CN110657989A - Method and system for monitoring vibration state of tobacco packaging unit - Google Patents
Method and system for monitoring vibration state of tobacco packaging unit Download PDFInfo
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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
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Abstract
The invention provides a method and a system for monitoring the vibration state of a tobacco packaging unit, wherein the method comprises the following steps: arranging an acceleration vibration sensor at a preset position of the tobacco packaging machine to acquire a vibration signal of a rolling bearing; acquiring the rotating frequency of the rolling bearing to be tested, and performing frequency spectrum analysis and envelope spectrum analysis according to the vibration signal to obtain the main vibration frequency of the rolling bearing; and comparing the main vibration frequency with the rotation frequency of the rolling bearing to be tested, if the main vibration frequency is within the set threshold range of the rotation frequency, judging that the rolling bearing to be tested is in a normal state, and if not, judging that the rolling bearing to be tested is in a fault state. The invention can solve the problems that the bearing fault diagnosis of the existing tobacco packaging machine is not timely, and the maintenance cost of the equipment is high, can reduce the maintenance cost of the equipment, and improves the safety of the equipment.
Description
Technical Field
The invention relates to the technical field of tobacco packaging machinery, in particular to a method and a system for monitoring the vibration state of a tobacco packaging unit.
Background
The tobacco packing machine is an important device in the cigarette packing workshop of tobacco industry enterprises, and the cigarette equipment generally comprises a small box packing machine, a cellophane small bag packing machine, a strip pack (box) packing machine, a cellophane strip pack packing machine and the like. The tobacco packaging machine is a result of comprehensive application of advanced technologies such as variable-frequency speed regulation, photoelectric detection, quality monitoring, modular structural design, video display, mechanical arm and the like, has higher automation degree and higher packaging speed and quality, and can meet different packaging requirements. In a packaging unit, a plurality of important core components are rolling bearings, which are key components of a plurality of rotating machines and are called joints of the machines. Under extreme environment, the rotating machine is influenced by various factors, is a part with the worst reliability in the whole rotating mechanical system, becomes a 'short water bucket plate', and directly influences the operational reliability of the whole mechanical equipment. When a rolling bearing is operated, the performance of the rolling bearing generally gradually declines from a normal state until the rolling bearing is completely damaged. If the performance degradation degree of the bearing can be detected through vibration monitoring in the bearing damage process, the traditional timing or after-repair can be changed into the condition-based repair, and the active maintenance of the bearing is realized. Therefore, how to realize real-time evaluation of equipment by monitoring the vibration state of the rolling bearing of the tobacco packaging machine and furthest utilize the vibration of the bearing to carry out fault diagnosis so as to reduce the maintenance and guarantee cost and avoid further accidents and huge loss.
Disclosure of Invention
The invention provides a method and a system for monitoring the vibration state of a tobacco packaging unit, which solve the problems that the bearing fault diagnosis of the conventional tobacco packaging machine is not timely, and the maintenance cost of equipment is high, can reduce the maintenance cost of the equipment, and improve the safety of the equipment.
In order to achieve the above purpose, the invention provides the following technical scheme:
a method for monitoring the vibration state of a tobacco packaging unit comprises the following steps:
arranging an acceleration vibration sensor at a preset position of the tobacco packaging machine to acquire a vibration signal of a rolling bearing;
acquiring the rotating frequency of the rolling bearing to be tested, and performing frequency spectrum analysis and envelope spectrum analysis according to the vibration signal to obtain the main vibration frequency of the rolling bearing;
and comparing the main vibration frequency with the rotation frequency of the rolling bearing to be tested, if the main vibration frequency is within the set threshold range of the rotation frequency, judging that the rolling bearing to be tested is in a normal state, and if not, judging that the rolling bearing to be tested is in a fault state.
Preferably, the method further comprises the following steps:
decomposing the vibration signal based on an EEMD Hilbert spectrum time-frequency analysis method to obtain an IMF component, and screening the IMF component through Hilbert-yellow transformation to remove a false component and the IMF component insensitive to rolling bearing faults;
and performing signal reconstruction according to the screened IMF components to obtain a reconstruction signal, and performing state analysis on the rolling bearing to be tested by using the reconstruction signal.
