CN109226352B - Method for monitoring bearing degradation state of transmission speed reducer of multi-roller driven straightener - Google Patents
Method for monitoring bearing degradation state of transmission speed reducer of multi-roller driven straightener Download PDFInfo
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- CN109226352B CN109226352B CN201811060422.2A CN201811060422A CN109226352B CN 109226352 B CN109226352 B CN 109226352B CN 201811060422 A CN201811060422 A CN 201811060422A CN 109226352 B CN109226352 B CN 109226352B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D3/00—Straightening or restoring form of metal rods, metal tubes, metal profiles, or specific articles made therefrom, whether or not in combination with sheet metal parts
- B21D3/02—Straightening or restoring form of metal rods, metal tubes, metal profiles, or specific articles made therefrom, whether or not in combination with sheet metal parts by rollers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
Abstract
The invention discloses a method for monitoring the deterioration state of a bearing of a transmission speed reducer of a multi-roll driven straightener, wherein a control program comprises the following functional units: the device comprises an actual armature current sampling control unit, a motor armature current sampling quantity control unit, No. 2, No. 4, No. 6 and No. 8 straightening roller transmission motor steady-state no-load armature current sampling and average value calculation control units, and No. 2, No. 4, No. 6 and No. 8 four straightening roller transmission speed reducer bearing degradation state judgment subunits. By adopting the technical scheme, the state information of the transmission bearing which is degraded can be timely and accurately obtained, the equipment maintenance personnel can conveniently and timely process the speed reducer with the degraded transmission bearing, and the straightening roller transmission speed reducer is prevented from being seriously damaged.
Description
Technical Field
The invention belongs to the technical field of monitoring of the running quality of a mechanical transmission mechanism. More particularly, the invention relates to a method for monitoring the deterioration state of a bearing of a transmission speed reducer of a multi-roll driven straightener.
Background
A large H-shaped steel production line of a third steel rolling main plant of the horse steel adopts a cantilever roller type variable pitch straightener to straighten H-shaped steel rolled pieces on line, the straightener totally comprises nine cantilever type straightening rollers, four of the straightening rollers are upper straightening rollers, and five of the straightening rollers are lower straightening rollers, and the straightening rollers are arranged in a vertically staggered mode.
The four upper straightening rollers are active straightening rollers which are respectively numbered as a No. 2 straightening roller, a No. 4 straightening roller, a No. 6 straightening roller and a No. 8 straightening roller, and each upper straightening roller is respectively driven by a direct current motor with 220KW power through a speed reducer; the transmission speed reducer of each upper straightening roller is four-stage speed change.
The five lower straightening rollers are driven straightening rollers which are respectively numbered as a No. 1 straightening roller, a No. 3 straightening roller, a No. 5 straightening roller, a No. 7 straightening roller and a No. 9 straightening roller and only adopt a hydraulic motor for assisting movement.
The schematic structural diagram of the speed reducer is shown in fig. 1.
Since 1998, the transmission reducer of the No. 4 straightening roll of the straightening machine has the phenomenon that a bearing and a gear are damaged for many times in the practical use process.
Through research and analysis on damage of the straightening roller bearing and the gear, the damage of the straightening roller speed reducer is mainly caused by frequent overload or serious overload of the speed reducer. The long-term overload of the speed reducer firstly causes the deterioration of a gear shaft support bearing (namely, a speed reducer bearing), and the deteriorated speed reducer bearing is inevitably cracked after being used for a certain time, thereby causing the damage of a transmission speed reducer gear.
Based on the situation, if the state that the speed reducer bearing is degraded can be detected in time and processed in time, the serious damage of the straightening roller transmission speed reducer can be avoided. The problem is how to realize timely and accurate monitoring of the state of the straightening roller speed reducer bearing in degradation.
Generally, after a transmission shaft bearing of a high-speed rotating transmission mechanism is slightly damaged, the load is subjected to pulsation interference by taking the rotating speed as a reference, so that the transmission mechanism generates mechanical vibration with a certain frequency, and the vibration of the transmission mechanism in a working state (namely, frequency spectrum analysis) can be analyzed by a digital signal analyzer, so that the use condition of the transmission mechanism bearing can be obtained.
However, in the case of a digital signal analyzer, it is often difficult to obtain information on the state of deterioration of a drive bearing by a spectral analysis of vibration using the digital signal analyzer because the drive bearing operating speed is low in the case of a diagnosis of the state of a drive bearing operating at a low speed and a diagnosis of the state of a low-speed end bearing of a reduction gear having a large reduction ratio.
