CN102520052A - Electrostatic induction based metal surface contact damage on-line monitoring system and monitoring method - Google Patents
Electrostatic induction based metal surface contact damage on-line monitoring system and monitoring method Download PDFInfo
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Abstract
The invention discloses an electrostatic induction based metal surface contact damage on-line monitoring system and a monitoring method. The system provided by the invention contains an electrostatic transducer, a signal acquisition and processing analysis system and an auxiliary part, wherein the electrostatic transducer is composed of an electrostatic induction head, a shielding cover, an insulation part and a charge amplifying circuit; the signal acquisition and processing analysis system is composed of a computer, a signal processing program and a signal conditioning acquisition hardware; and the auxiliary part contains a sensor mounting rack. The system can be utilized to monitor metal surface contact damage on line, determine whether there is contact damage on the metal surface and determine the degree of the damage. The monitoring system and the method belong to the field of direct monitoring of damaged surface and can replace commonly-used monitoring systems and methods by secondary influence parameters such as vibration signal monitoring, temperature monitoring and the like.
Description
Technical Field
The invention discloses an on-line monitoring system and a monitoring method for metal surface contact damage based on electrostatic induction, relates to comprehensive detection of metal surface contact damage, and belongs to the field of sensor measuring instruments.
Background
There are tens of methods for detecting or monitoring contact damage on metal surfaces, and the most common methods include: ray detection, ultrasonic detection, eddy current detection, acoustic emission, and the like.
The ray detection is to evaluate the quality, the size and the characteristics of a detected piece according to the obtained image by utilizing the transmission performance of various rays to materials and the different absorption attenuation degrees of different materials to the rays, and has the defects of low detection sensitivity to plane defects and high detection cost; the ultrasonic detection has comprehensive advantages of determining the size, the position and the like of the defect, the equipment is light, and the field detection can be carried out; the magnetic powder detection is a nondestructive detection method for displaying defects on the surface and near surface of a ferromagnetic material and a workpiece thereof by utilizing the aggregation of magnetic powder, can be used for detecting the quality of the surface and near surface, and has the advantages of high detection sensitivity, simple process, high detection speed and low cost, and the shape, the position and the size of the defects can be visually displayed, and the properties of the defects can be roughly determined; the eddy current detection is a nondestructive detection method for finding defects by measuring the change of induced eddy current in a tested piece by using the electromagnetic induction principle, and has higher sensitivity on the defects on the surface and near surface of a conductive material.
None of the above detection methods is versatile, and there are few methods that can realize online monitoring. The method realizes online monitoring of contact damage of the metal surface by utilizing the electrostatic induction technology, belongs to direct measurement of fault parts and products, can realize real-time monitoring of the surface state of a component, brings abundant preparation time for maintenance plans, and enables predicted maintenance to be possible.
Disclosure of Invention
The invention aims to provide an online monitoring system and an online monitoring method for metal surface contact damage based on electrostatic induction, which are simple to use and reliable in performance. The system and the method for monitoring the damage surface of the metal surface can be used for monitoring the contact damage of the metal surface on line, judging whether the contact damage occurs on the metal surface or not and judging the degree of the damage, belong to the monitoring system and the method for directly monitoring the damage surface, and can replace the commonly used monitoring system and method for secondary influence parameters such as vibration signal monitoring, temperature monitoring and the like.
In order to solve the technical problems, the invention adopts the technical scheme that:
the utility model provides a metal surface contact damage on-line monitoring system based on electrostatic induction, includes the electrostatic sensor who comprises electrostatic induction head, shield cover, insulating part, charge amplifier circuit, and the signal acquisition analytic system who comprises computer and signal processing procedure, signal conditioning acquisition hardware to and the auxiliary component that the sensor mounting bracket constitutes, its characterized in that:
the sensor is composed of an electrostatic induction head, a shielding cover, an insulating part and a charge amplifying circuit, wherein the electrostatic induction head is in a disc shape, a metal rod is arranged on the back surface of the disc to lead out a signal to the charge amplifying circuit, the shielding cover is in a cylindrical shape, one end of the shielding cover is closed, the other end of the shielding cover is not closed, the electrostatic signal after the charge amplification is led out from the closed end of the shielding cover, the signal shielding is in contact with the shielding cover at the same potential, and the unclosed end of the shielding cover is used for installing the charge amplifying circuit, the induction head.
