CN110553723B - Vibration signal processing system and method - Google Patents
Vibration signal processing system and method Download PDFInfo
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- CN110553723B CN110553723B CN201910788597.3A CN201910788597A CN110553723B CN 110553723 B CN110553723 B CN 110553723B CN 201910788597 A CN201910788597 A CN 201910788597A CN 110553723 B CN110553723 B CN 110553723B
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- G01H—MEASUREMENT OF MECHANICAL VIBRATIONS OR ULTRASONIC, SONIC OR INFRASONIC WAVES
- G01H17/00—Measuring mechanical vibrations or ultrasonic, sonic or infrasonic waves, not provided for in the preceding groups
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- G01M13/00—Testing of machine parts
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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
- G01M13/028—Acoustic or vibration analysis
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M13/00—Testing of machine parts
- G01M13/04—Bearings
- G01M13/045—Acoustic or vibration analysis
Abstract
The invention discloses a vibration signal processing system and a corresponding processing method, wherein the system comprises a plurality of vibration signal acquisition sensors, a background data processing module and a foreground data processing module; the background data processing module comprises a vibration data storage unit, a plug-in unit and a result sending unit; the foreground data processing module comprises a plug-in combination setting unit and a result display unit. The invention realizes diversified combination of various vibration analysis methods by using the plug-in unit, not only effectively solves the problems of limited functions, fixed operation and the like of the existing vibration analysis instrument or analysis software, but also obviously improves the accuracy and reliability of the final vibration analysis result.
Description
Technical Field
The invention relates to a signal processing system and a corresponding processing method, in particular to a vibration signal processing system and a processing method, and belongs to the technical field of data analysis and fault diagnosis.
Background
The vibration analysis is an analysis method commonly used for fault diagnosis of rotary mechanical equipment, and mainly utilizes a vibration sensor mounted on the mechanical equipment to acquire vibration signals such as vibration acceleration, speed and displacement signals of the mechanical equipment, and then the acquired vibration signals are subjected to conversion processing and graphic display through specific analysis software or tools such as Matlab and Labview. After the processing is finished, a professional vibration analyst gives a comprehensive analysis to the mechanical equipment according to the processing result and by combining information such as part parameters, operation parameters and the like of the mechanical equipment, so that possible fault points and possible fault reasons of the equipment are diagnosed.
Because mechanical equipment is various in types and complex in working conditions, and a plurality of choices also exist in a vibration sensor for collecting data, in the actual vibration analysis process, different analysis tools and methods need to be adopted to process and analyze vibration data according to different conditions. Specifically, the processing and analyzing methods of the vibration data commonly used at present include time domain images and time domain parameters, integration, FFT (fast fourier transform), envelope spectrum, wavelet analysis, wavelet de-noising, low-pass filtering or band-pass filtering, auto-correlation, real cepstrum, refined spectrum, waterfall graph, and the like.
Because the processing and analyzing methods exist in the prior art, and the types and working conditions of the mechanical equipment in the actual operation process are different and may be complex, a vibration analyst often combines a plurality of different analyzing methods for use when processing and analyzing the vibration data. For example, before FFT, digital filtering operations such as low-pass filtering or band-pass filtering are generally performed, and before bearing analysis using envelope spectrum, wavelet denoising operations are generally performed. In general, as the related art is continuously advanced and matured, the vibration analysis fault diagnosis mode is more and more diversified, and new analysis methods are continuously provided, which correspond to the more and more accurate vibration analysis results, and the vibration analysis process is gradually complicated.
In terms of actual application, in an existing vibration analysis instrument or software tool, programmed and fixed analysis pages and methods are preset for common faults, such as faults of bearings, shafting, gears and the like, and when the vibration analysis instrument or software tool is used, a vibration analyst selects corresponding pages or menus to analyze according to actual needs. However, when complex conditions are met, especially when multiple analysis methods are needed for processing for multiple times, even some analysis methods are needed to be used for multiple times, the existing instruments or software tools are difficult to complete processing, and therefore accurate equipment failure causes are difficult to obtain finally. In this case, some programmability vibration analysts usually write their own code by using software such as Matlab or Labview, and make a dedicated analysis program to perform vibration analysis fault diagnosis. However, few vibration analysts who know software such as Matlab or Labview are available in China, and the talents are difficult to cultivate.
