CN103868689A - Vibration frequency analysis-based gear defect rapid detection system and method - Google Patents
Vibration frequency analysis-based gear defect rapid detection system and method Download PDFInfo
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Abstract
The invention discloses a vibration frequency analysis-based gear defect rapid detection system and method. The method comprises the steps of mounting a gear to be detected, i.e. rocking the gear to be detected to a fixed position by a hand wheel, then obtaining a mounting distance of the gear and adjusting so that the gear is located in the position; mounting a gear special for detection, i.e. rocking a small wheel to an indefinite position, obtaining a mounting distance of the small wheel and adjusting, when adjusting for the first time, keeping the slight rotation of the gear to be detected to avoid damage to the gear by collision, when the gear special for detection is already located in a proper position, recording the position of a pointer, then retreating the gear special for detection until the gear special for detection is not in contact with a dial indicator touchpen; tightly locking the gear special for detection; starting the detection system, when a driving wheel and a driven wheel both start to rotate at a lower constant speed, monitoring and recording data by a frequency analyzer after 0.5S, and automatically stopping the system after a collection system collects data of more than three cycles. The gear defect detection efficiency is high, the accuracy is high, the detection standard consistency is good, the operation is simple, and the types of detected gears are wide.
Description
Technical field
The present invention relates to gear defects detection technique field, in particular a kind of gear defects rapid detection system and method based on vibration Frequency Analysis.
Background technology
Due to manufacturing fast development, gear is as the basic part in mechanical manufacturing field, and turnout at home has scale.In Gear Production process due to reasons such as techniques, can produce all kinds of defects, such as burr, crackle etc., but the harmless feature of master gear is most important for the engagement of gear and transmission performance, detection for gear defects mainly rests on the artificial subjective judgement stage at present, exists efficiency low, the low deficiency that waits of accuracy rate.Although also there is now the mode detecting instruments such as optics, this method complicated operation, instrument cost is expensive, and detection has no thoroughness, the so just very difficult requirement that meets the production precision that gear is strengthened day by day.Realization of the present invention is carried out 100% high-level efficiency to the manufacturing defect of gear and is detected online, will produce far-reaching and important impact to Gear Production industry.
Therefore, prior art has yet to be improved and developed.
Summary of the invention
The technical problem to be solved in the present invention is, for the above-mentioned defect of prior art, provides a kind of gear defects rapid detection system and method based on vibration Frequency Analysis, aim to provide a kind of rational in infrastructure, low cost of manufacture, simple to operate, the gear testing system and method that accuracy of detection is high.
In order to realize above-mentioned object, the technical scheme that technical solution problem of the present invention adopts is as follows:
A gear defects method for quick based on vibration Frequency Analysis, comprises step:
A, fill gear to be detected, gear to be detected is shaken to a fixed position by handwheel, then get this
Wheel locating distance adjusting make it on this position, repeatedly regulate more than three times, more locked Large Gear Shaft During;
B, dress detect dedicated gear, the delocalization of shake steamboat to is set up, and gets steamboat locating distance and regulates, while adjusting for the first time, keep the fine rotation of gear to be detected, avoid breaking, when after correct position, remember pointer position, rollback detects dedicated gear again, to not contacting dial gauge stylus place, repeat above-mentioned control method more than three times, if three above dial gauge registration difference are considered as correct installation during for ± 0.01mm;
C, locked detection dedicated gear;
D, open detection system, when first driving wheel and engaged wheel all at the uniform velocity start to rotate with lower speed, after 0.5S, frequency analyzer is monitored record data automatically, after the data of systematic collection to 3 to be collected more than the cycle, the automatic stall of system;
E, overall analysis system compare analysis to 3 of system acquisition data more than cycle, and the power density of characteristic frequency is carried out to fuzzy principle judgement, in the time thinking that the power density of this characteristic frequency reaches user's setting value, judge this gear defectiveness.
