CN102426102A - Resonance demodulation double isolate frequency spectrum method for detecting crack of gear shaft - Google Patents
Resonance demodulation double isolate frequency spectrum method for detecting crack of gear shaft Download PDFInfo
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- CN102426102A CN102426102A CN201110318937XA CN201110318937A CN102426102A CN 102426102 A CN102426102 A CN 102426102A CN 201110318937X A CN201110318937X A CN 201110318937XA CN 201110318937 A CN201110318937 A CN 201110318937A CN 102426102 A CN102426102 A CN 102426102A
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Abstract
The invention discloses a resonance demodulation double isolate frequency spectrum method for detecting crack of a gear shaft. Analysis of resonance demodulation wave is obtained by performing resonance demodulation separation processing and AD (Analog-Digital) converter sampling on a vibration impact signal detected on a bearing close to a gear; and if discovering that the resonance demodulation time domain waveform occurs two clusters of basically symmetric meshing impact waves in each rotation period of a shaft where the gear is positioned, a meshing impact spectrum of the gear occurs in an FFT (Fast Fourier Transform) analytical spectrum of the resonance deformation time domain waveform and double isolate frequency spectrum equal to rotation speed frequency of the gear shaft occurs, it is reported that the shaft has the crack. The method provided by the invention has the advantages of low cost, low loss and capability of on-line frequent detection, and plays an important role in guaranteeing safety of equipment, particularly personal safety.
Description
Technical field
The present invention relates to the input and the analyzing and diagnosing technical field of equipment fault diagnosis, particularly a kind of resonance and demodulation two lonely spectral methods of detection of gear axle crackle.
Background technology
No matter be to be installed on the geared rotor system on the axle through interference fit with the geared rotor system of the whole processing of gear or with gear; When all transmitting moment of torsion owing to them; Because of the equivalent diameter of axle of different parts, equivalent cross-sectional area, equivalent stiffness different, and the intermediate location generation stress of the diameter of axle, sectional area, stiffness variation concentrate and alternation tired, and then crackle take place, fracture; Cause the major accident of mechanized equipment, for example the axletree of some high-speed train crackle occurs in the transitional zone of gear and axletree.Shown in Figure 1 is the structural representation of gear transmission part; The running of motor drive power source pinion shafts such as (01); This driving pinion (02) running, pinion wheel (02) drive another gear wheel that is engaged with (03) running, and this gear wheel drives its axle and coaxial mounted another gear (04) or wheel or wheel disc (05) running; The axle of gear wheel is installed on the bearing (06), and the axle of pinion wheel is installed on the bearing (07) of (drive source etc.); Usually be different from the diameter of axle at other positions at the diameter of axle of gear and its connecting portion, between two different diameters of axle, be processed as the arcuation transitional zone usually; The sensor of faults such as monitoring bearing, gear, wheel is installed on the bearing seat near gear or wheel.Because gear (also or wheel) and axle connecting portion not only the diameter of axle be different from other positions; Also because former thereby increased local torsional rigidity with axle interference fit etc.; Make axle be rendered as the nonuniform stiffness characteristic, so that locate to certainly exist stress in " transitional zone " that become rigidity and concentrate and be easy to fatigue, crack along axis direction.
Cut off and the initiation bad accident for the axle that prevents crackle develops into, prior art mainly is through under the state that shuts down, and countershaft carries out visual inspection or crackle is found in flaw detection.In case the discovery crackle just must be changed axle or its assembly.
Existing inspection technique commonly used mainly contains:
Dyeing inspection: spread upon on the detected object with having dark pool and mobile good " penetrating fluid "; This penetrating fluid rapid permeability is gone in the crack that possibly exist; Wipe the penetrating fluid on axle surface then, coat lacquer or other coating of light color (like white), at this moment; The penetrating fluid that infiltrates crackle is oppositely towards the axle surface seepage, makes the light-coloured coating that covers cracks painted and be easy to found this crackle by the artificial visually examine.
Magnetic powder inspection: the axle to ferromagnetic material is made is done hard magnetization along axis direction or part; The spray or spill iron powder on the surface of axle then; Because the magnetic resistance of crack site is greater than other position; So iron powder is concentrated to reduce magnetic resistance to crack site by magnetic attraction, it promptly is crack site that the iron powder that the artificial visually examine finds is concentrated the position.Fluorescent penetrating inspection in addition similarly etc.
