development machine overall operation security and reliability.
Description of drawings
Fig. 1 is this fault diagnosis device for spindle bearing of roadheader cutting head embodiment one-piece construction synoptic diagram;
Fig. 2 is a monitor module block diagram among Fig. 1;
Fig. 3 is a signal conditioning circuit structural representation among Fig. 1;
Fig. 4 is interior vibration signal of online detection gained a period of time of sensor among this fault diagnosis device for spindle bearing of roadheader cutting head using method embodiment;
Fig. 5 is a vibration signal spectrogram among Fig. 4.
Embodiment
This fault diagnosis device for spindle bearing of roadheader cutting head embodiment one-piece construction comprises monitor and acceleration transducer as shown in Figure 1, at cutting head of roadheader main spindle front bearing shell, rear bearing shell 2 acceleration transducers is installed respectively; Acceleration transducer inserts monitor through signal conditioning circuit.
Monitor is the ARM embedded system, comprises that as shown in Figure 2 original signal module, characteristic extracting module and maintenance instruct module.The original signal module contains the live signal receiving element of acceleration transducer, the peak-to-peak value storage unit and the vibration values comparing unit of each monitoring position spindle vibration of development machine; Characteristic extracting module contains time domain index analytic unit, fast Fourier transform (FFT) analytic unit, typical fault frequency spectrum storage unit and frequency spectrum The matching analysis unit; Maintenance instructs module to contain the maintenance suggestion storage unit of fault signature correspondence, the instruction analysis decision unit of maintenance.
Monitor is connected to display, is used to accept and show development machine running status detection information and the repair message that each module of monitor is sent here.Different operatings such as " original signal ", " signal characteristic extraction ", " maintenance is instructed " can be selected in the main interface of the monitor that shows on display, are convenient to the use of this device.
The unloading interface that monitor is connected with ground analysis system in addition, monitor is connected with ground analysis system, the data of monitor can be dumped to ground analysis system from coal mine evacuation working face, help the Facilities Engineer to understand main shaft of boring machine bearing running status on each workplace, for production management scheduling reference.
Described acceleration transducer is explosion-proof acceleration transducer, and this sensor is a kind of piezoelectric vibration survey sensor of built-in IEPE circuit.For example adopt the CA-YD-188GF explosion-proof type piezoelectric acceleration sensor of the explosion-proof sign Exib II CT4-T6 requirement of explosion proof that meets national regulation.
Described vibration signal modulate circuit comprises as shown in Figure 3 every straight bandwidth-limited circuit, gain adjustment circuit, D/A converting circuit and anti-aliasing filter circuit.Sensor signal insert the vibration signal modulate circuit every straight bandwidth-limited circuit, gain adjustment circuit, D/A converting circuit and be connected monitor after the anti-aliasing filter circuit is connected in proper order.
The using method embodiment of this fault diagnosis device for spindle bearing of roadheader cutting head comprises the steps:
I, by test, obtain spindle bearing of roadheader cutting head wear-out failure characteristic frequency spectrum, it is stored in the monitor, and, works out corresponding maintenance instruction at different main shaft bearing state of wear, also be stored in the monitor;
II, monitor the main shaft and the bearing vibration signal thereof of acquisition in real time by sensor, the original signal module of monitor is extracted the peak-to-peak value of each monitoring position spindle vibration of development machine according to the live signal of acceleration transducer, on-line monitoring development machine running status has tentatively judged whether fault in view of the above; Characteristic extracting module is carried out the respective value of time domain index, fast Fourier transform (FFT) analysis extraction frequency and Oscillation Amplitude to the data of original signal module, extract signal characteristic, compare with the spindle bearing of roadheader cutting head wear-out failure characteristic frequency spectrum of storage, analyze according to match condition, judge the development machine running status; Analyzing and diagnosing main shaft bearing wear-out failure and the order of severity thereof of module by characteristic extracting module instructed in maintenance, makes a strategic decision, and provides the instruction of maintenance.
Present embodiment is used for certain mineral bureau's roadway head development machine, and this main shaft of boring machine bearing designation is SKF23176, bearing bore diameter: 380mm, bearing outside diameter: 620mm, roller diameter: 65mm, roller number: 21.The cutting head of roadheader speed of mainshaft is 47.15 rev/mins.The sample frequency of each sensor vibration signal is 1500Hz, and sampling number is 4096.Obtain main shaft bearing inner ring fault characteristic frequency f after the detection
i=9.32Hz, rolling body fault characteristic frequency f
b=5.89Hz.Figure 4 shows that one of them sensor on-line monitoring in 2.75 seconds obtains vibration signal, Figure 5 shows that among Fig. 4 gained frequency spectrum after the vibration signal data analysis, (2 * f) locate to occur big peak value, and the pulse shock that 3 amplitudes are bigger in gyro frequency f and the vibration signal is corresponding at interval for its gyro frequency f and 2 frequencys multiplication thereof as seen from the figure.Monitor judges that the gyro frequency of main shaft is the fault modulating frequency that causes bear vibration violent thus, and this is the feature of bearing heavy wear fault just.The decision-making of monitor is maintenance immediately.Find bearing inner race and axle matching loose during field-strip, and there is severe marking in inner ring.
