CN104318851A - Rotating machinery fault simulation platform - Google Patents

Abstract

The invention relates to a rotating machinery fault simulation platform. The simulation platform is a laboratory device for verification experiment and diagnosis experiment teaching of rotating machinery faults. The rotating machinery fault simulation platform comprises a sliding gear mechanism, a geneva wheel mechanism, a triple sliding gear mechanism, a lead screw nut mechanism and a combination mechanism formed by a worm gear and inner gearing incomplete gear. All the mechanisms are independent to one another, and power can be obtained through a gear pair formed by gears and power gears at the ends of the mechanisms. By means of the rotating machinery fault simulation platform, the problems that it is difficult to replace fault parts in the experiment process, and the experiment function is single and the teaching requirement cannot be met are mainly solved. The integrated building is conducted in combination with the teaching purpose, and the blank of rotating machinery type fault experiment in colleges and universities is filled; based on construction of machinery transmission and test devices of certain existing machinery type experiment platform, the reliability, practicability and usability of the novel rotating machinery fault simulation platform are improved beneficially, and the experiment platform is made to have good popularization value.

Description

Rotating Machinery Fault Simulation Platform

technical field

The invention belongs to the field of electromechanical integration experiments, and in particular relates to a detection platform for rotating machinery faults. The invention relates to a rotating machinery fault simulation platform.

Background technique

At present, the existing rotating machinery fault simulation platforms at home and abroad are basically used in industrial production and scientific research, and their costs are generally high. However, the rotating machinery failure simulation platform that can be used in teaching has the problems of inconvenient operation and limited functions.

The analysis of rotating machinery faults is an important content in the courses of mechanical design, equipment condition monitoring and fault diagnosis in colleges and universities in my country, and the simulation experiment of rotating machinery faults is also one of the innovative experiments of mechanical majors in colleges and universities across the country. Based on the needs of teaching, we have designed a comprehensive experimental platform that can demonstrate and analyze typical fault problems of rotating machinery. It can simulate typical shaft faults, typical faults of bearings, and typical faults of gears.

However, there are generally problems in the following aspects when teachers use the rotating machinery failure simulation experiment platform in the existing classroom: ① It is necessary to frequently disassemble the faulty parts, which is time-consuming and laborious, and affects the normal progress of the course; The method is easy to cause damage to the faulty parts and cannot be used; ③students may lose enthusiasm due to the cumbersome process when operating; ④There is only a single type of fault on the experimental platform, and students cannot fully understand the faults of rotating machinery features.

Therefore, in order to achieve the following three classroom teaching purposes: ①The teacher can conveniently perform the simulation demonstration of rotating machinery faults, so that students can have an intuitive experience of rotating machinery faults; ②Students can use the experimental bench to verify the typical faults of rotating machinery Experiments, to deepen the understanding of related principles through experiments; ③Master the commonly used fault diagnosis methods through the experimental platform. We intend to design a new type of fault simulation platform for rotating machinery.

Contents of the invention

The technical problem to be solved by the present invention is to provide a rotating machinery failure simulation platform so as to solve the problem that the current rotating machinery failure detection experiment platform has a single function.

The present invention solves its technical problem and adopts the following technical solutions:

The rotating machinery failure simulation platform provided by the present invention includes a sliding gear mechanism, a sheave mechanism, a triple sliding gear mechanism, a screw nut mechanism, and a combined mechanism composed of a worm gear and an incomplete internal meshing gear; each mechanism is mutually Independent, the power can be obtained through the gear pair at the end of each mechanism and the power gear to form a gear pair.

The slipping gear mechanism, which makes the gears on the AC motor mesh with the input end gears of the three fault simulation modules respectively through the slip gear mechanism, and provides power for them; the three fault simulation modules are respectively gear fault Simulation module, shafting fault simulation module, bearing fault simulation module.

The grooved wheel mechanism can switch between three types of faulty bearings and normal bearings, simulating three types of bearing faults, so as to avoid the difficult problem of disassembly and assembly when replacing faulty bearings; typical faults of bearings include inner ring points Corrosion, outer ring pitting, cage damage.

The triple sliding gear mechanism includes a normal gear, a pitting gear and a tooth surface wear gear, and the shift fork can slide left and right on the triple sliding gear shaft by controlling the movement of the triple sliding gear. , respectively mesh with the normal gear, the pitting gear, and the gear with tooth surface wear on the other shaft.

The triple sliding gear mechanism avoids frequent disassembly of gears by simulating three gear working conditions. The three gear working conditions are: a pair of normal gear meshing, a pair of pitting gear meshing, a pair of Tooth face wear gear mesh.

