CN104111391A - Three-phase instantaneous power based motorized spindle fault monitoring and diagnosing method - Google Patents
Three-phase instantaneous power based motorized spindle fault monitoring and diagnosing method Download PDFInfo
- Publication number
- CN104111391A CN104111391A CN201410335945.9A CN201410335945A CN104111391A CN 104111391 A CN104111391 A CN 104111391A CN 201410335945 A CN201410335945 A CN 201410335945A CN 104111391 A CN104111391 A CN 104111391A
- Authority
- CN
- China
- Prior art keywords
- main shaft
- instantaneous power
- phase
- electric main
- phase instantaneous
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Landscapes
- Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)
- Control Of Ac Motors In General (AREA)
Abstract
The invention discloses a three-phase instantaneous power based motorized spindle fault monitoring and diagnosing method and belongs to the technical field of motorized spindle fault monitoring. According to the three-phase instantaneous power based motorized spindle fault monitoring and diagnosing method, by means of signal demodulation properties and three-phase symmetry characteristics of three-phase instantaneous power, three-phase input voltage and three-phase stator current signals are collected when a motorized spindle is stably operated, three-phase instantaneous power signals are calculated, the influence of supply frequency modulation, frequency rotating and frequency doubling on monitoring and diagnosing results is eliminated through a design of a junction filter, whether the motorized spindle breaks down is determined according to comparison between a mean value and a root-mean-square (RMS) value of the three-phase instantaneous power signals and standard reference values during the operation process, and a fault type is determined according to generation of fault character frequency during spectral analysis, so that monitoring and diagnosing of faults of the motorized spindle are achieved. According to the three-phase instantaneous power based motorized spindle fault monitoring and diagnosing method, the signal collection and processing process is simple, bearing wearing and rotor broken bar faults of the motorized spindle can be effectively monitored, and the method is applicable to state monitoring and fault diagnosing of the motorized spindle on an industrial scene.
Description
Technical field
The invention belongs to electric main shaft fault detection technique field, be specifically related to a kind of electric main shaft malfunction monitoring diagnostic method based on three-phase instantaneous power.
Background technology
Electricity main shaft is a kind of drive mechanism form that spindle drive motor and machine tool chief axis " are united two into one ", machine tool chief axis is directly driven by built-in motor, not only there is compact conformation, lightweight, inertia is little, it is little to vibrate, noise is low, respond the advantages such as fast, also have that rotating speed is fast, power is large, simplify Machine Tool design, being easy to realize the advantages such as main shaft orientation, is a kind of ideal structure in high-speed main spindle unit.Along with the fast development of modern industry, the application of electric main shaft is extensively promoted, himself also towards high speed, high precision and accurately standard the future development such as stop, should be noted that electric main shaft accounts for more than 40% in the main shaft fault of current motor driven systems simultaneously.Developing into from the generation of electric main shaft fault that to cause the fault of device damage be a process, whether can find early fault, is to extend lathe serviceable life thereby electric main shaft is carried out to repair and maintenance, improves the important guarantee of machining precision.The modal fault of electricity main shaft is bearing wear and rotor bar breaking fault, traditional malfunction monitoring diagnostic method adopts analysis of vibration signal bearing fault more, adopt stator current signal to analyze rotor bar breaking fault, determine the generation of corresponding failure by the appearance of characteristic frequency component in spectrum analysis.
For the malfunction monitoring diagnosis of electric main shaft, due to design feature and the high-revolving operation characteristic of electric main shaft, while using vibratory drilling method and stator current method, there is following shortcoming: 1) electric main shaft generally adopts hybrid ceramic ball bearing, bearing wear is comparatively even, the general even pit of spot corrosion that produces on rolling body and raceway, bearing does not also produce and peels off breakage and made Precision Machining not meet quality requirements, does not form obvious fault characteristic frequency component when vibration analysis.2) fault signature that is different from motor normal condition that electric main shaft initial failure shows is normally very faint, and transducer drive makes to exist a large amount of supply frequencies in electric main shaft input voltage signal and modulates and harmonic components, can in current spectrum, produce a lot of additional interfering frequencies, be disturbed the impact of noise, in frequency spectrum, fault signature is not obvious.3) the electric speed of mainshaft is higher, generally 10000rpm and more than, high rotating speed makes signal frequency larger, stator current is not only higher to sampling request while analysis, and failure message is more subject to the interference of high frequency noise.Rotor bar breaking fault generation meeting characteristic frequency in stator current signal is f
b=(1 ± 2ks) f
1component, when spectrum analysis because revolutional slip s is very little, the most obvious characteristic component 1-2sf
1with centre frequency f
1very approaching.Be subject to the restriction of spectral resolution, f
1spectral leakage is larger, and at f
1under the impact of high frequency noise, fault signature component is submerged and is difficult for detecting.
