CN109283102A - A kind of real-time monitoring system of movable machinery component wear state - Google Patents
A kind of real-time monitoring system of movable machinery component wear state Download PDFInfo
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- CN109283102A CN109283102A CN201810960174.0A CN201810960174A CN109283102A CN 109283102 A CN109283102 A CN 109283102A CN 201810960174 A CN201810960174 A CN 201810960174A CN 109283102 A CN109283102 A CN 109283102A
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- 238000012544 monitoring process Methods 0.000 title claims abstract description 28
- 239000002184 metal Substances 0.000 claims abstract description 50
- 229910052751 metal Inorganic materials 0.000 claims abstract description 50
- 230000005284 excitation Effects 0.000 claims abstract description 31
- 230000006698 induction Effects 0.000 claims abstract description 28
- 230000003321 amplification Effects 0.000 claims abstract description 12
- 238000003199 nucleic acid amplification method Methods 0.000 claims abstract description 12
- 239000003208 petroleum Substances 0.000 claims abstract description 11
- 238000000110 selective laser sintering Methods 0.000 claims abstract description 4
- 238000012545 processing Methods 0.000 claims description 16
- 230000007613 environmental effect Effects 0.000 claims description 9
- 238000001914 filtration Methods 0.000 claims description 8
- 238000001514 detection method Methods 0.000 claims description 6
- 239000000306 component Substances 0.000 description 21
- 239000010687 lubricating oil Substances 0.000 description 9
- 230000000694 effects Effects 0.000 description 7
- 238000004458 analytical method Methods 0.000 description 5
- 238000011161 development Methods 0.000 description 5
- 230000018109 developmental process Effects 0.000 description 5
- 230000001939 inductive effect Effects 0.000 description 5
- 238000000034 method Methods 0.000 description 5
- 239000003921 oil Substances 0.000 description 5
- 238000005299 abrasion Methods 0.000 description 3
- 238000009825 accumulation Methods 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 230000036541 health Effects 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 238000005070 sampling Methods 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 230000002596 correlated effect Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000004907 flux Effects 0.000 description 2
- 238000012423 maintenance Methods 0.000 description 2
- 230000013011 mating Effects 0.000 description 2
- 238000012806 monitoring device Methods 0.000 description 2
- 238000005457 optimization Methods 0.000 description 2
- 238000001228 spectrum Methods 0.000 description 2
- 239000006061 abrasive grain Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 239000008358 core component Substances 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000005672 electromagnetic field Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 230000001050 lubricating effect Effects 0.000 description 1
- 238000005461 lubrication Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000010742 number 1 fuel oil Substances 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 238000010183 spectrum analysis Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N15/00—Investigating characteristics of particles; Investigating permeability, pore-volume or surface-area of porous materials
- G01N15/02—Investigating particle size or size distribution
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N15/00—Investigating characteristics of particles; Investigating permeability, pore-volume or surface-area of porous materials
- G01N15/06—Investigating concentration of particle suspensions
- G01N15/0656—Investigating concentration of particle suspensions using electric, e.g. electrostatic methods or magnetic methods
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- Biochemistry (AREA)
- General Health & Medical Sciences (AREA)
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- Pathology (AREA)
- Investigating Or Analyzing Materials By The Use Of Magnetic Means (AREA)
- Geophysics And Detection Of Objects (AREA)
Abstract
The invention discloses a kind of real-time monitoring systems of movable machinery component wear state, including host computer, it further include the controller box being connect with host computer, the controller box connects sensor by coaxial cable, the sensor includes the shell with electromagnetic protection function, petroleum pipeline is arranged in the enclosure interior, 2 coil groups is arranged on petroleum pipeline, the coil group includes two excitation coils and the induction coil positioned at two excitation coil centers;It include DDS module, amplification filter module, demodulation amplification filter module, computing module and selective laser sintering module in the controller box, the DDS module generates high-frequency AC excitation signal and is applied to sensor excitation coil, the opposite induced magnetic field of the size same direction is generated at 2 induction coils, when metal filings pass through excitation coil, induction coil generates an amplitude-modulated signal relevant to metal filings attribute and size, and two groups of induction coils generate two paths of signals;Filter module is amplified in the demodulation.
Description
Technical field
The present invention relates to a kind of real-time watch devices of the mechanical component state of wear of movement, and in particular to a kind of fitness machine
The real-time monitoring system of tool component wear state.
