CN108225762A - A kind of single gear tooth crackle broken teeth fault identification diagnostic method - Google Patents
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- G—PHYSICS
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- 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
- G01M13/02—Gearings; Transmission mechanisms
- G01M13/021—Gearings
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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
- G01M13/02—Gearings; Transmission mechanisms
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Abstract
A kind of single gear tooth crackle broken teeth fault identification diagnostic method, the sensor impacted using detection failure and the corresponding detecting instrument being attached thereto, the resonance and demodulation data that acquisition impact is converted by the resonance and demodulation of corresponding detecting instrument during gear operation；Monodentate failure, then the differential A of failure to being exported according to corresponding detecting instrument decision are identified by frequency-domain analysisdBCCarry out differential compensating approach.The present invention can accurately identify gear from numerous and diverse, powerful noise background signal and monodentate crackle or broken teeth fault type occurs, and identifying and diagnosing accuracy rate is high, effectively avoids consequence caused by the extension and extension of single gear tooth failure；Compensated revised identifying and diagnosing result is corresponding with the severity of physical fault preferably, has larger contribution to the formulation of scientific maintenance decision.
Description
Technical field
The invention belongs to condition monitoring for rotating machinery and fault diagnosis field, more particularly to a kind of single gear tooth crackle broken teeth
Fault identification diagnostic method.
Background technology
Gear is the important part of passing power in rotating machinery, and gear drive has the spies such as steady, reliable, efficient
Point is usually applied in the form of gear-box in numerous mechanical equipments, such as traffic, oil, chemical industry, ship, metallurgy, space flight etc.
Field.Gear transmits torque, and mostly work in heavy mechanical equipment during utilization with the movement to move in circles
Under the complex working conditions such as heavy duty, impact, varying load, therefore it is easier to break down.There is statistics to be shown in pinion unit
80% failure is as caused by gear in system, and rotating machinery middle gear failure accounts for 10% of its failure or so.Gear is typical
Failure mode has spot corrosion, gluing, abrasion, crackle, broken teeth, and is primarily referred to as straight tooth structure gear for single gear tooth fault type
Monodentate crackle or monodentate broken teeth failure, such fault harm is larger, and tooth root crack fault is easy under the effect of gear driving torque power
Cause gear tooth breakage, and broken teeth is fallen in gear-box or Qia enters between cog and can cause secondary injury, while the gear of broken teeth destroys
Continuous meshing state between gear at the beginning of design so that the neighbouring tooth engagement of edentulous site is worse off, and easily causes the gear teeth tired
Labor and cause once again crackle even broken teeth failure.Therefore it is the expansion for avoiding causing mechanical equipment accident due to single gear tooth failure
Change, have for the fault diagnosis of single gear tooth crackle broken teeth with failure mechanism research to the stabilization safe operation of guarantee mechanical equipment
It is significant.
The fault diagnosis particularly real-time online of gear is diagnosed, is acquisition gear using vibration information detection and diagnosis
The conventional method of fault signature.Traditional analysis of vibration signal processing method, on the basis of Fast Fourier Transform, for tooth
The characteristics of taking turns non-linear signal in operation process, non-stationary, has developed such as Short Time Fourier Transform, wavelet analysis, Empirical Mode
The Time-Frequency Analysis Methods such as formula decomposition method (EMD, EmpiricalModeDecomposition).These methods are for the tooth of processing
Wheel vibration signal all has some disadvantages and insufficient, the difficulty faced such as wavelet analysis when selecting suitable wavelet basis function
Topic；Existing for EMD methods the problems such as end effect, negative frequency.Especially it is being during engineering application is put into practice, the table that these methods obtain
The characteristic parameter and scientific guidance repair for levying failure still have larger distance.
Therefore, the failure modes such as single gear tooth crackle broken teeth are carried out with the research of diagnostic techniques and method, it can by establishing
Capable state monitoring method and fault identification diagnostic method, accurately carry out qualitative and quantitative knowledge to single gear tooth crackle broken teeth failure
It does not diagnose, provides pre-alarm in time, to improve mechanical equipment reliability of operation and safety, guide maintenance system is tieed up to depending on feelings
The progress for repairing system has important theory value and engineering application value.
Invention content
In view of the above-mentioned problems, the object of the present invention is to provide a kind of single gear tooth crackle broken teeth fault identification diagnostic method,
The parameter characterized by failure impact information by etiologic diagnosis and quantitative calculating, realizes the pre- of single gear tooth crackle broken teeth failure
Warning output.