Summary of the invention
The object of the invention is to overcome the deficiency that existing stator current is analyzed, a kind of electric main shaft malfunction monitoring diagnostic method based on three-phase instantaneous power is provided, the method on-line real time monitoring electricity main shaft operation characteristic parameter, the electric main shaft running status of identification in time, by with the comparison of standard operational factor, can effectively find fault and alarm.
In order to achieve the above object, the present invention is achieved by the following technical solutions:
Based on an electric main shaft malfunction monitoring diagnostic method for three-phase instantaneous power, comprise the following steps:
1) gather three-phase voltage, the three-phase current signal of healthy electric main shaft under no-load running state, and calculate the three-phase instantaneous power signal of healthy electric main shaft, set three-phase instantaneous power signal under this state as standard, set up the electric main shaft runtime database under health status;
2) start lathe, after stable operation, gather three-phase voltage, the three-phase current signal of electric main shaft to be measured under light condition, and by calculating the three-phase instantaneous power signal of electric main shaft to be measured;
3) by junction filter, the three-phase instantaneous power signal of electric main shaft to be measured is carried out to filtering processing, eliminate 2 times of supply frequency modulation signals and turn the interference of frequency multiplication frequently;
4) the three-phase instantaneous power signal of filtering electric main shaft to be measured after treatment is carried out to time-domain analysis, if being less than it, the RMS value of filtering three-phase instantaneous power after treatment signal sets fluctuation threshold value, by the average of three-phase instantaneous power signal after treatment filtering compared with active power threshold value, if its average is less than active power threshold value, judge that electric main shaft to be measured is in health status, otherwise, judge the bearing wear of electric main shaft to be measured; If being greater than it, the RMS value of filtering three-phase instantaneous power after treatment signal sets fluctuation threshold value, filtering three-phase instantaneous power after treatment signal is carried out to spectrum analysis, if there is fault characteristic frequency 2ksf1 to produce, judge the rotor broken bar of electric main shaft to be measured, otherwise, judge that electric main shaft to be measured is in health status.
The present invention further improves and is, step 1) and step 2) in, one end of three Micro-Transformer of Voltages is connected on modulate circuit plate, and its other end is connected in the terminal box of power distribution cabinet, and three current clamps are arranged on the output electric wire of frequency converter in power distribution cabinet; First extract respectively electric main shaft three-phase voltage, three-phase current by Micro-Transformer of Voltage and current clamp, secondly by the amplification filtering pre-service of signal condition module, then input the data collecting card collection signal of data channel to comprise 24,6 tunnel, and in real time data upload to host computer is carried out to analyzing and processing online by Ethernet interface.
The present invention further improves and is, step 3) in, junction filter is Low-pass Elliptic Filter and multiple trapper, by the high frequency noise of Low-pass Elliptic Filter filtering electric main shaft three-phase instantaneous power signal to be measured, 2 times of supply frequency modulation products by multiple trappers series connection filtering electric main shaft three-phase instantaneous power signal to be measured and turn 2 frequencys multiplication and harmonic component thereof frequently.
Compared with existing stator current analytical approach, the present invention has the following advantages:
Diagnosable go out bearing initial failure, diagnose more reliable
For high-speed electric main shaft, the hybrid ceramic ball bearings that adopt more, pottery rolling body is wear-resistant, while there is wear-out failure, produce the even pit of spot corrosion, it is the bearing fault later stage that generation damage class is peeled off, in bearing fault vibration analysis in earlier stage, there is no typical fault characteristic frequency, cause diagnosis not go out bearing fault.The present invention adopts three-phase instantaneous power monitoring, diagnosing electricity main shaft fault, and during electric main shaft no-load running, power signal is with respect to the increased power value representation bearing wear amount of health status calibration power, effectively monitoring bearing abrasion condition.
2. frequency spectrum is simple, and fault characteristic frequency is obvious
Due to the three-phase symmetrical characteristic of power supply, in three-phase instantaneous power signal, eliminate single-phase instantaneous power signal transfer 2 frequencys multiplication and harmonic thereof frequently, compared with stator current signal, three-phase instantaneous power signal is by the demodulation of fault modulation signal, centre frequency spectral leakage and the impact of high frequency noise on failure-frequency while having eliminated fault modulation, in signal, only have the DC component of active power of expression and the fault characteristic frequency component of demodulation, frequency spectrum is succinct, fault characteristic signals is obvious, can effectively monitor the generation of rotor bar breaking fault.
