CN111367260A - Fault diagnosis device and method for rotor unbalance - Google Patents
Fault diagnosis device and method for rotor unbalance Download PDFInfo
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- CN111367260A CN111367260A CN202010200495.8A CN202010200495A CN111367260A CN 111367260 A CN111367260 A CN 111367260A CN 202010200495 A CN202010200495 A CN 202010200495A CN 111367260 A CN111367260 A CN 111367260A
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- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
- G05B23/0221—Preprocessing measurements, e.g. data collection rate adjustment; Standardization of measurements; Time series or signal analysis, e.g. frequency analysis or wavelets; Trustworthiness of measurements; Indexes therefor; Measurements using easily measured parameters to estimate parameters difficult to measure; Virtual sensor creation; De-noising; Sensor fusion; Unconventional preprocessing inherently present in specific fault detection methods like PCA-based methods
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Abstract
The invention discloses a fault diagnosis device and a diagnosis method for rotor unbalance, wherein the fault diagnosis device for rotor unbalance comprises a sleeve frame, two distance sensors and a diagnosis terminal, the sleeve frame is a ring with a notch, the two distance sensors are symmetrically arranged on the sleeve frame, the diagnosis terminal is connected with the distance sensors, the diagnosis terminal stores a standard range of rotor curvature, and receives data of the distance sensors to judge whether the rotor curvature exceeds the standard range.
Description
Technical Field
The invention relates to the technical field of rotor fault diagnosis, in particular to a fault diagnosis device and a fault diagnosis method for rotor unbalance.
Background
A rotary machine is a machine that performs a main function by a rotational motion of a rotor, and it is necessary to have a most basic structure of parts such as a rotor and a bearing. A failure of a rotating machine is a functional failure of the machine, i.e. its dynamic performance deteriorates, not complying with the technical requirements. For example, the machine is running unstably or the rotor is unbalanced. The method for diagnosing the rotor imbalance fault of the rotary machine is to judge the rotor imbalance of the rotary machine, and means that the rotor is influenced by various factors in material quality, processing, assembly and operation, a certain amount of eccentricity exists between a mass center and a rotating center line, or the rotor is bent. The conventional fault diagnosis device for the rotary machine is designed more traditionally, and fault diagnosis can not be carried out according to the bending degree of a rotor, so that the diagnosis process is not targeted, and the maintenance time is missed.
Disclosure of Invention
This section is for the purpose of summarizing some aspects of embodiments of the invention and to briefly introduce some preferred embodiments. In this section, as well as in the abstract and the title of the invention of this application, simplifications or omissions may be made to avoid obscuring the purpose of the section, the abstract and the title, and such simplifications or omissions are not intended to limit the scope of the invention.
The present invention has been made in view of the above-mentioned problem that the conventional failure diagnosis device cannot diagnose the failure of the rotor with respect to the degree of bending thereof, and therefore the diagnosis process is not targeted.
Therefore, an object of the present invention is to provide a device and a method for diagnosing a rotor imbalance fault, which are specifically installed at a rotor of a rotary machine, coaxially installed around the rotor, and can diagnose and monitor a bending degree of the rotor in a targeted manner, so as to quickly diagnose the rotor imbalance fault.
In order to solve the technical problems, the invention provides the following technical scheme: the device for diagnosing the unbalanced rotor fault comprises a sleeve frame, two distance sensors and a diagnosis terminal, wherein the sleeve frame is a ring with a notch, the two distance sensors are symmetrically arranged on the sleeve frame, the diagnosis terminal is connected with the distance sensors, the standard range of the curvature of the rotor is stored in the diagnosis terminal, and the diagnosis terminal receives data of the distance sensors and judges whether the curvature of the rotor exceeds the standard range.