Preferably, the method further comprises the following steps:
extracting vibration characteristic quantity according to the vibration signal or the reconstruction signal, and carrying out state analysis on the rolling bearing to be tested according to the vibration characteristic quantity, wherein the vibration characteristic quantity comprises: the peak value of the vibration acceleration, the effective value of the vibration speed, the kurtosis of the IMF component and the frequency.
Preferably, the method further comprises the following steps:
and establishing a bearing evaluation model according to the vibration characteristic quantity, and carrying out state analysis on the rolling bearing to be tested through the bearing evaluation model.
Preferably, the decomposition of the vibration signal by the EEMD-based Hilbert spectral time-frequency analysis method includes:
adding normal distribution white noise to the vibration signal, and decomposing the white noise-added signal through EEMD.
Preferably, the acceleration vibration sensor is arranged at a preset position of the tobacco packaging machine, and comprises:
the cigarette warehouse mould box driving driven wheel, the main motor flexible connector, the strip box packaging machine main transmission shaft, the downstream machine forming wheel and the downstream main motor of the tobacco packaging machine are arranged at corresponding positions.
The invention also provides a system for monitoring the vibration state of the tobacco packaging unit, which is characterized by comprising the following components:
the detection unit is used for arranging an acceleration vibration sensor at a preset position of the tobacco packaging machine so as to acquire a vibration signal of the rolling bearing;
the first signal processing unit is used for acquiring the rotating frequency of the rolling bearing to be tested, and carrying out frequency spectrum analysis and envelope spectrum analysis according to the vibration signal to obtain the main vibration frequency of the rolling bearing;
and the judging unit is used for comparing the main vibration frequency with the rotation frequency of the rolling bearing to be tested, judging that the rolling bearing to be tested is in a normal state if the main vibration frequency is within a set threshold range of the rotation frequency, and otherwise, judging that the rolling bearing to be tested is in a fault state.
Preferably, the method further comprises the following steps:
the second signal processing unit is used for decomposing the vibration signal based on a Hilbert spectrum time-frequency analysis method of the EEMD to obtain an IMF component, and screening the IMF component through Hilbert-yellow transformation to remove a false component and the IMF component insensitive to rolling bearing faults;
and the signal reconstruction unit is used for reconstructing a signal according to the screened IMF component to obtain a reconstruction signal and analyzing the state of the rolling bearing to be tested by using the reconstruction signal.
Preferably, the method further comprises the following steps:
the characteristic extraction unit is used for extracting vibration characteristic quantity according to the vibration signal or the reconstruction signal and analyzing the state of the rolling bearing to be tested according to the vibration characteristic quantity, and the vibration characteristic quantity comprises: the peak value of the vibration acceleration, the effective value of the vibration speed, the kurtosis of the IMF component and the frequency.
Preferably, the method further comprises the following steps:
and the bearing evaluation model unit is used for establishing a bearing evaluation model according to the vibration characteristic quantity and carrying out state analysis on the rolling bearing to be tested through the bearing evaluation model.
The invention provides a method and a system for monitoring the vibration state of a tobacco packaging unit. The problem of current tobacco packagine machine's bearing fault diagnosis untimely, easily cause the equipment maintenance cost high is solved, can reduce the cost of maintenance of equipment, improve the security of equipment.
Drawings
In order to more clearly describe the specific embodiments of the present invention, the drawings to be used in the embodiments will be briefly described below.
FIG. 1 is a flow chart of a method for monitoring the vibration state of a tobacco packaging machine set according to the present invention;
FIG. 2 is a flow chart of a method for monitoring the vibration state of a tobacco packaging machine set according to an embodiment of the present invention;
FIG. 3 is a time domain waveform diagram of a vibration signal provided by an embodiment;
FIG. 4 is a diagram illustrating an IMF component of the vibration signal obtained by EEMD decomposition according to the embodiment;
FIG. 5 is a diagram illustrating a reconstructed signal obtained after EEMD decomposition according to an embodiment.
Fig. 6 is a schematic view of a system for monitoring the vibration state of the tobacco packaging unit provided by the invention.