Brief description of the drawings
Fig. 1 is the equipment scheme of installation of signals collecting of the present invention;
Fig. 2 is the electric main shaft malfunction monitoring diagnostic method process flow diagram based on three-phase instantaneous power;
When Fig. 3 is non-fault, the theoretical spectrum of stator current signal, single-phase instantaneous power signal, three-phase instantaneous power signal contrast: Fig. 3 (a) is the amplitude spectrum of stator current signal, Fig. 3 (b) is the amplitude spectrum of single-phase instantaneous power signal, and Fig. 3 (c) is the amplitude spectrum of three-phase instantaneous power signal;
When Fig. 4 is rotor bar breaking fault, the simulated spectrum of stator current signal, single-phase instantaneous power signal, three-phase instantaneous power signal contrast: Fig. 4 (a) is the amplitude spectrum of stator current signal, Fig. 4 (b) is the amplitude spectrum of single-phase instantaneous power signal, and Fig. 4 (c) is the amplitude spectrum of three-phase instantaneous power signal;
Fig. 5 is three-phase instantaneous power signal spectrum when electric main shaft is unloaded under failure-free operation state;
Fig. 6 is the amplitude-frequency response figure of junction filter;
Fig. 7 is three-phase instantaneous power signal spectrum when electric main shaft is unloaded under filtered failure-free operation state;
Fig. 8 is the three-phase instantaneous power signal of the good electric main shaft of running status when unloaded: Fig. 8 (a) is filtered three-phase instantaneous power time-domain signal, and Fig. 8 (b) is filtered three-phase instantaneous power signal spectrum;
There is the electric main shaft of the rotor bar breaking fault three-phase instantaneous power signal when unloaded in Fig. 9: Fig. 9 (a) is filtered three-phase instantaneous power time-domain signal, and Fig. 9 (b) is filtered three-phase instantaneous power signal spectrum.
Embodiment
Below in conjunction with accompanying drawing, the present invention will be further described.
Consult Fig. 1 and Fig. 2, a kind of electric main shaft malfunction monitoring diagnostic method based on three-phase instantaneous power of the present invention, comprises the following steps:
1) gather three-phase voltage, the three-phase current signal of healthy electric main shaft under no-load running state, and calculate the three-phase instantaneous power signal of healthy electric main shaft, set three-phase instantaneous power signal under this state as standard, set up the electric main shaft runtime database under health status.
2) start lathe, after stable operation, gather three-phase voltage, the three-phase current signal of electric main shaft to be measured under light condition, and by calculating the three-phase instantaneous power signal of electric main shaft to be measured.
3) by junction filter, the three-phase instantaneous power signal of electric main shaft to be measured is carried out to filtering processing, eliminate 2 times of supply frequency modulation signals and turn the interference of frequency multiplication frequently; Wherein, junction filter is Low-pass Elliptic Filter and multiple trapper, by the high frequency noise of Low-pass Elliptic Filter filtering electric main shaft three-phase instantaneous power signal to be measured, 2 times of supply frequency modulation products by multiple trappers series connection filtering electric main shaft three-phase instantaneous power signal to be measured and turn 2 frequencys multiplication and harmonic component thereof frequently; Selecting of junction filter not only can filtering be wanted the component of filtering and not affect other component in pass band, can filtering fault characteristic frequency in the time having fault characteristic frequency to produce and affect the monitoring, diagnosing of fault.
Specifically, step 2) the three-phase instantaneous power signal of the electric main shaft to be measured that obtains can not directly carry out analyzing and processing.Electricity main shaft is by transducer drive, and the rectifying and wave-filtering link of frequency converter can be introduced the modulation signal of 2 times of supply frequencies and harmonic wave thereof in its three-phase voltage output signal.The main shaft that power supply three-phase imbalance brings turns frequency 2 harmonics and harmonic wave and high frequency noise thereof also can affect the analysis of electric main shaft three-phase instantaneous power signal, therefore will first carry out filtering processing to the three-phase instantaneous power signal of electric main shaft to be measured.
4) the three-phase instantaneous power signal of filtering electric main shaft to be measured after treatment is carried out to time-domain analysis, if being less than it, the RMS value of filtering three-phase instantaneous power after treatment signal sets fluctuation threshold value, by the average of three-phase instantaneous power signal after treatment filtering compared with active power threshold value, if its average is less than active power threshold value, judge that electric main shaft to be measured is in health status, otherwise, judge the bearing wear of electric main shaft to be measured; Set fluctuation threshold value if the RMS value of filtering three-phase instantaneous power after treatment signal is greater than it, filtering three-phase instantaneous power after treatment signal is carried out to spectrum analysis, if there is fault characteristic frequency 2ksf
1produce, judge the rotor broken bar of electric main shaft to be measured, otherwise, judge that electric main shaft to be measured is in health status.