In summary, how to provide a fully new vibration signal processing system and a corresponding processing method based on the prior art makes a vibration analyst implement vibration data processing and analysis of different devices and working conditions by a flexible analysis method combination without independently writing codes, so as to achieve the purpose of accurately analyzing the failure cause of the devices, which is also a problem to be solved by technical personnel in the field.
Disclosure of Invention
In view of the above-mentioned drawbacks of the prior art, the present invention provides a vibration signal processing system and a corresponding processing method, as follows.
A vibration signal processing system comprising:
the vibration signal acquisition sensors are fixedly arranged on the mechanical equipment and used for monitoring and acquiring operation data of the mechanical equipment in real time and generating original vibration data;
the background data processing module is used for acquiring original vibration data generated by the vibration signal acquisition sensor, performing vibration analysis on the original vibration data according to a data processing method stored in the background data processing module, generating a vibration analysis result and issuing the vibration analysis result;
the foreground data processing module is used for receiving and displaying the vibration analysis result from the background data processing module and finishing data interaction with the background data processing module;
the background data processing module comprises a background data processing module,
a vibration data storage unit for receiving the raw vibration data from the vibration signal acquisition sensor and storing the data in a file form,
a plurality of plug-in units which are connected with the vibration data storage unit and are connected in series in a chain mode for recording and executing a data processing method and generating a result data array, wherein each plug-in unit stores a plug-in, and each plug-in corresponds to a data processing method,
the result sending unit is connected with the plug-in unit and used for collecting all result data arrays generated by the plug-in unit, packaging the result data arrays and selectively sending the result data arrays to the foreground data processing module;
the foreground data processing module comprises a front-end data processing module,
a plug-in combination setting unit connected with the vibration data storage unit and the plug-in unit and used for selecting and combining the plug-in units according to the requirements, setting the processing parameters of each plug-in combination, sending a vibration data file list, a plug-in unit combination result and a processing parameter setting result to the background data processing module,
and the result display unit is connected with the result sending unit and used for receiving and displaying the result data array from the result sending unit.
Preferably, the background data processing module further comprises:
the vibration data reading unit is respectively connected with the vibration signal acquisition sensor and the vibration data storage unit and is used for reading original vibration data in the vibration signal acquisition sensor according to analysis requirements, converting the read original vibration data into time domain original data and then forwarding the time domain original data;
and the format definition unit is respectively connected with the vibration data reading unit, the plug-in unit and the foreground data processing module and is used for defining a universal data format and a plug-in structure in the system.
Preferably, the format definition unit includes:
the data format definition subunit is used for defining a universal data format in the system, and the data format comprises vibration time domain data, vibration frequency domain data and dimensional parameters or dimensionless parameters calculated by the plug-in unit;
the plug-in structure defines a subunit and is used for defining a universal plug-in structure in the system, the plug-in structure comprises a plug-in name, an input and output data array, a data processing method, a processing parameter, a preorder plug-in name and whether to display output or not,
each of the input and output data arrays contains one or more data in accordance with a common data format within the system.
Preferably, the data format includes: data name, data length, X-axis data array, X-axis data unit, Y-axis data array, and Y-axis data unit.
Preferably, each of the plug-in units includes:
the parameter analysis subunit is connected with the plug-in combination setting unit and used for analyzing the processing parameters, converting the processing parameters into data meeting the plug-in execution requirement and forwarding the data;
and the plug-in execution subunit is connected with the parameter analysis subunit and is used for storing and recording the data processing method, processing the data according to the data processing method and generating a result data array.
Preferably, the method for processing data in the plug-in execution subunit includes: high pass filtering, low pass filtering, band pass filtering, integration, FFT transformation, Hilbert transformation, wavelet de-noising, auto-correlation, real cepstrum, refined spectrum, and order analysis.
Preferably, the insert combination setting unit includes:
the data selection subunit is used for displaying all the plug-in units, selecting and extracting one or more original vibration data and time domain original data corresponding to the plug-in units from the vibration data storage unit according to analysis requirements, generating a vibration data file list and sending the vibration data file list;
the plug-in combination subunit is used for selecting the corresponding plug-in units according to the analysis requirement to carry out combination and setting the processing parameter of each plug-in unit;
and the setting and sending subunit is respectively connected with the data selecting subunit and the plug-in unit combination subunit and is used for sending the vibration data file list, the plug-in unit combination result and the processing parameter setting result to the background data processing module.
