CN103868689B - Vibration frequency analysis-based gear defect rapid detection system and method - Google Patents

Abstract

The invention discloses a gear defect rapid detection system and method based on vibration frequency analysis. The method includes the steps of: installing the gear to be detected, shaking the gear to be detected to a fixed position through the hand wheel, then taking the installation distance of the wheel and adjusting it to be at this position; installing the special gear for detection, shaking the small wheel to a fixed position In the position, take the installation distance of the small wheel and adjust it. When adjusting for the first time, keep the gear to be detected slightly rotating to avoid damage. Contact the stylus of the dial indicator; the special gear for lock detection; when the detection system is turned on, firstly, when the driving wheel and the driven wheel start to rotate at a low speed and uniform speed, the frequency analyzer will automatically monitor and record data after 0.5S, and the data will be collected by the acquisition system After reaching more than 3 cycles of data, the system will automatically stop. The detection of gear defects has high efficiency, high precision, good consistency of detection standards, simple operation, and a wide range of detection gear types.

Description

A rapid detection system and method for gear defects based on vibration frequency analysis

technical field

The invention relates to the technical field of gear defect detection, in particular to a system and method for rapid detection of gear defects based on vibration frequency analysis.

Background technique

Due to the rapid development of the manufacturing industry, gears, as basic parts in the field of machinery manufacturing, have a very large domestic production volume. In the gear production process, various defects, such as burrs and cracks, will occur due to the process and other reasons. However, the non-destructive characteristics of standard gears are very important for the meshing and transmission performance of the gears. Currently, the detection of gear defects mainly remains In the artificial subjective judgment stage, there are shortcomings such as low efficiency and low accuracy. Although there are optical and other detection instruments nowadays, this method is complicated to operate, the cost of the instrument is expensive, and the detection is not thorough, so it is difficult to meet the requirements for the increasing production accuracy of gears. The realization of the present invention carries out 100% high-efficiency on-line detection of gear manufacturing defects, which will have a profound and important impact on the gear production industry.

Therefore, the prior art still needs to be improved and developed.

Contents of the invention

The technical problem to be solved by the present invention is to provide a rapid detection system and method for gear defects based on vibration frequency analysis in view of the above-mentioned defects of the prior art. High gear detection system and method.

In order to achieve the above-mentioned purpose, the technical solution adopted by the present invention to solve technical problems is as follows:

A rapid detection method for gear defects based on vibration frequency analysis, comprising steps:

A. Install the gear to be detected, turn the gear to be detected to a fixed position through the hand wheel, and then take the gear

Wheel installation distance and adjust it to this position, adjust it repeatedly for more than three times, and then lock the big gear shaft;

B. Install the special gear for detection, shake the small wheel to a certain position, take the installation distance of the small wheel and adjust it. When adjusting for the first time, keep the gear to be detected slightly rotating to avoid damage. When it is in a suitable position, record Hold the pointer position, then return the special gear for detection, to the place where it does not touch the stylus of the dial indicator, repeat the above adjustment method for more than three times, if the difference of the percentage indication for more than three times is ±0.01mm, it is considered to be installed correctly;

C. Special gear for lock detection;

D. Turn on the detection system. Firstly, when both the driving wheel and the driven wheel start to rotate at a low speed and uniform speed, the frequency analyzer will automatically monitor and record data after 0.5 seconds. After the acquisition system collects more than 3 cycles of data, the system will automatically stop. change;

E. The comprehensive analysis system compares and analyzes the data collected by the system for more than 3 periods, and makes a fuzzy judgment on the power density of a specific frequency. When the power density of the specific frequency reaches the user's set value, it is determined that the gear is defective. .

In the rapid detection method for gear defects based on vibration frequency analysis, the fuzzy principle judgment refers to establishing at least one fuzzy set between the existing highest power density value and the smallest value, and redistributing the power density value of each time domain To the corresponding membership set, and stipulate the minimum value in the power density set of the collected gear defect. When the power density of a certain place is not less than the minimum value, it is determined that the gear is defective.