To achieve the above object, the present invention uses following technical scheme：A kind of single gear tooth crackle broken teeth fault identification is examined
Disconnected method, the sensor impacted using detection failure and the corresponding detecting instrument being attached thereto, are acquired during gear operation
The resonance and demodulation data that impact is converted by the resonance and demodulation of corresponding detecting instrument；It is characterized in that, pass through frequency-domain analysis
Identify monodentate failure, then the differential A of failure to being exported according to the software kit decision on corresponding detecting instrumentdBCCarry out differential benefit
Amendment is repaid, is specifically realized in the steps below：
Step 1, during the gear operation Integer N week of required diagnosis, acquisition impact being total to through corresponding detecting instrument
Shake the resonance and demodulation data Si that demodulation transformation obtains；
Step 2, Fast Fourier Transform (FFT) is carried out to the resonance and demodulation data Si of step 1, obtains corresponding shock frequency spectrum number
According to Fi；
Step 3, according to the gear ratio parameter of detection object, institute is calculated by the software kit on corresponding detecting instrument
Obtain the fault signature clef P1 of gear；Gear 1 is searched for from the shock frequency spectrum data Fi that step 2 obtains to compose to M ranks fault signature
Line P1, P2=2*P1, P3=3*P1 ... PM=M*P1, and 1 is obtained to amplitude Pmax maximum in M ranks fault signature spectrum；M is
Integer more than or equal to 10, empirical value 20；
Step 4, statistic procedure 3 obtain 1 to M ranks fault signature compose in amplitude be more than or equal to 0.5Pmax number n；If n
>=INT (0.4M), then etiologic diagnosis be there are single gear tooth crackle broken teeth failure, and according to 1 to M ranks fault signature compose amplitude
The original differential A of failure is exported by the software kit decision on corresponding detecting instrumentdBC；
Step 5, step 4 is qualitatively judged as there are the original differential A that single gear tooth crackle broken teeth failure corresponds todBC
It compensates and corrects and is compensated very poor AdB, and be compared with preset impact pre-alarm threshold value, obtain identifying and diagnosing knot
Fruit.
In the step 1, the acquisition of resonance and demodulation data Si, using rotating-speed tracking sampling technique, to the tooth of required diagnosis
Wheel sampling, 3 times or more compositions, the one resonance and demodulation data Si of gear operation Integer N >=10 week, weekly sampling number for the number of teeth
Sample.
In the step 5, to original differential AdBCIt compensates and corrects acquisition and compensates very poor AdBFormula be：
It is described for very poor after compensating approach when being compared with preset impact pre-alarm threshold value in the step 5
AdBMore than or equal to impact, pre-alarm threshold value, that is, limitation standard person sends out corresponding alarm；Alert Standard is 54dB, and level-one alarm is marked
Standard is 60dB, and secondary alarm standard is 66dB.
The corresponding detecting instrument is existing apparatus (such as locomotive running gear of Beijing Tangzhi Science Development Co., Ltd's production
Vehicle-bone monitoring device, the software kit in locomotive running gear vehicle-bone monitoring device are to have software.).
The present invention due to using the technology described above, has the following advantages：
(1) gear can be accurately identified from numerous and diverse, powerful noise background signal, monodentate crackle or broken teeth failure classes occurs
Type, identifying and diagnosing accuracy rate is high, effectively avoids consequence caused by the extension and extension of single gear tooth failure；
(2) compensated revised identifying and diagnosing result is corresponding with the severity of physical fault preferably, to scientific maintenance
The formulation of decision has larger contribution.
Description of the drawings
Fig. 1 is Tooth Breaking for Bull Gear failure shock characteristic schematic diagram；
Fig. 2 is the non-compensating approach schematic diagram of pinion crack identifying and diagnosing result；
Fig. 3 is schematic diagram after the compensated amendment of pinion crack identifying and diagnosing result.
Specific embodiment
It is carried out below in conjunction with the accompanying drawings with specific implementation method of the present invention in the detection of locomotive running gear gearbox fault detailed
Thin description.
In the gear engagement of locomotive running gear gear-box, if there is single gear tooth crackle, broken teeth failure, this was impacted
Journey shows as the feature that the time is of short duration and impact strength is big；After resonance and demodulation, then it is narrow thin to show impact cluster, but ballistic throw
It is worth big feature.Such impact information periodically occurs according to the speed of axis where gear simultaneously, is fourier transformed it
Afterwards, frequency spectrum is shown as with failure gear shaft rotation frequency as 1 rank frequency, and the higher-order spectrum of a large amount of rule attenuation occurs, as shown in Figure 1.