The reduction ratio of the transmission speed reducer of the large-H-shaped steel straightener for the horse steel is 25.35, the running speed of the low-speed end of the straightener is 48 rpm when the straightener is loaded, and the running speed of the straightener is only 10 rpm when the straightener is unloaded, so that the monitoring of the transmission bearing of the low-speed end of the straightener roller speed reducer is difficult to realize by utilizing a digital signal analyzer.
And the damage of the speed reducer transmission bearing of the large-H-shaped steel straightener of the horse steel occurs at the low-speed end for many times. In view of the structure of the large-H-shaped steel speed reducer made of the horse steel, no existing method and means for monitoring the degradation of the transmission bearing of the speed reducer are available at present.
Disclosure of Invention
The invention provides a method for monitoring the deterioration state of a bearing of a transmission speed reducer of a multi-roller driven straightener, and aims to avoid serious damage of the transmission speed reducer of the straightener roller due to the deterioration of the transmission bearing.
In order to achieve the purpose, the invention adopts the technical scheme that:
the invention relates to a monitoring method for the deterioration state of a bearing of a transmission speed reducer of a multi-roller driven straightener, which is applied to a cantilever roller type variable pitch straightener on a large H-shaped steel production line, wherein the straightener comprises nine cantilever straightening rollers, four of the straightening rollers are upper straightening rollers, and five of the straightening rollers are lower straightening rollers, and the straightening rollers are arranged in a vertically staggered manner;
the four upper straightening rollers are active straightening rollers, namely No. 2 straightening rollers, No. 4 straightening rollers, No. 6 straightening rollers and No. 8 straightening rollers; each upper straightening roller is driven by a direct current motor through speed reduction;
the five lower straightening rollers are driven straightening rollers, namely No. 1, No. 3, No. 5, No. 7 and No. 9 straightening rollers, and are assisted by a hydraulic motor;
the control program of the monitoring method comprises the following functional units:
1) the actual motor armature current sampling control unit consists of JJZLJC 01-JZLJC 05 function blocks;
2) the motor armature current sampling number control unit consists of JJZLJC 06-JZLJC 12 function blocks;
3) the No. 2, No. 4, No. 6 and No. 8 straightening roller transmission motor steady-state no-load armature current sampling and average value calculation control units are respectively composed of JJZLJC 13-JJJZLJC 16 functional blocks, JJZLJC 19-JJZLJC 22 functional blocks, JJZLJC 25-JJZLJC 28 functional blocks and JJJZLJC 31-JZLJC 34 functional blocks;
4) the bearing degradation state judgment sub-unit of the straightening roller transmission speed reducer comprises four bearing degradation state judgment sub-units of No. 2, No. 4, No. 6 and No. 8 straightening roller transmission speed reducers, wherein the four bearing degradation state judgment sub-units respectively comprise a JJJZLJC 17 functional block, a JJZLJC18 functional block, a JJZLJC23 functional block, a JJZLJC24 functional block, a JJZLJC29 functional block, a JZLJC30 functional block and a JJJZLJC 35 functional block and a JJZLJC36 functional block.
For an actual armature current sampling control unit:
the sampling control unit is controlled by 3 decision conditions, namely: a cold metal detector signal at the inlet side of the straightener, a cold metal detector signal at the outlet side of the straightener and an acceleration and deceleration state signal of the straightener;
when the cold metal detectors on the inlet side and the outlet side of the straightener do not detect rolled pieces, the straightener is in an idle state, at the moment, if the change rate of the speed reference value of the straightener is zero, the straightener is further judged to be in a steady idle state, and at the moment, the output Q of the JJZLJC01 functional block of the sampling control unit is '0';
in order to prevent the armature current sampling of the straightening roll motor when the straightening machine straightens an abnormal short rolled piece, thereby causing the false alarm of the bearing degradation state monitoring system, the sampling control unit sets a signal back edge delay functional block JJJZLJC 02 at the output of the JJZLJC01 functional block;
considering that the time of the rolled piece disappearing from the inlet side to the outlet side of the straightener is less than 2 seconds when the straightener straightens the abnormal short rolled piece, the time of the trailing edge delay is set to be 2 seconds;
therefore, when the output of the JJZLJC02 function block of the sampling control unit is '0' and the output of the jzljc04 function block is '1', the bearing degradation state monitoring system is provided with the sampling conditions of the armature currents of the 4 straightening roll drive motors of the straightener.