A metal surface contact damage on-line monitoring method based on electrostatic induction is suitable for monitoring whether contact damage occurs on a metal surface, and comprises the following steps:
a. during monitoring, a sensor mounting frame is used for mounting a sensor induction head close to a monitored surface, and the vertical distance h between the sensor induction head and the monitored surface is 1-2 mm;
b. the sensor induction head collects the static signal of the detected surface and conditions, amplifies and filters the obtained signal;
c. and comparing the conditioned electrostatic signal with a background noise quotation mark, wherein the amplitude u of the electrostatic signal corresponding to the contact damage is more than 2-3 times of the background noise signal, and the contact damage can be judged to occur.
The metal surface contact damage on-line monitoring method based on the electrostatic induction comprises a plurality of sensors and is suitable for positioning the damage position of the metal surface, and the method comprises the following steps:
a. during monitoring, at least two sensors are arranged at equal intervals by means of a sensor mounting frame, sensor heads are arranged close to a monitored surface, and the vertical distance h between the sensor heads and the monitored surface is 1-2 mm;
b. collecting static signals of two adjacent sensors, conditioning, amplifying and filtering the obtained signals to obtain two static signal amplitudes
And
；
c. determining the distance of the contact damage site from the two sensors:
wherein,
、
is the horizontal distance between the lesion and the two sensors.
An online monitoring method for metal surface contact damage based on electrostatic induction is suitable for quantitatively identifying the damage degree of a metal surface, and comprises the following steps:
a. during monitoring, a sensor mounting frame is used for mounting a sensor induction head close to a monitored surface, and the vertical distance h between the sensor induction head and the monitored surface is 1-2 mm;
b. the sensor induction head collects the static signal of the detected surface and conditions, amplifies and filters the obtained signal;
c. seven statistical indexes of a harmonic mean value V1, a quartile difference V2, a kurtosis V3, a mean value V4, a sample range V5, a skewness V6 and a standard deviation V7 are obtained for signals within 2 minutes, and the index data are subjected to dimensionality reduction by a factor analysis method;
d. and identifying and classifying the data subjected to the dimensionality reduction by using a pattern identification method, so as to realize quantitative monitoring on the contact damage of the metal surface.
The factor analysis method model is as follows:
wherein, variable
Is a measured data variable;
is a common factor;
is a variable of
In the common factor
A score of (a);
is a variable quantity
A unique special factor.
The output of the decision function of the pattern recognition method is expressed as:
wherein
Is the Lagrange coefficient;
for the kernel function, there are many kinds of kernel functions, such as polynomial kernel function:
，qis a constant; b is a fitting constant. Scoring the factors
And taking the decision function output as an input, wherein the decision function output is a damage quantitative index.
The research shows that the phenomenon of generating static electricity by the contact damage of the metal surface comprises the following steps: a. the metal surface is damaged by friction to form a new surface, and meanwhile, emitted electrons, photons, ions and neutral particles are ionized, and static electricity is generated. b. Both scratching of the metal surface and the formation of a white layer can cause static electricity to the metal surface. Therefore, when the metal surface is in contact damage, the sensor induction head close to the damaged part can sense the electrostatic signal corresponding to the damage, and whether the metal surface is in contact damage or not can be judged by comparing the electrostatic signal corresponding to the damage with the background noise signal. In addition, the positioning of the contact damage part can be realized by utilizing a plurality of sensors and corresponding software algorithms; the method can also be used for extracting the characteristics of electrostatic signals with different degrees of surface contact damage, obtaining seven statistical indexes for the signals in unit time, reducing the dimensions by using a factor analysis method, classifying the data after the dimensions are reduced by using a pattern recognition method, and realizing the quantitative monitoring of the metal surface contact damage.