Background technique
The mechanical component that the mechanical component moved in mechanical equipment especially runs at high speed is often to determine equipment performance
Important Parts are not only the important means of monitoring device operating condition to the real-time monitoring of its health degree, even more construct the number of trend analysis
According to source, to provide early warning or alarm signal in health management system arranged, high-cost moving link is directed in time
The maintenance of property, avoids the occurrence of serious accident and serious economic loss.
In the fault mode of mechanical component, abrasion is to cause one of principal element of failure, although modern machinery is set
It is standby that there is perfect lubricating system, but it is severe for the operating condition of such as aero-engine and its transmission system class complexity, operating condition
The equipment for carving, revolving speed height and being in high dry running, because it is very high to each mechanical component required precision, lubricating oil is chronically at
Under the condition of high temperature, once breaking down, the loss that can not be retrieved will be caused, therefore state of wear is carried out in the process of running real-time
Monitoring is very important.The degree of wear of mechanical component can be characterized by the metal filings amount in lubricating oil, currently, to metal fillings
The monitoring means at end is divided into two classes of online and offline monitoring by timeliness.
Domestic main monitoring means used at present is offline, such as analyzing iron spectrum, spectrum analysis, power spectrum, is all logical
It crosses magnetic and gets lodged in collection magnetic metal bits end in oil system, sampling analysis considers last type, size, quantity to be worth doing again after aircraft landing,
But the period is very long, and process is cumbersome, and belongs to intermittent analysis.Although to available higher point of the magnetic metal bits end collected
Precision, but the stifled magnetic metal bits end that can not be collected completely in lubricating oil of magnetic are analysed, is even more that can not search for nonmagnetic metal bits end
Collection, therefore off-line monitoring acquirement metal filings amount is not accurate enough, estimates judgement to the degree of wear of mechanical component and is not allowed, serious shadow
The rate of attendance and the maintenance of aircraft are rung.Because it is mounted in the lubricating oil circulatory system, full flow liquid monitoring has good on-line monitoring
Timeliness, be capable of real-time statistics magnetic metal bits end and nonmagnetic metal bits end size, quantity, it is more acurrate to reflect in time
The state of wear of mechanical component provides more reliably early warning for equipment.External on-line monitoring technique development is more early, now develops
There is Debris Analysis device, online abrasive grain counter, MetalSCAN online lubricating oil bits end monitoring sensor etc. to answer in industrial circle
Product.Wherein, the MetalSCAN of GasTops company development and production online lubricating oil bits end monitoring sensor is aiming at F-
The 119 mating developments of type aero-engine, which is the mating power of F-22 opportunity of combat.The online lubricating oil bits of MetalSCAN
End monitoring sensor is made of sensor, controller, cable etc., and wherein sensor includes three and is looped around on non-conductive skeleton
Coil, two outside coil two opposite polarity magnetic fields, and the phase at centering coil are generated under the driving of alternating current
It mutually offsets, the magnetic field generated when metal filings pass through sensor to two outer coils forms the interference of different timing, thus
Centering coil produces inductive signal because magnetic field is unbalance, and inductive signal is transferred to controller by cable, judges by signal processing
Consider type, the size at end to be worth doing out.Online lubricating oil bits end monitoring sensor fails into always in view of being mainly used for military use in foreign countries
Function introduces domestic air mail market, and the Related product of domestic development requires stringent, development because of complexity, the use environment of its technology
Difficulty is big, is not widely used yet.
Summary of the invention
The present invention is that solution is above-mentioned, and it is an object of the present invention to provide a kind of real-time monitoring system of movable machinery component wear state.
The present invention is achieved through the following technical solutions:
A kind of real-time monitoring system of movable machinery component wear state, including host computer, further include connecting with host computer
Controller box, the controller box by coaxial cable connect sensor, the sensor include have electromagnetic protection function
Shell, the enclosure interior is arranged petroleum pipeline, 2 coil groups is arranged on petroleum pipeline, and the coil group includes two excitation lines
Circle and the induction coil positioned at two excitation coil centers;It include DDS module, amplification filtering mould in the controller box
Block, demodulation amplification filter module, computing module and selective laser sintering module, the DDS module generate high-frequency AC excitation signal
It is applied to sensor excitation coil, the opposite induced magnetic field of the size same direction is generated at 2 induction coils, when metal filings are logical
When overdriving coil, induction coil generates an amplitude-modulated signal relevant to metal filings attribute and size, two groups of induction coils
Generate two paths of signals;Filter module is amplified in the demodulation: above-mentioned demodulation amplification filter module being used two-way detection, passes through operation
After module reduces the noise of environmental factor, obtains the higher amplitude-modulated signal of a signal-to-noise ratio and be sent to microprogram processing module;
The microprogram processing module: treated that signal samples to computing module by the ADC carried with processor, to acquisition
Data carry out the algorithm based on Kalman filtering and obtain actual signal, are sent to host computer;The host computer: receive true letter
Number, the weight and type of metal filings, and store historical data are judged according to the intensity of actual signal and phase.