The combination mechanism composed of worm gear and worm gear with incomplete internal meshing, and the screw and nut mechanism are used to simulate the typical faults of the shaft system, thereby avoiding the disassembly and assembly of parts; the typical faults include angular misalignment, dynamic and static unbalanced.

The screw and nut mechanism described above realizes the simulation of static unbalance in combination with the small parts of bolts and nuts, and adjusts the sliding of bolts and nuts on the mounting holes of the discs, thereby changing the balance mass of the rotating discs on the shaft to simulate the mass eccentricity of the rotor and, using two rotating disks to simulate the dynamic unbalance with different distances between them, adjusting the distance between the two rotating disks through the screw nut mechanism, simulating the dynamic unbalance under various distances.

Compared with the prior art, the present invention has the following main advantages:

Through the sliding gear mechanism and the groove wheel mechanism, the switching between various faulty gears and multiple faulty bearings is realized, avoiding the inconvenience caused by their disassembly and assembly;

The fault simulation of angular misalignment is realized by using the combined mechanism of worm gear and worm gear with incomplete internal meshing, and at the same time, the state of angular misalignment is maintained unchanged by cleverly combining the reverse self-locking characteristics of worm gear and worm.

Using virtual instrument software to obtain experimental data results not only realizes the visualization of experimental data, but also reduces the cost and enhances the detection function.

Description of drawings

Fig. 1 is a structural schematic diagram of the present invention.

Fig. 2 is the power module in Fig. 1.

Fig. 3 is a schematic diagram of the shafting fault simulation module in Fig. 1 .

Fig. 4 is a schematic diagram of the bearing fault simulation module in Fig. 1 .

Fig. 5 is a left side view of Fig. 4 .

Fig. 6 is a schematic diagram of the gear fault simulation module in Fig. 1 .

Fig. 7 is a schematic diagram of the present invention for detecting faults of rotating machinery.

FIG. 8 is a flow chart of the present invention for detecting a fault in a rotating machine.

Fig. 9 is a flow chart of the detection principle for detecting a rotating machine failure in the present invention.

Fig. 10 is a schematic diagram of frequency spectrum corresponding to common faults.

In the figure: 1. Power module; 1.1 AC motor; 1.2 Slip gear mechanism; 2. Shaft failure simulation module; 2.1 Reducer; 2.2 Adjusting screw; 2.3 Rotating disc; 2.4 Worm gear; 2.6 Screw nut mechanism; 3. Bearing fault simulation module; 3.1 Normal bearing; 3.2-3.4 Three fault bearings; 3.5 Sheave mechanism; 4. Gear fault simulation module; 4.1 Reducer; Gear; 4.4 pitting gear; 4.5 tooth surface wear gear; 4.6 magnetic powder brake.

Detailed ways

The present invention will be further described below in conjunction with the embodiments and accompanying drawings.

The rotating machinery failure simulation platform provided by the present invention has a structure as shown in Figures 1 to 6, including a sliding gear mechanism 1.2, a combined mechanism of a worm gear 2.4 and an incomplete internal meshing gear 2.5, a screw nut mechanism 2.6, and a sheave Mechanism 3.5 and Triple Sliding Gear Mechanism 4.2 etc. The above-mentioned mechanisms are independent of each other, and the power can be obtained through the gear pair formed by the gear at the end of each module and the sliding gear mechanism 1.2 on the power module.

The slip gear mechanism 1.2, which engages with the input end gears of the three fault simulation modules respectively through the slip gear on the power module 1, makes the AC motor 1.1 provide power for them; and through the reducer in front of each fault simulation module , such as the reducer 2.1 in the shaft fault simulation module, which reduces the speed, transmits power, and increases torque. The three fault simulation modules are a shafting fault simulation module 2 , a bearing fault simulation module 3 , and a gear fault simulation module 4 .

Typical failures of the shaft system of the combined mechanism of the worm gear 2.4 and the incomplete internal meshing gear 2.5 include: misalignment of angles, dynamic and static imbalance. The present invention uses the combined mechanism of the worm gear 2.4 and the incomplete internal meshing gear 2.5 to simulate the angle misalignment fault, so that there is no need to use pins, bolts and nuts for positioning, and the disassembly and assembly of these positioning parts are avoided. Manually rotate the worm to drive the worm gear to rotate. The pinion coaxial with the worm wheel rotates, and under the action of the incomplete internal meshing gear mechanism, the entire driven shaft part forms an angular misalignment with the driving shaft. At the same time, the reverse self-locking characteristics of the worm gear and worm can be used to maintain the angular misalignment of the driven shaft part during fault simulation and detection, and keep it fixed.