As a preferable aspect of the fault diagnosis device of the rotor unbalance of the present invention, wherein: the sleeve frame comprises a sleeve frame I and a sleeve frame II, the sleeve frame I and the sleeve frame II are both of semicircular tubular structures, the size of the sleeve frame I is the same as that of the sleeve frame II, and the sleeve frame I and the sleeve frame II are spliced into the sleeve frame.
As a preferable aspect of the fault diagnosis device of the rotor unbalance of the present invention, wherein: and the two distance sensors are respectively arranged on the first sleeve frame and the second sleeve frame, and are arranged in the middle of the first sleeve frame and the second sleeve frame.
As a preferable aspect of the fault diagnosis device of the rotor unbalance of the present invention, wherein: the hinge is passed through to one of them one end of cover frame one and cover frame two and is linked to each other, the other end absorption of cover frame one and cover frame two is in the same place, the equal relative access board of installing of the other end of cover frame one and cover frame two, the access board is parallel with the center pin of cover frame, just install the suction disc on the access board of cover frame one.
As a preferable aspect of the fault diagnosis device of the rotor unbalance of the present invention, wherein: the mounting plates are arranged at the side end parts, far away from the butt strap, of the first sleeve frame and the second sleeve frame, the two mounting plates are located on the same plane, the mounting plates are perpendicular to the butt strap, and the mounting plates are parallel to the central shaft of the sleeve frame.
As a preferable aspect of the fault diagnosis device of the rotor unbalance of the present invention, wherein: and the mounting plate is also provided with a plurality of mounting holes.
As a preferable aspect of the fault diagnosis device of the rotor unbalance of the present invention, wherein: the first sleeve frame, the second sleeve frame, the butt strap and the mounting plate are made of stainless steel materials, and the suction plate is made of magnet materials.
As a preferable aspect of the fault diagnosis device of the rotor unbalance of the present invention, wherein: the diagnosis terminal is a computer and comprises a signal amplifier, a data acquisition card and a diagnosis module, wherein the signal amplifier is used for amplifying received measurement data of the distance sensor, the data acquisition card is used for setting data acquisition parameters and receiving data of the signal amplifier, and the diagnosis module is used for judging whether the measurement data exceeds the range.
A method of diagnosing the fault diagnosis apparatus of the rotor unbalance as described above is as follows:
data acquired by the distance sensor pass through a signal amplifier and are acquired by a data acquisition card in a diagnosis terminal, wherein the model ADA16-8/2(LPCI) of the data acquisition card is connected with 8 channels at a single end, and the precision is 16 bits;
the data acquisition is carried out by setting the sampling frequency, the storage channel, the display channel and the sampling point of the data acquisition card, and then the data is exported to a diagnosis module in a diagnosis terminal;
the diagnostic module stores a standard range of the curvature of the rotor, compares the standard range of the received data space, adds a wavelet transform fault diagnosis algorithm when obvious fault signal fluctuation occurs, denoises and judges the frequency and the range of the fault.
As a preferable aspect of the diagnosis method of the rotor unbalance failure diagnosis apparatus of the present invention, wherein: the wavelet transformation fault diagnosis algorithm converts an infinite-length trigonometric function base of Fourier transformation into a finite-length wavelet base which can be attenuated, and performs spectrum analysis and time domain analysis on the transformed wavelet base, so that the frequency can be obtained, and the time of the frequency can be positioned:
wherein α is a scale variable, α is inversely proportional to frequency, and τ is a time variable;
and (3) reconstructing an arbitrary f (t) function by using a group of wavelet basis functions to perform continuous wavelet transformation, wherein under the continuous wavelet transformation, a scale variable α and a time variable tau are continuously changed, and the method adopts a mathematical expression:
is provided with
Then
Called the continuous wavelet function, the continuous wavelet transform is defined as:
the analysis values of the formulas (1-1), (1-2) and (1-3) are graphically displayed, and the failure frequency range is judged by observing the peak value
The invention has the beneficial effects that: the device can be arranged at the rotor of the rotary machine through the sleeve frame, and the bending degree of the rotor can be diagnosed and monitored in a targeted manner through the real-time diagnosis of the distance diagnostor, so that the unbalanced fault of the rotor can be diagnosed quickly.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the description of the embodiments will be briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without inventive exercise. Wherein:
fig. 1 is a schematic view of the entire structure of a fault diagnosis apparatus for rotor unbalance according to the present invention.