Core component of the present invention is mounted in the sensor on lubrication duct, and the signal source of sensor is based on electromagnetism
Totally 6 coils of two groups of principle of induction.Each group of coil is there are two excitation coil and positioned at two excitation coil centers
Induction coil has certain gap to avoid the occurrence of the case where electromagnetic field interferes with each other between two groups of coils, so constitutes two-way
Input, two-way output.4 excitation coils of two groups of coils are parallel to identical pumping signal, and input synchronizes, in two lines of induction
It is identical to enclose the inductive signal amplitude generated, phase.Sensor output original signal inevitably will receive temperature, electromagnetism,
The interference of the environmental factors such as vibration generates noise.
The high-frequency AC excitation signal that DDS module in controller box generates is applied to sensor excitation coil, and two groups are swashed
It encourages coil and generates the opposite induced magnetic field of the size same direction respectively at two groups of induction coils, at this time nothing on two groups of induction coils
Magnetic flux change, the amplitude-modulated signal output of no metal filings.When metal filings pass through excitation coil, magnetic metal considers foot couple magnetic to be worth doing
Field generates gain effect, and nonmagnetic metal considers foot couple magnetic field to be worth doing and generates detraction effect, has thereby resulted in magnetic field mistake between excitation coil
Weighing apparatus, and gain caused by metal filings or detraction effect power and the size at bits end are positively correlated, therefore induction coil generates one
A amplitude-modulated signal relevant to metal filings attribute and size, two groups of induction coils generate two paths of signals, exist between two paths of signals
The time difference.For metal filings below for 0.3mm, the signal of generation is generally fainter, for rear class sampling detection very
Difficulty, therefore amplified in sensor output stage.Bandpass filtering is carried out to amplified signal, it is relatively high to obtain a noise
Amplitude-modulated signal.Demodulation amplification filter module uses two-way detection to two paths of signals, and the modular structure is simple, practical, energy
Enough reduce common-mode noise.It is consistent substantially in view of the noise frequency in two-way inductive signal, phase, amplitude, metal filings
Amplitude-modulated signal has the time difference, therefore noise caused by environmental factor can be greatly lowered using operation appropriate in computing module,
This is also the core processing part of the controller box.The ADC that microprogram processing module is carried with processor is to computing module
Treated, and signal is sampled, and is carried out the algorithm based on Kalman filtering to the data of acquisition and is obtained actual signal, thus more
Add and is effectively reduced noise, optimization processing environmental disturbances.
2 coil groups are integrated on the same coil rack, and coil rack is enclosed in shell in the form of encapsulating
It is internal.Further, entire coil rack is completely enclosed in the form of encapsulating and is fastened inside housings, therefore noise is defeated in two-way
On out while reflecting identical feature, and metal filings have the time difference by output when two induction coils with lubricating oil, pass through control
Device calculation process two-way output signal processed obtains waveform accurately comprising metal filings information.
The caliber of the petroleum pipeline includesFurther, oil transportation caliber can exist according to requirement of engineeringIt is selected in range, and not cause oil system pressure drop, each binding site has carried out leakproofness and set
Meter.
The host computer, controller box, coaxial cable and sensor are coupled using RS232 or RS422/485 series interfaces.
Further, as a preferred solution of the present invention, installation convenience.
Compared with prior art, the present invention having the following advantages and benefits:
1, a kind of real-time monitoring system of movable machinery component wear state of the present invention, sensor of the present invention use
Two groups of inputs, two groups of export structures, the matching two paths of signals processing circuit of controller box, the noise that environmental disturbances are generated
With excellent processing capacity, metal filings can be more accurately monitored, monitoring accuracy is high, strong antijamming capability;
2, a kind of real-time monitoring system of movable machinery component wear state of the present invention, while two groups two groups of sensor are defeated
Enter, two groups of outputs are absolute construction, two processing circuits of controller box work independently, and have no effect on after breaking down all the way another
Normal work all the way, thus the present invention in industrial application have higher reliability, can nuclear power station, wind turbine gearbox,
It is applied in the oil system of the heavy mechanical equipments such as compressor, pump;
3, a kind of real-time monitoring system of movable machinery component wear state of the present invention, the design of sensor of the invention structure
It can satisfy the requirement of larger range oil transportation caliber, and coil rack has selected excellent temperature-resistant material, resistance to extreme temperature is 500
DEG C, it can satisfy the oil system operating ambient temperature requirement of the engines such as aircraft, naval vessel.