In the rapid detection method for gear defects based on vibration frequency analysis, the detection system further includes a sensor for collecting signals.

In the rapid detection method for gear defects based on vibration frequency analysis, the detection system further includes a general controller, a communication bus, an interface circuit, a display, an electronic control unit, a signal acquisition instrument, a DSP digital signal processor, and an analysis system; The general controller, communication bus, interface circuit, display, electronic control unit, signal acquisition instrument, DSP digital signal processor, and analysis system described above are connected to the general controller through the interface circuit.

Said method for quick detection of gear defects based on vibration frequency analysis, said comprehensive analysis system further includes: a PC display for displaying the analysis results of said frequency analyzer.

In the method for quickly detecting gear defects based on vibration frequency analysis, the sensor is a torque sensor or a rotational speed sensor.

In the fast detection method for gear defects based on vibration frequency analysis, the DSP digital signal processor is a KeyStone multi-core processor C667x.

A system of a rapid detection method for gear defects based on vibration frequency analysis as described above, comprising:

A gear detection platform with adjustable installation distance including drive shaft 1, handwheel 2, mobile workbench 3, transmission box 4, connecting shaft 5, dial indicator 8, extension shaft 9, belt 10, and driven shaft 11. The dial gauge 8 is used to adjust the center distance between the gear to be detected 6 and the detection-specific gear 7;

A power device system that can provide uniform or uniformly variable speed rotation is used to provide driving force for the gear 6 to be detected;

A fixture system, used to reduce the interference of signals collected by the rapid detection system for gear defects based on vibration frequency analysis;

An automatic vibration frequency analysis system including a frequency analyzer 14 and a PC display 15 is used to collect the measurement data of the gear 6 to be detected and analyze the collected data;

An automatic detection module, configured to automatically detect defects of the gear 6 to be detected according to the analysis data of the automatic vibration frequency analysis system;

Wherein; the gear to be detected 6 is installed on the driving shaft 1, the special gear 7 for detection is installed on the driven shaft 11, or the gear 6 to be detected is installed on the driven shaft, the special gear 7 for detection is installed on the driving shaft 1, and the transmission box 4 Placed on the mobile workbench 3, the driving shaft 1, the transmission box 4, and the connecting shaft 5 are connected in sequence.

In the system of the rapid detection method for gear defects based on vibration frequency analysis, there are two handwheels 2, which are respectively used to fix the gear 6 to be detected and the special gear 7 for detection.

In the system of the rapid detection method for gear defects based on vibration frequency analysis, the power device system is further composed of a servo motor and a synchronous motor drive system.

In the system of the rapid detection method for gear defects based on vibration frequency analysis, the fixed device system further includes a fixed table 16, an extension shaft 9, and a sensor 13, and the fixed table 16 follows the rotation of the driven shaft 11, and the The fixing table 16 fixes the sensor 13 on the end of the extension shaft 9 of the detection special gear 7 .

The system of the rapid detection method for gear defects based on vibration frequency analysis, the automatic vibration frequency analysis system further includes a total controller, a communication bus, an interface circuit, a display, an electronic control unit, a signal acquisition instrument, and a DSP digital signal processor , Analysis system; said general controller, communication bus, interface circuit, display, electronic control unit, signal acquisition instrument, DSP digital signal processor, and analysis system are connected with the general controller through the interface circuit.

In the system of the rapid detection method for gear defects based on vibration frequency analysis, the automatic detection module detects the data of the vibration frequency analysis system, and judges the power density of a specific frequency according to the fuzzy principle. When the power density reaches the standard set by the user, the automatic detection module will give an alarm and determine that the gear to be detected (6) is defective.

In the system of the rapid detection method for gear defects based on vibration frequency analysis, the sensor 13 is a torque sensor or a rotational speed sensor.