For a motor armature current sample number control unit:
in this unit, a periodic pulse generation subunit is constituted by the functional blocks JJZLJC 06-jzljc 10, which generates a positive-going count pulse for the following counter functional block JJZLJC11 at each program cycle period;
the functional blocks jjjzljc 11 and jzljc12 constitute a count number control subunit in which the upper limit value of the count of the counter functional block jzljc11 is set to 100, and when the count value of the counter reaches 100, the state of the output terminal QU of the counter becomes '1'.
The control unit for sampling the steady-state no-load armature current of the straightening roller transmission motor and calculating the average value:
in the bearing degradation state monitoring system program, the function blocks JJZLJC 13-JZLJC 16, the function blocks JJZLJC 19-JZLJC 22, the function blocks JJZLJC 25-JZLJC 28 and the function blocks JZLJC 31-JZLJC 34 respectively form No. 2, No. 4, No. 6 and No. 8 straightening roller transmission motor steady-state no-load armature current sampling and average value calculation control units;
when the armature current of the straightening roller transmission motor has sampling conditions, the control unit samples the armature current of each straightening roller transmission motor once in each program cycle period and accumulates each sampling value with the previous sampling value;
before the sampling is started, the initial value of the sampling accumulated value is zero, so that when the sampling times reach the set sampling times, the numerical value storage functional blocks JJZLJC15, JJJZLJC 21, JJZLJC27 and JZLJC33 in the unit store and maintain the armature current accumulated value corresponding to the set sampling times, and then the steady-state no-load armature current average value of each straightening roll transmission motor is respectively obtained through dividers arranged behind the numerical value storage functional blocks;
the armature current instantaneous value sampling accumulation sub-units of all the straightening rollers are respectively composed of JJZLJC13, JJZLJC14, JJZLJC19, JJZLJC20, JJZLJC25, JZLJC26, JJZLJC31 and JZLJC32 functional blocks;
in order to prevent the sub-unit from continuously sampling and accumulating the armature current instantaneous value after the armature current average value is calculated, thereby causing program operation errors, a back edge delay function block JJZLJC04 is arranged in the sampling control unit of the bearing degradation state monitoring system, and the function block delays for a certain time after the sampling counting pulse reaches the set value, so that the output state of the sampling control unit is '0', namely the output end Q of the function block JZLJC05 is '0', and the armature current instantaneous value sampling and accumulating sub-unit stops accumulating operation.
For the straightening roller transmission reducer bearing deterioration state determination subunit:
after obtaining the steady-state no-load armature current average value of 4 straightening roller transmission motors, the bearing degradation state monitoring system respectively judges the steady-state no-load armature current average value of the 4 straightening roller transmission motors through 4 straightening roller transmission speed reducer bearing degradation state judging subunits consisting of JJJZLJC 17, JJJZLJC 18, JJZLJC23, JJZLJC24, JJZLJC29, JJZLJC30, JJZLJC35 and JJZLJC36 functional blocks in the system;
under the condition that the straightening roller transmission speed reducer bearing normally operates, the average value of the steady-state no-load armature current of each straightening roller transmission motor is below 19 amperes; when the straightening roller transmission speed reducer bearing is degraded to a certain degree, the average value of the steady no-load armature current of the straightening roller transmission motor is far greater than 19 amperes, so that in the bearing degradation state judgment subunit, the bearing degradation state judgment value is set to be 25 amperes, namely when the average value of the steady no-load armature current of any straightening roller transmission motor is greater than the judgment value, the bearing degradation state monitoring system gives the corresponding degradation state information of the straightening roller transmission speed reducer bearing.
By adopting the technical scheme, the state information of the transmission bearing which is degraded can be timely and accurately obtained, the speed reducer with the degraded transmission bearing can be conveniently and timely processed by equipment maintenance personnel, and the severe damage of the straightening roller transmission speed reducer is avoided.
Drawings
FIG. 1 is a schematic view of a leveling roller deceleration drive mechanism of the present invention;
FIG. 2 is a schematic diagram of actual armature current of a transmission motor in a degraded state of a bearing of a No. 4 straightening roll speed reducer;
fig. 3 is a block diagram of a control system of the present invention.
Detailed Description
The following detailed description of the embodiments of the present invention will be given in order to provide those skilled in the art with a more complete, accurate and thorough understanding of the inventive concept and technical solutions of the present invention.