The shortcoming of above-mentioned two kinds of technology not only is necessary static state operation, and needs range estimation, and particularly inconvenience finds to occur in often the axle crackle in the narrow slit between the big parts, more can not find by the axle crackle of other parts covering;
Ultrasonic inspection: with surface or the end emission ultrasound wave of ultrasonic emitting/receiver to axle; Receive its reflection wave; The velocity of propagation of ultrasound wave in iron and steel class material is about V=5000m/s, if the time T that begins to arrive to reflection from emission is long, then means at L=0.5VT and do not reflect with interior; If there is reflection L (to launch vertically and then be axial length less than the shaft size of transmit direction; Radially emission then is the diameter of axle), mean then have abnormal reflection that doubting is crackle or other problems from launching site L place.This technological shortcoming not only is necessary static state operation, and need make exploded to machinery and operate to expose test surfaces (or test point), particularly can not find near inner (for example 10mm is with interior) crackle or the trouble spot of test surfaces (point).
Because above-mentioned technology all need be when machinery shuts down even is local or all decompose laggard line operate; And make and can not frequently with these technology machinery be detected; Since these technology can't find to come into being than crackle; And crackle possibly develop into off-axis before regularly detecting next time; Therefore; The detection technique of this non-online (promptly can not in machinery utilization process, carry out at any time) is very limited for the effect that prevents accident, and uses the cost that these technology detect (stopping transport for the loss of productivity effect, the loss of cycle that when detecting machinery is decomposed, the overhaul additional injury for machinery) high, therefore can not satisfy well machinery is carried out low-cost, low-loss and frequently detects to guarantee safe demand.
Summary of the invention
Technical matters to be solved by this invention is, and is not enough to prior art, and a kind of resonance and demodulation two lonely spectral methods of online detection of gear axle crackle are provided, and satisfies machinery is carried out low-cost, low-loss and frequently detects and guarantee safe demand.
For solving the problems of the technologies described above; The technical scheme that the present invention adopted is: a kind of resonance and demodulation two lonely spectral methods of detection of gear axle crackle; The pick-up unit that comprises detection of gear axle crackle; Pick-up unit comprises the speed probe (3) near the vibratory impulse detecting sensor (1) on the bearing seat of gear, resonance and demodulation detector (2) and detection of gear axle rotating speed that is installed in the supporting gear axle; Resonance and demodulation transducer (2-1) and tach signal processor (2-3) are installed in the resonance and demodulation detector; Also have computing machine in the resonance and demodulation detector, AD converter and resonance and demodulation two lonely analysis of spectrum softwares are installed in the computing machine, the step of utilizing said pick-up unit to carry out the gear shaft crack detection is:
1) the gear rotational speed signal of speed probe output is delivered among the tach signal processor 2-3, and the resonance and demodulation two lonely analysis of spectrum softwares that the tach signal of exporting is after treatment delivered to the identification gear shaft crackle of computing machine 2-2 carry out tachometric survey to obtain rotary speed data; Also deliver to the AD transducer signal of resonance and demodulation transducer 2-1 output is carried out rotating-speed tracking control AD conversion, or, obtain the resonance and demodulation data with astronomical clock control AD conversion;
2) signal that contains the gearing mesh vibration and impact that vibratory impulse detecting sensor 1 detects is transferred to resonance and demodulation detector 2; Extract the signal of gear engagement impact with resonance and demodulation transducer 2-1; Be transformed to the Resonance Solutions harmonic then, carry out the resonance and demodulation data acquisition by the AD transducer;
3) resonance and demodulation two lonely analysis of spectrum softwares read in the number N of teeth of the gear that gear shaft installs from the database of having imported data in advance, and read in the resonance and demodulation data and 1 by the input of AD transducer) in the rotary speed data that obtains, Calculation Speed frequency FN;
4) resonance and demodulation two lonely analysis of spectrum softwares carry out the FFT conversion to the resonance and demodulation data, obtain the resonance and demodulation frequency spectrum;
5) resonance and demodulation two lonely analysis of spectrum softwares carry out two lonely analysis of spectrums, engagement analysis of spectrum to the resonance and demodulation frequency spectrum; In each axletree speed cycle, whether there are 2 bunches of mesh impact ripples to analyze to the resonance and demodulation data simultaneously; If meet the following conditions then send corresponding diagnostic alarms information: have in the speed cycle have in 2 bunches of mesh impact ripples, the frequency spectrum N doubly to the gearing mesh spectrum of FN characteristic frequency and 2 times to the FN characteristic frequency, isolated frequency spectrum; Promptly two lonely spectrums report that then crackle appears in gear shaft; If two lonely spectrums are arranged, and not engagement spectrum and 2 bunches of mesh impact ripples then send crack warning; If there are not two lonely spectrum, then flawlesses;
6) if do not withdraw from the instruction of detection then return 1) carry out the duplicate detection diagnosis, otherwise withdraw from and return master routine.
