CN106586841A - Method and system for monitoring running states of speed reducer of lifting equipment - Google Patents
Method and system for monitoring running states of speed reducer of lifting equipment Download PDFInfo
- Publication number
- CN106586841A CN106586841A CN201611184261.9A CN201611184261A CN106586841A CN 106586841 A CN106586841 A CN 106586841A CN 201611184261 A CN201611184261 A CN 201611184261A CN 106586841 A CN106586841 A CN 106586841A
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- China
- Prior art keywords
- acceleration signal
- reductor
- acceleration
- bearing
- hoisting equipment
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C15/00—Safety gear
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/16—Applications of indicating, registering, or weighing devices
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C15/00—Safety gear
- B66C15/06—Arrangements or use of warning devices
- B66C15/065—Arrangements or use of warning devices electrical
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)
Abstract
The invention provides a method and system for monitoring the running states of a speed reducer of lifting equipment. The monitoring method comprises the following steps that bearing acceleration signals generated when the monitored speed reducer runs are collected and stored; and according to a preset pre-warning value and the acceleration signals, the monitored speed reducer is subjected to malfunction diagnosis. According to the embodiment of the method and system for monitoring the running states of the speed reducer of the lifting equipment, the method that the acceleration signals of a bearing of the speed reducer are collected for diagnosing the current running states of the speed reducer is beneficial to improving the running efficiency of equipment, optimized running is achieved, and the running and managing cost is reduced; through analysis of the states of the equipment, reasonable overhauling opportunities and schemes are determined, the maintenance mode is promoted to change from preventative maintenance to predicative maintenance, unnecessary machine halt is avoided, and the maintenance cost is reduced by improving the repair speed and reducing downtime; and through data recording and analyzing, establishing of documentation information of the equipment is facilitated, powerful evidences are provided for accident analysis after accidents happen, accumulating of diagnosis experience is facilitated, and the overall level of malfunction diagnosis is improved.
Description
Technical field
The present invention relates to monitoring of equipment technical field, more particularly to a kind of hoisting equipment reductor method for monitoring operation states
And system.
Background technology
The reductor of large-scale hoisting equipment is its core apparatus, and in running, reductor breaks down, and is likely to
Cause than larger loss.And the critical component bearing of reductor, the failure that bearing fault is mainly produced including fatigue and overload.
Bearing fatigue damage principal mode be bearing it is inside and outside circle or rolling element on occur " spot corrosion ", i.e., due to for a long time by alternation should
Power is acted on, and in material list surface layer micro-crack is produced, and as bearing run time is lengthened, crackle gradually extends, and ultimately results in local
Metal peeling, forms spot corrosion.If changing bearing not in time, spot corrosion position will gradually extend, and cause bearing failure.Overload is caused
Bearing local plastic deformation and impression, lack of lubrication can then cause bearing burn, gluing, and lubricating oil is unclean to cause Bearing Grinding
Damage, it is improper to assemble, be likely to result in bearing is stuck, inner ring bursts and structure is broken etc..
At present, although heavy mechanical equipment is generally mounted with Data collecting and analysis system, but when plant equipment occurs
When abnormal, it is desirable to which operator quickly make a policy, the seriousness of the consequence caused by decision-making complexity and error in judgement is continuous
Ground increases.Rapid increase and the deficiency of experienced maintenance and inspection personnel with facility information amount, traditional detection with examine
Disconnected technology can not meet the needs of, it is necessary to using advanced monitoring instrument and the diagnostic techniquess of automatization.
The content of the invention
Safe engineering actual demand is run under complex working condition around mechanisms such as Large Complex Equipment reductors, based on rise
Heavy equipment reductor may be pumped into the abrasion fault mode such as crackle and off-axis in actual motion, and the embodiment of the present invention is provided
A kind of hoisting equipment reductor method for monitoring operation states and system.
On the one hand the embodiment of the present invention provides a kind of hoisting equipment reductor method for monitoring operation states, the monitoring side
Method includes:
Gather when monitored reductor runs the acceleration signal of bearing and store;
Fault diagnosis is carried out to monitored reductor according to default early warning value and the acceleration signal.