Practical application shows that this fault diagnosis device for spindle bearing of roadheader cutting head can diagnose out faults such as main shaft bearing wearing and tearing reliably, and the diagnostic accuracy height, can carry out on-line monitoring and diagnosis to the main shaft of boring machine cutting head reliably in engineering.
The foregoing description is the specific case that purpose of the present invention, technical scheme and beneficial effect are further described only, and the present invention is defined in this.All any modifications of within scope of disclosure of the present invention, being made, be equal to replacement, improvement etc., all be included within protection scope of the present invention.
Claims (8)
1. fault diagnosis device for spindle bearing of roadheader cutting head comprises center processing unit and acceleration transducer, it is characterized in that:
Described center processing unit is a monitor, at cutting head of roadheader main spindle front bearing shell, rear bearing shell 1～3 acceleration transducer is installed respectively; Each acceleration transducer inserts monitor through signal conditioning circuit; Described monitor is an embedded real-time multi-task operating system.
2. fault diagnosis device for spindle bearing of roadheader cutting head according to claim 1 is characterized in that:
The embedded real-time multi-task operating system of described monitor comprises that original signal module, characteristic extracting module and maintenance instruct module, and the original signal module contains the live signal receiving element of acceleration transducer, the peak-to-peak value storage unit and the vibration values comparing unit of each monitoring position spindle vibration of development machine; Characteristic extracting module contains time domain index analytic unit, fast fourier transform analytic unit, typical fault frequency spectrum storage unit and frequency spectrum The matching analysis unit; Maintenance instructs module to contain the maintenance suggestion storage unit of fault signature correspondence, the instruction analysis decision unit of maintenance.
3. fault diagnosis device for spindle bearing of roadheader cutting head according to claim 1 and 2 is characterized in that:
Described monitor is connected to display.
4. fault diagnosis device for spindle bearing of roadheader cutting head according to claim 1 and 2 is characterized in that:
Described acceleration transducer is explosion-proof acceleration transducer.
5. fault diagnosis device for spindle bearing of roadheader cutting head according to claim 1 and 2 is characterized in that:
Described acceleration transducer is the piezoelectric vibration survey sensor of built-in piezoelectricity integrated circuit.
6. fault diagnosis device for spindle bearing of roadheader cutting head according to claim 1 and 2 is characterized in that:
Described vibration signal modulate circuit comprises every straight bandwidth-limited circuit, gain adjustment circuit, D/A converting circuit and anti-aliasing filter circuit, sensor signal insert the vibration signal modulate circuit every straight bandwidth-limited circuit, insert monitor through gain adjustment circuit, D/A converting circuit and the anti-aliasing filter circuit of order series connection.
7. fault diagnosis device for spindle bearing of roadheader cutting head according to claim 1 and 2 is characterized in that:
Described monitor has the unloading interface that is connected with ground analysis system, and monitor is connected with ground analysis system.
8. the using method of fault diagnosis device for spindle bearing of roadheader cutting head according to claim 1 and 2 is characterized in that comprising the steps:
I, by test, obtain spindle bearing of roadheader cutting head wear-out failure characteristic frequency spectrum, it is stored in the monitor, and, works out corresponding maintenance instruction at different main shaft bearing state of wear, also be stored in the monitor;
II, monitor the main shaft bearing vibration signal of acquisition in real time by sensor, the original signal module of monitor is extracted the peak-to-peak value of each monitoring position spindle vibration of development machine according to the live signal of acceleration transducer, on-line monitoring development machine running status has tentatively judged whether fault; Characteristic extracting module is carried out the frequency spectrum that the fast fourier transform analysis obtains current vibration signal to the data of original signal module, extract signal characteristic, compare with the spindle bearing of roadheader cutting head wear-out failure characteristic frequency spectrum of storage, according to match condition, analyze, judge the development machine running status; Analyzing and diagnosing main shaft bearing wear-out failure and the order of severity thereof of module by characteristic extracting module instructed in maintenance, makes a strategic decision, and provides the instruction of maintenance.