In the system of the rapid detection method for gear defects based on vibration frequency analysis, the DSP digital signal processor is a KeyStone multi-core processor C667x.

The system and method for rapid detection of gear defects based on vibration frequency analysis provided by the present invention have the beneficial effects of high efficiency of detection of gear defects, high accuracy, good consistency of detection standards, simple operation, and wide range of detection gear types.

Description of drawings

Fig. 1 is the flowchart of the rapid detection method for gear defects based on vibration frequency analysis of the present invention;

Fig. 2 is a flowchart of a preferred application embodiment of the rapid detection method for gear defects based on vibration frequency analysis of the present invention;

Fig. 3 is a graph of the membership function of the fuzzy set of the gear defect rapid detection method based on the vibration frequency analysis of the present invention;

Fig. 4 is a schematic structural diagram of a rapid detection system for gear defects based on vibration frequency analysis of the present invention;

Fig. 5 is the handwheel type gear detection installation platform of the gear defect rapid detection system based on the vibration frequency analysis of the present invention;

Fig. 6 is the motion-controlled gear detection installation platform of the rapid detection system for gear defects based on vibration frequency analysis of the present invention.

In the figure, 1-driving shaft; 2-hand wheel; 3-mobile workbench; 4-transmission box; 5-connecting shaft; 6-gear to be detected; 7-special gear for detection; 10-belt; 11-driven shaft; 12-power plant system; 13-sensor; 14-frequency analyzer; 15-PC display; 16-fixed table.

detailed description

In order to make the object, technical solution and advantages of the present invention more clear and definite, the present invention will be further described in detail below with reference to the accompanying drawings and examples. It should be understood that the specific embodiments described here are only used to explain the present invention, not to limit the present invention.

Please refer to FIG. 1 , which is a flowchart of the rapid detection method for gear defects based on vibration frequency analysis of the present invention. Before the rapid detection method of the present invention starts, the user needs to define the eligibility criteria and select the evaluation criteria. The method comprises the steps of:

S100, install the gear to be tested, shake the gear to be tested to a fixed position through the hand wheel, then take the installation distance of the wheel and adjust it to be in this position, repeat the adjustment for more than three times, and then lock the large gear shaft.

S200. Install the special gear for detection, shake the small wheel to a certain position, take the installation distance of the small wheel and adjust it. When adjusting for the first time, keep the gear to be detected rotating slightly to avoid damage. When it is in a suitable position, record Hold the pointer position, then return the special gear for detection, to the place where it does not touch the stylus of the dial indicator, repeat the above adjustment method for more than three times, if the difference of the percentage indication for more than three times is ±0.01mm, it is considered to be installed correctly.

S300, special gear for lock detection.

S400. Turn on the detection system. First, when both the driving wheel and the driven wheel start to rotate at a low speed and uniform speed, the frequency analyzer will automatically monitor and record data after 0.5 seconds. After the acquisition system collects data for more than 3 cycles, the system will automatically stop. change.

S500. The comprehensive analysis system compares and analyzes the data collected by the system for more than 3 periods, and judges the power density of a specific frequency based on the fuzzy principle. When the power density of the specific frequency reaches the user's set value, it is determined that the gear is defective .

Please refer to Fig. 2, which is a flow chart of a preferred application embodiment of the rapid detection method for gear defects based on vibration frequency analysis of the present invention; as shown in Fig. 2, it includes the following steps:

Automatic detection program starts; fuzzy judgment initialization; waits for input signal, ready to enter the next stage; automatically assigns membership function; judges eligibility; if the system is not in one of the six incremental fuzzy sets T, N, S, M, B , VB, the system will alarm, otherwise the result will be transmitted to the main program, and the automatic detection program will end. Then input the judgment result, output the judgment result and point out the phase of the defect of the unqualified gear, then enter the next gear inspection, and automatically return to the cycle inspection. Entering the next detection process, the system starts, the system rotates at a constant speed for more than three cycles, collects the time-frequency torsional fluctuation data of the doctor for three cycles, converts the time-frequency signals, and searches for specific frequency signals. If no qualified signal is found, the system rotates at a constant speed for more than three cycles; if a qualified signal is found, it is ready to enter the signal power density fuzzy judgment program, output the result and point out the phase of the unqualified gear.