In one embodiment, carry out failure to monitored reductor according to default early warning value and the acceleration signal to examine
It is disconnected, specifically include:
Judge the acceleration signal whether more than default early warning value;
When the acceleration signal exceedes the early warning value, warning is performed.
In one embodiment, when judging whether the acceleration signal exceedes the judged result of the early warning value for no,
The monitoring method also includes:
Recall a preset time period from current time, obtain the acceleration signal waveform in the preset time period;
By the acceleration signal waveform in the preset time period and the default different running statuses in sign factbase
Corresponding waveform is compared, and determines the corresponding running status of the Acceleration pulse.
In one embodiment, when the acceleration signal of bearing when monitored reductor runs is gathered, at least gather described
Acceleration signal of the bearing on axial direction, radial direction vertical direction, radial level direction.
On the other hand the embodiment of the present invention additionally provides a kind of hoisting equipment reductor operating state monitoring system, the prison
Examining system includes:Acceleration transducer, data transmission unit and fault diagnosis server;Wherein,
The acceleration transducer is used to gather the acceleration signal of bearing when monitored reductor runs, and by described
Data transmission unit is transferred to the fault diagnosis server;The fault diagnosis server be used for according to default early warning value with
The acceleration signal carries out fault diagnosis to monitored reductor.
In one embodiment, the fault diagnosis server includes:Threshold value judgment module and warning module;Wherein,
Whether the threshold value judgment module is used to judge the acceleration signal more than default early warning value;
The warning module is used to perform warning when the acceleration signal is more than the early warning value.
In one embodiment, the fault diagnosis server also includes:Memorizer, sign factbase and sign judge mould
Block;
The memorizer is used to store the acceleration signal of the acceleration transducer collection, and the sign factbase is used for
The corresponding waveform of the different running statuses of storage;
When the judged result of the threshold value judgment module is no, the sign judge module is used for from current time backtracking
One preset time period, obtains the acceleration signal waveform in the preset time period, and by the acceleration in the preset time period
Degree signal waveform is compared from the corresponding waveform of default different running statuses in sign factbase, determines the acceleration
The corresponding running status of waveform.
In one embodiment, the quantity of the acceleration transducer is at least three, is respectively arranged at the outer of the bearing
On housing box body, at least along bearing radial direction vertical direction, radial level direction and axially three directions settings, the radial direction Vertical Square
It is vertical two-by-two to, radial level direction and axial place direction.
In one embodiment, the acceleration transducer adopts the piezoelectric accelerometer of built-in preamplifier circuit.
In one embodiment, the data transmission unit is adopted the acceleration transducer using direct memory access mode
The acceleration signal of collection is transmitted to the fault diagnosis server.
The acceleration signal running status current to diagnose reductor of embodiment of the present invention collection bearing in reduction gears, helps
In the operational efficiency of the equipment of raising, optimization operation is realized, save operation and administration fee;By the state analysiss to equipment, really
Fixed rational maintenance opportunity and maintenance solution, promote transformation of the maintenance mode from preventative maintenance to prospective maintenance, it is to avoid no
Necessary shutdown, and speed reduction downtime can be repaired by improving, save maintenance cost;By data record and analysis,
Be conducive to setting up the document information of equipment, strong evidence is provided for accident analysiss after accident occurs, be conducive to accumulation diagnosis
Experience, improves the integral level of fault diagnosis.
Description of the drawings
In order to be illustrated more clearly that the embodiment of the present invention or technical scheme of the prior art, below will be to embodiment or existing
The accompanying drawing to be used needed for having technology description is briefly described, it should be apparent that, drawings in the following description are only this
Some embodiments of invention, for those of ordinary skill in the art, on the premise of not paying creative work, can be with
Other accompanying drawings are obtained according to these accompanying drawings.
