CN105352588A - Design of vibration detection system of brushless direct current motor - Google Patents
Design of vibration detection system of brushless direct current motor Download PDFInfo
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- 238000001514 detection method Methods 0.000 title claims abstract description 11
- 238000012360 testing method Methods 0.000 claims abstract description 107
- 238000000034 method Methods 0.000 claims abstract description 48
- 230000008569 process Effects 0.000 claims abstract description 30
- 238000012544 monitoring process Methods 0.000 claims abstract description 20
- 238000006731 degradation reaction Methods 0.000 claims abstract description 11
- 230000015556 catabolic process Effects 0.000 claims abstract description 10
- 230000003412 degenerative effect Effects 0.000 claims abstract description 10
- 238000009434 installation Methods 0.000 claims abstract description 6
- 238000005259 measurement Methods 0.000 claims abstract description 6
- 238000005516 engineering process Methods 0.000 claims abstract description 4
- 238000013480 data collection Methods 0.000 claims description 15
- 238000004458 analytical method Methods 0.000 claims description 10
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 3
- 229910052782 aluminium Inorganic materials 0.000 claims description 3
- 239000004411 aluminium Substances 0.000 claims description 3
- 229920001821 foam rubber Polymers 0.000 claims description 3
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- 238000002474 experimental method Methods 0.000 claims description 2
- 239000000203 mixture Substances 0.000 claims description 2
- 230000010355 oscillation Effects 0.000 claims description 2
- 238000001228 spectrum Methods 0.000 claims description 2
- 230000007850 degeneration Effects 0.000 abstract 2
- 238000011002 quantification Methods 0.000 abstract 1
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Abstract
The present invention discloses a design of a vibration detection system of a brushless direct current motor. The design of the vibration detection system of the brushless direct current motor comprises a test bed module, a signal control module, a data acquisition module, a supervisory control computer module and a vibration signal test module. The method flow comprises the following steps: (1) the design of installation of the clamp on the brushless direct current motor and a fixation method of the brushless direct current motor; (2) stress control and quantification input of the brushless direct current motor; (3) selection of test points; (4) measurement and monitoring of the system; and (5) the design of an acquisition system of vibration degradation signals. According to the invention, the acquisition of vibration signals in the running condition of a brushless direct current motor with oars may be realized to obtain degeneration trends of performance parameters of the brushless direct current motor in the degenerative process, and the degeneration trends of performance parameters may be used in the fault detection and life prediction technologies of brushless direct current motors of products such as a multi-rotor unmanned plane, a washing machine and the like.
Description
Technical field
The present invention is a kind of design for brshless DC motor vibration signal detection method in acceleration degenerative process.To providing the method for high efficient and reliable by result of design at the vibration signal characteristics parameter acquisition of operational process for brshless DC motor, belong to method and test field.
Background technology
In the During Process of Long-term Operation of brshless DC motor, there will be performance degradation phenomenon, its structure, parts can be deteriorated gradually, and lose original performance and function gradually, axle there will be wearing and tearing, can expose some up-set conditions, and this will bring safety issue.For avoiding product to be in operation generation security incident, just need to repair or replace product before accident symptom occurs.At present, concrete method is not also had to make guidance to the maintenance in brshless DC motor operational process or replacing decision-making.So just make the maintenance of brshless DC motor or change decision-making that there is great blindness, not only cannot ensure the security in product operational process, and too early change to scrap and also can cause the great wasting of resources.
On the other hand, when brshless DC motor generation exception or when breaking down, the jitter conditions in operational process can be aggravated.In fact, in the whole mission life of brushless electric machine, the Vibration Condition of motor can change gradually along with the increase of working time, and this vibration signal is measurable.Therefore can obtain the effective information of its performance state to the monitoring of the vibration response signal of motor, be a kind of non-destructive monitoring mode, and monitoring means is relatively simple.