Further, step 1) and step 2) in, one end of three Micro-Transformer of Voltages is connected on modulate circuit plate, and its other end is connected in the terminal box of power distribution cabinet, and three current clamps are arranged on the output electric wire of frequency converter in power distribution cabinet; First extract respectively electric main shaft three-phase voltage, three-phase current by Micro-Transformer of Voltage and current clamp, secondly by the amplification filtering pre-service of signal condition module, then input the data collecting card collection signal of data channel to comprise 24,6 tunnel, and in real time data upload to host computer is carried out to analyzing and processing online by Ethernet interface.
Consult Fig. 1, Fig. 1 the present invention is based on the test macro installation of sensors figure that picks up electric main shaft three-phase voltage, three-phase current signal in the electric main shaft malfunction monitoring diagnostic method of three-phase instantaneous power.Three-phase voltage signal extracts by Micro-Transformer of Voltage, and what mutual inductor was selected is the TV19E type Micro-Transformer of Voltage of Yao Hua Dechang, Beijing company, is directly welded on the modulate circuit plate of signal condition module; Three-phase current signal extracts by current clamp, and what current clamp adopted is the i200s alternating current pincers of U.S.'s fluke (FLUKE) company, is arranged on the inverter output terminal of power distribution cabinet.
Consult Fig. 2, Fig. 2 is the observation process process flow diagram that the present invention is based on the electric main shaft malfunction monitoring diagnostic method of three-phase instantaneous power.Flow process: starter motor, after stable operation, start to gather three-phase voltage and the three-phase current signal of electric main shaft, and calculate the three-phase instantaneous power signal of electric main shaft, eliminate supply frequency modulation that frequency converter introduces and electric main shaft and turn the interference of frequency and harmonic wave thereof by junction filter filtering.Time-domain analysis, determine signal complexity with the size of RMS value, there is non-fault to produce, RMS value is greater than threshold value and carries out spectrum analysis, determine corresponding failure from the generation of fault characteristic frequency, RMS value is normally carried out the judgement of average, and average is greater than setting threshold and represents bearing wear, and average represents that in normal range electric main shaft non-fault can normal process.Compare with stator current analytical technology with traditional vibration analysis, the directly demodulation fault characteristic frequency of the electric main shaft malfunction monitoring diagnostic method based on three-phase instantaneous power that the present invention proposes, easy to use, and can determine bearing wear situation according to the variation of active power, can better monitor early stage bearing fault situation.
Consult Fig. 3, Fig. 3 is the three-phase instantaneous power signal that adopts in the present invention and stator current signal, the spectral contrast of single-phase instantaneous power signal in the time of non-fault modulation product.The frequency spectrum that Fig. 3 (a) is stator current signal, Fig. 3 (b) is the frequency spectrum of single-phase instantaneous power signal, Fig. 3 (c) is the frequency spectrum of three-phase instantaneous power signal.The structure of electricity main shaft is three-phase symmetrical, and when electric main shaft normally moves, when power supply is perfect symmetry, the current amplitude of each phase voltage of collection, each phase, frequency equate, 120 ° of phase phasic differences, can be expressed as
In formula: u
a---the A phase voltage/V of electric main shaft; u
b---the B phase voltage/V of electric main shaft; u
c---the C phase voltage/V of electric main shaft; i
a---the A phase current/A of electric main shaft; i
b---the B phase current/A of electric main shaft; i
c---the C phase current/A of electric main shaft; U
m---the effective value/V of electric main shaft three-phase voltage; I
m---the effective value/V of electric main shaft three-phase current; ω
1---the angular frequency/rad/s of electric main shaft;
---the initial phase/rad of electric main shaft three-phase current.
Can see, in the time of non-fault modulating frequency component, in stator current signal, only having the frequency component that turns of electric main shaft.In single-phase instantaneous power signal, due to the multiplying each other of voltage and current, through long-pendingization and the poor effect of trigonometric function, not only have the DC component that represents active power in signal, also have electric main shaft to turn 2 harmonics frequently, the single-phase instantaneous power signal of each phase can be expressed as:
In formula: P
a---the instantaneous power/W of electric principal axis A phase; P
b---the instantaneous power/W of electric main shaft B phase; P
c---the instantaneous power/W of electric main shaft C phase.
Three-phase instantaneous power signal is three single-phase instantaneous power sums, and due to three-phase symmetrical characteristic, 2 times in single-phase instantaneous power signal turn frequency component counteracting, only have the DC component that represents active power in signal, can be expressed as:
In formula: P
3---the three-phase instantaneous power/W of electric main shaft.
Under non-fault characteristic frequency generation state, in three-phase instantaneous power signal, only has the DC component that represents active power.In the time of no-load running, three-phase instantaneous power signal represents with respect to the increase of standard value the mechanical friction power attenuation that the wearing and tearing of electric main shaft internal bearings bring, and can carry out by this variable quantity the wear condition of monitoring bearing, is out of order in bearing fault early diagnosis.