As shown in FIG. 1, the present invention relates to a structure of a transmission reducer of a multi-roll driven leveler. The actual armature current of the drive motor in the degraded state of the bearing of the speed reducer of the No. 4 straightening roll of the large H-beam straightener is shown in FIG. 2.
The comparison of the actual armature currents of the motor before and after the straightening roller reducer bearing is degraded shows that the armature current of the straightening roller transmission motor is slightly increased once the straightening roller reducer bearing is degraded no matter in a no-load state or a load state.
In addition, in the process of deterioration development of the transmission bearing, the no-load armature current of the straightening roller transmission motor will be increased in stages.
When the deterioration of the transmission bearing develops to the later stage, the transmission bearing is cracked instantly, and finally the straightening roller transmission speed reducer is blocked.
However, it is worth noting that after the straightening roller reducer bearing is degraded, the no-load armature current increment of the transmission motor is relatively stable; it is difficult to determine the change of the armature current after the bearing is degraded from the change of the actual armature current of the motor under load, because the magnitude of the armature current of the motor of the straightening roll under load (i.e., the magnitude of the load of the straightening roll) will depend on many process and equipment factors, such as the temperature of the rolled piece, the deformation of the rolled piece, the size and wear of the straightening roll segments, and the degradation of the speed reducer bearing of the straightening roll.
Therefore, the degradation state of the straightening roller speed reducer bearing is judged according to the change of the actual armature current of the straightening roller transmission motor, and the degradation state can be only realized through the change of the actual steady-state no-load armature current of the straightening roller transmission motor.
For a large H-shaped steel straightener, due to the detection deviation of a speed detection encoder of a straightening roller direct current transmission motor, the large proportional coefficient of a speed regulator of a control system, the quick response of the system and the like, the steady-state no-load armature current of the straightening roller transmission motor has a certain fluctuation amount, and the fluctuation frequency of the armature current reaches 5-10 Hz.
Therefore, the deterioration state of the straightening roll speed reducer bearing cannot be determined by the change of the steady-state no-load instantaneous armature current of the straightening roll drive motor.
Considering that the load of the straightening roll drive motor (only the drive reduction mechanism and the straightening roll body) is substantially constant in the steady-state no-load running state of the straightening roll, the steady-state average value of the motor armature current should be substantially constant even in the case of fluctuations.
Thus, the deterioration state of the straightening roll speed reducer bearing can be judged by completely adopting the change of the no-load steady-state average current of the straightening roll transmission motor.
The damage of the transmission reducer of the multi-roll straightener is considered to be mainly caused by the serious deterioration of the bearing of the transmission reducer. Therefore, based on the characteristic presented by the steady-state no-load armature current average value of the transmission motor of the straightening roller transmission reducer bearing in the degradation process, the invention provides a system (or a method) for monitoring the degradation state of the multi-roller drive straightening machine transmission reducer bearing, and the program block diagram of the control system is shown in FIG. 3.
Specifically, in order to solve the problems and overcome the defects of the prior art and achieve the purpose of avoiding the straightening roller transmission reducer from being seriously damaged due to the deterioration of a transmission bearing, the technical scheme adopted by the invention is as follows:
as shown in FIGS. 1 and 3, the method for monitoring the deterioration state of the bearing of the transmission reducer of the multi-roller driven straightener is applied to the large H-shaped steel production line and adopts a cantilever roller type variable pitch straightener to straighten H-shaped steel rolled pieces on line, wherein the straightener has nine cantilever type straightening rollers, four of the straightening rollers are upper straightening rollers, and five straightening rollers are lower straightening rollers which are arranged in a vertically staggered manner;
the four upper straightening rollers are active straightening rollers, namely No. 2 straightening rollers, No. 4 straightening rollers, No. 6 straightening rollers and No. 8 straightening rollers; each upper straightening roller is driven by a direct current motor through speed reduction;
the five lower straightening rollers are driven straightening rollers, namely No. 1, No. 3, No. 5, No. 7 and No. 9 straightening rollers, and are assisted by a hydraulic motor;
the control program of the monitoring method comprises the following functional units:
1) the actual motor armature current sampling control unit consists of JJZLJC 01-JZLJC 05 function blocks;
2) the motor armature current sampling number control unit consists of JJZLJC 06-JZLJC 12 function blocks;
3) the No. 2, No. 4, No. 6 and No. 8 straightening roller transmission motor steady-state no-load armature current sampling and average value calculation control units are respectively composed of JJZLJC 13-JJJZLJC 16 functional blocks, JJZLJC 19-JJZLJC 22 functional blocks, JJZLJC 25-JJZLJC 28 functional blocks and JJJZLJC 31-JZLJC 34 functional blocks;
4) the bearing degradation state judgment sub-unit of the straightening roller transmission speed reducer comprises four bearing degradation state judgment sub-units of No. 2, No. 4, No. 6 and No. 8 straightening roller transmission speed reducers, wherein the four bearing degradation state judgment sub-units respectively comprise a JJJZLJC 17 functional block, a JJZLJC18 functional block, a JJZLJC23 functional block, a JJZLJC24 functional block, a JJZLJC29 functional block, a JZLJC30 functional block and a JJJZLJC 35 functional block and a JJZLJC36 functional block.