According to Pa Saiwaer principles of conservation of energy, when a large amount of higher-order spectrums occurs in gear distress frequency spectrum, failure impact signal energy quilt
Dispersion if the amplitude detection value calculating only composed with 1 rank of gear gets characterization failure impact amplitude, cannot be quantified effectively
Failure strength carrys out scientific guidance condition maintenarnce so as to cannot provide pre-alarm information in time, also by locomotive with causing to pacify
Full hidden danger.
A kind of specific identifying and diagnosing method for the software that single gear tooth crackle broken teeth fault identification diagnostic method is worked out
Include the following steps：
Step 1, compound sensor on locomotive running gear gear-box is installed and is connected to the detecting instrument of installation in the car, institute
Gear distress impact can be detected, and online acquisition impacts data during locomotive operation by stating compound sensor and detecting instrument；
Wherein patent is respectively adopted in impulse detection《A kind of vibratory impulse compound sensor for improving low frequency characteristic》
(CN201210558707.5)、《A kind of generalized resonance composite sensor for detecting vibratory impulse》(CN200810200735.3) with
And《A kind of resonance demodulation detection method of mechanical failure impact》(CN200910056925.7) the method；Impact data acquisition
Using patent《The rotating-speed tracking sampling of varying-speed machinery fault diagnosis and clef curing analysis method》(CN201010169783.8)
Rotating-speed tracking sampling technique, with rolling stock EEF bogie wheel to rotation turn around acquisition 200 points or more, and take turns to rotation 10 circle
It is above a sample cycle, sample length is at least 2048, to meet sampling gear operation week number N >=10 week, sample weekly
3 times or more to count as the number of teeth.Software kit is worked out on corresponding detecting instrument according to the above method, data acquisition is carried out, obtains
To the impact resonance and demodulation data Si of acquisition, such as attached drawing 1 to attached drawing 3.
Step 2, Fast Fourier Transform (FFT) is carried out to the resonance and demodulation data Si of step 1, obtains corresponding shock frequency spectrum number
According to Fi, such as attached drawing 3；
Step 3, it is calculated according to locomotive running gear gear ratio parameter by the software kit on corresponding detecting instrument
To the fault signature clef of large and small gear, this example is specially gear wheel feature clef P1=10, the impact frequency obtained from step 2
Gear 1 is searched in modal data Fi to M rank fault signature spectral line P1, P2=2*P1, P3=3*P1 ... PM=M*P1, and obtains 1
Maximum amplitude Pmax in being composed to M ranks fault signature；M is the integer more than or equal to 10, and this example takes M=20；
Step 4, statistic procedure 3 obtain 1 to M ranks fault signature compose in amplitude be more than or equal to 0.5Pmax number n；If n
>=INT (0.4M), the n=8 that this example counts meet and are more than or equal to INT (0.4M)=8, then etiologic diagnosis is there are gears
Monodentate crackle broken teeth failure；And the amplitude composed according to 1 to M ranks fault signature is calculated with the software kit on corresponding detecting instrument and is determined
The original differential A of plan output failuredBC=37dB；Such as attached drawing 3.
Step 5, step 4 is qualitatively judged as there are the original differential A that single gear tooth crackle broken teeth failure corresponds todBC
It compensates and corrects and is compensated very poor AdB, and be compared with preset impact pre-alarm threshold value, obtain identifying and diagnosing knot
Fruit.
In the step 1, the acquisition of impact resonance and demodulation data Si, using rotating-speed tracking sampling technique, to required diagnosis
Gear sampling, gear operation Integer N >=10 week, weekly sampling number form a resonance and demodulation number for 3 times or more of the number of teeth
According to the sample of Si.
The step 4 is to original differential AdBCIt compensates and corrects acquisition and compensates very poor AdBFormula be：
Due to M=20, n=8, AdBC=37,
So AdB=AdBC+n/M*(100-AdBC)=37+8/20* (100-37)=62.2.
In the step 5, when being compared with preset impact pre-alarm threshold value, for A very poor after compensating approachdBGreatly
In equal to impact pre-alarm threshold value, that is, limitation standard person send out corresponding alarm；Alert Standard is 54dB, and level-one alarm criteria is
60dB, secondary alarm standard are 66dB.
In the present embodiment as only with the original differential A for calculating gaineddBCValue carries out alert levels judgement, and result of calculation is only
37dB (as shown in Figure 2), not up to gear warning level, do not have reasonability compared with failure actual conditions.And according to upper
It states worked out software application dB value complements and repays amendment scheme, the diagnosis A being calculateddBValue reaches 62dB (as shown in Figure 3), reaches
To gear first stage alert levels, so as to which user be prompted to repair, science, the effect of reasonable guide maintenance are achieved.