Detailed Description
In order to make the technical field of the invention better understand the scheme of the embodiment of the invention, the embodiment of the invention is further described in detail with reference to the drawings and the implementation mode.
Aiming at the problem that equipment maintenance cost is high due to the fact that fault diagnosis of a bearing is not timely when a current tobacco packing machine operates, the invention provides a method and a system for monitoring the vibration state of a tobacco packing machine set. The problem of current tobacco packagine machine's bearing fault diagnosis untimely, easily cause the equipment maintenance cost high is solved, can reduce the cost of maintenance of equipment, improve the security of equipment.
As shown in fig. 1, a method for monitoring the vibration state of a tobacco packaging machine set comprises the following steps:
s1: an acceleration vibration sensor is arranged at a preset position of the tobacco packaging machine so as to acquire a vibration signal of a rolling bearing.
S2: and acquiring the rotating frequency of the rolling bearing to be tested, and performing frequency spectrum analysis and envelope spectrum analysis according to the vibration signal to obtain the main vibration frequency of the rolling bearing.
S3: and comparing the main vibration frequency with the rotation frequency of the rolling bearing to be tested, if the main vibration frequency is within the set threshold range of the rotation frequency, judging that the rolling bearing to be tested is in a normal state, and if not, judging that the rolling bearing to be tested is in a fault state.
Specifically, the temperature of the bearing is detected by arranging a temperature sensor, the frequency conversion of the bearing of the detected component is calculated according to the collected vibration signal and temperature information and by combining the characteristics of a tobacco packing machine, the main vibration frequency of the bearing of the detected component is obtained by adopting a frequency spectrum analysis and spectrum enveloping method, and the vibration state of the bearing is preliminarily judged by utilizing information such as kurtosis, the main vibration frequency and the temperature. Meanwhile, the acceleration vibration sensor can be powered in a wired or wireless mode, data transmission is carried out by utilizing an enterprise internal wireless network, and the acquired data are automatically downloaded to a server to realize data acquisition. Because the tobacco packaging machine is high-speed operation equipment, the environment is complex, and the temperature in the equipment is high, the performance requirement and the installation position of the acceleration vibration sensor are strict.
As shown in fig. 2, the method further comprises:
s4: and decomposing the vibration signal by using a Hilbert spectrum time-frequency analysis method based on EEMD to obtain an IMF component, and screening the IMF component by using Hilbert-yellow transformation to remove a false component and the IMF component insensitive to the rolling bearing fault.
S5: and performing signal reconstruction according to the screened IMF components to obtain a reconstruction signal, and performing state analysis on the rolling bearing to be tested by using the reconstruction signal.
Specifically, aiming at the problem that an Intrinsic Mode Function (IMF) component obtained by decomposing a vibration signal of the rolling bearing based on an Ensemble Empirical Mode (EEMD) still contains a false component and an IMF component insensitive to the fault of the rolling bearing, an original signal is processed through Hilbert-Huang transform, and then the processed signal is screened to obtain a new reconstructed signal. Meanwhile, after empirical mode decomposition is integrated, signals can be analyzed by calculating the component kurtosis value of the eigenmode function. And the state of the bearing in the tested part can be comprehensively evaluated by utilizing marginal spectrum analysis and information such as a peak value of vibration acceleration, an effective value of vibration speed, a kurtosis value of the bearing and the like through the collected vibration data.
As shown in fig. 2, the method further comprises:
s6: extracting vibration characteristic quantity according to the vibration signal or the reconstruction signal, and carrying out state analysis on the rolling bearing to be tested according to the vibration characteristic quantity, wherein the vibration characteristic quantity comprises: the peak value of the vibration acceleration, the effective value of the vibration speed, the kurtosis of the IMF component and the frequency.
Specifically, the signals capable of representing the state characteristics are analyzed by extracting the vibration characteristic quantity of the vibration signals, or EEMD decomposition is performed on the signals to obtain eigenmode function components, screening is performed, and the screened signals are reconstructed.
As shown in fig. 2, the method further comprises:
s7: and establishing a bearing evaluation model according to the vibration characteristic quantity, and carrying out state analysis on the rolling bearing to be tested through the bearing evaluation model.