This patent proposes a kind of method for designing gathering brshless DC motor vibration signal detection system in acceleration degenerative process.First, a pilot system has been built in design, simulate the real work situation of tested motor, the mode accelerated by rotating speed and frequency of utilization carries out acceleration decline test, and the vibration signal then by measuring tested motor carrys out the degenerate case of indirect observation motor.Thus be reached through treatment and analysis is carried out to vibration signal, the object of final prediction brshless DC motor life-span and detection failure.
And the design of vibration signal detection system in the performance degradation process of brshless DC motor, also do not study accordingly, therefore this patent propose the method be have necessarily Promethean.
Summary of the invention
The object of the invention is to solve the problem, proposing a kind of method for designing that effectively can gather brshless DC motor vibration signal acquisition system in acceleration degenerative process, obtaining performance degradation data accurately and effectively with this.
Concrete steps of the present invention are:
The design of step one, motor installing fixture and brshless DC motor fixing means;
Step 2, brshless DC motor Stress Control and quantitatively input;
The selection of step 3, test point;
Step 4, measurement and supervisory system;
The acquisition system of step 5, vibration degraded signal.
The invention has the advantages that:
(1) the present invention can realize the quantitative input of brshless DC motor working signal, thus makes brshless DC motor acceleration decline test have feasibility;
(2) the present invention is that the vibration signals collecting of brshless DC motor provides simply, detection system efficiently, has great practicality and replicability.
Accompanying drawing explanation
Fig. 1 is module relationship schematic diagram of the present invention;
Fig. 2 is method flow diagram of the present invention;
Fig. 3 is the quantitative input method principle schematic of working signal of the present invention;
Fig. 4 is supervisory control comuter module diagram of the present invention;
Fig. 5 is vibrating data collection module diagram of the present invention;
Fig. 6 is the fixture schematic diagram of embodiments of the invention;
Fig. 7 is the quantitative input method schematic diagram of working signal of embodiments of the invention;
Fig. 8 is the selecting test point schematic diagram of embodiments of the invention;
Fig. 9 is the acceleration decline testing table schematic diagram of embodiments of the invention.
Embodiment
The brshless DC motor vibration detecting system of invention mainly comprises testing table module, signal control module, data acquisition module, supervisory control comuter module and vibration signal and tests five module compositions, and the relation schematic diagram of these modules as shown in Figure 1.Below in conjunction with drawings and Examples, the present invention is described in further detail.
The process flow diagram of method as shown in Figure 2, comprises following step:
The design of step one, motor installing fixture and brshless DC motor fixing means
1) motor installing fixture
For simulating vibrational state when brshless DC motor (being applied to many rotors unmanned systems) runs truly, in test of the present invention, brshless DC motor needs bringing onto load to test.Design fixture, the power that the reacting force of fixture is produced with load balances each other simultaneously, as I shape fixture, and stablizing with testing table in warranty test.Another basis " motor test manual of standards " specifies, for ensureing that vibration signal can be surveyed and not affect by ground, elasticity installation need be carried out to tested motor, then need place the suitable cushion of elasticity coefficient under fixture, and the area of cushion should be greater than 1.2 times of motor projected area.Therefore, in this patent, under fixture, placed the cushion that area is fixture area 1.2 times, as foam-rubber cushion.
2) brshless DC motor fixing means
The material of fixture should have that plasticity is strong, surface rationality is good, nonmagnetic, elasticity coefficient is little and the sparkproof premium properties of collision friction, as aluminium section bar, to ensure fixture to test without impact.In addition, resonance is produced, the collection of interference test data for avoiding between motor and fixture, affect the authenticity of test figure, being rigidly connected between tested motor and fixture need be ensured, and tested motor is rigidly fixed, avoid the uneven vibration signal that causes of testing table total quality to disturb.The bottom surface of fixture should be enough smooth, to avoid fixture de-stabilising effect vibration signal, so the fixed form of tested motor should ensure the planarization of fixture bottom surface.
