CN106017932B - Motor bearing on-line monitoring and intelligent early warning system - Google Patents
Motor bearing on-line monitoring and intelligent early warning system Download PDFInfo
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- CN106017932B CN106017932B CN201610620339.0A CN201610620339A CN106017932B CN 106017932 B CN106017932 B CN 106017932B CN 201610620339 A CN201610620339 A CN 201610620339A CN 106017932 B CN106017932 B CN 106017932B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M13/00—Testing of machine parts
- G01M13/04—Bearings
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D21/00—Measuring or testing not otherwise provided for
- G01D21/02—Measuring two or more variables by means not covered by a single other subclass
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M13/00—Testing of machine parts
- G01M13/04—Bearings
- G01M13/045—Acoustic or vibration analysis
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- General Physics & Mathematics (AREA)
- Acoustics & Sound (AREA)
- Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)
Abstract
The invention relates to an online monitoring and intelligent early warning system for a motor bearing, and belongs to the field of intelligent online monitoring of motors. The system comprises a bearing temperature sensor, an environment temperature sensor, a bearing noise sensor, a measurement and analysis module, a display module, a communication module and a field alarm module; the bearing temperature sensor measures the real-time temperature of the outer ring of the bearing, the environment temperature sensor measures the working environment temperature of the motor, the temperature is sent to the measurement and analysis module and is combined with the data measured by the bearing noise sensor to analyze and judge the running and working states of the bearing, and early warning or alarming is carried out through the display module, the communication module or the field alarm module. The system realizes early warning and alarming of the motor bearing, timely discovers and processes the motor bearing, effectively avoids expansion of bearing faults and greatly improves maintenance efficiency. And simple structure, simple to operate, cost are lower, but wide application in the bearing intelligence on-line monitoring of middle-size and small-size motor.
Description
Technical Field
The invention relates to an online monitoring system for a motor bearing, in particular to a system which can realize online monitoring of the motor bearing and can also carry out intelligent early warning, and belongs to the field of intelligent online monitoring of motors.
Background
The bearing is a universal device which is widely applied to motors in the fields of electric power, metallurgy, aviation and the like, and the working condition of the bearing is very bad. The bearing plays a role in bearing load and transmitting load in the motor, the performance of the whole motor is directly influenced if the running state of the bearing is normal, the failure of the bearing can cause the damage of a motor winding and a shaft, the equipment is burnt out and damaged, meanwhile, the performance of the motor is degraded or the motor is shut down accidentally, and the immeasurable loss can be brought to industrial production, so that the monitoring and early warning of the running state of the shaft carrier are very necessary. However, due to the problems of cost and the like, particularly for small and medium-sized motors, the monitoring and early warning of the bearing are not always carried out.
The bearing detection method adopted at the present stage is generally manual detection and single information source detection, and the working state of the bearing is judged by listening abnormal sound by testers and using a portable temperature detector. A single information source detection method, such as Chinese patent 'a motor bearing state monitoring system' (application number: 201220323453.4), provides on-line monitoring of bearing temperature, but only carries out limit value judgment alarm according to the temperature of a bearing, is greatly influenced by environmental temperature, has high false alarm rate, and can not carry out early warning on bearing failure foreboding in advance according to single judgment; the failure rechecking of the bearing is lacked, so that the failure reason is difficult to quickly find out, and the production is influenced; and under the unattended condition, the operator cannot be informed in time so as to take measures at the initial stage of the fault, avoid the expansion of the fault and the like.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention provides an online monitoring and intelligent early warning system for a motor bearing. The motor bearing fault early warning device has the advantages that the outer ring temperature change and the bearing noise change caused by the abnormality of the motor bearing are monitored, the motor bearing fault early warning device can diagnose, early warn and process timely when a fault foreboding occurs in the motor bearing, and serious consequences such as equipment damage and unexpected production halt caused by the fault early warning device are effectively avoided. The system has the advantages of simple structure, convenience in installation and lower cost, effectively improves the accuracy of early warning and alarming, avoids false alarm, and is convenient for operators to handle on site.
The technical scheme adopted by the invention for solving the technical problems is as follows:
the motor bearing on-line monitoring and intelligent early warning system comprises a bearing temperature sensor (1), an environment temperature sensor (2), a measurement and analysis module (3), a display module (4), a communication module (5) and a field alarm module (6); the bearing temperature sensor (1) is arranged in a drilled hole in the motor end cover and is in close contact with the outer ring of the motor bearing, the measured real-time temperature of the outer ring of the bearing is sent to the measurement and analysis module (3), the environment temperature sensor (2) measures the working environment temperature of the motor and sends the temperature to the measurement and analysis module (3), and the temperature of the outer ring of the bearing is subtracted from the environment temperature to obtain the real-time temperature rise of the outer ring of the bearing.