Consult Fig. 4, the spectral contrast of stator current signal, single-phase instantaneous power signal and the three-phase instantaneous power signal of electricity main shaft when Fig. 4 is rotor bar breaking fault.The frequency spectrum that Fig. 4 (a) is stator current signal, Fig. 4 (b) is the frequency spectrum of single-phase instantaneous power signal, Fig. 4 (c) is the frequency spectrum of three-phase instantaneous power signal.Because the electric speed of mainshaft is higher, starting current is larger, easily causes rotor bar breaking fault, is one of modal fault of electric main shaft.In the time of electric main shaft generation rotor bar breaking fault, conventionally can in stator current signal, produce the modulating frequency to first-harmonic, make first-harmonic both sides occur sideband, producing frequency is f
b=(1 ± 2ks) f
1fault characteristic frequency, and left side frequency band component is to be caused by asymmetric rotating magnetic field and velocity perturbation two parts, and the right frequency band component is only caused by velocity perturbation, left side frequency band component amplitude is larger than the right frequency band conventionally.If i '
as(t) be the left side frequency band fault signature electric current of A phase current, i "
as(t) be the right frequency band fault signature electric current of A phase current, have
In formula: i '
as---the left side frequency band fault current/A of electric main shaft three-phase current; I '
sk---the left side frequency band fault current k component of degree n n amplitude/A of electric main shaft three-phase current; The revolutional slip of s---electric main shaft; The order of k---three-phase current; f
1---electric main shaft turn frequency/Hz; α '
sk---the left side frequency band fault current k component of degree n n initial phase angle/rad of electric main shaft three-phase current; I "
as---the right frequency band fault current/A of electric main shaft three-phase current; I "
sk---the right frequency band fault current k component of degree n n amplitude/A of electric main shaft three-phase current; α "
sk---the right frequency band fault current k component of degree n n initial phase angle/rad of electric main shaft three-phase current.
Stator current signal is
i′
A(t)＝i
A+i′
As+i″
As (9)
In formula: i '
a---stator current signal/A when electric main shaft generation rotor bar breaking fault.
The product that single-phase instantaneous power signal is voltage and current, makes original stator current signal become more complicated, and wants clear and see that HFS frequency information is higher to bandwidth requirement.Three single-phase instantaneous powers can be expressed as:
In formula: P '
a---the instantaneous power/W of A phase when electric main shaft generation rotor bar breaking fault; P '
b---the instantaneous power/W of B phase when electric main shaft generation rotor bar breaking fault; P '
c---the instantaneous power/W of C phase when electric main shaft generation rotor bar breaking fault.
To three single-phase instantaneous power signal summations, the three-phase instantaneous power while obtaining rotor bar breaking fault.In single-phase instantaneous power signal, 2 harmonics and both sides fault sideband component thereof, because hree-phase symmetry is offset, only have the fault characteristic frequency component 2sk ω of DC component and demodulation in three-phase instantaneous power signal spectrum now
1.Can be expressed as
In formula: P '
3---three-phase instantaneous power/W when electric main shaft generation rotor bar breaking fault.
Three-phase instantaneous power signal can demodulation fault characteristic frequency, and signal spectrum is succinct, easy to operate.
Consult Fig. 5, Fig. 5 is three-phase instantaneous power signal spectrum when electric main shaft is unloaded under actual acquisition failure-free operation state.Speed of mainshaft 30000rpm, sampling rate 12.8kHz, the transducer drive main shaft of single phase poaer supply input, three-phase instantaneous power signal is now not as in theoretical analysis, to only have DC component, can see that the electric main shaft that not only has the DC component that represents active power be subject in addition frequency converter rectifying and wave-filtering link to affect 2 times of supply frequencies modulation of introducing and harmonic wave (100Hz, 200Hz, 300Hz, 400Hz, 500Hz) thereof in signal and to introduce due to unbalanced power supply turns 2 frequencys multiplication and harmonic wave thereof frequently from amplitude spectrum.Supply frequency is modulated and turned frequency 2 frequencys multiplication affects the judgement of active power average and the variation of RMS value, needs filtering processing.
Consult Fig. 6, Fig. 6 is the amplitude-frequency response of junction filter.Junction filter is constituted by Low-pass Elliptic Filter and trapper.The cutoff frequency that Low-pass Elliptic Filter is set is 2000Hz, and the centre frequency of trapper is respectively 100Hz, 200Hz, 300Hz, 400Hz, 500Hz, 1000Hz, 1500Hz.Can see, trapper only has filter action to center frequency components, and other frequency component in Low-pass Elliptic Filter passband is not affected.Use junction filter to carry out filtering processing to three-phase instantaneous power signal, only need 2 frequencys multiplication and harmonic wave and the high frequency noise that turn frequency except supply frequency modulation product, main shaft, other frequency component in passband is not affected.