Preferably, the result presentation unit includes:
the graph display subunit is used for displaying the analysis processing result in the form of a graph, wherein the graph comprises a time domain graph, an amplitude spectrum, a power spectrum, an envelope spectrum, an order spectrum, an autocorrelation spectrum, a wavelet analysis, a real cepstrum, a refined spectrum and a waterfall graph;
and the parameter display subunit is used for displaying the dimensional parameters or the dimensionless parameters calculated by the plug-in unit in a form of a table, wherein the dimensional parameters or the dimensionless parameters comprise peak values, mean values, effective values and kurtosis.
A vibration signal processing method using the vibration signal processing system as described above, comprising the steps of:
s1, establishing a vibration signal processing system to realize communication connection among modules and units;
s2, defining the general data format and plug-in structure in the system through the format definition unit;
s3, the vibration data storage unit acquires original vibration data from the vibration signal acquisition sensor and stores the original vibration data in a file form;
s4, selecting a vibration data file list to be analyzed through a plug-in combination setting unit, combining plug-in units, setting processing parameters of each plug-in unit, and sending the vibration data file list, the plug-in unit combination result and the processing parameter setting result to the background data processing module;
s5, after the background data processing module obtains the vibration data file list and the plug-in unit combination result, processing the data according to the set processing parameters to obtain a result data array, and then feeding the result data array back to the result display unit;
and S6, the result display unit displays all data to be displayed in the form of graphs and tables, and a vibration analyst can perform fault diagnosis according to the display result.
Preferably, S5 includes the steps of:
s51, reading the original vibration data in the vibration signal acquisition sensor according to analysis requirements by a vibration data reading unit, converting the read original vibration data into time domain original data conforming to a general data format in a system, and then forwarding the data;
s52, the background data processing module reads the plug-in unit combination result and the processing parameter setting result in the plug-in combination setting unit, and calls the plug-in units one by one in sequence to process data;
s53, the plug-in unit obtains processing parameters, sets plug-in information according to the processing parameters, and judges whether the current plug-in has a preorder plug-in, if so, the output data of the preorder plug-in is used as the input data of the current plug-in, and if not, the time domain original data is used as the input data of the current plug-in;
s54, the plug-in unit processes the input data according to the data processing method corresponding to the plug-in stored in the plug-in unit;
s55, judging whether the output of the current plug-in unit needs to be displayed or not, if so, adding the output data of the current plug-in unit into a result data array, otherwise, defaulting that the processing of the current plug-in unit is finished and jumping to S56;
s56, judging whether the current plug-in unit is the last plug-in unit, if so, jumping to S57, if not, entering the processing flow of the next plug-in unit, and repeating S53 to S55;
and S57, after the processing flow of the last plug-in unit is finished, the result sending unit packs the result data array in a general data format in the system and sends the result data array to the result display unit.
Compared with the prior art, the advantages of the invention comprise the following aspects:
according to the vibration signal processing system and the corresponding processing method provided by the invention, diversified combinations of various vibration analysis methods are realized through the application of the plug-in unit, the problems of limited functions, fixed operation and the like of the conventional vibration analysis instrument or analysis software are effectively solved, and the accuracy and reliability of the final vibration analysis result are remarkably improved.
In the practical application process of the invention, a vibration analyst can flexibly combine various signal analysis methods and apply the signal analysis methods to data processing without using software knowledge such as Matlab, Labview and the like for coding, and can realize the combination of any plug-in unit only by simple operation during operation.
In the vibration signal processing system, except the last plug-in unit in the processing flow, any plug-in unit can select whether to output result data, and a vibration analyst can determine which plug-in units to display the output results according to actual operation requirements, so that the subsequent analysis process is facilitated, and the system has personalized and customized functions. Meanwhile, the vibration signal processing system can increase and decrease the number of the plug-in units at will, and the plug-in units can also be flexibly expanded and continuously update the analysis method, so that the compatibility of the system is further improved, and the application range of the vibration signal processing system is expanded.
In addition, the invention also provides reference for other related problems in the same field, can be expanded and extended on the basis of the reference, is applied to other technical schemes related to vibration analysis in the same field, and has very wide application prospect.
The following detailed description of the embodiments of the present invention is provided in connection with the accompanying drawings for the purpose of facilitating understanding and understanding of the technical solutions of the present invention.
Drawings
FIG. 1 is a schematic overall topology of the system of the present invention;
FIG. 2 is a schematic flow chart of S5 in the method of the present invention;
FIG. 3 is a schematic flow chart of vibration analysis of a reduction gearbox using the method of the present invention.