Please refer to FIG. 3 , which is a graph of the membership function of the fuzzy set of the method for rapid detection of gear defects based on vibration frequency analysis of the present invention. The initialization stipulates six progressively increasing fuzzy sets of T, N, S, M, B, and VB. According to different gear uses and detection rigor, this automatic detection program can establish different evaluation standards for gear defects according to requirements, and can In the actual situation, define any initialized fuzzy set as the minimum power density set at the gear defect, and the minimum power density value in this set is the critical value of the gear defect and intact; assuming that the user sets X (X Refers to any one of the five initialized fuzzy sets) is the minimum power density set at the gear defect, if the detected power density belongs to X or the incremental fuzzy set after X, then the corresponding detected gear, judge It is an unqualified gear, that is, the gear is defective. If the detected power density belongs to the decreasing fuzzy set before X, then the corresponding detected gear is judged as a qualified gear, that is, the gear is not defective.

Please refer to Fig. 4, which is a structural schematic diagram of the rapid detection system for gear defects based on vibration frequency analysis of the present invention. As shown in Figure 4, in the gear defect rapid detection system based on vibration frequency analysis provided by the present invention, at least include:

A gear detection platform with adjustable installation distance including drive shaft 1, handwheel 2, mobile workbench 3, transmission box 4, connecting shaft 5, dial indicator 8, extension shaft 9, belt 10, and driven shaft 11. The dial gauge 8 is used to adjust the center distance between the gear to be detected 6 and the detection-specific gear 7;

A power device system that can provide uniform or uniformly variable speed rotation is used to provide driving force for the gear 6 to be detected;

A fixture system, used to reduce the interference of signals collected by the rapid detection system for gear defects based on vibration frequency analysis;

An automatic vibration frequency analysis system including a frequency analyzer 14 and a PC display 15 is used to collect the measurement data of the gear 6 to be detected and analyze the collected data;

An automatic detection module, configured to automatically detect defects of the gear 6 to be detected according to the analysis data of the automatic vibration frequency analysis system;

Wherein; the gear to be detected 6 is installed on the drive shaft 1, and the detection-specific gear 7 is installed on the driven shaft (11), or the gear to be detected 6 is installed on the driven shaft, and the detection-specific gear 7 is installed on the drive shaft 1, and the transmission The box 4 is placed on the mobile workbench 3, and the driving shaft 1, the transmission box 4, and the connecting shaft 5 are connected in sequence.

Preferably, there are two handwheels 2, which are respectively used to fix the gear to be detected 6 and the special gear 7 for detection.

Preferably, the power device system is further composed of a servo motor and a synchronous motor drive system.

Preferably, the fixing device system further includes a fixing table 16, an extension shaft 9, and a sensor 13, and the fixing table 16 follows the rotation of the driven shaft 11, and the fixing table 16 fixes the sensor 13 on Described detection special-purpose gear 7 stretches out the end of axle.

Preferably, the automatic vibration frequency analysis system further includes a general controller, a communication bus, an interface circuit, a display, an electronic control unit, a signal acquisition instrument, a DSP digital signal processor, and an analysis system; The bus, interface circuit, display, electronic control unit, signal acquisition instrument, DSP digital signal processor, and analysis system are connected with the general controller through the interface circuit.

Preferably, the automatic detection module detects the data of the vibration frequency analysis system, and judges the power density of a specific frequency according to the fuzzy principle. When it is considered that the power density of the specific frequency reaches the standard set by the user, The automatic detection module gives an alarm and determines that the gear 6 to be detected is defective.

Preferably, the sensor 13 is a torque sensor or a rotational speed sensor.