Consult Fig. 7, Fig. 7 is the three-phase instantaneous power signal spectrum under the filtered non-fault no-load running of junction filter condition.Main shaft turns 503Hz frequently, sample frequency 12.8kHz, junction filter low-pass cut-off frequencies 1950Hz, trapper centre frequency 100Hz, 200Hz, 300Hz, 400Hz, 500Hz, 1006Hz, 1509Hz.Filtered three-phase instantaneous power signal only has the DC component that represents active power, can be according to the variation monitoring bearing wear situation of power magnitude.
Consult Fig. 8, the electric main shaft three-phase instantaneous power signal of normal operation when Fig. 8 is actual acquisition unloaded.Electricity main shaft model is DGZ-0860, and number of pole-pairs is 2, frequency converter output frequency 1069Hz, sample frequency 28.8kHz, sampling number 30k.Time-domain analysis after filtering, its signal average 120.66W, RMS value is 12.69.Frequency spectrum is comparatively clean, only has the DC component that represents active power.Fig. 8 (a) is filtered three-phase instantaneous power time-domain signal, and Fig. 8 (b) is filtered three-phase instantaneous power signal spectrum.
Consult Fig. 9, the electric main shaft three-phase instantaneous power signal of rotor bar breaking fault when Fig. 9 is actual acquisition unloaded.Electricity main shaft model is DGZ-0860, and number of pole-pairs is 2, frequency converter output frequency 1069Hz, sample frequency 28.8kHz, sampling number 30k.This electric main shaft is longer service time, and processing characteristics is poor, turns 1065Hz frequently, and slip s is 0.0037,2sf
1for 8Hz (the about 1Hz of spectral resolution).After filtering, carry out time-domain analysis, signal average 190.04W, RMS value 143.14, compared with three-phase instantaneous power signal with Fig. 8 under normal running (operation) conditions, average increases, and represents that certain wearing and tearing occur bearing, RMS value increases, and represents that signal fluctuation increases, and has new frequency component to produce.In three-phase instantaneous power signal spectrum, can see that signal spectrum is comparatively complicated, there are the significantly frequency component relevant to rotor bar breaking fault: 7.68Hz, 15.36Hz, 23.04Hz, 30.72Hz in low frequency place.Fig. 9 (a) is filtered three-phase instantaneous power time-domain signal, and Fig. 9 (b) is filtered three-phase instantaneous power signal spectrum.
The present invention is carried out to emulation and verification experimental verification, and three-phase instantaneous power signal can judge the abrasion condition of electric main shaft by time-domain analysis, can judge the fault that the rotor bar breaking fault etc. of electric main shaft has fault characteristic frequency to produce by spectrum analysis.Three-phase instantaneous power signal not only signals collecting is convenient, also has signal demodulation character, and analyzing and processing is convenient, and can effectively diagnose out electric mainshaft bearing fault.
Above content is in conjunction with concrete preferred implementation further description made for the present invention; can not assert that the specific embodiment of the present invention only limits to this; for general technical staff of the technical field of the invention; without departing from the inventive concept of the premise; can also make some simple deduction or replace, all should be considered as belonging to the present invention and determine scope of patent protection by submitted to claims.
Claims (3)
1. the electric main shaft malfunction monitoring diagnostic method based on three-phase instantaneous power, is characterized in that, comprises the following steps:
1) gather three-phase voltage, the three-phase current signal of healthy electric main shaft under no-load running state, and calculate the three-phase instantaneous power signal of healthy electric main shaft, set three-phase instantaneous power signal under this state as standard, set up the electric main shaft runtime database under health status;
2) start lathe, after stable operation, gather three-phase voltage, the three-phase current signal of electric main shaft to be measured under light condition, and by calculating the three-phase instantaneous power signal of electric main shaft to be measured;
3) by junction filter, the three-phase instantaneous power signal of electric main shaft to be measured is carried out to filtering processing, eliminate 2 times of supply frequency modulation signals and turn the interference of frequency multiplication frequently;
4) the three-phase instantaneous power signal of filtering electric main shaft to be measured after treatment is carried out to time-domain analysis, if being less than it, the RMS value of filtering three-phase instantaneous power after treatment signal sets fluctuation threshold value, by the average of three-phase instantaneous power signal after treatment filtering compared with active power threshold value, if its average is less than active power threshold value, judge that electric main shaft to be measured is in health status, otherwise, judge the bearing wear of electric main shaft to be measured; Set fluctuation threshold value if the RMS value of filtering three-phase instantaneous power after treatment signal is greater than it, filtering three-phase instantaneous power after treatment signal is carried out to spectrum analysis, if there is fault characteristic frequency 2ksf
1produce, judge the rotor broken bar of electric main shaft to be measured, otherwise, judge that electric main shaft to be measured is in health status.