By this step, namely complete the testing table module of this patent.
Step 2, brshless DC motor Stress Control and quantitatively input
The work of brshless DC motor completes under the acting in conjunction controlled by electrical energy drive and pulsating wave, the main involving vibrations data of parameter, rotating speed, electric current, voltage and temperature that this test unit can be measured; The stress that can apply mainly comprises: electric stress and rotating speed stress.Because motor is comparatively large by the impact of voltage in actual motion, therefore this patent is selected to carry out fixing quantity to the input voltage of brushless electric machine.
The method that this patent adopts is: first by power supply fixing quantity input voltage value; Then launch pulse signal by control panel, realize the fixing quantity of machine operation stress.By this step, namely complete the signal control module design of this patent.
The selection of step 3, test point
According to the design feature of brshless DC motor, if the size of tested motor is enough large, then can be set directly on the shell of motor by test point, the vibration of tested like this motor bearings drives shell synchronous vibration; If the size of tested motor is less, so its stator does not have enough areas to paste sensor, and rotor is the parts of a High Rotation Speed, cannot paste sensor by area equally.So directly on motor sensor installation to carry out Real-Time Monitoring to it not too reasonable.And in real electrical machinery operational process, rotor oscillation can be delivered on bearing, and bearing and frame are fabricated to one, and in this patent, brshless DC motor and test fixture are rigidly connected, so the vibration of frame then can drive fixture synchronous vibration, and the vibration of such fixture is the vibration of bearing.So, to the vibration monitoring of rotor indeed through carrying out vibration monitoring to realize to test fixture.General mensuration motor oscillating needs from three direction detections, i.e. axis, horizontal direction, vertical (up and down) direction, and wherein horizontal and vertical direction is also called radial direction.Desirable test point should be X, Y, and the sensor of Z axis is all placed near motor, but should be taken into account the permission of the powerful and fixture condition of vibration signal simultaneously, carries out suitable adjustment.In test process, for ensureing measuring accuracy, point position will remain unchanged.By this step, namely complete the data acquisition module blocks design of this patent.
Step 4, measurement and supervisory system
Because brshless DC motor sensitive stress also comprises rotating speed stress and temperature stress, so also need to measure the operating rotating speed of motor and temperature.The rotating speed of knotmeter to blade is adopted to monitor, as reflecting type knotmeter, infrared ray knotmeter etc.; The temperature of temperature measurer to tested motor fuselage is adopted to monitor, as infrared thermometer, multi-channel intelligent temperature measurer etc.The data recorded not only contribute to the degenerative character of assistant analysis brshless DC motor other performances in degenerative process; But also the security contributed in process of the test, avoid that temperature is too high to cause the accident.Supervisory system also comprises remote wireless monitoring, can carry out real-time video monitoring, monitor at the scene without the need to testing crew in process of the test to the ruuning situation of whole testing table, and the efficiency that improve test also ensures the safety of personnel.By this step, namely complete the supervisory control comuter modular design of this patent.
The acquisition system of step 5, vibration signal
By above four steps, the jig Design of brshless DC motor, the quantitative input of control signal, the choosing and the test of whole process of the test and monitoring of vibration-testing point can be completed.So next, then can gather the vibration signal of tested motor.The design of the acquisition system of vibration signal mainly comprises following components:
1) selection of vibration transducer
The selection of vibration transducer should meet test request, if the brshless DC motor vibration frequency chosen is at χ Hz, so the frequency test scope of vibration transducer just should comprise χ Hz; Simultaneously in order to improve the quality of collection signal, avoiding noise jamming signal, the sensor that sensitivity is higher should be chosen, to meet the reliability of test figure.In addition, also should consider the size of test fixture, the diameter of sensor should be less than the thickness of fixture.
2) vibrating data collection card is selected
Vibrating data collection card completes Sensor Analog Relay System exactly or digital voltage simulating signal converts digital signal to, and digital data transmission to the circuit-board card of computing machine.The vibrating data collection cartoon number of channels selected should be more than or equal to the axial number gathering vibration signal.