Detailed Description
The processing process of the vibration signal processing system and the corresponding processing method provided by the invention is similar to that of audio and video editing software, namely, a vibration analyst can add all or part of original vibration data to one or more plug-in units containing the analysis method. It is understood that in this scheme, a data processing method is referred to as a plug-in, and a plurality of plug-ins are connected in series in a chain. The system reads information such as parameters and input data in each plug-in one by one from beginning to end, and then calls a corresponding data processing method to process the data, so as to finally obtain a complete data analysis result.
Specifically, as shown in fig. 1, the vibration signal processing system includes:
the vibration signal acquisition sensors are fixedly arranged on the mechanical equipment and used for monitoring and acquiring operation data of the mechanical equipment in real time and generating original vibration data;
the background data processing module is used for acquiring original vibration data generated by the vibration signal acquisition sensor, performing vibration analysis on the original vibration data according to a data processing method stored in the background data processing module, generating a vibration analysis result and issuing the vibration analysis result;
and the foreground data processing module is used for receiving and displaying the vibration analysis result from the background data processing module and finishing data interaction with the background data processing module.
The background data processing module comprises:
the vibration data storage unit is used for receiving the original vibration data from the vibration signal acquisition sensor and storing the data in a file form;
the plurality of plug-in units are connected with the vibration data storage unit, are connected in series in a chain mode and are used for recording and executing a data processing method and generating a result data array, a plug-in is stored in each plug-in unit, and each plug-in corresponds to one data processing method;
and the result sending unit is connected with the plug-in unit and used for collecting all result data arrays generated by the plug-in unit, packing the result data arrays and selectively sending the result data arrays to the foreground data processing module.
The foreground data processing module comprises:
the plug-in combination setting unit is connected with the vibration data storage unit and the plug-in unit and is used for selecting and combining the plug-in units according to requirements, setting processing parameters of each plug-in combination and sending a vibration data file list, a plug-in unit combination result and a processing parameter setting result to the background data processing module;
and the result display unit is connected with the result sending unit and used for receiving and displaying the result data array from the result sending unit.
The background data processing module further comprises:
the vibration data reading unit is respectively connected with the vibration signal acquisition sensor and the vibration data storage unit and is used for reading original vibration data in the vibration signal acquisition sensor according to analysis requirements, converting the read original vibration data into time domain original data and then forwarding the time domain original data;
and the format definition unit is respectively connected with the vibration data reading unit, the plug-in unit and the foreground data processing module and is used for defining a universal data format and a plug-in structure in the system.
The format definition unit includes:
the data format definition subunit is used for defining a universal data format in the system, and the data format comprises vibration time domain data, vibration frequency domain data and dimensional parameters or dimensionless parameters calculated by the plug-in unit;
the plug-in structure defines a subunit and is used for defining a universal plug-in structure in the system, wherein the plug-in structure comprises a plug-in name, an input and output data array, a data processing method, a processing parameter, a preorder plug-in name and whether to display and output.
Each of the input and output data arrays herein contains one or more data that conforms to a common data format within the system.
The data format comprises a data name, a data length, an X-axis data array, an X-axis data unit, a Y-axis data array, a Y-axis data unit and the like.
Each of the plug-in units includes:
the parameter analysis subunit is connected with the plug-in combination setting unit and used for analyzing the processing parameters, converting the processing parameters into data meeting the plug-in execution requirement and forwarding the data;
the plug-in execution subunit is connected with the parameter analysis subunit and is used for storing and recording the data processing method, processing the data according to the data processing method and generating a result data array,
it should be noted that the data processing method in the plug-in execution subunit includes high-pass filtering, low-pass filtering, band-pass filtering, integration, FFT transformation, Hilbert transformation, wavelet de-noising, autocorrelation, real cepstrum, refined spectrum, order analysis, and the like.
The plug-in combination setting unit includes:
the data selection subunit is used for displaying all the plug-in units, selecting and extracting one or more original vibration data and time domain original data corresponding to the plug-in units from the vibration data storage unit according to analysis requirements, generating a vibration data file list and sending the vibration data file list;
the plug-in combination subunit is used for selecting the corresponding plug-in units according to the analysis requirement to carry out combination and setting the processing parameter of each plug-in unit;
and the setting and sending subunit is respectively connected with the data selecting subunit and the plug-in unit combination subunit and is used for sending the vibration data file list, the plug-in unit combination result and the processing parameter setting result to the background data processing module.