Fig. 2 is a schematic side view of a fault diagnosis device for rotor imbalance according to the present invention.
Fig. 3 is a schematic diagram of signals after wavelet decomposition in the diagnosis method of the rotor imbalance fault diagnosis apparatus according to the present invention.
Fig. 4 is a schematic frequency spectrum diagram of a signal after wavelet decomposition in the diagnosis method of the rotor imbalance fault diagnosis apparatus of the present invention.
Detailed Description
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in detail below.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention, but the present invention may be practiced in other ways than those specifically described and will be readily apparent to those of ordinary skill in the art without departing from the spirit of the present invention, and therefore the present invention is not limited to the specific embodiments disclosed below.
Furthermore, reference herein to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one implementation of the invention. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments.
Furthermore, the present invention is described in detail with reference to the drawings, and in the detailed description of the embodiments of the present invention, the cross-sectional view illustrating the structure of the device is not enlarged partially according to the general scale for convenience of illustration, and the drawings are only exemplary and should not be construed as limiting the scope of the present invention. In addition, the three-dimensional dimensions of length, width and depth should be included in the actual fabrication.
Example 1
Referring to fig. 1, a first embodiment of the present invention provides a fault diagnosis device for rotor imbalance, which includes a housing 100, a distance sensor 200 and a diagnosis terminal 300, wherein the housing 100 is a circular ring with a gap, and the gap is mainly used to enable the housing 100 to be sleeved on a rotor of a rotating machine and coaxially installed around the rotor. Specifically, the sleeve frame 100 comprises a first sleeve frame 101 and a second sleeve frame 102, the first sleeve frame 101 and the second sleeve frame 102 are both in a semicircular tubular structure, the first sleeve frame 101 and the second sleeve frame 102 are identical in size, and the first sleeve frame 101 and the second sleeve frame 102 are oppositely spliced to form the sleeve frame 100. One end of the first sleeve frame 101 is connected with one end of the second sleeve frame 102 through a hinge 103, the other ends of the first sleeve frame 101 and the second sleeve frame 102 are adsorbed together to form a gap, the other ends of the first sleeve frame 101 and the second sleeve frame 102 are both oppositely provided with an attachment strap 104, the attachment strap 104 is parallel to the central shaft of the sleeve frame 100, the attachment strap 104 of the first sleeve frame 101 is provided with a suction plate 105, and the suction plate 105 can adsorb the attachment strap 104 on the second sleeve frame 102.
In the invention, the first sleeve frame 101, the second sleeve frame 102 and the butt strap 104 are all made of stainless steel, and the suction plate 105 is made of magnet.
The two distance sensors 200 are symmetrically arranged on the sleeve frame 100, specifically, the two distance sensors 200 are respectively arranged on the sleeve frame I101 and the sleeve frame II 102, and the distance sensors 200 are arranged in the middle of the sleeve frame I101 and the sleeve frame II 102.
The diagnosis terminal 300 is connected with the distance sensor 200, the standard range of the rotor curvature is stored in the diagnosis terminal 300, and the diagnosis terminal 300 receives data of the distance sensor 200 to judge whether the rotor curvature exceeds the standard range. Specifically, the diagnostic terminal 300 is a computer, and the diagnostic terminal 300 includes a signal amplifier, a data acquisition card and a diagnostic module, wherein the signal amplifier is used for amplifying the received measurement data of the distance sensor 200, the data acquisition card is used for setting data acquisition parameters and receiving data of the signal amplifier, and the diagnostic module is used for judging whether the measurement data exceeds the range.