In fig. 3:
PDF is a 'trailing edge delay' functional block;
RSR is an RS trigger function block with preferential reset end R, and when S is '1' and R is '0', Q is '1'; when S is '1' and R is '1', Q is '0'; when S is '0' and R is '0', Q is kept in the original state; when S is '0' and R is '1', Q is '0';
ETE is a function block of 'front and back edge identification', when an input end I is changed from '0' to '1', the QP end only outputs a positive pulse with the length of 1 cycle period, and the QP end is kept in a '0' state under other states; when the input end I is changed from '1' to '0', the QN end only outputs a positive pulse with the length of 1 cycle period, and the QN end is kept in a '0' state under the rest states;
CTR is a function block of a bidirectional counter, wherein IU and ID are respectively a positive and negative counting pulse input end, R and S are respectively a reset end and a set end of a counter counting value, SV is a set value of the counter, LU and LL are respectively an upper limit and a lower limit of the counter counting value, and when the counting value of the counter reaches the upper limit value, QU is '1', otherwise QU is '0';
NSW is a "two-way digital input selector" function block, and when I is equal to '0', Y is equal to X1, and when I is equal to '1', Y is equal to X2;
NCM is a "numerical comparison" function block, QU is '1' when X1 > X2, and QE is '1' when X1 ═ X2; when X1 < X2, QL is '1';
SAV is a "value store" function block, when M is '1', Y ═ X; when M is '0', Y keeps the original value unchanged;
ADD is an "adder" function block, Y ═ X1+ X2;
DIVI is the "divider" function block, Y ═ X1 ÷ X2;
OR is an OR gate;
AND is an AND gate;
NOT is a NOT gate.
The monitoring method for the bearing degradation state of the transmission speed reducer of the multi-roller driven straightener realizes timely and accurate acquisition of the state information of the transmission bearing degradation, facilitates equipment maintenance personnel to timely process the speed reducer with the transmission bearing degradation, and avoids serious damage to the transmission speed reducer of the straightening roller.
The control idea of the monitoring system for the bearing degradation state of the transmission speed reducer of the multi-roll driven straightener is as follows:
1. for an actual motor armature current sampling control unit:
based on the analysis, the invention designs an actual armature current sampling control unit in a transmission reducer bearing degradation state monitoring system, wherein the unit consists of JJJZLJC 01-JJZLJC 05 functional blocks.
In order to ensure that the bearing degradation state monitoring system can sample the armature current under the condition that 4 active straightening roll driving motors of the straightening machine are in steady state and are unloaded, the sampling control unit is controlled by 3 judgment conditions (or signals), namely: a signal of a cold metal detector at an inlet side of the leveler, a signal of a cold metal detector at an outlet side of the leveler, and an acceleration/deceleration state signal of the levelerMachine acceleration/deceleration state signal, i.e., rate of change of reference value of speed (dn) of leveler*/dt))。
Normally, the length of the rolled piece to be straightened is larger than that of the straightener body, so that when the cold metal detector on the inlet side and the outlet side of the straightener does not detect the rolled piece, the straightener is in an idle state, at the moment, if the change rate of the speed reference value of the straightener is zero, the straightener can be further judged to be in a steady idle state, and the output Q of the JJJZLJC 01 functional block of the sampling control unit is 0'.