In the said step 3); The computing formula of speed-frequency FN is: FN=S/M; The computing formula of SF FC is: FC=M * FN=S; Wherein S is that the umber of pulse that the tach signal processor that reads in 1 second is exported to AD transducer and computing machine is the tach signal frequency, M for the tach signal processor preset to axle whenever circle produce be uniformly distributed with the tach signal pulse number.
The resonance and demodulation two lonely spectral analysis methods of identification gear shaft crackle are according to principle design as follows:
There is mutual radial thrust in two gears when the engagement running, balance this mutual thrust be the elastic force that rigidity determined at gear place spool.If crackle takes place the axle of a gear, then this fortune circles and changes rigidity and elastic force with 4 times, shown in accompanying drawing 3: establish pinion shaft generation crackle; Then when the crackle of pinion shaft during towards gear wheel (to the top); Pinion shaft rigidity is minimum, and gear wheel forces pinion shaft generation maximum deflection to its thrust, and the crackle maximum is opened; Pinion wheel is deflection left, like Fig. 3 (1); When the crackle side direction gear wheel of pinion shaft, it is big that pinion shaft rigidity becomes, and gear wheel forces pinion shaft generation minimum bend to its thrust, and crackle opens (less) naturally, and deflection such as Fig. 3 (2) take place pinion wheel hardly; When the crackle (downwards) of pinion shaft dorsad during gear wheel, pinion shaft rigidity is less, and gear wheel forces pinion shaft to take place than macrobending to its thrust, and crackle is closed basically, and the also little deflection left of pinion wheel is like Fig. 3 (3); When the crackle side direction gear wheel of pinion shaft, it is big that pinion shaft rigidity becomes, and gear wheel forces pinion shaft generation minimum bend to its thrust, and crackle opens (less) naturally, and deflection also takes place pinion wheel hardly, like Fig. 3 (4).The rigidity that when axle of crackle is rotated a week 4 times change is called " transition rigidity ".Because being the elastic force that is determined by its rigidity, the reaction thrust of pinion mate gear wheel produces; So the transition rigidity behind this pinion shaft crackle will cause that 4 pulsation take place big or small gear meshing radial thrust in the pinion rotation process in one week; The core wheel distance of big pinion wheel also changes 4 times, and corresponding diagram 3 (1)～3 (4) is in order: big-little-inferior big-little.Owing to gear only have rational core wheel apart from the time just have only mesh vibration not have mesh impact; The pulsation of above-mentioned core wheel distance; Then cause when the every fortune of this pinion wheel circles and two bunches of impacts of gear wheel generation; Corresponding diagram 3 (1)～3 (4) is in order: little-big-inferior little-inferior big, impact little impact and time little impact if ignore, what then show is that the every fortune of this pinion wheel circles and small one and large one two bunches of impacts of near symmetrical occur; In like manner, there is crackle in Large Gear Shaft During if pinion shaft does not have crackle, and what then show is that the every fortune of this gear wheel circles and small one and large one two bunches of impacts of near symmetrical occur; Described two bunches of impacts are because the gear centre distance change does not suddenly change, but along with rotation gradually changes, thereby make the mesh impact that therefore gear takes place also gradually change along with rotation.
The resonance and demodulation that gear meshing is impacted detects the frequency FNIE of frequency spectrum, equals the product of number N of teeth of speed-frequency FN and the gear of gear: FNIE=N*FN, like Fig. 4; This gear wheel has N=68 tooth, and the characteristic clef of this Large Gear Shaft During is FN=10.24, owing to exist axle to split hidden danger, the clef theoretical value that causes gear engagement impact is FNIE=N*FN=696.32.Spectral line has then been found in test No. 696.4; The single tooth fault of gear (as broken teeth, roller seating space split, heel splits or the like) resonance and demodulation repetition frequency FC=FN; " characteristic frequency " that is called this gear; Its corresponding clef is " a characteristic clef "; And have multistage property, promptly have abundant integral multiple in the frequency spectrum of characteristic frequency and multiple in the spectral line of characteristic clef, like Fig. 5; The repetition frequency that single bunch of tooth of gear impacts (rupturing and eccentric, distortion like the gear attachment screw) fault also is characteristic frequency FC=FN, is number higher-order spectrum seldom but have only, or does not have higher-order spectrum, like Fig. 6; Whenever circle because of the axle crackle repetition frequency of two bunches of impacts that near symmetrical takes place of gear is FLIE=2FC=2FN; Be that FLIE equals 2 times of characteristic frequencies; And almost have only the 1 rank spectrum of FLIE or also have the small of it to compose to negligible 2,3 rank; That is the isolated characteristic frequency spectrum in only cogged 2 rank; Abbreviate " 2 lonely spectrum " or " two lonely spectrums " as; Like Fig. 7, Fig. 8, have only an axle crackle that has gear just to have above-mentioned rule, gear engagement impact that just utilizable crackle is arranged and caused bunch and 2 lonely composing thereof; Have unidirectional load but do not have other axle of gear, gear engagement impact that does not for example have the axle (it is bearing the unidirectional load in the sensing the earth's core due to the flywheel weight) of the axletree (it is bearing the unidirectional load due to the car body weight that applies through bearing, point to the earth's core) of gear, the axle of belt pulley (it is bearing the unidirectional load that points to another belt pulley that same belt connects), cantilever support flywheel then not have utilizable crackle to be caused bunch and 2 lonely composing thereof.