In use, the diagnostic terminal 300 performs the following steps:
data acquired by the distance sensor 200 is acquired by a data acquisition card in the diagnostic terminal 300 after passing through a signal amplifier, wherein the model ADA16-8/2(LPCI) of the data acquisition card is connected with 8 channels at one end, and the precision is 16 bits;
the data acquisition is carried out by setting parameters such as sampling frequency, a storage channel, a display channel, sampling points and the like of a data acquisition card, and then the data is exported to a diagnosis module in the diagnosis terminal 300;
the diagnostic module stores a standard range of the curvature of the rotor, compares the standard range of the received data space, adds a wavelet transform fault diagnosis algorithm when obvious fault signal fluctuation occurs, performs denoising analysis, and judges the frequency and the range of the fault.
Specifically, the bearing is divided into three parts: the bearing outer ring, the bearing inner ring and the rolling body fault characteristic frequency calculation formula is as follows:
outer ring:
inner ring:
rolling element:
in the formula:
D＝(d1+d2)/2；
d1、d2the diameters of the inner ring and the outer ring of the bearing are shown;
n is the rotation speed;
n is the number of rolling bodies in the rolling bearing;
d is the diameter of the rolling body;
d is the pitch diameter of the bearing;
α is the contact angle.
The wavelet transform fault diagnosis algorithm directly changes the basis of Fourier transform by using wavelets, namely, an infinite-length trigonometric function basis is changed into a finite-length wavelet basis which can be attenuated. The frequency can be obtained by performing spectrum analysis and time domain analysis on the transformed wavelet basis, and the time when the frequency appears can be located:
where α is a scale variable that is inversely proportional to frequency and τ is a time variable.
An arbitrary f (t) function (squared integrable function) is reconstructed using a set of wavelet basis functions, called Continuous Wavelet Transform (CWT), under which both the scale variable α and the time variable τ are continuously varied, using the mathematical expression:
is provided with
Then
Called the continuous wavelet function, the continuous wavelet transform is defined as:
formulas (1-1), (1-2) and (1-3), which are an analysis method of wavelet transformation: an analysis method of continuous wavelet transform. In equations 1-4, f (w) represents the function values at a certain time point, and each function value can be expressed by decomposition and integration through taylor expansion. And dt is the expression form of time differentiation. And the conversion form of the formula is an operation process of continuous wavelet transform, wherein f (t) is Taylor expansion,
it belongs to a two-dimensional variable function. This is equivalent to replacing the solution of the formula to the higher power of the imaginary number. The graph obtained by the analysis method is used for judging the fault frequency range and the frequency multiplication size of the fault frequency range by observing the peak value, and the harmonic frequency is judged to be several times of frequency, so that the position of the fault can be judged to be positioned at any position of the rolling body, the inner ring and the outer ring, and the fault frequency can be expressed by the graph, generally speaking, the maximum peak value position is the fault frequency, and the graph can be verified and analyzed with the formulas (1-4), (1-5) and (1-6), and the fault frequency algorithm can be used without actually disassembling the rolling rollerThe bearing is obtained, namely the position of the bearing can be shown, and a large amount of time and cost are saved in practical application.
Example 2
Referring to fig. 1, a second embodiment of the present invention, which is different from the first embodiment, is: the mounting plates 400 are mounted on the end parts, far away from the access board 104, of the first sleeve frame 101 and the second sleeve frame 102.