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Cited By (14)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN102798529A (en) * | 2012-08-30 | 2012-11-28 | 桂林电子科技大学 | Method and system for diagnosing bearing faults of large-size wind turbine bearing |
| CN104457973A (en) * | 2014-12-29 | 2015-03-25 | 中铁隧道集团有限公司 | Vibration signal detection and fault diagnosis system in shield tunneling process |
| CN105569667A (en) * | 2015-12-31 | 2016-05-11 | 石家庄铁道大学 | Safety state detection system and method for main drive seal of total section tunneling machine |
| CN106568598A (en) * | 2016-11-08 | 2017-04-19 | 温州大学 | Transmission shaft damage detection method and detection device |
| CN108225772A (en) * | 2017-12-27 | 2018-06-29 | 合肥新沪屏蔽泵有限公司 | A kind of number shows bearing wear measuring instrument |
| CN109405889A (en) * | 2018-12-13 | 2019-03-01 | 中国航空工业集团公司上海航空测控技术研究所 | System and method for for the prediction of development machine working arm decelerator trouble |
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| CN110082078A (en) * | 2019-03-13 | 2019-08-02 | 中交广州航道局有限公司 | Trend prediction method, device, computer equipment and the storage medium of ship tail axis |
| CN110617982A (en) * | 2019-09-19 | 2019-12-27 | 苏州时辰智能机电设备有限公司 | Rotating machinery equipment fault identification method based on voiceprint signals |
| US10663372B2 (en) | 2018-05-21 | 2020-05-26 | Caterpillar Inc. | Bearing failure detection in a hydraulic fracturing rig |
| CN111442924A (en) * | 2019-01-16 | 2020-07-24 | 斯凯孚公司 | System and program |
| CN112033679A (en) * | 2020-10-13 | 2020-12-04 | 济南重工集团有限公司 | Nondestructive testing device and method for main bearing of shield machine |
| CN115106839A (en) * | 2021-03-19 | 2022-09-27 | 株式会社理光 | Machining determination device, machining determination method, machining system, and storage medium |
| CN117686224A (en) * | 2024-02-02 | 2024-03-12 | 太原理工大学 | Fault diagnosis experiment platform for simulating cutting head bearing of heading machine |
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Cited By (16)
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| CN102798529A (en) * | 2012-08-30 | 2012-11-28 | 桂林电子科技大学 | Method and system for diagnosing bearing faults of large-size wind turbine bearing |
| CN104457973A (en) * | 2014-12-29 | 2015-03-25 | 中铁隧道集团有限公司 | Vibration signal detection and fault diagnosis system in shield tunneling process |
| CN105569667A (en) * | 2015-12-31 | 2016-05-11 | 石家庄铁道大学 | Safety state detection system and method for main drive seal of total section tunneling machine |
| CN106568598A (en) * | 2016-11-08 | 2017-04-19 | 温州大学 | Transmission shaft damage detection method and detection device |
| CN106568598B (en) * | 2016-11-08 | 2018-12-14 | 温州大学 | A kind of transmission shaft damage detecting method and detection device |
| CN108225772A (en) * | 2017-12-27 | 2018-06-29 | 合肥新沪屏蔽泵有限公司 | A kind of number shows bearing wear measuring instrument |
| US10663372B2 (en) | 2018-05-21 | 2020-05-26 | Caterpillar Inc. | Bearing failure detection in a hydraulic fracturing rig |
| CN109405889A (en) * | 2018-12-13 | 2019-03-01 | 中国航空工业集团公司上海航空测控技术研究所 | System and method for for the prediction of development machine working arm decelerator trouble |
| CN109405889B (en) * | 2018-12-13 | 2021-07-13 | 中国航空工业集团公司上海航空测控技术研究所 | System and method for predicting fault of working arm reducer of heading machine |
| CN111442924A (en) * | 2019-01-16 | 2020-07-24 | 斯凯孚公司 | System and program |
| CN110082078A (en) * | 2019-03-13 | 2019-08-02 | 中交广州航道局有限公司 | Trend prediction method, device, computer equipment and the storage medium of ship tail axis |
| CN110044631A (en) * | 2019-03-13 | 2019-07-23 | 中交广州航道局有限公司 | Trend prediction method, device and the computer equipment of ship machine diesel engine |
| CN110617982A (en) * | 2019-09-19 | 2019-12-27 | 苏州时辰智能机电设备有限公司 | Rotating machinery equipment fault identification method based on voiceprint signals |
| CN112033679A (en) * | 2020-10-13 | 2020-12-04 | 济南重工集团有限公司 | Nondestructive testing device and method for main bearing of shield machine |
| CN115106839A (en) * | 2021-03-19 | 2022-09-27 | 株式会社理光 | Machining determination device, machining determination method, machining system, and storage medium |
| CN117686224A (en) * | 2024-02-02 | 2024-03-12 | 太原理工大学 | Fault diagnosis experiment platform for simulating cutting head bearing of heading machine |
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