Fig. 1 is the schematic flow sheet of embodiment of the present invention hoisting equipment reductor method for monitoring operation states;
Fig. 2 is the schematic flow sheet of another embodiment of the present invention hoisting equipment reductor method for monitoring operation states;
Fig. 3 is the structural representation of embodiment of the present invention hoisting equipment reductor operating state monitoring system;
Fig. 4 is the structural representation of embodiment of the present invention fault diagnosis server 3;
Fig. 5 is the arrangement schematic diagram of embodiment of the present invention acceleration transducer;
Fig. 6 a are the installation top view of embodiment of the present invention acceleration transducer;
Fig. 6 b are the installation side view of embodiment of the present invention acceleration transducer.
Specific embodiment
Below in conjunction with the accompanying drawing in the embodiment of the present invention, the technical scheme in the embodiment of the present invention is carried out clear, complete
Site preparation is described, it is clear that described embodiment is only a part of embodiment of the invention, rather than the embodiment of whole.It is based on
Embodiment in the present invention, it is every other that those of ordinary skill in the art are obtained under the premise of creative work is not made
Embodiment, belongs to the scope of protection of the invention.
Large-scale hoisting equipment bearing in reduction gears is damaged makes bearing working state degenerate, frictional resistance increase, rotation motility
Lose, running accuracy is reduced, bearing temperature is raised, vibration noise aggravation, and accident generation is likely to result in when serious.
When reductor runs, main intrinsic vibration, the load effect including bearing partss of vibration produced in bearing operation
The vibration that the vibration and failure that the vibration that causes, manufacture assembling reason cause causes.When bearing breaks down, vibrational state
To change, new composition will be will appear from vibration signal.The Variation Features of the corresponding vibration signal of different fault types
It is different.Wherein, what part intrinsic vibration referred between bearing roller and Internal and external cycle excited by impact makes inner ring, outer ring and rolling
Body produces intrinsic vibration, and frequency of vibration depends on the natural frequency of these parts, generally all higher.Manufacture assembling reason causes
Vibration include that bending shaft, inclinations, bearing deflection, rolling element size uneven, raceway face ripple or roughness, assembling are elastic
Deng.The vibration that load effect causes is that spindle rotates to diverse location, and loading ability of bearing rolling element number difference sends out load-bearing rigidity
Changing, causes axle center to rise and fall.The vibration that failure causes is referred to when there is the failures such as spot corrosion, peeling, crackle on bearing partss, rolled
Kinetoplast will produce impact shock by trouble location, and the frequency that this impact shock occurs is referred to as " by frequency ", with rotating speed,
Bearing arrangement size, rolling element quantity and trouble location are relevant, including inner ring passes through frequency, rolling element by frequency, outer ring
By frequency and retainer frequency.
Essence from fault diagnosis of the invention, the vibration information reality of bearing when being run according to the reductor for being collected
Now to the monitoring of reductor operation conditions.
Fig. 1 is the schematic flow sheet of embodiment of the present invention hoisting equipment reductor method for monitoring operation states.Such as Fig. 1 institutes
Show, the monitoring method is mainly included the following steps that:
Step S1, gather when monitored reductor runs the acceleration signal of bearing and store.
Step S2, fault diagnosis is carried out to monitored reductor according to default early warning value and the acceleration signal.
The application of the embodiment of the present invention can reduce the time of failure judgement and maloperation, and the promptness of fault diagnosis and
Accuracy rate has decisive action for the development for preventing failure.
An embodiment of the invention, when fault diagnosis is carried out using step S2, can enter according to step shown in Fig. 2
OK:
Step S21, judge the acceleration signal whether more than default early warning value.The early warning value for example can be multiple
The accekeration during bearing breaking that test is obtained, or bearing it is stuck when accekeration, in the specific implementation, can will be many
It is secondary to test accekeration corresponding when the bearing that obtains occurs different faults therefrom to choose a more serious failure corresponding
Accekeration is used as early warning value.Herein described " more serious failure " refers to there occurs after the failure, it is necessary to stop immediately
The failure that only reductor is operated and alerted.
Step S22, when the acceleration signal exceed the early warning value when, perform warning.If the judgement knot of step S21
Fruit is no, then into the process of step S23.