The invention can be used for on-line monitoring of metal surface contact damage, the damage identification precision is 1 millimeter level, the damage positioning precision is 0.5 millimeter, the system hardware structure is compact, and the invention can bear the common working environment with high and low temperature, large vibration and certain electromagnetic interference. The invention is mainly used for monitoring the contact damage of the metal surface of the mechanical equipment with the rolling contact phenomenon, realizes diagnosis and prevention when millimeter-scale damage occurs on the contact surface of the mechanical equipment, analyzes the damage position and degree, and prevents damage from further increasing to influence the safety of the mechanism.
Drawings
FIG. 1 is a configuration diagram of an online monitoring system for contact damage of a metal surface.
Fig. 2 is a schematic structural diagram of the sensor.
Fig. 3 is a schematic view of a sensor mounting position.
Fig. 4 is a schematic diagram of a sensor mounting position.
Fig. 5 is a schematic diagram of a sensor mounting position three.
Fig. 6 is a fourth schematic diagram of the installation position of the sensor.
Fig. 7 is a schematic diagram of a sensor mounting position.
Fig. 8 is a sixth schematic view of the sensor mounting position.
FIG. 9 is a schematic diagram of the location of a metal surface contact damage.
FIG. 10 is a schematic diagram of online monitoring of contact damage to a metal surface.
Number designation in the figures: 1. the sensor comprises an electrostatic sensor, 2, a sensor induction head, 3, one of a metal contact pair, 4, two of a metal contact pair, 5, a computer and a signal processing program, 6, signal conditioning and acquisition hardware, 7, a sensor mounting frame, 8, a shielding cover, 9, a charge amplifying circuit, 10 and an insulating component.
Detailed Description
The system is described in detail below with reference to the accompanying drawings:
1. the system is composed of an electrostatic sensor (comprising an electrostatic induction head 2, a shielding cover 8, an insulating part 10 and a charge amplifying circuit 9), a signal acquisition and analysis system (comprising a computer, a signal processing program 5 and signal conditioning and acquisition hardware 6), a sensor mounting rack 7 and other auxiliary parts, wherein a signal acquisition card in the acquisition hardware adopts a WLS9234 digital acquisition card of NI company, and the computer adopts a general PC based on a windows platform.
The sensor is a core device of the system, and the structure of the sensor is shown in fig. 2 and comprises an electrostatic induction head 2, a shielding case 8, an insulating part 10 and a charge amplifying circuit 9.
The installation mode of the sensor is based on the principle that the static induction head is as close to the monitored surface as possible, the installation mode of the static induction head is as shown in fig. 3, 4, 5, 6, 7 and 8 (but not limited to the listed modes), the installation positions of the static induction head can be in various modes, and the sensor can be perpendicular to the monitoring surface, parallel to the monitoring surface, or simultaneously adopt a plurality of sensors for monitoring.
2. The principle of monitoring whether the metal surface is in contact damage is as follows:
when contact damage occurs, static periodic signals corresponding to the motion period of the contact pair can be seen from time domain signals, and the amplitude of signals of the damaged part is higher than that of background noise by more than dozens of times. However, because the electrostatic signal contains a large number of non-stationary signals, the electrostatic signal is analyzed by using time domain parameters or by using a Short Time Fourier Transform (STFT) method.
3. The method and the principle for monitoring the position of the contact damage on the metal surface are as follows:
referring to fig. 3, 4, 5, 6, 7 and 8, a plurality (2 or more) of identical electrostatic sensors were used, mounted at equal intervals in the x-direction, and other test conditions were unchanged. According to the electrostatic induction model, when electrostatic charge caused by damage passes through the vicinity of a plurality of sensors, the phases of waveforms of output voltage signals of the sensors are the same, and the waveforms are similar.
3.1 xDirectional damage positioning method
If static electricity caused by surface damage passes between two adjacent sensors (# 2 and # 3), the static electricity is setTwo sensors of load and distance are arranged atxThe distances in the directions are respectivelyd 1、d 2Then the surface can be damaged according to the voltage relationship measured by the two sensorsxAnd (5) positioning the direction.