In order to prevent the armature current sampling of the straightening roll motor when the straightening machine straightens an abnormal short rolled piece, thereby causing false alarm of the bearing degradation state monitoring system, the sampling control unit is provided with a signal back edge delay functional block JJJZLJC 02 at the output of the JJZLJC01 functional block;
considering that the time of the rolled piece disappearing from the inlet side to the outlet side of the straightener is less than 2 seconds when the straightener straightens the abnormal short rolled piece, the time of the trailing edge delay is set to be 2 seconds;
it can be seen that the bearing deterioration state monitoring system has the sampling conditions of the armature currents of the 4 straightening roll drive motors of the straightener when the output of the JJZLJC02 functional block of the sampling control unit is '0' and the output of the jzljc04 functional block is '1'.
On the premise that the sampling condition of the armature current of the transmission motor of the straightening machine is met, the next step is to calculate the number of armature current sampling times required by the steady-state no-load armature current of the transmission motor of the straightening machine.
2. For a motor armature current sample number control unit:
in view of the fact that the steady-state no-load armature current of the transmission motor of the straightener has large fluctuation in amplitude and frequency, in order to obtain a more accurate average value of the steady-state no-load armature current of the motor, a sufficient number of samples of the instantaneous value of the armature current of the motor are generally needed within a certain time period.
For a horse steel large H-shaped steel straightener, two 12-meter rolled pieces are generally adopted for continuous straightening (note: the two 12-meter rolled pieces are actually one rolled piece rolled by a rolling mill and are cut into two sections, the two sections of rolled pieces are simultaneously fed into the straightener for straightening by an upper cooling bed and a lower cooling bed, and are continuously fed into the straightener from front to back), and the straightening between every two rolled pieces has longer waiting time, which is generally about 40 seconds; and the cycle time of the program of the straightener control system (namely a programmable controller) is about 100 milliseconds, based on the cycle time, for the bearing degradation state monitoring system, the armature current of 4 straightener roll drive motors is sampled once and continuously sampled for 100 times by adopting each program cycle period, then the average value of the 100 armature current instantaneous values of the 4 straightener roll drive motors is calculated respectively, and finally the steady-state no-load armature current average value of each straightener roll drive motor is obtained.
Therefore, the invention designs a motor armature current sampling quantity control unit consisting of JJZLJC 06-JZLJC 12 functional blocks in the bearing degradation state monitoring system.
In this unit, a periodic pulse generation subunit is constituted by the functional blocks JJZLJC 06-jzljc 10, which generates a positive-going count pulse for the following counter functional block JJZLJC11 at each program cycle period;
the functional blocks jjjzljc 11 and jzljc12 constitute a count number control subunit in which the upper limit value of the count of the counter functional block jzljc11 is set to 100, and when the count value of the counter reaches 100, the state of the output terminal QU of the counter becomes '1'.
3. The control unit for sampling the steady-state no-load armature current of the straightening roller transmission motor and calculating the average value:
(1) the control unit for sampling the steady-state no-load armature current of the straightening roller transmission motor and calculating the average value comprises the following steps:
in the bearing degradation state monitoring system program, the function blocks JJZLJC 13-JZLJC 16, the function blocks JJZLJC 19-JZLJC 22, the function blocks JJZLJC 25-JZLJC 28 and the function blocks JZLJC 31-JZLJC 34 respectively form No. 2, No. 4, No. 6 and No. 8 straightening roller transmission motor steady-state no-load armature current sampling and average value calculation control units;
when the armature current of the straightening roller transmission motor has sampling conditions, the control unit samples the armature current of each straightening roller transmission motor once in each program cycle period and accumulates each sampling value with the previous sampling value;
however, before the sampling is started, the initial value of the sample accumulated value is zero, so that when the number of samples reaches a set number of samples (e.g., 100), the value storage function blocks jjjzljc 15, jzljc21, jzljc27, and jzljc33 in this unit will store and maintain the armature current accumulated values corresponding to the set number of samples, and then the steady state no-load armature current average value of each of the straightening roll drive motors is obtained by dividers (jzljc 16, jzljc22, jzljc28, jzljc34) provided after these value storage function blocks, respectively.
(2) And the motor armature current instantaneous value sampling and accumulating subunit:
each straightening roll motor armature current instantaneous value sampling accumulation subunit is respectively composed of JJZLJC13, JJZLJC14, JJZLJC19, JJZLJC20, JJZLJC25, JZLJC26, JJZLJC31 and JZLJC32 functional blocks;
in order to prevent the sub-unit from continuously sampling and accumulating the armature current instantaneous value after the armature current average value is calculated, thereby causing program operation errors, a back edge delay function block JJZLJC04 is arranged in the sampling control unit of the bearing degradation state monitoring system, and the function block delays for a certain time (more than one program cycle time, such as 200 milliseconds) after the sampling counting pulse reaches the set value, so that the output state of the sampling control unit is '0', namely the output end Q of the function block JZLJC05 is '0', and thus, the armature current instantaneous value sampling and accumulating sub-unit stops accumulating operation.