3) vibrating data collection analysis software
Vibrating data collection analysis software is the software systems that the digital signal transmitted data collecting card carries out the display of the coherent signal such as waveform, frequency spectrum, analysis and storage.
By this step, namely complete the vibration signal test module design of this patent.
In sum, the building of brshless DC motor degradation experiment platform of this patent can complete.By this testing table, collection analysis can be carried out to the degraded data of brshless DC motor in operational process, for the fault of product and life prediction provide analysis data.The method also can be applicable in the fail-test such as accelerated degradation test, accelerated life test technology, thus provides more fully reliability assessment for product.
Embodiment:
Certain model brshless DC motor needs to carry out fault detect and life prediction, to carry out reliability assessment and Production Safety Precaution Work better.The method now utilizing this patent to propose, carries out corresponding test, to obtain this model brshless DC motor vibration signal degraded data.
Step one, test fixture and brshless DC motor fixing means
1) test fixture
According to this model brshless DC motor parameter specification, it is 20N that band oar runs the maximum pull produced, and so in order to the stability of testing table in warranty test, avoid motor pulling force to disturb vibration signal, clamp weight should much larger than 20N.This model blade length is of a size of 700mm in addition, so conveniently placement sensor, can be " work " font by jig Design, and the length of fixture should be greater than 700mm.The schematic diagram of this model brshless DC motor vibration table design, as Fig. 6.The material of fixture can select aluminium block, and weight is about 75N, much larger than 20N.Certain thickness foam-rubber cushion is placed in addition, to ensure that vibration signal is enough obvious under fixture.
3) brshless DC motor fixing means
In order to ensure being rigidly connected between tested motor and fixture, both are avoided to produce resonance, interference test data.By 4 screws in this test, brshless DC motor is fixed on fixture, as Fig. 6.The diameter of threaded hole should be determined according to the brshless DC motor of different model.In addition, in order to make the planarization of fixture and earth surface, certain size that threaded hole is sunk.
Step 2, brshless DC motor Stress Control and quantitatively input
First by the input voltage value of D.C. regulated power supply fixing quantity current regulator; Then send instruction by computer system to control panel, launch pulse signal; Finally, current regulator is when given magnitude of voltage and pulse signal, and quantitative output current value, thus the fixing quantity realizing machine operation load, as Fig. 7.
The brshless DC motor maximum operating currenbt selected in the present embodiment reaches 25A, so meet testing requirements and ensure sufficient security, the current regulator maximum operating currenbt selected should be greater than 25A.Operating voltage range is 20 ~ 26V, and the D.C. regulated power supply range of voltage values so selected should comprise the operating voltage range of motor.
The selection of step 3, test point
The comparatively typical brshless DC motor of structure is have employed in present case, cannot direct sensor installation on motor.So, to the vibration monitoring of rotor indeed through carrying out vibration monitoring to realize to test fixture.Desirable test point should be X, Y, and the sensor of Z axis is all placed near motor, but should be taken into account the permission of the powerful and fixture condition of vibration signal simultaneously, carries out suitable adjustment, as Fig. 8.In test process, for ensureing measuring accuracy, point position will remain unchanged.
Step 4, measurement and supervisory system
In order to measure the operating rotating speed of brshless DC motor and temperature, in test process, knotmeter is adopted to test and record motor speed; Multiple-path temperature measurement is adopted to test and record motor temperature.The measurement data obtained not only contributes to the degenerative character of assistant analysis brshless DC motor other performances in degenerative process, but also contributes to the security in process of the test, avoids that temperature is too high to cause the accident.Supervisory system adopts wireless camera to carry out remote monitoring, and in process of the test, carry out real-time video monitoring to the ruuning situation of whole testing table, the efficiency that improve test also ensures the safety of personnel.