From available in the electrostatic charge rimyWhen the direction passes near the sensor sensing surface, the maximum value of the output voltage of the measuring signal is as follows:
therefore, the maximum value of the voltage output by the two sensors # 2 and #3d 1、d 2The relationship of (1) is:
3.2 ydirectional damage positioning method
The phase of the electrostatic extremum in one cycle of any one sensor corresponds to the position of the damage to the plate in the direction parallel to the direction of motion (referred to simply as the position in the y-direction). The peak of the electrostatic signal corresponds to the damage center position, and the y-direction positioning can be carried out on the surface damage by combining a displacement sensor of the friction and wear test bed, and the adjacent damage also has high resolution.
4. Identification of degree of surface contact damage
4.1 selection of indices and dimensionality reduction
For typical electrostatic induction signals of different damages in monitoring, 7 statistical indexes of harmonic mean value V1, quartering difference V2, kurtosis V3, mean value V4, sample range V5, skewness V6 and standard deviation V7 are adopted, wherein,
；
wherein Q is1Position of = (n +1)/4, Q3Position =3(n + 1)/4;；
；
；
；
(ii) a N is the length of the sample length,
is the standard deviation.
A large amount of correlation and redundancy exist among index data, so that a factor analysis method is adopted for dimensionality reduction, and 7 types of indexes are expressed by fewer common factors, so that the function of compressing data is achieved.
The factor analysis method model is as follows:
wherein, variableIs a measured data variable;
is a common factor;
is a variable of
In the common factorA score of (a);
is a variable quantity
A unique special factor.
The factor analysis process is to find a few common factors capable of expressing most information of the original data from the original data
And replaces the information of the original data with these common factors.
4.2 quantitative monitoring of contact Damage
The output of the decision function of the monitoring and identifying method of the contact damage is expressed as:
wherein
Is the Lagrange coefficient;
for the kernel function, there are many kinds of kernel functions, such as polynomial kernel function:，qis a constant; b is a fitting constant. Scoring the factorsAnd taking the decision function output as an input, wherein the decision function output is a damage quantitative index.
Claims (6)
1. The utility model provides a metal surface contact damage on-line monitoring system based on electrostatic induction, includes the electrostatic sensor who comprises electrostatic induction head (2), shield cover (8), insulating part (10), charge amplifier circuit (9), and the signal acquisition analytic system who comprises computer and signal processing program (5), signal conditioning collection hardware (6) to and the auxiliary component that sensor mounting bracket (7) are constituteed, its characterized in that:
the sensor comprises an electrostatic induction head (2), a shielding case (8), an insulating part (10), a charge amplifying circuit (9) and the like, wherein the electrostatic induction head (2) is disc-shaped, a metal rod is arranged on the back surface of the disc to lead out a signal to the charge amplifying circuit (9), the shielding case (8) is cylindrical, one end of the shielding case is closed, the other end of the shielding case is not closed, the closed end of the shielding case (8) is used for leading out an electrostatic signal after the charge amplification, the signal shielding is in equal potential with the shielding case (8) in contact, and the unclosed end of the shielding case (8) is used for installing the charge amplifying circuit (9), the induction head (2) and the insulating part (10).
2. An on-line monitoring method for the contact damage of the metal surface by adopting the monitoring system of claim 1, which adopts an electrostatic sensor to detect the contact damage of the metal surface, and is characterized by comprising the following steps:
a. during monitoring, a sensor mounting frame (7) is used for mounting a sensor induction head (2) close to a monitored surface, and the vertical distance h between the sensor induction head and the monitored surface is 1-2 mm;
b. the sensor induction head (2) collects the electrostatic signal of the detected surface and conditions, amplifies and filters the obtained signal;
c. and comparing the conditioned electrostatic signal with a background noise quotation mark, wherein the amplitude u of the electrostatic signal corresponding to the contact damage is more than 2-3 times of the background noise signal, and the contact damage can be judged to occur.