When the bearing operates, because foreign matters enter the inside of the bearing, the lubrication is improper and impurities exist in oil to cause abrasion, the bearing operates under heavy load and high speed, and the high temperature is locally reached in a short time, so that the speed of bearing fault development can be judged by analyzing the temperature rising trend and the temperature rising value of the bearing, and measures can be taken in time. Based on the situation, the measurement and analysis module (3) in the system analyzes the variation trend of the temperature rise of the outer ring of the bearing, and the condition that the rising trend of the temperature rise is intensified in a short time or exceeds a set rising threshold value is taken as a criterion for early warning of bearing abnormity; the temperature rise is adopted here in order to eliminate the influence of the change of the ambient temperature as much as possible.
Different bearings respectively have fixed temperature rise rising trends under the normal operation, and the temperature rise can rise to a stable value in the operation process, once the bearing has a fault, the rising trend can have obvious abnormal change, and the temperature rise can exceed the stable value under the normal condition. Therefore, the trend change and the temperature rise value are used as fault precursors to carry out early warning.
In addition, the temperature value of the bearing outer ring can directly reflect the working and health states of the bearing, and under the condition that the temperature rise is not excessive, the working performance and the service life of the bearing are influenced due to overhigh environment temperature and difficult heat dissipation of the bearing. The measurement analysis module (3) compares the measured temperature value of the bearing outer ring with a set early warning threshold value and a set alarm threshold value, and performs early warning when the measured temperature value exceeds the set early warning threshold value and performs alarm when the measured temperature value exceeds the set alarm threshold value; when the early warning threshold value is exceeded, the working staff is reminded that the bearing works abnormally, and when the early warning threshold value is exceeded, an alarm is given out to remind the working staff that the bearing has serious faults and needs to be shut down for maintenance.
The measurement analysis module (3) carries out early warning or alarming through the display module (4), the communication module (5) or the field alarming module (6). When the bearing works abnormally, the field alarm module (6) can remind field workers in a sound mode, a light mode and the like, the display module (4) can also display alarm states and concrete operation data such as bearing temperature values, noise values and the like, the display module can also inform the central server (10) through the communication module (5), and the control center can schedule and arrange the workers to take measures in time.
In order to facilitate auxiliary workers to overhaul and maintain abnormal working states of the bearing, the system further comprises a key (7), when the measurement and analysis module (3) carries out early warning and field processing of operators, a processing completion instruction is sent to the measurement and analysis module (3) through the key (7) or the communication module (5), and then the measurement and analysis module (3) does not carry out early warning or alarming within a set delay time interval. The main reasons for the occurrence of early warning are that the environmental temperature is too high, the bearing lubricating oil is missing, and the bearing failure foreboding is three, the environmental temperature is too high, and the environmental temperature and the bearing temperature rise can be directly judged, and the bearing lubricating oil is missing and the bearing failure foreboding need to be distinguished.
After a set delay time interval, the measurement and analysis module (3) automatically enters a rechecking working state, the measurement and analysis module (3) detects the condition meeting the early warning again in the set rechecking time interval, an alarm is given, and the measurement and analysis module (3) automatically restores to a normal working state after the rechecking time interval is finished.
The motor no longer detects the condition that accords with the early warning through the set reinspection time interval, explains that lubrication acts, and the problem has been solved. And the early warning is generated again in the set rechecking time interval, which shows that the heating of the bearing is not caused by the lubrication problem, namely the bearing has serious defects, so that the alarm is needed. After the rechecking time interval, the measurement and analysis module (3) needs to be automatically reset whether early warning occurs or not, and is restored to a normal working state.
In order to further improve the accuracy of early warning, the system further comprises a bearing noise sensor (8) which is arranged on a motor end cover near a motor bearing, collected noise is sent to a measurement and analysis module (3), the measurement and analysis module (3) extracts noise characteristics, the working state of the bearing is analyzed and judged, and the bearing temperature and bearing temperature rise data are combined to perform state early warning and warning on the bearing.
Even if the bearing is slightly stripped and damaged, irregular abnormal sound can be generated, about 14 percent of the bearing is damaged early due to pollution, and external impurities enter the working surface of the bearing to cause aperiodic vibration and noise. If the noise is continuous, the roller path may be damaged; if the noise is not periodic or not, the rolling elements are damaged: if the rolling body is broken, the 'tooth filing sound, impact sound' and the like are generated. Therefore, the noise characteristics also have visual reflection on the failure foreboding of the bearing, the temperature and the noise are taken as information sources together, the failure foreboding can be better judged, and the failure development can be accurately predicted.