The acquisition system of step 5, vibration signal
The design of the acquisition system of vibration signal mainly comprises following components:
1) selection of vibration transducer
The brshless DC motor vibration frequency chosen in present case is 40Hz, and the vibration transducer frequency so selected surveys scope should wrap 40Hz, and sensitivity is recommended to be more than or equal to 100mV/g, to meet testing requirements.In addition, in this test, the diameter of vibration transducer is 20mm, and the thickness of test fixture then should be greater than 20mm, meets testing requirements equally, but should note unsuitable blocked up, in order to avoid produce considerable influence to vibration signal.
2) vibrating data collection card is selected
The axial number of usual collection vibration signal is X, Y, Z tri-axis, so what adopt in the present embodiment is that certain model vibrating data collection jig has 5 passages, meets testing requirements.
3) vibrating data collection analysis software
Certain the model vibrating data collection analysis software adopted in the present embodiment can simultaneously display waveform figure, spectrogram, and can Real-time Collection and storage, so meet testing requirements.
In sum, the design drawing of the many rotors brshless DC motor accelerated degradation test platform building method in the present embodiment can be drawn, as Fig. 9.
By accelerated degradation test method, the vibration degraded signal of brshless DC motor under different electric stress value is gathered and analyzed, and is detected and life prediction by the fault of fitting function model to its life cycle.Such as, if the vibration signal degradation trend of this model brshless DC motor, meet Weibull function distribution, then can judge the life-span of time and the pre-measured motor that may break down according to Weibull distribution curve map.
Claims (1)
1. brshless DC motor vibration detecting system mainly comprises testing table module, signal control module, data acquisition module, supervisory control comuter module and vibration signal and tests five modules composition.The flow process of concrete grammar comprises following step:
The design of step one, motor installing fixture and brshless DC motor fixing means
1) motor installing fixture
For simulating vibrational state when brshless DC motor (being applied to many rotors unmanned systems) runs truly, in test of the present invention, brshless DC motor needs bringing onto load to test.Design fixture, the power that the reacting force of fixture is produced with load balances each other simultaneously, as I shape fixture, and stablizing with testing table in warranty test.Another basis " motor test manual of standards " specifies, for ensureing that vibration signal can be surveyed and not affect by ground, elasticity installation need be carried out to tested motor, then need place the suitable cushion of elasticity coefficient under fixture, and the area of cushion should be greater than 1.2 times of motor projected area.Therefore, in this patent, under fixture, placed the cushion that area is fixture area 1.2 times, as foam-rubber cushion.
2) brshless DC motor fixing means
The material of fixture should have that plasticity is strong, surface rationality is good, nonmagnetic, elasticity coefficient is little and the sparkproof premium properties of collision friction, as aluminium section bar, to ensure fixture to test without impact.In addition, resonance is produced, the collection of interference test data for avoiding between motor and fixture, affect the authenticity of test figure, being rigidly connected between tested motor and fixture need be ensured, and tested motor is rigidly fixed, avoid the uneven vibration signal that causes of testing table total quality to disturb.The bottom surface of fixture should be enough smooth, to avoid fixture de-stabilising effect vibration signal, so the fixed form of tested motor should ensure the planarization of fixture bottom surface.
By this step, namely complete the testing table module of this patent.
Step 2, brshless DC motor Stress Control and quantitatively input
The work of brshless DC motor completes under the acting in conjunction controlled by electrical energy drive and pulsating wave, the main involving vibrations data of parameter, rotating speed, electric current, voltage and temperature that this test unit can be measured; The stress that can apply mainly comprises: electric stress and rotating speed stress.Because motor is comparatively large by the impact of voltage in actual motion, therefore this patent is selected to carry out fixing quantity to the input voltage of brushless electric machine.
The method that this patent adopts is: first by power supply fixing quantity input voltage value; Then launch pulse signal by control panel, realize the fixing quantity of machine operation stress.By this step, namely complete the signal control module design of this patent.