Claims (5)
1. a kind of single gear tooth crackle broken teeth fault identification diagnostic method using the sensor for detecting failure impact and is attached thereto
Corresponding detecting instrument, during gear operation acquisition impact by corresponding detecting instrument being total to of converting of resonance and demodulation
Solution of shaking adjusting data；It is characterized in that, monodentate failure is identified by frequency-domain analysis, then to according to mating soft on corresponding detecting instrument
The differential A of failure of part decision outputdBCDifferential compensating approach is carried out, is specifically realized in the steps below：
Step 1, during the gear operation Integer N week of required diagnosis, resonance solution of the acquisition impact through corresponding detecting instrument
The resonance and demodulation data Si that modulation is got in return；
Step 2, Fast Fourier Transform (FFT) is carried out to the resonance and demodulation data Si of step 1, obtains corresponding shock frequency spectrum data Fi；
Step 3, according to the gear ratio parameter of detection object, the tooth as obtained by calculating the software kit on corresponding detecting instrument
The fault signature clef P1 of wheel；From the shock frequency spectrum data Fi that step 2 obtains search for gear 1 to M rank fault signature spectral lines P1,
P2=2*P1, P3=3*P1 ... PM=M*P1, and 1 is obtained to amplitude Pmax maximum in M ranks fault signature spectrum；
Step 4, statistic procedure 3 obtain 1 to M ranks fault signature compose in amplitude be more than or equal to 0.5Pmax number n；If n >=
INT (0.4M), then etiologic diagnosis is to lead to there are single gear tooth crackle broken teeth failure, and according to the amplitude of 1 to M ranks fault signature spectrum
Cross the original differential A of software kit decision output failure on corresponding detecting instrumentdBC；
Step 5, step 4 is qualitatively judged as there are the original differential A that single gear tooth crackle broken teeth failure corresponds todBCIt carries out
Compensating approach is compensated very poor AdB, and be compared with preset impact pre-alarm threshold value, obtain identifying and diagnosing result.
2. a kind of single gear tooth crackle broken teeth fault identification diagnostic method according to claim 1, which is characterized in that described
In step 1, the acquisition of impact resonance and demodulation data Si samples the gear of required diagnosis using rotating-speed tracking sampling technique, will
Gear operation Integer N >=10 week, weekly sampling number form a resonance and demodulation data for 3 times or more of sampled result of the number of teeth
The sample of Si.
3. a kind of single gear tooth crackle broken teeth fault identification diagnostic method according to claim 1, which is characterized in that described
In step 5, to original differential AdBCIt compensates and corrects acquisition and compensates very poor AdBFormula be：
4. a kind of single gear tooth crackle broken teeth fault identification diagnostic method according to claim 1, which is characterized in that with it is pre-
If impact pre-alarm threshold value when being compared, for A very poor after compensating approachdBIt is more than or equal to impact pre-alarm threshold value
Limitation standard person sends out corresponding alarm；Alert Standard is 54dB, and level-one alarm criteria is 60dB, and secondary alarm standard is 66dB.
5. a kind of single gear tooth crackle broken teeth fault identification diagnostic method according to claim 1, which is characterized in that M is
Integer more than or equal to 10；Empirical value is 20.
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| CN109253882A (en) * | 2018-10-08 | 2019-01-22 | 桂林理工大学 | A kind of rotor crack fault diagnostic method based on variation mode decomposition and gray level co-occurrence matrixes |
| CN113516159A (en) * | 2021-04-15 | 2021-10-19 | 成都运达科技股份有限公司 | Fault diagnosis method and system for cracks of pinion shaft of running part of railway vehicle |
| CN114997000A (en) * | 2022-05-24 | 2022-09-02 | 湖南大学 | Dynamic response analysis method for multi-stage gear transmission system under different types of cracks |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109253882A (en) * | 2018-10-08 | 2019-01-22 | 桂林理工大学 | A kind of rotor crack fault diagnostic method based on variation mode decomposition and gray level co-occurrence matrixes |
| CN113516159A (en) * | 2021-04-15 | 2021-10-19 | 成都运达科技股份有限公司 | Fault diagnosis method and system for cracks of pinion shaft of running part of railway vehicle |
| CN113516159B (en) * | 2021-04-15 | 2023-05-26 | 成都运达科技股份有限公司 | Rail vehicle running part pinion shaft crack fault diagnosis method and system |
| CN114997000A (en) * | 2022-05-24 | 2022-09-02 | 湖南大学 | Dynamic response analysis method for multi-stage gear transmission system under different types of cracks |
| CN114997000B (en) * | 2022-05-24 | 2024-04-16 | 湖南大学 | Dynamic response analysis method for multi-stage gear transmission system under different types of cracks |
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| CN108225762B (en) | 2019-09-20 |
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