Because the front end and the rear end of the motor are provided with bearings, the number of the bearing temperature sensors (1) is 2, and the bearings are respectively connected with the measurement analysis module (3) to monitor the front bearing and the rear bearing of the motor simultaneously; correspondingly, the number of the bearing noise sensors (8) is also 2, and the bearing noise sensors are respectively connected with the measurement and analysis module (3) to monitor the front bearing and the rear bearing of the motor simultaneously.
The system comprises a portable device (9) and a central server (10), wherein a measurement analysis module (3) sends bearing operation temperature, temperature rise and noise data, early warning and warning information to the portable device (9) or the central server (10) through a communication module (5); meanwhile, the portable device (9) or the central server (10) sends information to the measurement and analysis module (3) through the communication module (5) and sets various working parameters of the system. The working personnel can know the working state of the bearing at any time and any place by means of the portable device (9), and can respond and process in time when abnormality occurs, and meanwhile, the field operation is convenient; the central server (10) can also record the bearing state at any time, so that the reference of the bearing service life prediction is facilitated.
The system comprises a data interface (11) which is directly connected with an external electronic device (12) for data exchange. The measured temperature and noise data can be exported to other external electronic equipment (12) such as a computer, and further in-depth analysis of the shaft carrying state by field test maintenance personnel is facilitated.
Compared with the prior art, the invention has the following advantages:
1) the temperature rise is combined with the temperature and the variation trend to carry out the failure forewarning of the motor bearing, so that the conditions of degradation, lack of lubricating oil and the like of the motor bearing can be found as early as possible, the warning accuracy is improved, and the serious consequences of expansion of the failure, equipment damage, unexpected production stop and the like caused by the failure are effectively avoided.
2) The outer ring temperature and the bearing noise caused by the abnormity of the motor bearing are jointly monitored and early warned, so that the accuracy of early warning and warning is further improved.
3) The design of the re-inspection working state is beneficial to assisting operators to timely process and rapidly solve faults, avoids the loss caused by deepening faults or long-time production halt, and greatly improves the maintenance efficiency.
4) By adopting the portable device or the central server, the operating personnel can know the state of the bearing at any time, the early warning and processing speed is greatly improved, the operation personnel are facilitated, and the bearing damage caused by the further development of faults is avoided.
In addition, the design of the system also has the advantages of simple structure, convenient installation, lower cost and the like.
Drawings
FIG. 1: the system is schematically constructed.
In the figure: 1-bearing temperature sensor, 2-environment temperature sensor, 3-measurement analysis module, 4-display module, 5-communication module, 6-field alarm module, 7-key, 8-bearing noise sensor, 9-portable device, 10-central server, 11-data interface, 12-external electronic equipment.
Detailed Description
The invention is described in further detail below with reference to the accompanying drawings:
as shown in figure 1, a bearing temperature sensor (1) and a bearing noise sensor (8) are respectively arranged on the front bearing and the rear bearing of the motor, the four sensors are all inserted into a drill hole of a motor end cover and tightly attached to the outer ring of the bearing, and measured bearing temperature and noise data are sent to a measurement and analysis module (3). The environment temperature sensor (2) measures the environment temperature and is connected with the measurement analysis module (3). And the measurement analysis module (3) subtracts the temperature of the outer ring of the bearing from the ambient temperature to obtain the real-time temperature rise of the outer ring of the bearing.
The measurement and analysis module (3) analyzes the temperature rise and temperature change trend of the bearing outer ring, and performs noise feature extraction, analysis and judgment by combining the data of the bearing noise sensor (8) to realize the state early warning and alarm of the bearing.
The measurement analysis module (3) carries out early warning or alarming through the display module (4), the communication module (5) or the field alarming module (6). When the bearing works abnormally, the field alarm module (6) can remind field workers in a sound mode, a light mode and the like, the display module (4) can also display alarm states and concrete operation data such as bearing temperature values, noise values and the like, the display module can also inform the central server (10) through the communication module (5), and the control center can schedule and arrange the workers to take measures in time.
The key (7) is connected with the measurement and analysis module (3) and is used for setting the working state of the system and assisting workers in overhauling and maintaining the abnormal working state of the bearing.
The portable device (9) can be communicated with the measurement and analysis module (3) through the communication module (5), receive bearing operating temperature, temperature rise and noise data, and early warning and alarm information, know and analyze the working state of the bearing at any time and any place, and can set various working parameters of the measurement and analysis module (3).
The data interface (11) is generally a USB socket or an RJ45 network port and the like, is connected with the measurement analysis module (3) and is used for directly connecting external electronic equipment (12) such as a computer and the like and leading out the measured temperature and noise data for further in-depth analysis.