The screw and nut mechanism 2.6, combined with the small part of the adjusting screw 2.2, realizes the simulation of static unbalance, and adjusts the sliding of the adjusting screw 2.2 on the mounting hole of the rotating disc 2.3, thereby changing the balance mass of the rotating disc 2.3 on the shaft. Simulate the mass eccentricity (static imbalance) of the rotor; and, two rotating disks 2.3 can be used to simulate the dynamic imbalance with different distances between them, and the distance between the two rotating disks can be adjusted by the screw nut mechanism 2.6 to simulate multiple dynamic unbalance at different distances.

Described sheave mechanism 3.5, it can carry out the switching of three kinds of faulty bearing bearings 3.2-3.4 and normal bearing 3.1, simulates three types of bearing faults, so just can avoid the difficult problem of dismounting when faulty bearings are replaced; Typical faults include inner ring pitting, outer ring pitting, and cage damage.

The triple slip gear mechanism 4.2 can realize the simulation of three gear working conditions, so that frequent dismounting of gears can be avoided; it reduces the speed of the incoming gear failure simulation module through the reducer 4.1 and increases the torque; The dynamometer loading and braking of the transmission machinery is performed through the magnetic powder brake 4.6. The three working conditions of gears refer to: working condition 1 is a pair of normal gears meshing; working condition 2 is a pair of pitting gears meshing; working condition 3 is a pair of tooth surface worn gears meshing. The triple sliding gear mechanism 4.2 includes a normal gear, a pitting gear and a gear with tooth surface wear. The movement of the triple sliding gear can be controlled by a shift fork so that it can slide left and right on the shaft, respectively with the gear on the other shaft. Normal gear 4.3, pitting gear 4.4, tooth surface wear gear 4.5 meshing.

The above-mentioned rotating machinery failure simulation platform provided by the present invention is used in the demonstration and analysis of typical failure problems of rotating machinery. The typical fault types of the rotating machinery are mainly divided into three types: gear faults, shafting faults, and bearing faults.

Common typical faults in the gear faults include: gear pitting and tooth surface wear.

Common typical faults in the shafting faults include: dynamic and static imbalance and angular misalignment;

Common typical faults in the bearing faults are: inner ring pitting, outer ring pitting, cage damage and bearing housing looseness.

Using this novel rotating machinery failure simulation platform designed by the present invention, the teacher can realize the simulation demonstration of these failure types in the experimental class, and the students can touch, listen to the sound, observe the data measured by the sensor on the computer display interface, etc. In this way, we can establish an intuitive understanding of the impact of a certain fault in the rotating machinery on the rotating machinery system, and through the comparison between the normal phenomenon and the phenomenon when the fault exists, we can better understand the degree of harm and characteristics of various faults, and can carry out verification of rotating machinery faults Experiments and fault diagnosis experiments.

The present invention can use the detection module and matching detection methods to realize the above functions.

1. Detection module

The rotating machinery fault simulation platform is divided into three types of fault detection modules, so they need to be powered separately. The solution is: through the slip gear mechanism 1.2, the slip gear and the gear at the power input end of the three fault detection modules are realized. mesh to power them individually.

1. Gear fault simulation module:

The triple sliding gear mechanism 4.2 is adopted, and the three gears of the triple sliding gear are normal gears, pitting gears, and tooth surface wear gears. It can be used to mesh with normal gear 4.3, pitted gear 4.4, and tooth surface worn gear 4.5 respectively, so as to simulate three working conditions of a pair of normal gears, a pair of pitted gears, and a pair of tooth surface worn gears.

2. Shaft fault simulation module:

The simulation method of dynamic and static unbalance is: rely on adjusting the rotating disc 2.3 and the adjusting screw 2.2 on the rotor slides on its hole slot to simulate static unbalance; rely on the two above-mentioned rotating discs and screw nut mechanism 2.6 to simulate two discs The dynamic unbalance of the rotor at different distances. The simulation method of angular misalignment is: through the combined mechanism of the worm gear 2.4 and the incomplete internal meshing gear 2.5, the right part of the universal joint is driven with the center of the universal joint as the center of the circle, so that the driven shaft and the driving shaft The shaft forms an angular misalignment, and the reverse self-locking characteristic of the worm gear 2.4 can ensure that the angular misalignment remains unchanged during fault simulation.

3. Bearing fault simulation module:

The fault simulation method is: using the sheave mechanism 3.5 to switch between the normal bearing 3.1 and the three faulty bearings 3.2-3.4. The simulation of bearing seat loosening can be realized by loosening bolts.