In practical application, through long-time monitoring, when the vibration monitoring and kurtosis value of the tobacco packaging machine set is lower than 3 and the temperature of the position of the bearing is lower than a critical value, the operation state of the bearing is good. And when the kurtosis value is lower than 3 and the temperature is lower than a critical value, the vibration monitoring and the state of the tobacco packaging unit are evaluated through a state evaluation model which is established by using the vibration intensity (evaluated by using a vibration speed effective value) as a reference quantity and marginal spectrum analysis.
Further, the decomposition of the vibration signal by the EEMD-based Hilbert spectral time-frequency analysis method includes: adding normal distribution white noise to the vibration signal, and decomposing the white noise-added signal through EEMD.
Specifically, the EEMD-based Hilbert spectrum time-frequency analysis method has the characteristics of high time and frequency resolution and modal aliasing resistance. And aiming at the selection problem of 2 important parameters of the noise amplitude and the set average times when EEMD decomposition is carried out, the criterion of adding white noise in the EEMD method is researched from the angle of energy standard deviation. The method comprises the steps of denoising a vibration signal by introducing a white noise mode, calculating a component kurtosis value of an eigenmode function after empirical mode decomposition is integrated, analyzing the signal and judging whether a bearing has a fault.
In practical application, set up acceleration vibration sensor at tobacco packaging machine's preset position, include: the cigarette warehouse mould box driving driven wheel, the main motor flexible connector, the strip box packaging machine main transmission shaft, the downstream machine forming wheel and the downstream main motor of the tobacco packaging machine are arranged at corresponding positions.
In one embodiment, the vibration state of the main transmission bearing of the packaging machine is monitored, signals (time domain waveforms) collected by the acceleration vibration sensor are shown in fig. 3, the sampling frequency is 4000HZ, and the sampling time is 10 s. When a rolling bearing is in fault, the damaged point periodically collides with other parts in the rotation process of the bearing, the vibration signal is expressed as a modulation characteristic, the acquired vibration signal not only contains modulation information, but also contains background signals and other noises related to the rotation speed, and the Hilbert spectrum time-frequency analysis method based on EEMD has the characteristics of high time and frequency resolution and modal aliasing resistance. Decomposing the signal by adopting the EEMD, and researching a criterion of adding white noise in the EEMD method from the angle of energy standard deviation aiming at the problem of selecting 2 important parameters of noise amplitude and set average times during EEMD decomposition. The IMF component is obtained by EEMD decomposition, and is shown in FIG. 4. Aiming at the problem that an Intrinsic Mode Function (IMF) obtained after the vibration signal of the rolling bearing is decomposed by the improved EEMD still contains a false component and an IMF component insensitive to the fault of the rolling bearing, the original signal is screened by the Hilbert-Huang transform to obtain a new reconstruction signal. Selecting IMF to reconstruct signal, and analyzing the reconstructed signal, the reconstructed signal is shown in FIG. 5.
Through practical empirical analysis, the conventional method of generally determining bearing failure is to listen to sound and touch temperature. However, in the early stage of bearing failure, slight abnormal sound is difficult to distinguish, and sudden rise phenomenon does not occur in temperature, so that bearing failure is difficult to find in time and accurately evaluate according to the traditional method. The bearing of the GDX2 packaging machine was measured in the examples and the measurement data are shown in table 1:
TABLE 1
Wherein A represents the peak value of the vibration acceleration of the bearing, V represents the effective value of the vibration speed, and Kur represents the kurtosis of the bearing.
Through data comparison, the vibration of the transmission bearing is in a normal level, the temperature does not exceed 55 ℃, the vibration frequency kurtosis value of the bearing is smaller than 3 or is close to 3, and therefore the fact that the bearings of all the machine tables are in a normal state can be obtained. Establishing a state evaluation model according to the reference quantity of an international standard ISO2372 vibration intensity table (evaluated by effective vibration speed values), and evaluating the bearing states of 7 existing packaging machines, wherein the bearing vibration intensities of the packaging machines are sorted: 0.9694>0.9330>0.6683>0.4483>0.4224>0.3701> 0.2967.