Detailed description of the invention
Attached drawing described herein is used to provide to further understand the embodiment of the present invention, constitutes one of the application
Point, do not constitute the restriction to the embodiment of the present invention.
In the accompanying drawings:
Fig. 1 is inventive sensor loop construction schematic diagram;
Fig. 2 is real-time monitoring device functional block diagram of the present invention;
Fig. 3 is that magnetic metal of the present invention considers last diameter distribution profile to be worth doing;
Fig. 4 is the amplitude-modulated signal figure when present invention passes through without metal filings in two-way output;
Fig. 5 is the amplitude-modulated signal figure when present invention has metal filings to pass through in two-way output.
Specific embodiment
To make the objectives, technical solutions, and advantages of the present invention clearer, below with reference to embodiment and attached drawing, to this
Invention is described in further detail, and exemplary embodiment of the invention and its explanation for explaining only the invention, are not made
For limitation of the invention.
Embodiment
As shown in Figs. 1-5, a kind of real-time monitoring system of movable machinery component wear state of the present invention, including host computer,
It is characterized by also including the controller box connecting with host computer, the controller box connects sensor, institute by coaxial cable
Stating sensor includes the shell with electromagnetic protection function, and petroleum pipeline is arranged in the enclosure interior, and 2 coils are arranged on petroleum pipeline
Group, the coil group include two excitation coils and the induction coil positioned at two excitation coil centers;The controller
Include DDS module, amplification filter module in box, demodulate amplification filter module, computing module and selective laser sintering module, it is described
DDS module generates high-frequency AC excitation signal and is applied to sensor excitation coil, generates the size same direction at 2 induction coils
Opposite induced magnetic field, when metal filings pass through excitation coil, induction coil generates one and metal filings attribute and size
Relevant amplitude-modulated signal, two groups of induction coils generate two paths of signals;Filter module is amplified in the demodulation: above-mentioned demodulation being amplified and is filtered
Wave module uses two-way detection, after the noise that environmental factor is reduced by computing module, obtains the higher amplitude modulation of signal-to-noise ratio
Signal is simultaneously sent to microprogram processing module;The microprogram processing module: with processor carry ADC to computing module at
Signal after reason is sampled, and is carried out the algorithm based on Kalman filtering to the data of acquisition and is obtained actual signal, is sent to
Position machine;The host computer: receiving actual signal, and the weight and kind of metal filings are judged according to the intensity of actual signal and phase
Class, and store historical data.2 coil groups are integrated on the same coil rack, and coil rack uses the form of encapsulating
Closing is inside housings.The caliber of the petroleum pipeline includesThe host computer, controller box, coaxial cable
Coupled with sensor using RS232 or RS422/485 series interfaces.
When work: the high-frequency AC excitation signal that the DDS module in controller box generates is applied to sensor excitation coil,
Two groups of excitation coils generate the opposite induced magnetic field of the size same direction respectively at two groups of induction coils, at this time two groups of lines of induction
Without magnetic flux change on circle, the amplitude-modulated signal of no metal filings is exported.When metal filings pass through excitation coil, magnetic metal bits
Foot couple magnetic field generates gain effect, and nonmagnetic metal considers foot couple magnetic field to be worth doing and generates detraction effect, thereby resulted between excitation coil
Magnetic field is unbalance, and gain caused by metal filings or detraction effect power and the size at bits end are positively correlated, therefore induction coil
An amplitude-modulated signal relevant to metal filings attribute and size is generated, two groups of induction coils generate two paths of signals, two paths of signals
Between there are the time differences.For metal filings below for 0.3mm, the signal of generation is generally fainter, and the sampling of rear class is examined
Wave is extremely difficult, therefore is amplified in sensor output stage.Bandpass filtering is carried out to amplified signal, obtains a noise
Relatively high amplitude-modulated signal.Demodulation amplification filter module uses two-way detection to two paths of signals, and the modular structure is simple, practicability
By force, it can reduce common-mode noise.It is consistent substantially in view of the noise frequency in two-way inductive signal, phase, amplitude, metal fillings
The amplitude-modulated signal at end has the time difference, therefore can be greatly lowered caused by environmental factor and be made an uproar using operation appropriate in computing module
Sound, this is also the core processing part of the controller box.The ADC that microprogram processing module is carried with processor is to operation mould
Treated that signal is sampled for block, carries out the algorithm based on Kalman filtering to the data of acquisition and obtains actual signal, thus
More efficiently reduce noise, optimization processing environmental disturbances.