The described gear defects method for quick based on vibration Frequency Analysis, described fuzzy principle judgement refers between existing power density mxm. and minimum value sets up at least one fuzzy set, the power density values of each time domain of sub-distribution is to being subordinate to accordingly set again, and minimum value in the power density set at the gear defects place that collects of regulation, in the time that the power density in somewhere is not less than this minimum value, judge this gear defectiveness.
The described gear defects method for quick based on vibration Frequency Analysis, described detection system further comprises the sensor for collection signal.
The described gear defects method for quick based on vibration Frequency Analysis, described detection system further comprises master controller, communication bus, interface circuit, display, electronic control unit, signal sampler, DSP digital signal processor, analytic system; Described master controller, communication bus, interface circuit, display, electronic control unit, signal sampler, DSP digital signal processor, analytic system are connected with master controller by interface circuit.
The described gear defects method for quick based on vibration Frequency Analysis, described overall analysis system further comprises: for showing the PC display of analysis result of described frequency analyzer.
The described gear defects method for quick based on vibration Frequency Analysis, described sensor is torque sensor or speed probe.
The described gear defects method for quick based on vibration Frequency Analysis, described DSP digital signal processor is KeyStone polycaryon processor C667x.
A system for gear defects method for quick based on vibration Frequency Analysis as above, comprising:
Comprise the gear testing platform of the adjustable locating distance of main drive shaft 1, handwheel 2, travelling table 3, transmission case 4, coupling shaft 5, dial gauge 8, projecting shaft 9, belt 10, driven shaft 11, wherein dial gauge 8 is for adjusting gear 6 to be detected and detecting the centre distance between dedicated gear 7;
Can provide at the uniform velocity or power plant system that evenly speed change is rotated, for expulsive force being provided to gear 6 to be detected;
Stationary installation system, for reducing the interference of the described gear defects rapid detection system collection signal based on vibration Frequency Analysis;
Comprise the automatic vibration frequency analysis system of frequency analyzer 14 and PC display 15, for gathering gear 6 measurement data to be detected and institute's image data being analyzed;
Automatic detection module, detects automatically for described gear to be detected 6 being carried out to defect according to described automatic vibration frequency analysis systematic analysis data;
Wherein, Gear 6 to be detected is installed on main drive shaft 1, detect dedicated gear 7 and be installed on driven shaft 11, or gear to be detected 6 is installed on driven shaft, detect dedicated gear 7 and be installed on main drive shaft 1, transmission case 4 is placed on travelling table 3, and main drive shaft 1, transmission case 4, coupling shaft 5 connect successively.
The system of the described gear defects method for quick based on vibration Frequency Analysis, described handwheel 2 is two, is respectively used to fixing described gear to be detected 6, detects dedicated gear 7.
The system of the described gear defects method for quick based on vibration Frequency Analysis, described power plant system is further made up of servomotor, Synchromous machine drive system.
The system of the described gear defects method for quick based on vibration Frequency Analysis, described stationary installation system further comprises fixed station 16, projecting shaft 9, sensor 13, described fixed station 16 is followed driven shaft 11 and is rotated, and described fixed station 16 is fixed on described sensor 13 end of described detection dedicated gear 7 projecting shafts 9.
The system of the described gear defects method for quick based on vibration Frequency Analysis, described automatic vibration frequency analysis system further comprises master controller, communication bus, interface circuit, display, electronic control unit, signal sampler, DSP digital signal processor, analytic system; Described master controller, communication bus, interface circuit, display, electronic control unit, signal sampler, DSP digital signal processor, analytic system are connected with master controller by interface circuit.
The system of the described gear defects method for quick based on vibration Frequency Analysis, described automatic detection module detects the data of described vibration Frequency Analysis system, and the power density of characteristic frequency is judged according to fuzzy principle, in the time thinking that the power density of this characteristic frequency reaches the standard that user sets, described automatic detection module is reported to the police, and judges described gear to be detected (6) defectiveness.
The system of the described gear defects method for quick based on vibration Frequency Analysis, described sensor 13 is torque sensor or speed probe.