The advantage of the existing relatively detection of gear axle crack technology of the present invention is: can be in the gear shaft operation process of plant equipment the continuous monitoring crackle; Safe condition identification, is carried out among having advanceed to the online at any time operation opportunity in traditional stoppage in transit detection; Just can find to send crack warning at the initial stage that the crackle of gear shaft takes place based on the information of resonance and demodulation two lonely spectrums; And just can send warning message when bigger at crack growth; Avoided vehicle equipments such as long-term non-stop-machine equipment and the vehicle stopping production loss of carrying out Static Detection out of service in the traditional detection method requirement process industry; And the man-hour of decompose detecting, spare parts consumption and decomposition detect the equipment damage that possibly cause etc.; Also avoided classic method owing to can not frequently detect; And the danger of crackle because of can not in time finding to cause the accident that possibly take place at the run duration between the very long detection twice interval time; Have low-cost, low-loss and the frequent superiority that detects, for the safety of guaranteeing equipment, particularly the safety of the person has vital role.
Description of drawings
Fig. 1 is the structural representation of existing gear transmission part;
Fig. 2 is the resonance and demodulation two lonely spectral method schematic block diagrams of detection of gear axle crackle;
Fig. 3 is crack position and pinion wheel skewed relationship synoptic diagram; (1) crackle is towards gear wheel, and axle is curved maximum, and the crackle maximum is opened, and pinion wheel is the deflection synoptic diagram left; (2) crackle is towards the top, and axle is curved minimum, and crackle opens naturally, and pinion wheel is the deflection synoptic diagram not; (3) crackle gear wheel dorsad, curved time of axle is big, and crack closure, pinion wheel be oblique synoptic diagram left also; (4) crackle is towards the below, and axle is curved minimum, and crackle opens naturally, and pinion wheel is the deflection synoptic diagram not;
Fig. 4 is the detection figure that the resonance and demodulation of gear engagement impact detects the frequency FNIE=N*FN of frequency spectrum;
Fig. 5 is characteristic frequency FC=FN and the detection figure with multistage property for the resonance and demodulation repetition frequency of single roller seating space crack fault;
Fig. 6 is characteristic frequency FC=FN for gear wheel because of single bunch of repetition frequency of impacting fault due to the loosening off-centre of attachment screw, but has only the detection figure for number higher-order spectrums seldom;
Fig. 7 whenever circles two bunches of impacts of near symmetrical takes place for crackle occurs because of pinion shaft, and repetition frequency equals the i.e. detection figure of " 2 lonely spectrum " of 2 times of characteristic frequency FLIE=2FC=2FN;
Fig. 8 whenever circles two bunches of impacts of near symmetrical takes place for crackle occurs because of pinion shaft, and repetition frequency equals the i.e. detection figure of " 2 lonely spectrum " of 2 times of characteristic frequency FLIE=2FC=2FN;
Fig. 9 is the resonance and demodulation two lonely analysis of spectrum software workflow figure of identification gear shaft crackle;
Figure 10 is same machinery of one embodiment of the invention and the different machineries enforcement proof diagram that the utilization rotating-speed tracking is sampled and analyzed under the different rotating speeds condition; (1) 0051 machine gear wheel rotating speed 510r/min detects and obtains the two lonely spectrum PXZ=57.5 that pinion shaft splits, the enforcement proof diagram of mesh impact spectrum PNIE=696.9; (2) 0051 machine gear wheel rotating speed 134r/min detect and obtain the two lonely spectrum PXZ=58.2 that pinion shaft splits, the enforcement proof diagram of mesh impact spectrum PNIE=696.9; (3) 0174 machine gear wheel rotating speed 502r/min detect and obtain the two lonely spectrum PXZ=58.2 that pinion shaft splits, the enforcement proof diagram of mesh impact spectrum PNIE=696.2; (4) 0036 machine gear wheel rotating speed 600r/min detect and obtain the two lonely spectrum PXZ=58.2 that pinion shaft splits, the enforcement proof diagram of mesh impact spectrum PNIE=696.9.