Step S23, recall a preset time period from current time, obtain the acceleration signal ripple in the preset time period
Shape.This is because some failures (such as bearing wear) are slow development, although the acceleration signal for collecting is not out
Early warning value in step S1, but not representing bearing does not have failure.Accordingly, it would be desirable to enter to the acceleration signal in a period of time
Row unitary analysiss.
Step S24, by the acceleration signal waveform in the preset time period from it is default different in sign factbase
The corresponding waveform of running status is compared, and determines the corresponding running status of the Acceleration pulse.
Before accident analysis is carried out, need rule of thumb in advance to deposit the corresponding sign waveform of various possible failures
To in sign factbase, in order to directly invoke in accident analysis.
Because the generation of many failures has an evolution from light to heavy, the embodiment of the present invention is by abnormal letter
Number detection, can the potential failure of early discovery equipment, take preventive measures in time, it is to avoid or reduce accident generation, prolong
The trouble-free life limit of long equipment, improves equipment availability.Also, the acceleration letter that the present invention passes through collection bearing in reduction gears
Number to diagnose the current running status of reductor, be favorably improved the operational efficiency of equipment, realize optimization operation, save operation and
Administration fee;By the state analysiss to equipment, it is determined that reasonably maintenance opportunity and maintenance solution, promotes maintenance mode from prevention
Property be repaired to the transformation of prospective maintenance, it is to avoid unnecessary shutdown, and can repair speed and reduce downtime by improving, section
About maintenance cost;By data record and analysis, be conducive to setting up the document information of equipment, be accident analysiss after accident occurs
Strong evidence is provided, is conducive to accumulating diagnostic experiences, improve the integral level of fault diagnosis.
Normally, in order to more accurately be monitored to reductor running status, when acceleration signal is gathered, at least
Acceleration signal of the collection bearing in axial direction, radial direction vertically and radially horizontal direction, respectively according to this three roads acceleration
Signal carries out accident analysis.
Based on the method for monitoring operation states identical inventive concept of hoisting equipment reductor shown in Fig. 1, the application is also provided
A kind of monitoring system, as described in example below.Due to the principle and hoisting equipment reductor in Fig. 1 of the system solve problem
Method for monitoring operation states is similar, therefore the enforcement of the system may refer to the hoisting equipment reductor monitoring running state of Fig. 1
Method it is real-time, repeat part repeat no more.
In another embodiment, present invention also offers a kind of hoisting equipment reductor operating state monitoring system, its knot
Structure is as shown in figure 3, the system includes:Acceleration transducer 1, data transmission unit 2 and fault diagnosis server 3.Wherein, accelerate
Degree sensor 1 is used to gather the acceleration signal of bearing when monitored reductor runs, and is transferred to by data transmission unit 2
Fault diagnosis server 3, fault diagnosis server 3 is used for according to default early warning value and acceleration signal 1 to monitored deceleration
Machine carries out fault diagnosis.
The application of the embodiment of the present invention can reduce the time of failure judgement and maloperation, and the promptness of fault diagnosis and
Accuracy rate has decisive action for the development for preventing failure.
An embodiment of the invention, the structure of fault diagnosis server 3 is as shown in figure 4, it mainly includes threshold decision
Module 31, warning module 32, memorizer 33, sign factbase 34 and sign judge module 35.Wherein, threshold value judgment module 31 is used
In whether the acceleration signal is judged more than default early warning value, warning module 32 is used for when the acceleration signal is more than institute
Warning is performed when stating early warning value.Memorizer 33 is used to store the acceleration signal of the collection of acceleration transducer 1, sign factbase 34
For depositing the corresponding waveform of different running statuses.When the judged result of threshold value judgment module 31 is no, sign judge module
35 are used to recall a preset time period from current time, obtain the acceleration signal waveform in the preset time period, and should
The corresponding waveform of acceleration signal waveform in preset time period different running statuses default from sign factbase 34 enters
Row compares, and determines the corresponding running status of the Acceleration pulse.