Compared with embodiment 1, further, the fault diagnosis device for the rotor unbalance comprises a sleeve frame 100, a distance sensor 200 and a diagnosis terminal 300, wherein the sleeve frame 100 is a circular ring with a notch, and the notch is mainly used for enabling the sleeve frame 100 to be sleeved on a rotor of a rotating machine and is coaxially arranged around the rotor. Specifically, the sleeve frame 100 comprises a first sleeve frame 101 and a second sleeve frame 102, the first sleeve frame 101 and the second sleeve frame 102 are both in a semicircular tubular structure, the first sleeve frame 101 and the second sleeve frame 102 are identical in size, and the first sleeve frame 101 and the second sleeve frame 102 are oppositely spliced to form the sleeve frame 100. One end of the first sleeve frame 101 is connected with one end of the second sleeve frame 102 through a hinge 103, the other ends of the first sleeve frame 101 and the second sleeve frame 102 are adsorbed together to form a gap, the other ends of the first sleeve frame 101 and the second sleeve frame 102 are both oppositely provided with an attachment strap 104, the attachment strap 104 is parallel to the central shaft of the sleeve frame 100, the attachment strap 104 of the first sleeve frame 101 is provided with a suction plate 105, and the suction plate 105 can adsorb the attachment strap 104 on the second sleeve frame 102.
In the invention, the first sleeve frame 101, the second sleeve frame 102 and the butt strap 104 are all made of stainless steel, and the suction plate 105 is made of magnet.
In the invention, the mounting plates 400 are mounted on the side ends of the first sleeve frame 101 and the second sleeve frame 102 far away from the access board 104, and the mounting plates 400 are also made of stainless steel. The two mounting plates 400 are located on the same plane, the mounting plates 400 are perpendicular to the attachment strap 104, the mounting plates 400 are parallel to the central axis of the jacket frame 100, and the mounting plates 400 are further provided with a plurality of mounting holes 401. Mounting plate 400 is primarily intended to facilitate mounting of the inventive apparatus to other devices.
The two distance sensors 200 are symmetrically arranged on the sleeve frame 100, specifically, the two distance sensors 200 are respectively arranged on the sleeve frame I101 and the sleeve frame II 102, and the distance sensors 200 are arranged in the middle of the sleeve frame I11 and the sleeve frame II 102.
The diagnosis terminal 300 is connected with the distance sensor 200, the standard range of the rotor curvature is stored in the diagnosis terminal 300, and the diagnosis terminal 300 receives data of the distance sensor 200 to judge whether the rotor curvature exceeds the standard range. Specifically, the diagnostic terminal 300 is a computer, and the diagnostic terminal 300 includes a signal amplifier, a data acquisition card and a diagnostic module, wherein the signal amplifier is used for amplifying the received measurement data of the distance sensor 200, the data acquisition card is used for setting data acquisition parameters and receiving data of the signal amplifier, and the diagnostic module is used for judging whether the measurement data exceeds the range.
The rest of the structure is the same as that of embodiment 1.
It should be noted that the above-mentioned embodiments are only for illustrating the technical solutions of the present invention and not for limiting, and although the present invention has been described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that modifications or equivalent substitutions may be made on the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, which should be covered by the claims of the present invention.
Claims (10)
1. A failure diagnosis device for rotor imbalance, characterized in that: comprises the steps of (a) preparing a mixture of a plurality of raw materials,
the sleeve frame (100), the sleeve frame (100) is a circular ring with a notch;
the number of the distance sensors (200) is two, and the two distance sensors (200) are symmetrically arranged on the sleeve frame (100);
the diagnosis terminal (300), the diagnosis terminal (300) is connected with the distance sensor (200), the diagnosis terminal (300) stores a standard range of the curvature of the rotor, and the diagnosis terminal (300) receives data of the distance sensor (200) to judge whether the curvature of the rotor exceeds the standard range.
2. The fault diagnosis device for rotor unbalance according to claim 1, characterized in that: the sleeve frame (100) comprises a first sleeve frame (101) and a second sleeve frame (102), the first sleeve frame (101) and the second sleeve frame (102) are both in a semicircular tubular structure, the first sleeve frame (101) and the second sleeve frame (102) are identical in size, and the first sleeve frame (101) and the second sleeve frame (102) are oppositely spliced to form the sleeve frame (100).