Wherein:
01: motor; 02: pinion wheel; 03: gear wheel; 04: gear; 05: wheel or wheel disc; 06: bearing.
Embodiment
Specify embodiment of the present invention below in conjunction with accompanying drawing.
Gear transmission part comprises motor (01), gear (02～04), gear shaft, bearing (06～07); Also comprise the vibratory impulse detecting sensor (1) that is installed near on the bearing seat of gear; Resonance and demodulation detector (2); The resonance and demodulation two lonely analysis of spectrum softwares of speed probe (3) and the AD transducer of in the contained computing machine (2-2) of resonance and demodulation detector (2), installing and identification gear shaft crackle and the tach signal processor (2-3) of installation in resonance and demodulation detector (2); The tach signal of speed probe (3) output is delivered to the tach signal processor (2-3) in the resonance and demodulation detector (2); The tach signal of output is delivered to AD convertor controls AD conversion after treatment, and the resonance and demodulation two lonely analysis of spectrum softwares of also delivering to the identification gear shaft crackle in the computing machine carry out rotating speed and detect; The signal that contains the gearing mesh vibration and impact that vibratory impulse detecting sensor (1) detects is transferred to resonance and demodulation detector (2); Extract the signal of gear engagement impact and be transformed to the resonance and demodulation signal with resonance and demodulation transducer (2-1); AD transducer by computing machine (2-2) contained in the resonance and demodulation detector (2) carries out the digital data collection; Again the data of being gathered are carried out analyzing and diagnosing with the resonance and demodulation two lonely analysis of spectrum softwares of discerning the gear shaft crackle; The crackle of identification respective teeth wheel shaft, output crack warning, warning message, as shown in Figure 2.
The resonance and demodulation two lonely spectral methods of detection of gear axle crackle are: through the vibration and shock signal that near the bearing the gear, detects being carried out the resonance and demodulation separating treatment and analyzing through the Resonance Solutions harmonic that the AD converter sample obtains; 2 bunches of mesh impact ripples of basic symmetry appear in each rotation period of gear place axle if find the resonance and demodulation time domain waveform; And in the fft analysis spectrum to the resonance and demodulation time domain waveform gear meshing shock response spectrum appears; And the frequency spectrum 2 times, isolated of the characteristic frequency that equals speed-frequency of this gear shaft appears equaling; Promptly two lonely spectrums report that then crackle appears in this axle; Two lonely spectrums are sufficient and necessary condition, and 2 bunches of mesh impact ripples of appearance of each rotation period are adequate condition in engagement spectrum and the time domain waveform.Resonance and demodulation two lonely analysis of spectrum softwares have a database when mounted; Wherein write time column data: control to speed-frequency FN carry out doubly coefficient M of frequency multiplication M, the axle that detected with number N of teeth, resonance and demodulation two lonely analysis of spectrum software workflow such as Fig. 9 of gear: software brings into operation, and reads in the number N of teeth of this gear of installing from database; When carrying out astronomical clock sampling; Software instructs to AD transducer tranmitting data register; The AD transducer instructs according to this; With the stable frequency that takes place by the crystal oscillator time clock control AD transducer that is F the resonance and demodulation signal of resonance and demodulation transducer (2-1) output is carried out analog to digital conversion, the resonance and demodulation Wave data of quantification is provided to software; When carrying out the rotating-speed tracking sampling; Software reads in Clock Multiplier Factor M from database; Send Clock Multiplier Factor M to tach signal processor (2-3), software sends the rotating-speed tracking instruction to the AD transducer, and the AD transducer instructs according to this; With tach signal processor (2-3) output, whenever circle M the pulse control AD transducer that is uniformly distributed with of gear shaft carries out analog to digital conversion to the resonance and demodulation signal of resonance and demodulation transducer (2-1) input, and the resonance and demodulation Wave data of quantification is provided to software; Software reads in the resonance and demodulation data by the input of AD transducer; Also read in rotary speed data simultaneously by the input of tach signal processor; Calculation Speed frequency FN (for example: read in the tach signal processor when exporting to the umber of pulse of AD transducer and being S when 1 second, then