2. the electric main shaft malfunction monitoring diagnostic method based on three-phase instantaneous power according to claim 1, it is characterized in that, step 1) and step 2) in, one end of three Micro-Transformer of Voltages is connected on modulate circuit plate, its other end is connected in the terminal box of power distribution cabinet, and three current clamps are arranged on the output electric wire of frequency converter in power distribution cabinet; First extract respectively electric main shaft three-phase voltage, three-phase current by Micro-Transformer of Voltage and current clamp, secondly by the amplification filtering pre-service of signal condition module, then input the data collecting card collection signal of data channel to comprise 24,6 tunnel, and in real time data upload to host computer is carried out to analyzing and processing online by Ethernet interface.
3. the electric main shaft malfunction monitoring diagnostic method based on three-phase instantaneous power according to claim 1, it is characterized in that, step 3) in, junction filter is Low-pass Elliptic Filter and multiple trapper, by the high frequency noise of Low-pass Elliptic Filter filtering electric main shaft three-phase instantaneous power signal to be measured, 2 times of supply frequency modulation products by multiple trappers series connection filtering electric main shaft three-phase instantaneous power signal to be measured and turn 2 frequencys multiplication and harmonic component thereof frequently.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201410335945.9A CN104111391B (en) | 2014-07-15 | 2014-07-15 | Three-phase instantaneous power based motorized spindle fault monitoring and diagnosing method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201410335945.9A CN104111391B (en) | 2014-07-15 | 2014-07-15 | Three-phase instantaneous power based motorized spindle fault monitoring and diagnosing method |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN104111391A true CN104111391A (en) | 2014-10-22 |
| CN104111391B CN104111391B (en) | 2017-04-26 |
Family
ID=51708254
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201410335945.9A Active CN104111391B (en) | 2014-07-15 | 2014-07-15 | Three-phase instantaneous power based motorized spindle fault monitoring and diagnosing method |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN104111391B (en) |
Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104965490A (en) * | 2015-07-01 | 2015-10-07 | 国家林业局北京林业机械研究所 | Real-time monitoring system for wood milling processing electric spindle |
| CN106646224A (en) * | 2016-09-22 | 2017-05-10 | 华北电力大学 | Three-phase asynchronous motor load fluctuation detection method |
| CN106680716A (en) * | 2017-01-20 | 2017-05-17 | 浙江大学 | Fault diagnosis method for the permanent magnet motor bearing based on the sensor-less |
| CN107153141A (en) * | 2017-05-19 | 2017-09-12 | 顺特电气设备有限公司 | Intelligent electric unit exception detection method based on virtual window |
| CN109425488A (en) * | 2017-08-17 | 2019-03-05 | 阿尔斯通运输科技公司 | Determine the method for bearing state, the module for determining bearing state, rail vehicle and system |
| CN109752654A (en) * | 2017-11-07 | 2019-05-14 | 西门子歌美飒可再生能源公司 | Diagnosing winding sets of a stator |
| CN109940456A (en) * | 2017-12-21 | 2019-06-28 | 上海铼钠克数控科技股份有限公司 | Machine tool chief axis method for testing performance and system |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2000147039A (en) * | 1998-11-06 | 2000-05-26 | Mitsubishi Electric Corp | Fault detecting device for three-phase capacitor |
| CN102928225A (en) * | 2012-10-31 | 2013-02-13 | 西安交通大学 | Self-adaptive resonance demodulation method for fault diagnosis of rolling bearing |
| CN103698699A (en) * | 2013-12-06 | 2014-04-02 | 西安交通大学 | Asynchronous motor fault monitoring and diagnosing method based on model |
| CN103712792A (en) * | 2013-12-16 | 2014-04-09 | 西安交通大学 | Fault diagnosis method for wind-power gear case |
-
2014
- 2014-07-15 CN CN201410335945.9A patent/CN104111391B/en active Active
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2000147039A (en) * | 1998-11-06 | 2000-05-26 | Mitsubishi Electric Corp | Fault detecting device for three-phase capacitor |
| CN102928225A (en) * | 2012-10-31 | 2013-02-13 | 西安交通大学 | Self-adaptive resonance demodulation method for fault diagnosis of rolling bearing |
| CN103698699A (en) * | 2013-12-06 | 2014-04-02 | 西安交通大学 | Asynchronous motor fault monitoring and diagnosing method based on model |
| CN103712792A (en) * | 2013-12-16 | 2014-04-09 | 西安交通大学 | Fault diagnosis method for wind-power gear case |