3. An on-line monitoring method for the contact damage of the metal surface by adopting the monitoring system of claim 1, which adopts an electrostatic sensor to detect the contact damage of the metal surface, and is characterized by comprising the following steps:
a. during monitoring, at least two sensors are arranged at equal intervals by means of a sensor mounting frame (7), a sensor sensing head (2) is mounted close to a monitored surface, and the vertical distance h between the sensor sensing head and the monitored surface is 1-2 mm;
b. collecting static signals of two adjacent sensors, conditioning, amplifying and filtering the obtained signals to obtain two static signal amplitudes
And
；
c. determining the distance of the contact damage site from the two sensors:
wherein,
、is the horizontal distance between the lesion and the two sensors.
4. An on-line monitoring method for contact damage to a metal surface using the detection system of claim 1, comprising: the method comprises the following steps:
a. during monitoring, a sensor mounting frame (7) is used for mounting a sensor induction head (2) close to a monitored surface, and the vertical distance h between the sensor induction head and the monitored surface is 1-2 mm;
b. the sensor induction head (2) collects the electrostatic signal of the detected surface and conditions, amplifies and filters the obtained signal;
c. seven statistical indexes of a harmonic mean value V1, a quartile difference V2, a kurtosis V3, a mean value V4, a sample range V5, a skewness V6 and a standard deviation V7 are obtained for signals within 2 minutes, and the index data are subjected to dimensionality reduction by a factor analysis method;
d. and identifying and classifying the data subjected to the dimensionality reduction by using a pattern identification method, so as to realize quantitative monitoring on the contact damage of the metal surface.
5. The on-line monitoring method according to claim 4, wherein: the factor analysis method model is as follows:
wherein,
for the number of m common factors, the number of m,
is a variable quantity
The unique special factors are all invisible hidden variables,
is a variable ofIn the common factorThe score of (3) reflects the importance of the common factor to the variable.
6. The on-line monitoring method according to claim 4, wherein: the pattern recognition method adopts a support vector machine, and the output of a decision function is expressed as:
wherein
Is Lagrange coefficient;
for the kernel function, there are many kinds of kernel functions, such as polynomial kernel function:
，qis a constant; b is a fitting constant, and the factors are scored
And taking the decision function output as an input, wherein the decision function output is a damage quantitative index.
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| CN107345927A (en) * | 2017-01-21 | 2017-11-14 | 北京理工大学 | A kind of dielectric material identification device for robot autonomous environment sensing |
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| CN114216935A (en) * | 2021-12-24 | 2022-03-22 | 上海工程技术大学 | Device for detecting performance of lubricating oil based on electrostatic induction |
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| CN104198571A (en) * | 2014-09-24 | 2014-12-10 | 如皋市非标轴承有限公司 | Method for detecting crack on surface of worm gear combined pivotal bearing |
| CN107045003A (en) * | 2016-12-20 | 2017-08-15 | 北京航空航天大学 | A kind of aluminium alloy structure corrosion damage monitoring method based on synchronous iteration algorithm for reconstructing |
| CN107345927A (en) * | 2017-01-21 | 2017-11-14 | 北京理工大学 | A kind of dielectric material identification device for robot autonomous environment sensing |
| CN107345927B (en) * | 2017-01-21 | 2021-02-19 | 北京理工大学 | Medium material recognition device for autonomous environment perception of robot |
| CN111220677A (en) * | 2020-01-17 | 2020-06-02 | 江苏理工学院 | Metal surface damage monitoring sensor, monitoring method and system |
| CN114216935A (en) * | 2021-12-24 | 2022-03-22 | 上海工程技术大学 | Device for detecting performance of lubricating oil based on electrostatic induction |
| CN114216935B (en) * | 2021-12-24 | 2023-11-21 | 沃伯瑞新材料(江苏)有限公司 | Device for detecting lubricating oil performance based on electrostatic induction |
| CN115426199A (en) * | 2022-11-03 | 2022-12-02 | 南京金易众和信息科技有限公司 | Website data security protection method |
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Application publication date: 20120627 |