Upper computer software system judges metal filings according to the intensity and phase of the finally obtained signal of controller box
Size and type, and store historical data.The abrasion of movable machinery component is one of its main failure mode, wears generation
Metal filings amount has directly reacted the degree of wear of mechanical component, therefore the health degree assessment system is exactly according to prison in real time
The historical data of measurement equipment accumulation carries out real-time judge and trend analysis, and entire mechanical equipment is provided alert or alerted.Whole
During a failure, the size distribution of metal filings caused by abrasion is unrelated with the size of movable machinery component, type, Fig. 3
It is that the magnetic metal that movable machinery component wear generates considers last typical profile to be worth doing, nonmagnetic metal bits end generally can be divided into 500 μm
With 900 μm of two grades.Software systems according to different specification statistic of classifications and can calculate the metal filings monitored
The quality and gross mass of dimension metal filings accumulation, and early warning and warning value can be pressed according to the parameter of movable machinery component
It is configured according to following formula:
MEarly warning=λ MAlarm(0 < λ < 1)
Wherein: K is a constant relevant to movable machinery element type;
N is moving link quantity;
D is pitch diameter;
D rolling element diameter.
Early warning value can select qualified early warning position according to the reliability and different degree of entire mechanical equipment, after issuing early warning
Statistic of classification can be checked to determine whether moving link belongs to normal wear, directly reported if big specification bits end has exceeded setting value
Alert, operator should observe immediately at this time shuts down equipment moving link is badly damaged or even calamity that thus cause to avoid occurring
Consequence.For equipment higher for reliability requirement, λ can use smaller value, and by specification classification more refinement to obtain more
Accurate accumulation data are safeguarded in advance with estimating accurate remaining life, to reduce use cost.
Above-described specific embodiment has carried out further the purpose of the present invention, technical scheme and beneficial effects
It is described in detail, it should be understood that being not intended to limit the present invention the foregoing is merely a specific embodiment of the invention
Protection scope, all within the spirits and principles of the present invention, any modification, equivalent substitution, improvement and etc. done should all include
Within protection scope of the present invention.
Claims (4)
1. a kind of real-time monitoring system of movable machinery component wear state, including host computer, it is characterised in that: further include with it is upper
The controller box of position machine connection, the controller box connect sensor by coaxial cable, and the sensor includes having electromagnetism
Petroleum pipeline is arranged in the shell of safeguard function, the enclosure interior, and 2 coil groups are arranged on petroleum pipeline, and the coil group includes two
A excitation coil and induction coil positioned at two excitation coil centers;It include DDS module, amplification in the controller box
Filter module, demodulation amplification filter module, computing module and selective laser sintering module,
The DDS module generates high-frequency AC excitation signal and is applied to sensor excitation coil, generates size at 2 induction coils
The opposite induced magnetic field of the same direction, when metal filings pass through excitation coil, induction coil generates one and metal filings category
Property and the relevant amplitude-modulated signal of size, two groups of induction coils generate two paths of signals;
Filter module is amplified in the demodulation: above-mentioned demodulation amplification filter module being used two-way detection, is reduced by computing module
After the noise of environmental factor, obtains the higher amplitude-modulated signal of a signal-to-noise ratio and be sent to microprogram processing module;
The microprogram processing module: treated that signal samples to computing module by the ADC carried with processor, to adopting
The data of collection carry out the algorithm based on Kalman filtering and obtain actual signal, are sent to host computer;
The host computer: receiving actual signal, and the weight and kind of metal filings are judged according to the intensity of actual signal and phase
Class, and store historical data.
2. a kind of real-time monitoring system of movable machinery component wear state according to claim 1, it is characterised in that: institute
It states 2 coil groups to be integrated on the same coil rack, coil rack is closed inside housings in the form of encapsulating.
3. a kind of real-time monitoring system of movable machinery component wear state according to claim 1, it is characterised in that: institute
The caliber for stating petroleum pipeline includes
4. a kind of real-time monitoring system of movable machinery component wear state according to claim 1, it is characterised in that: institute
Host computer, controller box, coaxial cable and sensor is stated to couple using RS232 or RS422/485 series interfaces.
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