Non-Patent Citations (2)
| Title |
|---|
| 徐梦圆等: "陶瓷电主轴损耗特性分析", 《微特电机》 * |
| 阳同光等: "瞬时功率频谱分析在牵引电机转子故障诊断的应用研究", 《电机与控制学报》 * |
Cited By (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104965490A (en) * | 2015-07-01 | 2015-10-07 | 国家林业局北京林业机械研究所 | Real-time monitoring system for wood milling processing electric spindle |
| CN104965490B (en) * | 2015-07-01 | 2018-02-16 | 国家林业局北京林业机械研究所 | Wood milling processing electro spindle real-time monitoring system |
| CN106646224A (en) * | 2016-09-22 | 2017-05-10 | 华北电力大学 | Three-phase asynchronous motor load fluctuation detection method |
| CN106680716A (en) * | 2017-01-20 | 2017-05-17 | 浙江大学 | Fault diagnosis method for the permanent magnet motor bearing based on the sensor-less |
| CN106680716B (en) * | 2017-01-20 | 2019-01-08 | 浙江大学 | A method of the magneto bearing failure diagnosis based on position-sensor-free |
| CN107153141A (en) * | 2017-05-19 | 2017-09-12 | 顺特电气设备有限公司 | Intelligent electric unit exception detection method based on virtual window |
| CN107153141B (en) * | 2017-05-19 | 2019-08-13 | 顺特电气设备有限公司 | Intelligent electric unit exception detection method based on virtual window |
| CN109425488A (en) * | 2017-08-17 | 2019-03-05 | 阿尔斯通运输科技公司 | Determine the method for bearing state, the module for determining bearing state, rail vehicle and system |
| CN109752654A (en) * | 2017-11-07 | 2019-05-14 | 西门子歌美飒可再生能源公司 | Diagnosing winding sets of a stator |
| CN109940456A (en) * | 2017-12-21 | 2019-06-28 | 上海铼钠克数控科技股份有限公司 | Machine tool chief axis method for testing performance and system |
Also Published As
| Publication number | Publication date |
|---|---|
| CN104111391B (en) | 2017-04-26 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN104111391A (en) | Three-phase instantaneous power based motorized spindle fault monitoring and diagnosing method | |
| CN102707232B (en) | Motor apparatus state on_line monitoring device and monitoring method thereof | |
| Yang et al. | Cost-effective condition monitoring for wind turbines | |
| Artigao et al. | Current signature analysis to monitor DFIG wind turbine generators: A case study | |
| Luong et al. | Smart sensor-based synergistic analysis for rotor bar fault detection of induction motors | |
| Siddiqui et al. | Health monitoring and fault diagnosis in induction motor-a review | |
| CN100487475C (en) | Method and apparatus of detecting internal motor faults in an induction machine | |
| Li et al. | A normalized frequency-domain energy operator for broken rotor bar fault diagnosis | |
| CN106249144B (en) | Doubly-fed wind turbine interturn short-circuit failure diagnosing method and fault monitoring method | |
| CN102520352B (en) | Brushless alternating current (AC) generator failure diagnosis instrument | |
| Dalvand et al. | A novel bearing condition monitoring method in induction motors based on instantaneous frequency of motor voltage | |
| CN103261904B (en) | The monitoring of electrically powered machine and fault diagnosis | |
| CN103698699A (en) | Asynchronous motor fault monitoring and diagnosing method based on model | |
| Ibrahim et al. | Neural networks for wind turbine fault detection via current signature analysis | |
| CN103620354A (en) | Method for monitoring demagnetization | |
| CA2739844A1 (en) | Device and method for monitoring and/or analyzing rotors of electric machines in operation | |
| CN103235260A (en) | Submersible motor rotor broken bar fault recognition method based on HHT (Hilbert-Huang transform) | |
| CN103558552A (en) | Mutual inductance type three-phase motor current noise fault detecting method and device for implementing method | |
| CN103076565B (en) | Phase asynchronous high-voltage electric machine overhauling health status check and evaluation system | |
| CN102706560B (en) | The state monitoring method and device of a kind of wind power generating set | |
| CN106199424A (en) | A kind of permagnetic synchronous motor interturn short-circuit failure diagnosing method | |
| CN106841900B (en) | The fault detection means and method of micro electromagnetic generator unit stator winding | |
| CN107845999A (en) | A kind of electrical fault detecting system and method based on current total harmonic coefficient | |
| CN203396914U (en) | Motor running state monitoring and fault detection system | |
| CN108169559B (en) | Method for judging abnormality of motor stator current spectrum analysis equipment |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| C06 | Publication | ||
| PB01 | Publication | ||
| C10 | Entry into substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| GR01 | Patent grant | ||
| GR01 | Patent grant |