After measurement research is carried out on the bearings of the packaging machine, the evaluation of the bearings of the packaging machine is respectively the vibration intensity and the temperature of the bearings, and the following state evaluation model can be established by utilizing the characteristic quantity: f is 2.8/V +55/T, wherein V represents the vibration intensity of the bearing, and T represents the temperature. The operating state of the driving bearing of the GDX2 packaging machine can be evaluated through the established state evaluation model.
The invention provides a method for monitoring the vibration state of a tobacco packaging unit, which comprises the steps of detecting the vibration of a bearing of equipment through a vibration acceleration sensor, carrying out frequency spectrum analysis and envelope spectrum analysis on an acquired vibration signal to obtain the main vibration frequency of a rolling bearing, and diagnosing the state of the bearing according to the main vibration frequency. The problem of current tobacco packagine machine's bearing fault diagnosis untimely, easily cause the equipment maintenance cost high is solved, can reduce the cost of maintenance of equipment, improve the security of equipment.
As shown in fig. 6, the present invention further provides a system for monitoring the vibration state of a tobacco packaging machine set, comprising: and the detection unit is used for arranging an acceleration vibration sensor at a preset position of the tobacco packaging machine so as to acquire a vibration signal of the rolling bearing. And the first signal processing unit is used for acquiring the rotating frequency of the rolling bearing to be tested, and carrying out frequency spectrum analysis and envelope spectrum analysis according to the vibration signal so as to obtain the main vibration frequency of the rolling bearing. And the judging unit is used for comparing the main vibration frequency with the rotation frequency of the rolling bearing to be tested, judging that the rolling bearing to be tested is in a normal state if the main vibration frequency is within a set threshold range of the rotation frequency, and otherwise, judging that the rolling bearing to be tested is in a fault state.
Further, the system further comprises: and the second signal processing unit is used for decomposing the vibration signal based on a Hilbert spectrum time-frequency analysis method of the EEMD to obtain an IMF component, and screening the IMF component through Hilbert-yellow transformation to remove a false component and the IMF component insensitive to the rolling bearing fault. And the signal reconstruction unit is used for reconstructing a signal according to the screened IMF component to obtain a reconstruction signal and analyzing the state of the rolling bearing to be tested by using the reconstruction signal.
Still further, the system further comprises: the characteristic extraction unit is used for extracting vibration characteristic quantity according to the vibration signal or the reconstruction signal and analyzing the state of the rolling bearing to be tested according to the vibration characteristic quantity, and the vibration characteristic quantity comprises: the peak value of the vibration acceleration, the effective value of the vibration speed, the kurtosis of the IMF component and the frequency.
The system further comprises: and the bearing evaluation model unit is used for establishing a bearing evaluation model according to the vibration characteristic quantity and carrying out state analysis on the rolling bearing to be tested through the bearing evaluation model.
The invention provides a monitoring system for the vibration state of a tobacco packaging unit, which detects the vibration of a bearing of equipment through a vibration acceleration sensor, performs frequency spectrum analysis and envelope spectrum analysis on an acquired vibration signal to obtain the main vibration frequency of a rolling bearing, and then diagnoses the state of the bearing according to the main vibration frequency. The problem of current tobacco packagine machine's bearing fault diagnosis untimely, easily cause the equipment maintenance cost high is solved, can reduce the cost of maintenance of equipment, improve the security of equipment.
The construction, features and functions of the present invention have been described in detail with reference to the embodiments shown in the drawings, but the present invention is not limited to the embodiments shown in the drawings, and all equivalent embodiments modified or modified by the spirit and scope of the present invention should be protected without departing from the spirit of the present invention.
Claims (10)
1. A method for monitoring the vibration state of a tobacco packaging unit is characterized by comprising the following steps:
arranging an acceleration vibration sensor at a preset position of the tobacco packaging machine to acquire a vibration signal of a rolling bearing;
acquiring the rotating frequency of the rolling bearing to be tested, and performing frequency spectrum analysis and envelope spectrum analysis according to the vibration signal to obtain the main vibration frequency of the rolling bearing;
and comparing the main vibration frequency with the rotation frequency of the rolling bearing to be tested, if the main vibration frequency is within the set threshold range of the rotation frequency, judging that the rolling bearing to be tested is in a normal state, and if not, judging that the rolling bearing to be tested is in a fault state.