As shown in figure 5, when being embodied as, the quantity of acceleration transducer 1 is at least three:Sensor 11, sensor 12
With sensor 13, it is respectively arranged on bearing in reduction gears container body of outer cover a, at least along axial direction (x-axis direction), the radial level of bearing
Direction (y-axis direction) and, radial direction vertical direction (z-axis direction) arrange, radial direction vertical direction, radial level direction and be axially located
Direction is vertical two-by-two.
Fig. 6 a show the top view that acceleration transducer is installed, and Fig. 6 b are side view, when acceleration transducer is installed,
Acceleration transducer can be fixed on the casing on the outside of bearing in reduction gears according to mode shown in Fig. 6.
In one embodiment, above-mentioned acceleration transducer can adopt the piezoelectric type of built-in preamplifier circuit to accelerate
Degree meter, i.e., the built-in piezoelectric accelerometer of IEPE circuits.It is by being mounted in the preamplifier of sensor internal by piezoelectricity
The quantity of electric charge of acceleration transducer output is converted into low-impedance magnitude of voltage.IEPE type sensors are usually two wires output form,
Constant current source power supply, power supply and signal is adopted to use same single line.Generally unidirectional current part passes through height in the outfan of constant-current source
Bandpass filter is filtered off.The great advantage of IEPE type sensors be that measurement signal quality is good, noise is little, external interference resistance is strong and
Telemeasurement, particularly new data actuation much has been provided with constant current source interface, therefore, IEPE types sensor can be adopted with number
System is joined directly together without any other secondary meter.In vibration-testing, IEPE types sensor has gradually replaced tradition
Electric charge output type piezoelectric accelerometer.
Data transmission unit 2 is passed using the acceleration signal that direct memory access mode gathers the acceleration transducer
Transport to the fault diagnosis server.
The acceleration signal running status current to diagnose reductor of embodiment of the present invention collection bearing in reduction gears, helps
In the operational efficiency of the equipment of raising, optimization operation is realized, save operation and administration fee;By the state analysiss to equipment, really
Fixed rational maintenance opportunity and maintenance solution, promote transformation of the maintenance mode from preventative maintenance to prospective maintenance, it is to avoid no
Necessary shutdown, and speed reduction downtime can be repaired by improving, save maintenance cost;By data record and analysis,
Be conducive to setting up the document information of equipment, strong evidence is provided for accident analysiss after accident occurs, be conducive to accumulation diagnosis
Experience, improves the integral level of fault diagnosis.
Those skilled in the art are it should be appreciated that embodiments of the invention can be provided as method, system or computer program
Product.Therefore, the present invention can be using complete hardware embodiment, complete software embodiment or with reference to the reality in terms of software and hardware
Apply the form of example.And, the present invention can be adopted and wherein include the computer of computer usable program code at one or more
The computer program implemented in usable storage medium (including but not limited to disk memory, CD-ROM, optical memory etc.) is produced
The form of product.
The present invention is the flow process with reference to method according to embodiments of the present invention, equipment (system) and computer program
Figure and/or block diagram are describing.It should be understood that can be by computer program instructions flowchart and/or each stream in block diagram
The combination of journey and/or square frame and flow chart and/or the flow process in block diagram and/or square frame.These computer programs can be provided
The processor of general purpose computer, special-purpose computer, Embedded Processor or other programmable data processing devices is instructed to produce
A raw machine so that produced for reality by the instruction of computer or the computing device of other programmable data processing devices
The device of the function of specifying in present one flow process of flow chart or one square frame of multiple flow processs and/or block diagram or multiple square frames.
These computer program instructions may be alternatively stored in can guide computer or other programmable data processing devices with spy
In determining the computer-readable memory that mode works so that the instruction being stored in the computer-readable memory is produced to be included referring to
Make the manufacture of device, the command device realize in one flow process of flow chart or one square frame of multiple flow processs and/or block diagram or
The function of specifying in multiple square frames.
These computer program instructions also can be loaded in computer or other programmable data processing devices so that in meter
Series of operation steps is performed on calculation machine or other programmable devices to produce computer implemented process, so as in computer or
The instruction performed on other programmable devices is provided for realizing in one flow process of flow chart or multiple flow processs and/or block diagram one
The step of function of specifying in individual square frame or multiple square frames.