3. The fault diagnosis device for rotor unbalance according to claim 2, characterized in that: the two distance sensors (200) are respectively arranged on the first sleeve frame (101) and the second sleeve frame (102), and the distance sensors (200) are respectively arranged in the middle of the first sleeve frame (101) and the second sleeve frame (102).
4. A fault diagnosis device of rotor unbalance according to claim 2 or 3, characterized in that: one end of the first sleeve frame (101) is connected with one end of the second sleeve frame (102) through a hinge (103), the other ends of the first sleeve frame (101) and the second sleeve frame (102) are adsorbed together, the other ends of the first sleeve frame (101) and the second sleeve frame (102) are respectively provided with an access board (104) oppositely, the access boards (104) are parallel to the central shaft of the first sleeve frame (100), and the access boards (105) are arranged on the access boards (104) of the first sleeve frame (101).
5. The fault diagnosis device for rotor unbalance according to claim 4, characterized in that: the side end parts, far away from the access board (104), of the first sleeve frame (101) and the second sleeve frame (102) are respectively provided with a mounting plate (400), the two mounting plates (400) are located on the same plane, the mounting plates (400) are perpendicular to the access board (104), and the mounting plates (400) are parallel to the central shaft of the sleeve frame (100).
6. The fault diagnosis device for rotor unbalance according to claim 5, characterized in that: the mounting plate (400) is also provided with a plurality of mounting holes (401).
7. The fault diagnosis device for rotor unbalance according to claim 6, characterized in that: the set frame I (101), the set frame II (102), the butt strap (104) and the mounting plate (400) are all made of stainless steel materials, and the suction plate (105) is made of magnet materials.
8. The fault diagnosis device for rotor unbalance according to claim 1 or 7, characterized in that: the diagnosis terminal (300) is a computer, the diagnosis terminal (300) comprises a signal amplifier, a data acquisition card and a diagnosis module, the signal amplifier is used for amplifying received measurement data of the distance sensor (200), the data acquisition card is used for setting data acquisition parameters and receiving data of the signal amplifier, and the diagnosis module is used for judging whether the measurement data exceeds the range.
9. A diagnosis method based on a failure diagnosis apparatus of a rotor unbalance according to any one of claims 1 to 8, characterized in that:
data collected by a distance sensor (200) passes through a signal amplifier and then is collected by a data acquisition card in a diagnostic terminal (300), wherein the model number of the data acquisition card is ADA16-8/2(LPCI), and the data acquisition card is connected with 8 channels at a single end and has 16-bit precision;
the data acquisition is carried out by setting the sampling frequency, the storage channel, the display channel and the sampling point of the data acquisition card, and then the data is exported to a diagnosis module in a diagnosis terminal (300);
the diagnostic module stores a standard range of the curvature of the rotor, compares the standard range of the received data space, adds a wavelet transform fault diagnosis algorithm when obvious fault signal fluctuation occurs, denoises and judges the frequency and the range of the fault.
10. The method of diagnosing a failure diagnosing device of a rotor unbalance according to claim 9, characterized in that: the wavelet transformation fault diagnosis algorithm converts an infinite-length trigonometric function base of Fourier transformation into a finite-length wavelet base which can be attenuated, and performs spectrum analysis and time domain analysis on the transformed wavelet base, so that the frequency can be obtained, and the time of the frequency can be positioned:
wherein α is a scale variable, α is inversely proportional to frequency, and τ is a time variable;
and (3) reconstructing an arbitrary f (t) function by using a group of wavelet basis functions to perform continuous wavelet transformation, wherein under the continuous wavelet transformation, a scale variable α and a time variable tau are continuously changed, and the method adopts a mathematical expression:
is provided with
Then
Called the continuous wavelet function, the continuous wavelet transform is defined as:
the analysis values of the formulas (1-1), (1-2) and (1-3) are graphically displayed, and the failure frequency range is determined by observing the peak values.
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