The system of the described gear defects method for quick based on vibration Frequency Analysis, described DSP digital signal processor is KeyStone polycaryon processor C667x.
Gear defects rapid detection system and method based on vibration Frequency Analysis provided by the present invention, its beneficial effect is: detection of gear defects efficiency is high, and precision high detection standard consistency is good, simple to operate, and detection of gear type is wide.
Brief description of the drawings
Fig. 1 gear defects method for quick process flow diagram based on vibration Frequency Analysis of the present invention;
Fig. 2 gear defects method for quick preferred application embodiment process flow diagram based on vibration Frequency Analysis of the present invention;
The figure of the membership function of Fig. 3 gear defects method for quick fuzzy set based on vibration Frequency Analysis of the present invention;
Fig. 4 is the gear defects rapid detection system structural representation based on vibration Frequency Analysis of the present invention;
Fig. 5 is the gear defects rapid detection system hand wheel type gear testing mounting platform based on vibration Frequency Analysis of the present invention;
Fig. 6 is the gear defects rapid detection system motion control formula gear testing mounting platform based on vibration Frequency Analysis of the present invention.
In figure, 1-main drive shaft; 2-handwheel; 3-travelling table; 4-transmission case; 5-coupling shaft; 6-gear to be detected; 7-detects dedicated gear; 8-dial gauge; 9-projecting shaft; 10-belt; 11-driven shaft; 12-power plant system; 13-sensor; 14-frequency analyzer; 15-PC display; 16-fixed station.
Embodiment
For making object of the present invention, technical scheme and advantage clearer, clear and definite, developing simultaneously referring to accompanying drawing, the present invention is described in more detail for embodiment.Should be appreciated that specific embodiment described herein, only in order to explain the present invention, is not intended to limit the present invention.
Referring to Fig. 1, is the gear defects method for quick process flow diagram based on vibration Frequency Analysis of the present invention.Before method for quick of the present invention starts, need User Defined criterion of acceptability, and select judgment criteria.Said method comprising the steps of:
S100, fill gear to be detected, gear to be detected is shaken to a fixed position by handwheel, then get this and take turns locating distance and regulate and make it on this position, repeatedly regulate more than three times, more locked Large Gear Shaft During.
S200, dress detect dedicated gear, the delocalization of shake steamboat to is set up, and gets steamboat locating distance and regulates, while adjusting for the first time, keep the fine rotation of gear to be detected, avoid breaking, when after correct position, remember pointer position, rollback detects dedicated gear again, to not contacting dial gauge stylus place, repeat above-mentioned control method more than three times, if three above dial gauge registration difference are considered as correct installation during for ± 0.01mm.
S300, locked detection dedicated gear.
S400, open detection system, when first driving wheel and engaged wheel all at the uniform velocity start to rotate with lower speed, after 0.5S, frequency analyzer is monitored record data automatically, after the data of systematic collection to 3 to be collected more than the cycle, the automatic stall of system.
S500, overall analysis system compare analysis to 3 of system acquisition data more than cycle, and the power density of characteristic frequency is carried out to fuzzy principle judgement, in the time thinking that the power density of this characteristic frequency reaches user's setting value, judge this gear defectiveness.
Referring to Fig. 2, is the gear defects method for quick preferred application embodiment process flow diagram based on vibration Frequency Analysis of the present invention; As shown in Figure 2, comprise the following steps:
Autotest starts; Fuzzy judgement initialization; Wait for input signal, prepare to enter next stage; Automatically distribute subordinate function; Qualification is judged; If system is not to increase progressively one of fuzzy set T, N, S, M, B, VB in six, system alarm, otherwise result transmission master routine, autotest finishes.Input result of determination, output result of determination is also pointed out the phase place of the defect of defective gear, then enters next gear testing, auto-returned cycle detection again.Enter next testing process, system starts, and system uniform rotation is more than three weeks, and the time-frequency that gathers three cycle doctors turns the moving data of torsional wave, and time frequency signal is being transformed, and set specific frequency signal is searched for.If do not search qualified signal, system uniform rotation is more than three weeks; If searched out qualified signal, prepare entering signal power density fuzzy Judgment program, Output rusults is also pointed out the phase place of defective gear.