Apply specific embodiment in the present invention to be set forth the principle and embodiment of the present invention, above example
Explanation be only intended to help and understand the method for the present invention and its core concept;Simultaneously for one of ordinary skill in the art,
According to the thought of the present invention, will change in specific embodiments and applications, in sum, in this specification
Appearance should not be construed as limiting the invention.
Claims (10)
1. a kind of hoisting equipment reductor method for monitoring operation states, it is characterised in that the monitoring method includes:
Gather when monitored reductor runs the acceleration signal of bearing and store;
Fault diagnosis is carried out to monitored reductor according to default early warning value and the acceleration signal.
2. hoisting equipment reductor method for monitoring operation states according to claim 1, it is characterised in that according to default
Early warning value and the acceleration signal carry out fault diagnosis to monitored reductor, specifically include:
Judge the acceleration signal whether more than default early warning value;
When the acceleration signal exceedes the early warning value, warning is performed.
3. hoisting equipment reductor method for monitoring operation states according to claim 2, it is characterised in that described when judging
Acceleration signal whether exceed the judged result of the early warning value for it is no when, the monitoring method also includes:
Recall a preset time period from current time, obtain the acceleration signal waveform in the preset time period;
Acceleration signal waveform in the preset time period is corresponding from the default different running statuses in sign factbase
Waveform be compared, determine the corresponding running status of the Acceleration pulse.
4. hoisting equipment reductor method for monitoring operation states according to claim 1, it is characterised in that supervised in collection
When surveying the acceleration signal of bearing when reductor runs, the bearing is at least gathered in axial direction, radial direction vertical direction, radial level
Acceleration signal on direction.
5. a kind of hoisting equipment reductor operating state monitoring system, it is characterised in that the monitoring system includes:Acceleration is passed
Sensor, data transmission unit and fault diagnosis server;Wherein,
The acceleration transducer is used to gather the acceleration signal of bearing when monitored reductor runs, and by the data
Transmission unit is transferred to the fault diagnosis server;The fault diagnosis server be used for according to default early warning value with it is described
Acceleration signal carries out fault diagnosis to monitored reductor.
6. hoisting equipment reductor operating state monitoring system according to claim 5, it is characterised in that the failure is examined
Disconnected server includes:Threshold value judgment module and warning module;Wherein,
Whether the threshold value judgment module is used to judge the acceleration signal more than default early warning value;
The warning module is used to perform warning when the acceleration signal is more than the early warning value.
7. hoisting equipment reductor operating state monitoring system according to claim 6, it is characterised in that the failure is examined
Disconnected server also includes:Memorizer, sign factbase and sign judge module;
The memorizer is used to store the acceleration signal of the acceleration transducer collection, and the sign factbase is used to deposit
The corresponding waveform of different running statuses;
When the judged result of the threshold value judgment module is no, the sign judge module is used for pre- from current time backtracking one
If the time period, the acceleration signal waveform in the preset time period is obtained, and the acceleration in the preset time period is believed
Number waveform is compared from the corresponding waveform of default different running statuses in sign factbase, determines the Acceleration pulse
Corresponding running status.
8. hoisting equipment reductor operating state monitoring system according to claim 5, it is characterised in that the acceleration
The quantity of sensor is at least three, is respectively arranged on the container body of outer cover of the bearing, at least along bearing radial direction vertical direction,
Radial level direction and axially three directions settings, the radial direction vertical direction, radial level direction and axial place direction two
Two is vertical.
9. hoisting equipment reductor operating state monitoring system according to claim 5, it is characterised in that the acceleration
Sensor adopts the piezoelectric accelerometer of built-in preamplifier circuit.
10. hoisting equipment reductor operating state monitoring system according to claim 5, it is characterised in that the data
Transmission unit is transmitted the acceleration signal that the acceleration transducer is gathered to the failure using direct memory access mode
Diagnosis server.
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CN116040487A (en) * | 2023-03-06 | 2023-05-02 | 中国电建集团山东电力建设第一工程有限公司 | Hoisting equipment operation safety supervision system based on big data |
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