Preferably, the DSP digital signal processor is KeyStone multi-core processor C667x.

Please refer to Fig. 5, which is a handwheel gear detection installation platform of the rapid detection system for gear defects based on vibration frequency analysis of the present invention. As shown in Figure 5, in order to accurately determine whether the installation distance meets the requirements, a dial indicator 8 is designed to fit the gear installation, which is located at the other end of the system. Generally, the indicator is set to zero when it touches the end surface of the mobile workbench; when used for When quickly installing similar gears, the hand wheel 2 can be replaced by a motion control automatic positioning system.

Please refer to Fig. 6, which is a motion-controlled gear detection installation platform of the rapid detection system for gear defects based on vibration frequency analysis of the present invention. As shown in Figure 6, the motion control automatic positioning system includes a motor and a motor control device. The motor control device is used to realize real-time control of the motor when setting different installation distances, to meet the needs of automatic positioning, and to quickly clamp a pair of matching gear. The power device system 12 can be replaced by a servo motor, which provides rotational power to the drive shaft; in order to enable the sensor 13 to achieve a better acquisition effect, it is generally required that the power source provide a low-speed and uniform rotation. In order to prevent the extension shaft from being interfered by other signals, a fixed table 16 is specially designed to reduce external interference and follow the rotation of the driven shaft; in order to meet the requirement that the signal of each tooth meshing state can be collected during the gear meshing transmission process The sensor 13 must be a torque sensor or rotational speed sensor with high precision and high acquisition efficiency.

The system and method for rapid detection of gear defects based on vibration frequency analysis provided by the present invention have high efficiency in detecting gear defects, high precision, good consistency in detection standards, simple operation, and a wide range of detection gear types.

It should be understood that the application of the present invention is not limited to the above examples, and those skilled in the art can make improvements or transformations according to the above descriptions, and all these improvements and transformations should belong to the protection scope of the appended claims of the present invention.

Claims (15)

1. a kind of gear defects method for quick based on vibration Frequency Analysis is it is characterised in that include step：

A, fill gear to be detected, gear to be detected is shaken to a fixed position by handwheel, then takes gear locating distance to be detected And adjust and be on this position, repeatedly adjust more than three times, more locked Large Gear Shaft；

B, dress detection dedicated gear, shake steamboat, to an indefinite position, takes steamboat locating distance and adjusts, when adjusting for the first time, Keep the fine rotation of gear to be detected, it is to avoid break, after being in correct position, remember pointer position, then rollback detection Dedicated gear, to not contacting at dial gauge stylus, repeats above-mentioned control method more than three times, if the dial gauge registration of more than three times Difference is to be considered as correctly installing during ± 0.01mm；

C, locked detection dedicated gear；

D, open detection system, first drivewheel and driven pulley all at the uniform velocity start to rotate with relatively low speed, and after 0.5S, frequency is divided Analyzer automatic monitoring record data, after systematic collection to be collected to 3 data more than cycle, the automatic stall of detecting system；

3 data more than cycle that E, overall analysis system gather to acquisition system are compared analysis, to characteristic frequency Power density carries out fuzzy principle and judges, when the power density thinking this characteristic frequency reaches user's setting value, judges this tooth Wheel is defective.

2. the gear defects method for quick based on vibration Frequency Analysis according to claim 1 is it is characterised in that institute State fuzzy principle to judge to refer to set up at least one fuzzy set between existing power density peak and minima, then The power density values of each time domain of sub-distribution are to being subordinate to set accordingly, and specify that the power at the gear defects that collect is close Minima in degree set, when the power density in somewhere is not less than this minima, then judges that this gear is defective.

3. the gear defects method for quick based on vibration Frequency Analysis according to claim 1 is it is characterised in that institute The detecting system stated further includes the sensor for gathering signal.