speed-frequency is FN=S/M) then; Software carries out the FFT conversion to the resonance and demodulation data sample by the input of AD transducer and obtains frequency spectrum; Frequency spectrum to being obtained carries out analysis on cracks; Two lonely analysis of spectrums wherein are: if exist in the frequency spectrum corresponding rotating shaft 2 times of frequency FN outstanding 2FN spectral line (be specially: in the scope that the 2FN spectral line frequency is from 0.97 to 1.01 times the amplitude of high spectral line greater than 3 times of the highest spectral line amplitude in the scope of from 0.97 to 1.01 times of 1FN, 3FN, each spectral line of 4FN); Then signature A is write A=1, otherwise A=0; Engagement analysis of spectrum wherein is: if exist in the frequency spectrum frequency FN of corresponding rotating shaft take advantage of this shaft gear number N of teeth outstanding N*FN spectral line (be specially: in the scope that the N*FN spectral line is from 0.99 to 1.01 times the amplitude of high spectral line greater than from other spectral line amplitude between 1.01* (N-1) * FN to 0.99* (N+1) the * FN); Then signature B is write B=1, otherwise B=0; Wherein there is the analysis of two bunches of shock waves to be among the speed cycle TN=1/FN: if contain X TN cycle in the sample; And have greater than (INT is the round numbers function in the individual cycle of INT (0.3*X); For example during X=10.24; INT (0.3*X)=3) have and only exist 2 maximum value at a distance of (0.9～1.1) TN/2, the amplitude of this maximum value is J, exists amplitude less than 0.9J and greater than the second largest value of 0.3J in the left and right sides TN/8 scope of each maximum value spectral line; Then signature C is write C=1, otherwise C=0; Whether have at last the voting of crackle according to the above-mentioned analysis conclusion of software: if A=0, (result of this detection) flawless is not then diagnosed if withdraw from instruction then the return information starting end duplicate detection of detection, not then withdraw from; Otherwise (when being A=1) is if B=0 and C=0 (being that B=1 or C=1 all are false) then send crack warning, if do not withdraw from instruction then the diagnosis of return information starting end duplicate detection of detection, not then withdraw from; Otherwise (being A=1 and B=1 or C=1) then sent crackle and reported to the police; If do not withdraw from instruction then the return information starting end duplicate detection diagnosis of detection, not then withdraw from.
In the machinery that rotating speed often changes; Like vehicle, aerogenerator, hydrogenerator, rolling mill, oil well squeezer and oil well pump etc.; If the resonance and demodulation signal to resonance and demodulation transducer (2-1) output is sampled with stablizing constant astronomical clock control AD transducer; Then obtaining just possibly not have periodic signal in the sample; But all different nonperiodic signal of time that exists rotating shaft whenever to circle for such signal, both had been not easy to carry out the adequate condition differentiation of described " there is the gear engagement impact bunch of near symmetrical in each rotating shaft cycle "; And the fft analysis of this signal do not have fixing gear rotational speed characteristic frequency spectrum FN and two lonely spectrums thereof, gearing mesh spectrum to say yet, promptly can't implement the diagnosis of a crackle with gear engagement impact (resonance and demodulation) information of the varying-speed machinery of astronomical clock sampling.
For overcome that the rotating speed random variation caused with astronomical clock sampling the time data defectives that can not accurately analyze; Use M doubly the SF FC=M*FN of the frequency of tach signal processor 2-3 output as speed-frequency FN, control AD transducer is done the rotating-speed tracking sampling to the resonance and demodulation signal of resonance and demodulation transducer 2-1 output.
In two gears of size of engagement; The number of teeth of gear wheel is D, and the number of teeth of pinion wheel is X, ratio of gear η=D/X; To the tach signal frequency FN that speed probe obtained; By tach signal processor (2-3) frequency multiplication M, obtain the SF of FC=M*FN, control AD transducer is to the resonance and demodulation signal sampling of resonance and demodulation transducer (2-1) output; Sample length N Y is 2 integral number power; The sample length (according to sampling thheorem) of fft analysis output is NF=NY/2; Analysis frequency upper limit FM=FC/2, spectral resolution DF=FM/NF then, the clef of gear wheel characteristic frequency then is PD=FN/DF; The clef of pinion wheel characteristic frequency then is PX=PD* η; The characteristic frequency clef of Large Gear Shaft During crackle then is PDZ=2PD, and the characteristic frequency clef of pinion shaft crackle then is PXZ=2PX, and it then is PNIE=PD*D=PX*X that big or small gear meshing is impacted clef.