4. For the straightening roller transmission reducer bearing deterioration state determination subunit:
after obtaining the steady-state no-load armature current average value of 4 straightening roller transmission motors, the bearing degradation state monitoring system respectively judges the steady-state no-load armature current average value of the 4 straightening roller transmission motors through 4 straightening roller transmission speed reducer bearing degradation state judging subunits consisting of JJJZLJC 17, JJJZLJC 18, JJZLJC23, JJZLJC24, JJZLJC29, JJZLJC30, JJZLJC35 and JJZLJC36 functional blocks in the system;
for a horse steel large H-shaped steel straightener, under the condition that a straightening roller transmission speed reducer bearing normally operates, the average value of the steady-state no-load armature current of each straightening roller transmission motor is below 19 amperes; when the straightening roller transmission speed reducer bearing is degraded to a certain degree, the average value of the steady no-load armature current of the straightening roller transmission motor is far greater than 19 amperes, so that in the bearing degradation state judgment subunit, the bearing degradation state judgment value is set to be 25 amperes, namely when the average value of the steady no-load armature current of any straightening roller transmission motor is greater than the judgment value, the bearing degradation state monitoring system gives the corresponding degradation state information of the straightening roller transmission speed reducer bearing.
The invention has been described above with reference to the accompanying drawings, it is obvious that the invention is not limited to the specific implementation in the above-described manner, and it is within the scope of the invention to apply the inventive concept and solution to other applications without substantial modification.
Claims (2)
1. A monitoring method for the deterioration state of a bearing of a transmission speed reducer of a multi-roller driven straightener is applied to a cantilever roller type variable pitch straightener on a large H-shaped steel production line, the straightener has nine cantilever type straightening rollers, wherein four of the straightening rollers are upper straightening rollers, and five straightening rollers are lower straightening rollers which are arranged in a vertically staggered manner;
the four upper straightening rollers are active straightening rollers, namely No. 2 straightening rollers, No. 4 straightening rollers, No. 6 straightening rollers and No. 8 straightening rollers; each upper straightening roller is driven by a direct current motor through speed reduction;
the five lower straightening rollers are driven straightening rollers, namely No. 1, No. 3, No. 5, No. 7 and No. 9 straightening rollers, and are assisted by a hydraulic motor;
the control program of the monitoring method comprises the following functional units:
1) the actual motor armature current sampling control unit consists of JJZLJC 01-JZLJC 05 function blocks;
2) the motor armature current sampling number control unit consists of JJZLJC 06-JZLJC 12 function blocks;
3) the No. 2, No. 4, No. 6 and No. 8 straightening roller transmission motor steady-state no-load armature current sampling and average value calculation control units are respectively composed of JJZLJC 13-JJJZLJC 16 functional blocks, JJZLJC 19-JJZLJC 22 functional blocks, JJZLJC 25-JJZLJC 28 functional blocks and JJJZLJC 31-JZLJC 34 functional blocks;
4) the bearing degradation state judgment sub-unit of the straightening roller transmission speed reducer consists of a JJZLJC17 and JJZLJC18 functional block, a JJZLJC23 and JZLJC24 functional block, a JJZLJC29 and JJZLJC30 functional block, a JJZLJC35 and a JZLJC36 functional block which respectively form a bearing degradation state judgment sub-unit of four straightening roller transmission speed reducers of No. 2, No. 4, No. 6 and No. 8;
the method is characterized in that:
for an actual motor armature current sampling control unit: the sampling control unit is controlled by 3 decision conditions, namely: a cold metal detector signal at the inlet side of the straightener, a cold metal detector signal at the outlet side of the straightener and an acceleration and deceleration state signal of the straightener;
when the cold metal detectors on the inlet side and the outlet side of the straightener do not detect rolled pieces, the straightener is in an idle state, at the moment, if the change rate of the speed reference value of the straightener is zero, the straightener is further judged to be in a steady idle state, and at the moment, the output Q of the JJZLJC01 functional block of the sampling control unit is '0';
in order to prevent false alarm of a bearing degradation state monitoring system caused by armature current sampling of a straightening roll motor when an abnormal short rolled piece is straightened by a straightening machine, a sampling control unit sets a signal trailing edge delay functional block JJJZLJC 02 at the output of a JJZLJC01 functional block;