The result display unit includes:
the graph display subunit is used for displaying the analysis processing result in the form of a graph, wherein the graph comprises a time domain graph, an amplitude spectrum, a power spectrum, an envelope spectrum, an order spectrum, an autocorrelation spectrum, a wavelet analysis, a real cepstrum, a refined spectrum, a waterfall graph and the like;
and the parameter display subunit is used for displaying the dimensional parameters or the dimensionless parameters calculated by the plug-in unit in a form of a table, wherein the dimensional parameters or the dimensionless parameters comprise peak values, mean values, effective values, kurtosis and the like.
In the practical application process of the vibration signal processing system, a vibration analyst can flexibly combine various signal analysis methods and apply the signal analysis methods to data processing without coding by using software knowledge such as Matlab, Labview and the like, and can realize the combination of any plug-in unit only by simple operation during operation.
Meanwhile, in the vibration signal processing system, any plug-in unit can select whether to output result data or not except the last plug-in unit in the processing flow, and a vibration analyst can determine which plug-in units to display the output results according to actual operation requirements, so that the subsequent analysis process is facilitated, and the system has personalized and customized functions. Meanwhile, the vibration signal processing system can increase and decrease the number of the plug-in units at will, and the plug-in units can also be flexibly expanded and continuously update the analysis method, so that the compatibility of the system is further improved, and the application range of the vibration signal processing system is expanded.
A vibration signal processing method using the vibration signal processing system as described above, comprising the steps of:
s1, establishing a vibration signal processing system to realize communication connection among modules and units;
s2, defining the general data format and plug-in structure in the system through the format definition unit;
s3, the vibration data storage unit acquires original vibration data from the vibration signal acquisition sensor and stores the original vibration data in a file form;
s4, selecting a vibration data file list to be analyzed through a plug-in combination setting unit, combining plug-in units, setting processing parameters of each plug-in unit, and sending the vibration data file list, the plug-in unit combination result and the processing parameter setting result to the background data processing module;
s5, after the background data processing module obtains the vibration data file list and the plug-in unit combination result, processing the data according to the set processing parameters to obtain a result data array, and then feeding the result data array back to the result display unit;
and S6, the result display unit displays all data to be displayed in the form of graphs and tables, and a vibration analyst can perform fault diagnosis according to the display result.
In the above flow, S5 specifically includes the following steps:
s51, reading the original vibration data in the vibration signal acquisition sensor according to analysis requirements by a vibration data reading unit, converting the read original vibration data into time domain original data conforming to a general data format in a system, and then forwarding the data;
s52, the background data processing module reads the plug-in unit combination result and the processing parameter setting result in the plug-in combination setting unit, and calls the plug-in units one by one in sequence to process data;
s53, the plug-in unit obtains processing parameters, sets plug-in information according to the processing parameters, and judges whether the current plug-in has a preorder plug-in, if so, the output data of the preorder plug-in is used as the input data of the current plug-in, and if not, the time domain original data is used as the input data of the current plug-in;
s54, the plug-in unit processes the input data according to the data processing method corresponding to the plug-in stored in the plug-in unit;
s55, judging whether the output of the current plug-in unit needs to be displayed or not, if so, adding the output data of the current plug-in unit into a result data array, otherwise, defaulting that the processing of the current plug-in unit is finished and jumping to S56;
s56, judging whether the current plug-in unit is the last plug-in unit, if so, jumping to S57, if not, entering the processing flow of the next plug-in unit, and repeating S53 to S55;
and S57, after the processing flow of the last plug-in unit is finished, the result sending unit packs the result data array in a general data format in the system and sends the result data array to the result display unit.
For the above technical solution, it should be added that both the processing parameters and the result data array may be stored in a format other than json format, and the above solution is only a preferred solution.
The system architecture and processing of the present invention will be described in detail below with reference to the vibration analysis process of the reduction gearbox as an example.
A reduction gearbox is a mechanical component widely used in rotary mechanical equipment, and is not only a key component in the equipment but also one of the most vulnerable components. Generally, common reduction gearbox faults mainly include faults of bearings, gears, shafts and the like, and when vibration analysis and fault diagnosis are performed on a reduction gearbox, the adopted analysis methods are different for faults in different aspects. The analysis and diagnosis of the bearing faults generally adopt an envelope spectrum method, namely Hilbert transformation is firstly carried out, then FFT is carried out, and finally the analysis is carried out by searching the characteristic frequency amplitude of the bearing parts. The analysis and diagnosis of the gear type faults are carried out in a mode of directly carrying out FFT (fast Fourier transform), then observing the frequency multiplication meshing frequency of the gear and the amplitude of a sideband thereof, and the analysis and diagnosis of the shaft type faults also need to carry out FFT, then observe amplitudes of 1/2, 2 frequency multiplication and the like of the rotating speed and then carry out deep analysis.