Claims (5)
1. Motor bearing on-line monitoring and intelligent early warning system, its characterized in that: the system comprises a bearing temperature sensor (1), an environment temperature sensor (2), a measurement and analysis module (3), a display module (4), a communication module (5) and a field alarm module (6);
the bearing temperature sensor (1) is drilled into a hole from a motor end cover and is tightly contacted with a motor bearing outer ring, the measured real-time temperature of the bearing outer ring is sent to the measurement and analysis module (3), the environment temperature sensor (2) measures the working environment temperature of the motor and sends the temperature to the measurement and analysis module (3), and the temperature of the bearing outer ring is subtracted from the environment temperature to obtain the real-time temperature rise of the bearing outer ring;
when the bearing runs, the bearing runs under heavy load and high speed due to the fact that foreign matters enter the inside of the bearing, lubrication is improper and impurities exist in oil, the bearing locally reaches high temperature in a short time, and therefore the speed of bearing fault development can be judged by analyzing the temperature rising trend and the temperature rising value of the bearing, and measures can be taken in time; the measurement analysis module (3) analyzes the change trend of the temperature rise of the outer ring of the bearing, and the condition that the rising trend of the temperature rise is intensified in a short time or exceeds a set rising threshold value is taken as a criterion for early warning of bearing abnormity; the temperature rise is adopted to eliminate the influence of the change of the environmental temperature as much as possible; different bearings respectively have fixed rising trends of temperature rise under normal operation, the temperature rise can rise to a stable value in the operation process, once the bearings have faults, the rising trends can have obvious abnormal changes, and the temperature rise can exceed the stable value under normal conditions; therefore, the trend change and the temperature rise value are used as failure precursors to carry out early warning;
the temperature value of the bearing outer ring can directly reflect the working and health states of the bearing, and under the condition that the temperature rise is not excessive, the working performance and the service life of the bearing can be influenced due to overhigh environment temperature and difficult heat dissipation of the bearing; the measurement analysis module (3) compares the measured temperature value of the bearing outer ring with a set early warning threshold value and a set alarm threshold value, and performs early warning when the measured temperature value exceeds the set early warning threshold value and performs alarm when the measured temperature value exceeds the set alarm threshold value; when the early warning threshold value is exceeded, reminding workers of abnormal work of the bearing, and when the early warning threshold value is exceeded, giving an alarm to remind the workers of serious bearing fault and need to be stopped for maintenance;
the measurement analysis module (3) carries out early warning or alarming through the display module (4), the communication module (5) or the field alarming module (6);
the system comprises a bearing noise sensor (8) which is arranged on a motor end cover near a motor bearing, the collected noise is sent to a measurement and analysis module (3), the measurement and analysis module (3) extracts noise characteristics, analyzes and judges the working state of the bearing, and performs state early warning and alarming of the bearing by combining bearing temperature and bearing temperature rise data.
2. The motor bearing on-line monitoring and intelligent early warning system of claim 1, characterized in that: the system comprises a key (7), when the measurement and analysis module (3) carries out early warning and field processing of operators, a processing completion instruction is sent to the measurement and analysis module (3) through the key (7) or the communication module (5), and the measurement and analysis module (3) does not carry out early warning or alarming within a set delay time interval; after a set delay time interval, the measurement and analysis module (3) automatically enters a rechecking working state, the measurement and analysis module (3) detects the condition meeting the early warning again in the set rechecking time interval, an alarm is given, and the measurement and analysis module (3) automatically restores to a normal working state after the rechecking time interval is finished.
3. The motor bearing on-line monitoring and intelligent early warning system of claim 1, characterized in that: the number of the bearing temperature sensors (1) is 2, and the bearing temperature sensors are respectively connected to the measurement analysis module (3) to monitor the front bearing and the rear bearing of the motor simultaneously; correspondingly, the number of the bearing noise sensors (8) is also 2, and the bearing noise sensors are respectively connected with the measurement and analysis module (3) to monitor the front bearing and the rear bearing of the motor simultaneously.
4. The motor bearing on-line monitoring and intelligent early warning system of claim 1, characterized in that: the system comprises a portable device (9) and a central server (10), wherein a measurement analysis module (3) sends bearing operation temperature, temperature rise and noise data, early warning and warning information to the portable device (9) or the central server (10) through a communication module (5); meanwhile, the portable device (9) or the central server (10) sends information to the measurement and analysis module (3) through the communication module (5) and sets various working parameters of the system.
5. The motor bearing on-line monitoring and intelligent early warning system of claim 1, characterized in that: the system comprises a data interface (11) which is directly connected with an external electronic device (12) for data exchange.
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| CN201610620339.0A CN106017932B (en) | 2016-08-02 | 2016-08-02 | Motor bearing on-line monitoring and intelligent early warning system |
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| CN201610620339.0A CN106017932B (en) | 2016-08-02 | 2016-08-02 | Motor bearing on-line monitoring and intelligent early warning system |
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| CN106017932A CN106017932A (en) | 2016-10-12 |
| CN106017932B true CN106017932B (en) | 2020-01-03 |
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