2. The method for monitoring the vibration state of a tobacco packaging unit as claimed in claim 1, further comprising:
decomposing the vibration signal based on an EEMD Hilbert spectrum time-frequency analysis method to obtain an IMF component, and screening the IMF component through Hilbert-yellow transformation to remove a false component and the IMF component insensitive to rolling bearing faults;
and performing signal reconstruction according to the screened IMF components to obtain a reconstruction signal, and performing state analysis on the rolling bearing to be tested by using the reconstruction signal.
3. The method for monitoring the vibration state of a tobacco packaging unit as claimed in claim 2, further comprising:
extracting vibration characteristic quantity according to the vibration signal or the reconstruction signal, and carrying out state analysis on the rolling bearing to be tested according to the vibration characteristic quantity, wherein the vibration characteristic quantity comprises: the peak value of the vibration acceleration, the effective value of the vibration speed, the kurtosis of the IMF component and the frequency.
4. The method for monitoring the vibration state of a tobacco packaging unit as claimed in claim 3, further comprising:
and establishing a bearing evaluation model according to the vibration characteristic quantity, and carrying out state analysis on the rolling bearing to be tested through the bearing evaluation model.
5. The method for monitoring the vibration state of the tobacco packaging unit as claimed in claim 4, wherein the decomposition of the vibration signal based on the EEMD Hilbert spectrum time-frequency analysis method comprises:
adding normal distribution white noise to the vibration signal, and decomposing the white noise-added signal through EEMD.
6. The method for monitoring the vibration state of the tobacco packaging unit as claimed in claim 1, wherein the step of arranging an acceleration vibration sensor at a preset position of the tobacco packaging machine comprises the following steps:
the cigarette warehouse mould box driving driven wheel, the main motor flexible connector, the strip box packaging machine main transmission shaft, the downstream machine forming wheel and the downstream main motor of the tobacco packaging machine are arranged at corresponding positions.
7. A system for monitoring the vibration status of a tobacco packaging unit, comprising:
the detection unit is used for arranging an acceleration vibration sensor at a preset position of the tobacco packaging machine so as to acquire a vibration signal of the rolling bearing;
the first signal processing unit is used for acquiring the rotating frequency of the rolling bearing to be tested, and carrying out frequency spectrum analysis and envelope spectrum analysis according to the vibration signal to obtain the main vibration frequency of the rolling bearing;
and the judging unit is used for comparing the main vibration frequency with the rotation frequency of the rolling bearing to be tested, judging that the rolling bearing to be tested is in a normal state if the main vibration frequency is within a set threshold range of the rotation frequency, and otherwise, judging that the rolling bearing to be tested is in a fault state.
8. The system for monitoring the vibration status of a tobacco packaging unit as set forth in claim 7, further comprising:
the second signal processing unit is used for decomposing the vibration signal based on a Hilbert spectrum time-frequency analysis method of the EEMD to obtain an IMF component, and screening the IMF component through Hilbert-yellow transformation to remove a false component and the IMF component insensitive to rolling bearing faults;
and the signal reconstruction unit is used for reconstructing a signal according to the screened IMF component to obtain a reconstruction signal and analyzing the state of the rolling bearing to be tested by using the reconstruction signal.
9. The system for monitoring the vibration status of a tobacco packaging unit as set forth in claim 8, further comprising:
the characteristic extraction unit is used for extracting vibration characteristic quantity according to the vibration signal or the reconstruction signal and analyzing the state of the rolling bearing to be tested according to the vibration characteristic quantity, and the vibration characteristic quantity comprises: the peak value of the vibration acceleration, the effective value of the vibration speed, the kurtosis of the IMF component and the frequency.
10. The system for monitoring the vibration state of a tobacco packaging unit as recited in claim 9, further comprising:
and the bearing evaluation model unit is used for establishing a bearing evaluation model according to the vibration characteristic quantity and carrying out state analysis on the rolling bearing to be tested through the bearing evaluation model.
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