When the reduction box analysis is carried out by using the traditional vibration analysis software or instrument, the envelope spectrum analysis of the bearing and the amplitude spectrum analysis of the gear and the shaft are generally carried out separately and relatively independently. And if filtering or wavelet denoising is required to be firstly carried out during envelope spectrum and amplitude spectrum analysis, and then selection is required to be carried out during envelope spectrum or amplitude spectrum analysis respectively, correspondingly, software carries out corresponding algorithm processing firstly and then carries out envelope spectrum or amplitude spectrum calculation during analysis.
If the system and the method are used for carrying out vibration analysis on the reduction gearbox, all operations can be carried out only by one-time operation and operation under the same page, the whole operation process is convenient and fast, and different methods can be compared.
When the vibration signal processing system and the processing method of the invention carry out vibration analysis on the reduction gearbox, the specific technical scheme is as follows:
the system comprises a plurality of vibration signal acquisition sensors, wherein the vibration signal acquisition sensors are fixedly arranged on a reduction gearbox of the mechanical equipment and can acquire original vibration data of the reduction gearbox;
the user selects plug-in combinations for vibration analysis, namely, two paths of analysis combinations of low-pass filtering → FFT → result and low-pass filtering → Hilbert transform → FFT → result, on the foreground analysis page according to the diagram shown in FIG. 3, and sets related parameters for each plug-in unit.
A background data processing module in the system firstly reads original vibration data and then calculates and processes vibration signals according to the plug-in combination. The background data processing module specifically comprises a background data processing module,
the first plug-in unit, i.e. the low pass filter plug-in unit. And the parameter analysis subunit reads the parameters of the low-pass filter plug-in the low-pass filter plug-in unit, wherein the parameters are mainly cut-off frequencies, and then, the original vibration time domain data is used as input parameters, the low-pass filter plug-in is called to process, and the filtered time domain data is generated and is used as output. Since the low-pass filtered pattern generally need not be shown, the output parameters of the low-pass filtering are not added to the result data array here.
And a second plug-in unit, namely a wavelet denoising plug-in unit. The parameter analysis subunit reads the parameters of the wavelet denoising plug-in unit in the wavelet denoising plug-in unit, and because the pre-order plug-in of the wavelet denoising plug-in is a low-pass filtering plug-in, the output data of the low-pass filtering is used as the input data of the wavelet denoising plug-in, and the time domain data after denoising is generated after the wavelet denoising algorithm is called and is used as the output. The graph after wavelet de-noising can be determined whether to be displayed according to the needs of a user, and if the graph needs to be displayed, the calculation result of wavelet de-noising is added into the result data array; if not, then not join.
And the third plug-in unit, namely an FFT plug-in unit, the parameter analysis subunit reads the parameters of the FFT plug-in the FFT plug-in unit, wherein the preorder plug-in of the FFT plug-in unit is a wavelet de-noising plug-in, so that the output data of the wavelet de-noising is used as the input data of the FFT plug-in, and the amplitude spectrum data generated after the FFT transformation is called as the output. The magnitude spectrum of the FFT needs to be used for final analysis, and therefore, the calculation result of the FFT needs to be added to the result data array.
And the parameter analysis subunit reads the parameters of the Hilbert plug-in unit in the Hilbert plug-in unit, and the preorder plug-in of the Hilbert plug-in is a wavelet denoising plug-in, so that output data of wavelet denoising is used as input data of the Hilbert plug-in, and envelope time domain data is generated as output after Hilbert transformation is called. The Hilbert envelope graph can determine whether to display according to the needs of a user, and if the Hilbert envelope graph needs to be displayed, the calculation result of wavelet denoising is added into a result data array; if not, then not join.
And the fifth plug-in unit is also an FFT plug-in unit, the parameter analysis subunit reads the parameters of the FFT plug-in the FFT plug-in unit, and the preamble plug-in of the FFT plug-in unit is a Hilbert plug-in, so that the output data of the Hilbert plug-in is used as the input data of the FFT plug-in, and the amplitude spectrum data generated after the FFT is called is used as the output. Similarly, the FFT magnitude spectrum is needed for final analysis, so the FFT computation result is added to the result data array.