Referring to Fig. 3, is the figure of the membership function of the gear defects method for quick fuzzy set based on vibration Frequency Analysis of the present invention.Initialization specifies T, N, S, M, B, six fuzzy sets that increase progressively successively of VB, for different gear purposes and the strict degree of detection, this autotest can be set up different gear defects judgment criteria as requested, can be the minimum power density set at gear defects place in the give a definition fuzzy set of arbitrary initial of tallying with the actual situation, the minimum power density value in this set be gear defects and intact critical value; While supposing the actual detection of user, set X(X according to oneself requirement and refer to any one in initialized 5 fuzzy sets) be the minimum power density set at gear defects place, if the power density detecting is under the jurisdiction of the fuzzy set that increases progressively after X or X, its corresponding detected gear, judge that it is defective gear, i.e. this gear defectiveness, if the power density detecting is under the jurisdiction of the fuzzy set of successively decreasing before X, its corresponding detected gear, judge that it is qualified gear, i.e. this gear zero defect.
Referring to Fig. 4, is the gear defects rapid detection system structural representation based on vibration Frequency Analysis of the present invention.As shown in Figure 4, in the gear defects rapid detection system based on vibration Frequency Analysis provided by the invention, at least comprise:
Comprise the gear testing platform of the adjustable locating distance of main drive shaft 1, handwheel 2, travelling table 3, transmission case 4, coupling shaft 5, dial gauge 8, projecting shaft 9, belt 10, driven shaft 11, wherein dial gauge 8 is for adjusting gear 6 to be detected and detecting the centre distance between dedicated gear 7;
Can provide at the uniform velocity or power plant system that evenly speed change is rotated, for expulsive force being provided to gear 6 to be detected;
Stationary installation system, for reducing the interference of the described gear defects rapid detection system collection signal based on vibration Frequency Analysis;
Comprise the automatic vibration frequency analysis system of frequency analyzer 14 and PC display 15, for gathering gear 6 measurement data to be detected and institute's image data being analyzed;
Automatic detection module, detects automatically for described gear to be detected 6 being carried out to defect according to described automatic vibration frequency analysis systematic analysis data;
Wherein, Gear 6 to be detected is installed on main drive shaft 1, detecting dedicated gear 7 is installed on driven shaft (11), or gear 6 to be detected is installed on driven shaft, detecting dedicated gear 7 is installed on main drive shaft 1, transmission case 4 is placed on travelling table 3, and main drive shaft 1, transmission case 4, coupling shaft 5 connect successively.
Preferably, described handwheel 2 is two, is respectively used to fixing described gear to be detected 6, detects dedicated gear 7.
Preferably, described power plant system is further made up of servomotor, Synchromous machine drive system.
Preferably, described stationary installation system further comprises fixed station 16, projecting shaft 9, sensor 13, described fixed station 16 is followed driven shaft 11 and is rotated, and described fixed station 16 is fixed on described detection dedicated gear 7 by described sensor 13 and stretches out the tip of the axis.
Preferably, described automatic vibration frequency analysis system further comprises master controller, communication bus, interface circuit, display, electronic control unit, signal sampler, DSP digital signal processor, analytic system; Described master controller, communication bus, interface circuit, display, electronic control unit, signal sampler, DSP digital signal processor, analytic system are connected with master controller by interface circuit.
Preferably, described automatic detection module detects the data of described vibration Frequency Analysis system, and the power density of characteristic frequency is judged according to fuzzy principle, in the time thinking that the power density of this characteristic frequency reaches the standard that user sets, described automatic detection module is reported to the police, and judges described gear to be detected 6 defectiveness.
Preferably, described sensor 13 is torque sensor or speed probe.