The selection of step 3, test point
According to the design feature of brshless DC motor, if the size of tested motor is enough large, then can be set directly on the shell of motor by test point, the vibration of tested like this motor bearings drives shell synchronous vibration; If the size of tested motor is less, so its stator does not have enough areas to paste sensor, and rotor is the parts of a High Rotation Speed, cannot paste sensor by area equally.So directly on motor sensor installation to carry out Real-Time Monitoring to it not too reasonable.And in real electrical machinery operational process, rotor oscillation can be delivered on bearing, and bearing and frame are fabricated to one, and in this patent, brshless DC motor and test fixture are rigidly connected, so the vibration of frame then can drive fixture synchronous vibration, and the vibration of such fixture is the vibration of bearing.So, to the vibration monitoring of rotor indeed through carrying out vibration monitoring to realize to test fixture.General mensuration motor oscillating needs from three direction detections, i.e. axis, horizontal direction, vertical (up and down) direction, and wherein horizontal and vertical direction is also called radial direction.Desirable test point should be X, Y, and the sensor of Z axis is all placed near motor, but should be taken into account the permission of the powerful and fixture condition of vibration signal simultaneously, carries out suitable adjustment.In test process, for ensureing measuring accuracy, point position will remain unchanged.By this step, namely complete the data acquisition module blocks design of this patent.
Step 4, measurement and supervisory system
Because brshless DC motor sensitive stress also comprises rotating speed stress and temperature stress, so also need to measure the operating rotating speed of motor and temperature.The rotating speed of knotmeter to blade is adopted to monitor, as reflecting type knotmeter, infrared ray knotmeter etc.; The temperature of temperature measurer to tested motor fuselage is adopted to monitor, as infrared thermometer, multi-channel intelligent temperature measurer etc.The data recorded not only contribute to the degenerative character of assistant analysis brshless DC motor other performances in degenerative process; But also the security contributed in process of the test, avoid that temperature is too high to cause the accident.Supervisory system also comprises remote wireless monitoring, can carry out real-time video monitoring, monitor at the scene without the need to testing crew in process of the test to the ruuning situation of whole testing table, and the efficiency that improve test also ensures the safety of personnel.By this step, namely complete the supervisory control comuter modular design of this patent.
The acquisition system of step 5, vibration signal
By above four steps, the jig Design of brshless DC motor, the quantitative input of control signal, the choosing and the test of whole process of the test and monitoring of vibration-testing point can be completed.So next, then can gather the vibration signal of tested motor.The design of the acquisition system of vibration signal mainly comprises following components:
1) selection of vibration transducer
The selection of vibration transducer should meet test request, if the brshless DC motor vibration frequency chosen is at χ Hz, so the frequency test scope of vibration transducer just should comprise χ Hz; Simultaneously in order to improve the quality of collection signal, avoiding noise jamming signal, the sensor that sensitivity is higher should be chosen, to meet the reliability of test figure.In addition, also should consider the size of test fixture, the diameter of sensor should be less than the thickness of fixture.
2) vibrating data collection card is selected
Vibrating data collection card completes Sensor Analog Relay System exactly or digital voltage simulating signal converts digital signal to, and digital data transmission to the circuit-board card of computing machine.The vibrating data collection cartoon number of channels selected should be more than or equal to the axial number gathering vibration signal.
3) vibrating data collection analysis software
Vibrating data collection analysis software is the software systems that the digital signal transmitted data collecting card carries out the display of the coherent signal such as waveform, frequency spectrum, analysis and storage.
By this step, namely complete the vibration signal test module design of this patent.
In sum, the building of brshless DC motor degradation experiment platform of this patent can complete.By this testing table, collection analysis can be carried out to the degraded data of brshless DC motor in operational process, for the fault of product and life prediction provide analysis data.The method also can be applicable in the fail-test such as accelerated degradation test, accelerated life test technology, thus provides more fully reliability assessment for product.
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