2. Detection method

1. Detection principle:

As shown in FIG. 8 , the present invention builds the detection module described in FIG. 8 . It is composed of piezoelectric acceleration sensor, triode amplifier circuit, data acquisition card and virtual instrument software. Firstly, the piezoelectric acceleration sensor can obtain vibration signals at the corresponding detection parts of each fault simulation module, and convert the high-impedance charge signal obtained by the sensor into a low-impedance voltage signal through the triode amplifier circuit, and then use the data acquisition card to convert the analog The signal is converted into a digital signal, which is sent to the virtual instrument software written by labview software for analysis and processing.

2. Design of detection method:

As shown in Figure 8, rely on the piezoelectric acceleration sensor to obtain the vibration signal, convert the high-impedance charge signal into a low-impedance voltage signal through the triode amplifier circuit, and then convert the analog quantity to the digital quantity through the data acquisition card, and then send it to the In the computer equipment, use the virtual instrument software compiled by labview to process and analyze, and observe the experimental phenomena.

3. Detection method process:

As shown in Figure 9, it includes the verification experiment function of typical faults of rotating machinery and the diagnosis function of rotating machinery faults.

(1) Confirmatory experiment function for typical faults of rotating machinery:

By switching the mechanism and detection module, you can observe the data finally displayed in the computer virtual instrument software to conduct confirmatory experiments on various fault conclusions.

(2) Diagnosis function of rotating machinery failure:

Learn and master common fault diagnosis methods to diagnose the types and locations of faults that occur. For example, the frequency spectrum of vibration can be observed to determine the type of fault.

The design of the virtual instrument detection method is beneficial to reduce the cost of the experimental platform, improve the economy, and make the functions more complete. Students can bring their own notebook equipment or computer equipment provided by the school to simulate typical faults of rotating machinery on the experimental platform, and conduct related verification experiments and diagnostic experiments. To understand the faults of rotating machinery more comprehensively through experiments, and to assist the learning of principle knowledge.

Table 1 Confirmatory experiment content table

Claims (7)

1. a rotating machinery fault analog platform, is characterized in that comprising shifting slide gear mechanism, Geneva mechanism, three shifting slide gear mechanisms, screw-nut body, and the combined mechanism be made up of worm and gear and internal messing partial gear; Each mechanism is separate, forms gear pair obtain power by the gear of each mechanism end and power gear.

2. rotating machinery fault analog platform according to claim 1, it is characterized in that described shifting slide gear mechanism, it makes the gear on alternating current generator engage with the input end gear of three fault simulation modules respectively by shifting slide gear mechanism, and for they provide power; Described three fault simulation modules are gear distress analog module, axle system fault simulation module, bearing fault simulation module respectively.

3. rotating machinery fault analog platform according to claim 1, it is characterized in that described Geneva mechanism, it passes through the switching of three kinds of faulty bearings and normal bearing, simulates the bearing fault of three types, dismounting difficult problem when faulty bearings so just can be avoided to change; The typical fault of bearing has inner ring spot corrosion, outer ring spot corrosion, retainer to damage.

4. rotating machinery fault analog platform according to claim 1, it is characterized in that described three shifting slide gear mechanisms, comprise a normal gear, a spot corrosion gear and a tooth surface abrasion gear, moved by fork controls three shifting slide gear and can make the left and right slippage on three shifting slide gear axles of this shift fork, respectively with the normal gear on another root axle, spot corrosion gear, tooth surface abrasion gears meshing.

5. rotating machinery fault analog platform according to claim 3, it is characterized in that described three shifting slide gear mechanisms, it avoids the frequent dismounting of gear by the simulation of three kinds of gear operating modes, described three kinds of gear operating modes respectively: a pair normal gears meshing, a pair spot corrosion gears meshing, a pair tooth surface abrasion gears meshing.

6. rotating machinery fault analog platform according to claim 1, it is characterized in that the described combined mechanism be made up of worm and gear and internal messing partial gear, and screw-nut body, simulate axle system typical fault, avoid the disassemble and assemble work of part with this; Described typical fault comprises that angle misaligns, sound is uneven.

7. rotating machinery fault analog platform according to claim 1, it is characterized in that described screw-nut body, its this widget of joint bolt nut achieves the simulation of static unbalance, regulate the slip of bolt and nut on disk mounting holes, thus on change axle, rotating circular disk balance mass carrys out the mass eccentricity of model rotor; Further, use the unbalance dynamic that two their spacings of rotating circular disk simulation are different, regulate the distance between two rotating circular disks by leading screw and nut mechanism, simulate the unbalance dynamic under multiple spacing.