Preferably, described DSP digital signal processor is KeyStone polycaryon processor C667x.
Referring to Fig. 5, is the gear defects rapid detection system hand wheel type gear testing mounting platform based on vibration Frequency Analysis of the present invention.As shown in Figure 5, in order accurately to judge whether locating distance meets the requirements, design a dial gauge 8 that the gear of working good is installed, in this system other end, when general gauge outfit contact travelling table end face, returned to zero; When during with type gear, handwheel 2 being replaced to motion control automatic station-keeping system for Fast Installation.
Referring to Fig. 6, is the gear defects rapid detection system motion control formula gear testing mounting platform based on vibration Frequency Analysis of the present invention.As shown in Figure 6, motion control automatic station-keeping system comprises motor and motor control assembly, and motor control assembly is set the real-time control to motor in different locating distance situations for realizing, and meets the needs of automatic alignment position, a pair of mate gear of quick-clamping.Power plant system 12 can be replaced by servomotor, and these propulsion system offer main drive shaft rotational power; In order to make sensor 13 can reach a good collection effect, General Requirements power source provides a low speed and rotates uniformly.In order to allow projecting shaft avoid the interference of other signals, special design play the fixed station 16 that driven shaft rotates of following that reduces external interference effect; The requirement that signal when meeting in meshed transmission gear process each tooth engagement can gather, sensor 13 must be high accurancy and precision, the torque sensor that collecting efficiency is high or speed probe.
Gear defects rapid detection system and method based on vibration Frequency Analysis provided by the present invention, detection of gear defects efficiency is high, and precision high detection standard consistency is good, simple to operate, and detection of gear type is wide.
Should be understood that, application of the present invention is not limited to above-mentioned giving an example, and for those of ordinary skills, can be improved according to the above description or convert, and all these improvement and conversion all should belong to the protection domain of claims of the present invention.
Claims (15)
1. the gear defects method for quick based on vibration Frequency Analysis, is characterized in that, comprises step:
A, fill gear to be detected, gear to be detected is shaken to a fixed position by handwheel, then get this and take turns locating distance and regulate and make it on this position, repeatedly regulate more than three times, more locked Large Gear Shaft During;
B, dress detect dedicated gear, the delocalization of shake steamboat to is set up, and gets steamboat locating distance and regulates, while adjusting for the first time, keep the fine rotation of gear to be detected, avoid breaking, when after correct position, remember pointer position, rollback detects dedicated gear again, to not contacting dial gauge stylus place, repeat above-mentioned control method more than three times, if three above dial gauge registration difference are considered as correct installation during for ± 0.01mm;
C, locked detection dedicated gear;
D, open detection system, when first driving wheel and engaged wheel all at the uniform velocity start to rotate with lower speed, after 0.5S, frequency analyzer is monitored record data automatically, after the data of systematic collection to 3 to be collected more than the cycle, the automatic stall of system;
E, overall analysis system compare analysis to 3 of system acquisition data more than cycle, and the power density of characteristic frequency is carried out to fuzzy principle judgement, in the time thinking that the power density of this characteristic frequency reaches user's setting value, judge this gear defectiveness.
2. the gear defects method for quick based on vibration Frequency Analysis according to claim 1, it is characterized in that, described fuzzy principle judgement refers between existing power density mxm. and minimum value sets up at least one fuzzy set, the power density values of each time domain of sub-distribution is to being subordinate to accordingly set again, and minimum value in the power density set at the gear defects place that collects of regulation, in the time that the power density in somewhere is not less than this minimum value, judge this gear defectiveness.
3. the gear defects method for quick based on vibration Frequency Analysis according to claim 1, is characterized in that, described detection system further comprises the sensor for collection signal.
4. the gear defects method for quick based on vibration Frequency Analysis according to claim 1, it is characterized in that, described detection system further comprises master controller, communication bus, interface circuit, display, electronic control unit, signal sampler, DSP digital signal processor, analytic system; Described master controller, communication bus, interface circuit, display, electronic control unit, signal sampler, DSP digital signal processor, analytic system are connected with master controller by interface circuit.