Figure 10 (1)～Figure 10 (4) is depicted as same machinery and different the machineries sampling of utilization rotating-speed tracking and analysis gained data under the different rotating speeds condition; Speed probe (3) is installed on the Large Gear Shaft During; The number of teeth D=68 of gear wheel, the number of teeth X=24 of pinion wheel, ratio of gear η=68/24=2.8333; To the tach signal frequency FN that speed probe obtained; By tach signal processor (2-3) frequency multiplication M=200, obtain the SF of FC=M*FN=200FN, control AD transducer is to the resonance and demodulation signal sampling of resonance and demodulation transducer (2-1) output; Sample length N Y=2048; The sample length (according to sampling thheorem) of fft analysis output is NF=N/2=1024; Analysis frequency upper limit FM=FC/2=100FN; Spectral resolution DF=FM/NF=100FN/1024=0.0976562FN then, the clef of gear wheel characteristic frequency then is PD=FN/DF=10.24, the clef of pinion wheel characteristic frequency then is PX=PD* η=29.01333; The characteristic frequency clef of pinion shaft crackle then is PXZ=2PX=58.02666, and it then is PNIE=PD*D=PX*X=696.32 that big or small gear meshing is impacted clef; Rotating speed does not change, slowly changes (rotating speed during beginning gradually becomes and is not equal to the final rotating speed that begins rotating speed) or random variation when no matter detecting; The automatic AD conversion of rotating-speed tracking can both obtain the spectral line that various failure messages meet above-mentioned PD, PX, PXZ (or also having PDZ), PNIE clef behind fft analysis; Thereby realize " clef solidifies analysis "; Not only solved under the speed change situation can not analysis of failure with sample that astronomical clock sampling was obtained problem, and be very easy to information Recognition.
Claims (3)
1. the resonance and demodulation two lonely spectral methods of a detection of gear axle crackle; The pick-up unit that comprises detection of gear axle crackle; Pick-up unit comprise be installed in the supporting gear axle near the vibratory impulse detecting sensor 1 on the bearing seat of gear, resonance and demodulation detector 2 and speed probe 3; The tach signal processor 2-3 of resonance and demodulation transducer 2-1 and detection of gear axle rotating speed is installed in the resonance and demodulation detector, also has computing machine 2-2 in the resonance and demodulation detector, AD converter and resonance and demodulation two lonely analysis of spectrum softwares are installed in the computing machine; It is characterized in that the step of utilizing said pick-up unit to carry out the gear shaft crack detection is:
1) the gear rotational speed signal of speed probe output is delivered among the tach signal processor 2-3, and the resonance and demodulation two lonely analysis of spectrum softwares that the tach signal of exporting is after treatment delivered to the identification gear shaft crackle of computing machine 2-2 carry out tachometric survey to obtain rotary speed data; Also deliver to the AD transducer signal of resonance and demodulation transducer 2-1 output is carried out rotating-speed tracking control AD conversion, or, obtain the resonance and demodulation data with astronomical clock control AD conversion;
2) signal that contains the gearing mesh vibration and impact that vibratory impulse detecting sensor 1 detects is transferred to resonance and demodulation detector 2; Extract the signal of gear engagement impact with resonance and demodulation transducer 2-1; Be transformed to the Resonance Solutions harmonic then, carry out the resonance and demodulation data acquisition by the AD transducer;
3) resonance and demodulation two lonely analysis of spectrum softwares read in the number N of teeth of the gear that gear shaft installs from the database of having imported data in advance, and read in the resonance and demodulation data and 1 by the input of AD transducer) in the rotary speed data that obtains, Calculation Speed frequency FN;
4) resonance and demodulation two lonely analysis of spectrum softwares carry out the FFT conversion to the resonance and demodulation data, obtain the resonance and demodulation frequency spectrum;
5) resonance and demodulation two lonely analysis of spectrum softwares carry out two lonely analysis of spectrums, engagement analysis of spectrum to the resonance and demodulation frequency spectrum; In each axletree speed cycle, whether there are 2 bunches of mesh impact ripples to analyze to the resonance and demodulation data simultaneously; If meet the following conditions then send corresponding diagnostic alarms information: have in the speed cycle have in 2 bunches of mesh impact ripples, the frequency spectrum N doubly to the gearing mesh spectrum of FN characteristic frequency and 2 times to the FN characteristic frequency, isolated frequency spectrum; Promptly two lonely spectrums report that then crackle appears in gear shaft; If two lonely spectrums are arranged, and not engagement spectrum and 2 bunches of mesh impact ripples then send crack warning; If there are not two lonely spectrum, then flawlesses;
6) if do not withdraw from the instruction of detection then return 1) carry out the duplicate detection diagnosis, otherwise withdraw from and return master routine.