considering that the time of the rolled piece disappearing from the inlet side to the outlet side of the straightener is less than 2 seconds when the straightener straightens the abnormal short rolled piece, the time of the trailing edge delay is set to be 2 seconds;
therefore, when the output of the JJZLJC02 function block of the sampling control unit is '0' and the output of the jzljc04 function block is '1', the bearing degradation state monitoring system is provided with the sampling conditions of the armature currents of the 4 straightening roll drive motors of the straightener;
for a motor armature current sample number control unit: in this unit, a periodic pulse generation subunit is constituted by the functional blocks JJZLJC 06-jzljc 10, which generates a positive-going count pulse for the following counter functional block JJZLJC11 at each program cycle period;
the functional blocks jjjzljc 11 and jzljc12 constitute a count number control subunit in which the upper limit value of the count of the counter functional block jzljc11 is set to 100, and when the count value of the counter reaches 100, the state of the output terminal QU of the counter becomes '1';
the control unit for sampling the steady-state no-load armature current of the straightening roller transmission motor and calculating the average value: in a bearing degradation state monitoring system program, a function block JJZLJC 13-JZLJC 16, a function block JJZLJC 19-JZLJC 22, a function block JJZLJC 25-JZLJC 28 and a function block JZLJC 31-JZLJC 34 respectively form a No. 2, No. 4, No. 6 and No. 8 straightening roller transmission motor steady-state no-load armature current sampling and average value calculation control unit;
when the armature current of the straightening roller transmission motor has sampling conditions, the control unit samples the armature current of each straightening roller transmission motor once in each program cycle period and accumulates each sampling value with the previous sampling value;
before the sampling is started, the initial value of the sampling accumulated value is zero, so that when the sampling times reach the set sampling times, the numerical value storage functional blocks JJZLJC15, JJJZLJC 21, JJZLJC27 and JZLJC33 in the unit store and maintain the armature current accumulated value corresponding to the set sampling times, and then the steady-state no-load armature current average value of each straightening roll transmission motor is respectively obtained through dividers arranged behind the numerical value storage functional blocks;
for the straightening roller transmission reducer bearing deterioration state determination subunit: after obtaining the steady-state no-load armature current average value of 4 straightening roller transmission motors, the bearing degradation state monitoring system respectively judges the steady-state no-load armature current average value of the 4 straightening roller transmission motors through 4 straightening roller transmission speed reducer bearing degradation state judging subunits consisting of JJJZLJC 17, JJJZLJC 18, JJZLJC23, JJZLJC24, JJZLJC29, JJZLJC30, JJZLJC35 and JJZLJC36 functional blocks in the system;
under the condition that the straightening roller transmission speed reducer bearing normally operates, the average value of the steady-state no-load armature current of each straightening roller transmission motor is below 19 amperes; when the straightening roller transmission speed reducer bearing is degraded to a certain degree, the average value of the steady no-load armature current of the straightening roller transmission motor is larger than 19 amperes, so that in the bearing degradation state judgment subunit, the bearing degradation state judgment value is set to be 25 amperes, namely when the average value of the steady no-load armature current of any straightening roller transmission motor is larger than the judgment value, the bearing degradation state monitoring system gives the corresponding degradation state information of the straightening roller transmission speed reducer bearing.
2. The method for monitoring the deterioration state of the bearing of the transmission reducer of the multi-roll driven leveler as set forth in claim 1, wherein: each straightening roll motor armature current instantaneous value sampling accumulation subunit is respectively composed of JJZLJC13, JJZLJC14, JJZLJC19, JJZLJC20, JJZLJC25, JZLJC26, JJZLJC31 and JZLJC32 functional blocks;
in order to prevent the sub-unit from continuously sampling and accumulating the armature current instantaneous value after the armature current average value is calculated, thereby causing program operation errors, a back edge delay function block JJZLJC04 is arranged in a sampling control unit of the bearing degradation state monitoring system, and the function block delays for a certain time after the sampling counting pulse reaches the set value, so that the output state of the sampling control unit is '0', namely the output end Q of the function block JZLJC05 is '0', and the motor armature current instantaneous value sampling and accumulating sub-unit stops accumulating operation.
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