The five plug-in units are connected in a chain mode.
And finally, the background data processing module outputs the result data array to the foreground data processing module, and the result display unit displays the data. Therefore, a user can simultaneously check the amplitude spectrum of the direct FFT and the envelope spectrum after Hilbert transformation in one page, and the faults of the bearing, the gear and the shaft of the reduction gearbox are flexibly and intuitively analyzed.
It can be seen from the above embodiments that the present invention can flexibly perform a plug-in combination according to the user's needs to perform one or more analyses on the vibration data, and finally obtain the analysis result. In the scheme, the analysis of the amplitude spectrum and the envelope spectrum is carried out in one page, and the two analysis methods share the low-pass filtering and the wavelet denoising plug-in, so that the defect that the traditional vibration analysis software and instrument possibly need to carry out repeated calculation twice is avoided, the calculation resources are greatly saved, the analysis efficiency is improved, in addition, each plug-in the system can determine whether to output data for display according to the requirements of users, and the system is very flexible and convenient.
In summary, the vibration signal processing system and the corresponding processing method provided by the invention realize diversified combinations of multiple vibration analysis methods through the application of the plug-in unit, thereby not only effectively solving the problems of limited functions, fixed operation and the like of the existing vibration analysis instrument or analysis software, but also remarkably improving the accuracy and reliability of the final vibration analysis result.
In addition, the invention also provides reference for other related problems in the same field, can be expanded and extended on the basis of the reference, is applied to other technical schemes related to vibration analysis in the same field, and has very wide application prospect.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein, and any reference signs in the claims are not intended to be construed as limiting the claim concerned.
Furthermore, it should be understood that although the present description refers to embodiments, not every embodiment may contain only a single embodiment, and such description is for clarity only, and those skilled in the art should integrate the description, and the embodiments may be combined as appropriate to form other embodiments understood by those skilled in the art.
Claims (5)
1. A vibration signal processing system, comprising:
the vibration signal acquisition sensors are fixedly arranged on the mechanical equipment and used for monitoring and acquiring operation data of the mechanical equipment in real time and generating original vibration data;
the background data processing module is used for acquiring original vibration data generated by the vibration signal acquisition sensor, performing vibration analysis on the original vibration data according to a data processing method stored in the background data processing module, generating a vibration analysis result and issuing the vibration analysis result;
the foreground data processing module is used for receiving and displaying the vibration analysis result from the background data processing module and finishing data interaction with the background data processing module;
the background data processing module comprises a background data processing module,
a vibration data storage unit for receiving the raw vibration data from the vibration signal acquisition sensor and storing the data in a file form,
a plurality of plug-in units which are connected with the vibration data storage unit and are connected in series in a chain mode for recording and executing a data processing method and generating a result data array, wherein each plug-in unit stores a plug-in, and each plug-in corresponds to a data processing method,
the result sending unit is connected with the plug-in unit and used for collecting all result data arrays generated by the plug-in unit, packaging the result data arrays and selectively sending the result data arrays to the foreground data processing module;
the background data processing module also comprises a background data processing module,
the vibration data reading unit is respectively connected with the vibration signal acquisition sensor and the vibration data storage unit and is used for reading original vibration data in the vibration signal acquisition sensor according to analysis requirements, converting the read original vibration data into time domain original data and then forwarding the time domain original data;
the foreground data processing module comprises a front-end data processing module,
a plug-in combination setting unit connected with the vibration data storage unit and the plug-in unit and used for selecting and combining the plug-in units according to the requirements, setting the processing parameters of each plug-in unit, sending a vibration data file list, a plug-in unit combination result and a processing parameter setting result to the background data processing module,
the result display unit is connected with the result sending unit and used for receiving and displaying the result data array from the result sending unit;
the format definition unit is respectively connected with the vibration data reading unit, the plug-in unit and the foreground data processing module and is used for defining a universal data format and a plug-in structure in the system;
the format definition unit includes a format definition unit including,
the data format definition subunit is used for defining a universal data format in the system, and the data format comprises vibration time domain data, vibration frequency domain data and dimensional parameters or dimensionless parameters calculated by the plug-in unit;