2. the resonance and demodulation two lonely spectral methods of detection of gear axle crackle according to claim 1 is characterized in that, resonance and demodulation two lonely analysis of spectrum software workflows are: software brings into operation, and reads in the number N of teeth of this gear of installing from database; When carrying out astronomical clock sampling; Software instructs to AD transducer tranmitting data register; The AD transducer instructs according to this; With the stable frequency that takes place by the crystal oscillator time clock control AD transducer that is F the resonance and demodulation signal of resonance and demodulation transducer 2-1 output is carried out analog to digital conversion, the resonance and demodulation Wave data of quantification is provided to software; When carrying out the rotating-speed tracking sampling; Software reads in Clock Multiplier Factor M from database; Send Clock Multiplier Factor M to tach signal processor 2-3, software sends the rotating-speed tracking instruction to the AD transducer, and the AD transducer instructs according to this; With tach signal processor 2-3 output, whenever circle M the pulse control AD transducer that is uniformly distributed with of gear shaft carries out analog to digital conversion to the resonance and demodulation signal of resonance and demodulation transducer 2-1 input, and the resonance and demodulation Wave data of quantification is provided to software; Software reads in the resonance and demodulation data by the input of AD transducer, also reads in the rotary speed data by the input of tach signal processor simultaneously, then Calculation Speed frequency FN=S/M; Software carries out the FFT conversion to the resonance and demodulation data sample by the input of AD transducer and obtains frequency spectrum; Frequency spectrum to being obtained carries out analysis on cracks; Two lonely analysis of spectrums wherein are: if there is 2 times the outstanding 2FN spectral line of the frequency FN of corresponding rotating shaft in the frequency spectrum; Be specially: in the scope that the 2FN spectral line frequency is from 0.97 to 1.01 times the amplitude of high spectral line greater than 3 times of the highest spectral line amplitude in the scope of from 0.97 to 1.01 times of 1FN, 3FN, each spectral line of 4FN; Then signature A is write A=1, otherwise A=0; Engagement analysis of spectrum wherein is: if exist the frequency FN of corresponding rotating shaft to take advantage of the outstanding N*FN spectral line of this shaft gear number N of teeth in the frequency spectrum; Be specially: in the scope that the N*FN spectral line is from 0.99 to 1.01 times the amplitude of high spectral line greater than from other spectral line amplitude between 1.01* (N-1) * FN to 0.99* (N+1) the * FN; Then signature B is write B=1, otherwise B=0; Wherein there is the analysis of two bunches of shock waves to be among the speed cycle TN=1/FN: if contain X TN cycle in the sample; And have greater than there being and only existing 2 maximum value in the individual cycle of INT (0.3*X) at a distance of (0.9～1.1) TN/2; The amplitude of this maximum value is J; Exist amplitude less than 0.9J and greater than the second largest value of 0.3J in the left and right sides TN/8 scope of each maximum value spectral line, then signature C is write C=1, otherwise C=0; Whether have at last the voting of crackle according to the above-mentioned analysis conclusion of software: if A=0, flawless is not then diagnosed if withdraw from instruction then the return information starting end duplicate detection of detection, not then withdraw from; Otherwise, if B=0 and C=0 then send crack warning, if do not withdraw from instruction then the diagnosis of return information starting end duplicate detection of detection, not then withdraw from; Otherwise, then send crackle and report to the police; If do not withdraw from instruction then the return information starting end duplicate detection diagnosis of detection, not then withdraw from.
3. the resonance and demodulation two lonely spectral methods of detection of gear axle crackle according to claim 1 and 2 is characterized in that, in two gears of size of engagement; The number of teeth of gear wheel is D, and the number of teeth of pinion wheel is X, ratio of gear η=D/X; To the tach signal frequency FN that speed probe obtained; By tach signal processor 2-3 frequency multiplication M, obtain the SF of FC=M*FN, control AD transducer is to the resonance and demodulation signal sampling of resonance and demodulation transducer 2-1 output; Sample length N Y is 2 integral number power, and the sample length of fft analysis output is NF=NY/2, analysis frequency upper limit FM=FC/2; Spectral resolution DF=FM/NF then; The clef of gear wheel characteristic frequency then is PD=FN/DF, and the clef of pinion wheel characteristic frequency then is PX=PD* η, and the characteristic frequency clef of Large Gear Shaft During crackle then is PDZ=2PD; The characteristic frequency clef of pinion shaft crackle then is PXZ=2PX, and it then is PNIE=PD*D=PX*X that big or small gear meshing is impacted clef.
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