5. the gear defects method for quick based on vibration Frequency Analysis according to claim 1, is characterized in that, described overall analysis system further comprises: for showing the PC display of analysis result of described frequency analyzer.
6. the gear defects method for quick based on vibration Frequency Analysis according to claim 3, is characterized in that, described sensor is torque sensor or speed probe.
7. the gear defects method for quick based on vibration Frequency Analysis according to claim 4, is characterized in that, described DSP digital signal processor is KeyStone polycaryon processor C667x.
8. a system that adopts the gear defects method for quick based on vibration Frequency Analysis described in claim 1-7 any one, is characterized in that, comprising:
Comprise the gear testing platform of the adjustable locating distance of main drive shaft (1), handwheel (2), travelling table (3), transmission case (4), coupling shaft (5), dial gauge (8), projecting shaft (9), belt (10), driven shaft (11), wherein dial gauge (8) is for adjusting gear to be detected (6) and detecting the centre distance between dedicated gear (7);
Can provide at the uniform velocity or power plant system that evenly speed change is rotated, for expulsive force being provided to gear to be detected (6);
Stationary installation system, for reducing the interference of the described gear defects rapid detection system collection signal based on vibration Frequency Analysis;
Comprise the automatic vibration frequency analysis system of frequency analyzer (14) and PC display (15), for gathering gear to be detected (6) measurement data and institute's image data being analyzed;
Automatic detection module, detects automatically for described gear to be detected (6) being carried out to defect according to described automatic vibration frequency analysis systematic analysis data;
Wherein, Gear to be detected (6) is installed on main drive shaft (1), detecting dedicated gear (7) is installed on driven shaft (11), or gear to be detected (6) is installed on driven shaft, detecting dedicated gear (7) is installed on main drive shaft (1), transmission case (4) is placed on travelling table (3), and main drive shaft (1), transmission case (4), coupling shaft (5) connect successively.
9. the system of the gear defects fast detecting based on vibration Frequency Analysis according to claim 8, is characterized in that, described handwheel (2) is two, is respectively used to fixing described gear to be detected (6), detects dedicated gear (7).
10. the system of the gear defects fast detecting based on vibration Frequency Analysis according to claim 8, is characterized in that, described power plant system is further made up of servomotor, Synchromous machine drive system.
The 11. gear defects rapid detection system based on vibration Frequency Analysis according to claim 8, it is characterized in that, described stationary installation system further comprises fixed station (16), projecting shaft (9), sensor (13), described fixed station (16) is followed driven shaft (11) and is rotated, and described fixed station (16) is fixed on described sensor (13) end of described detection dedicated gear (7) projecting shaft (9).
The 12. gear defects rapid detection system based on vibration Frequency Analysis according to claim 8, it is characterized in that, described automatic vibration frequency analysis system further comprises master controller, communication bus, interface circuit, display, electronic control unit, signal sampler, DSP digital signal processor, analytic system; Described master controller, communication bus, interface circuit, display, electronic control unit, signal sampler, DSP digital signal processor, analytic system are connected with master controller by interface circuit.
The 13. gear defects rapid detection system based on vibration Frequency Analysis according to claim 8, it is characterized in that, described automatic detection module detects the data of described vibration Frequency Analysis system, and the power density of characteristic frequency is judged according to fuzzy principle, in the time thinking that the power density of this characteristic frequency reaches the standard that user sets, described automatic detection module is reported to the police, and judges described gear to be detected (6) defectiveness.
The 14. gear defects rapid detection system based on vibration Frequency Analysis according to claim 11, is characterized in that, described sensor (13) is torque sensor or speed probe.
The 15. gear defects rapid detection system based on vibration Frequency Analysis according to claim 12, is characterized in that, described DSP digital signal processor is KeyStone polycaryon processor C667x.
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| CN103868689B (en) | 2017-02-22 |
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