the system comprises a plug-in structure definition subunit, a data processing unit and a data processing unit, wherein the plug-in structure definition subunit is used for defining a universal plug-in structure in the system, the plug-in structure comprises a plug-in name, an input and output data array, a data processing method, a processing parameter, a preorder plug-in name and whether to display output, and each input and output data array comprises one or more data conforming to a universal data format in the system;
each of the plug-in units includes,
the parameter analysis subunit is connected with the plug-in combination setting unit and used for analyzing the processing parameters, converting the processing parameters into data meeting the plug-in execution requirement and forwarding the data;
the plug-in execution subunit is connected with the parameter analysis subunit and is used for storing and recording a data processing method, processing data according to the data processing method and generating a result data array;
the plug-in combination setting unit includes:
the data selection subunit is used for displaying all the plug-in units, selecting and extracting one or more original vibration data and time domain original data corresponding to the plug-in units from the vibration data storage unit according to analysis requirements, generating a vibration data file list and sending the vibration data file list;
the plug-in combination subunit is used for selecting the corresponding plug-in units according to the analysis requirement to carry out combination and setting the processing parameter of each plug-in unit;
the setting and sending subunit is respectively connected with the data selecting subunit and the plug-in unit combination subunit and is used for sending the vibration data file list, the plug-in unit combination result and the processing parameter setting result to the background data processing module;
the result display unit includes:
the graph display subunit is used for displaying the analysis processing result in the form of a graph, wherein the graph comprises a time domain graph, an amplitude spectrum, a power spectrum, an envelope spectrum, an order spectrum, an autocorrelation spectrum, a wavelet analysis, a real cepstrum, a refined spectrum and a waterfall graph;
and the parameter display subunit is used for displaying the dimensional parameters or the dimensionless parameters calculated by the plug-in unit in a form of a table, wherein the dimensional parameters or the dimensionless parameters comprise peak values, mean values, effective values and kurtosis.
2. The vibration signal processing system of claim 1 wherein the data format comprises: data name, data length, X-axis data array, X-axis data unit, Y-axis data array, and Y-axis data unit.
3. The vibration signal processing system according to claim 1, wherein the plug-in execution subunit performs a data processing method including: high pass filtering, low pass filtering, band pass filtering, integration, FFT transformation, Hilbert transformation, wavelet de-noising, auto-correlation, real cepstrum, refined spectrum, and order analysis.
4. A vibration signal processing method using the vibration signal processing system according to any one of claims 1 to 3, comprising the steps of:
s1, establishing a vibration signal processing system to realize communication connection among modules and units;
s2, defining the general data format and plug-in structure in the system through the format definition unit;
s3, the vibration data storage unit acquires original vibration data from the vibration signal acquisition sensor and stores the original vibration data in a file form;
s4, selecting a vibration data file list to be analyzed through a plug-in combination setting unit, combining plug-in units, setting processing parameters of each plug-in unit, and sending the vibration data file list, the plug-in unit combination result and the processing parameter setting result to the background data processing module;
s5, after the background data processing module obtains the vibration data file list and the plug-in unit combination result, processing the data according to the set processing parameters to obtain a result data array, and then feeding the result data array back to the result display unit;
and S6, the result display unit displays all data to be displayed in the form of graphs and tables, and a vibration analyst can perform fault diagnosis according to the display result.
5. The vibration signal processing method according to claim 4, wherein S5 includes the steps of:
s51, reading the original vibration data in the vibration signal acquisition sensor according to analysis requirements by a vibration data reading unit, converting the read original vibration data into time domain original data conforming to a general data format in a system, and then forwarding the data;
s52, the background data processing module reads the plug-in unit combination result and the processing parameter setting result in the plug-in combination setting unit, and calls the plug-in units one by one in sequence to process data;
s53, the plug-in unit obtains processing parameters, sets plug-in information according to the processing parameters, and judges whether the current plug-in has a preorder plug-in, if so, the output data of the preorder plug-in is used as the input data of the current plug-in, and if not, the time domain original data is used as the input data of the current plug-in;
s54, the plug-in unit processes the input data according to the data processing method corresponding to the plug-in stored in the plug-in unit;
s55, judging whether the output of the current plug-in unit needs to be displayed or not, if so, adding the output data of the current plug-in unit into a result data array, otherwise, defaulting that the processing of the current plug-in unit is finished and jumping to S56;
s56, judging whether the current plug-in unit is the last plug-in unit, if so, jumping to S57, if not, entering the processing flow of the next plug-in unit, and repeating S53 to S55;
and S57, after the processing flow of the last plug-in unit is finished, the result sending unit packs the result data array in a general data format in the system and sends the result data array to the result display unit.
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