4. the gear defects method for quick based on vibration Frequency Analysis according to claim 1 is it is characterised in that institute The detecting system stated further includes master controller, communication bus, interface circuit, display, electronic control unit, signals collecting Instrument, DSP, analysis system；Described master controller, communication bus, interface circuit, display, electronics control Unit processed, signal sampler, DSP, analysis 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 it is characterised in that institute The overall analysis system stated further includes：For showing the PC display of the analysis result of described frequency analyzer.

6. the gear defects method for quick based on vibration Frequency Analysis according to claim 3 is it is characterised in that institute Stating sensor is torque sensor or speed probe.

7. the gear defects method for quick based on vibration Frequency Analysis according to claim 4 is it is characterised in that institute The DSP stated is KeyStone polycaryon processor C667x.

8. the gear defects method for quick based on vibration Frequency Analysis described in a kind of employing any one of claim 1-7 System is it is characterised in that include：Including driving shaft (1), handwheel (2), mobile work platform (3), transmission case (4), connecting shaft (5), Dial gauge (8), projecting shaft (9), belt (10), the gear testing platform of the scalable locating distance of driven shaft (11), wherein percentage Table (8) is used for adjusting the centre-to-centre spacing between gear to be detected (6) and detection dedicated gear (7)；Can provide at the uniform velocity or uniform speed change The power plant system rotating, for providing motive force to gear to be detected (6)；Fixing device system, for reducing described base Interference in the gear defects rapid detection system collection signal of vibration Frequency Analysis；Show including frequency analyzer (14) and PC The automatic vibration frequency analyses system of device (15), for gathering gear to be detected (6) measurement data and institute's gathered data being carried out Analysis；Automatic detection module, for according to described automatic vibration frequency analyses systematic analysiss data to described tooth to be detected Wheel (6) carries out defect automatic detection；Wherein；Gear (6) to be detected is installed on driving shaft (1), and detection dedicated gear (7) is installed on On driven shaft (11), or gear to be detected (6) is installed on driven shaft, and detection dedicated gear (7) is installed on driving shaft (1) On, transmission case (4) is placed on mobile work platform (3), and driving shaft (1), transmission case (4), connecting shaft (5) are sequentially connected.

9. the system of the gear defects method for quick based on vibration Frequency Analysis according to claim 8, its feature It is, described handwheel (2) is two, be respectively used to fixing described gear to be detected (6), detection dedicated gear (7).

10. the system of the gear defects method for quick based on vibration Frequency Analysis according to claim 8, its feature It is, described power plant system is made up of servomotor, Synchromous machine drive system further.

The system of the 11. gear defects method for quick based on vibration Frequency Analysis according to claim 8, its feature It is, described fixing device system further includes fixed station (16), projecting shaft (9), sensor (13), described fixed station (16) follow driven shaft (11) to rotate, it is special that described sensor (13) is fixed on described detection by described fixed station (16) The end of gear (7) projecting shaft (9).

The system of the 12. gear defects method for quick based on vibration Frequency Analysis according to claim 8, its feature It is, described automatic vibration frequency analyses system further includes master controller, communication bus, interface circuit, display, electricity Sub-control unit, signal sampler, DSP, analysis system；Described master controller, communication bus, interface Circuit, display, electronic control unit, signal sampler, DSP, analysis system pass through interface circuit with Master controller connects.

The system of the 13. gear defects method for quick based on vibration Frequency Analysis according to claim 8, its feature It is, the data of the described automatic vibration frequency analyses system of described automatic detection module detection, and the work(to characteristic frequency Rate density is judged according to fuzzy principle, reaches the standard set by user when the power density thinking this characteristic frequency When, described automatic detection module is reported to the police, and judges that described gear to be detected (6) is defective.

The system of the 14. gear defects method for quick based on vibration Frequency Analysis according to claim 11, it is special Levy and be, described sensor (13) is torque sensor or speed probe.

The system of the 15. gear defects method for quick based on vibration Frequency Analysis according to claim 12, it is special Levy and be, described DSP is KeyStone polycaryon processor C667x.