CN111783274A - Bearing fault simulation method and device - Google Patents
Bearing fault simulation method and device Download PDFInfo
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Abstract
The invention provides a bearing fault simulation method and device, and belongs to the technical field of bearing fault simulation. The method comprises the following steps: introducing a set bearing fault into a bearing dynamic model which is constructed in advance, and inputting basic characteristic parameters of a bearing into the bearing dynamic model; inputting the actual rotating speed output by a driving device on a bearing experiment bench and the actual load output by a loading device into the bearing dynamic model in real time; and solving the bearing dynamic model to obtain the bearing vibration acceleration corresponding to the set bearing fault, and completing bearing fault simulation. The bearing fault simulation method adopts a semi-physical simulation mode to realize bearing fault simulation, and the bearing experiment bench sends the actual rotating speed and the actual load generated by the bearing experiment bench to the bearing dynamic model in real time during fault simulation, so that the dynamic characteristics of the rotating speed and the load of the actual bench are input into the bearing dynamic model in real time, and the bearing fault simulation precision can be further improved.
Description
Technical Field
The invention relates to a bearing fault simulation method and device, and belongs to the technical field of bearing fault simulation.
Background
The bearing is an important component of all rotating equipment and is also the most main fault source of most rotating equipment. Taking the motor as an example, more than 50% of the failures come from the bearings. Therefore, the characteristic signals, especially the vibration signals, under various fault conditions of the bearing are obtained, and the method has very important significance for realizing fault early warning and residual life estimation of the bearing.
In practical industrial application, faults are generated artificially at different positions of a bearing mostly by means of electric sparks or wire cutting and the like, and then vibration signals of the bearing are measured to extract characteristics capable of being used for bearing fault early warning. Although the result of the experimental method is accurate and reliable, the experimental efficiency is low, the cost is high, and many extreme fault conditions cannot be tested in the actual bearing rack.
In order to solve the above problems, there is also a method of simulating a bearing fault by modifying model parameters instead of an actual bearing, for example, a vibration response simulation analysis method for a rolling bearing with a single point fault disclosed in chinese patent application No. CN103927414B, the method includes first establishing a 5-degree-of-freedom nonlinear vibration model for the rolling bearing, establishing different fault models for the position, shape and size of the single point fault of the bearing, then introducing the fault into the 5-degree-of-freedom nonlinear vibration model for the rolling bearing according to the change of contact deformation of a ball contacting a defect when the rolling bearing has a fault, and finally solving the vibration model to obtain a vibration acceleration response curve graph for the bearing with the single point fault in an outer ring, an inner ring and a rolling body. The method not only replaces the actual bearing with the simulation model, but also simulates the operation condition of the bearing in a simulation mode, and can solve the problem that many extreme fault conditions cannot be simulated when faults are generated artificially, but because the actual operation condition of the bearing is not fixed but changes in real time under the influence of various external environment factors and the mechanical or electrical characteristics of other parts in a bearing rack in industrial application, the actual operation condition of the bearing is very complex and is difficult to simulate and reproduce comprehensively and truly in a simulation mode, and once the operation condition of the bearing obtained by simulation has deviation from the actual operation condition of the bearing, the fault simulation precision obtained by the method can be reduced.
In summary, at present, bearing fault simulation experiments are performed completely based on actual bearings, and the experiments cannot complete extreme fault simulation; or the bearing fault simulation experiment is completely carried out in a simulation mode, and the bearing operation condition obtained by simulation is not consistent with the actual operation condition of the bearing easily in the experiment, so that the fault simulation precision is reduced.
Disclosure of Invention
The invention aims to provide a bearing fault simulation method and device, which are used for solving the problem that the fault simulation precision is reduced because the bearing running condition obtained by simulation is not consistent with the actual running condition of a bearing easily when the bearing fault simulation experiment is completely carried out in a simulation mode at present.
In order to achieve the purpose, the invention provides a bearing fault simulation method, which comprises the following steps:
1) introducing a set bearing fault into a bearing dynamic model which is constructed in advance, and inputting basic characteristic parameters of a bearing into the bearing dynamic model;
2) inputting the actual rotating speed output by a driving device on a bearing experiment bench and the actual load output by a loading device into the bearing dynamic model in real time;
3) solving the bearing dynamic model to obtain the bearing vibration acceleration corresponding to the set bearing fault, and completing bearing fault simulation;
the set bearing faults are determined according to set fault positions, fault sizes and fault numbers, deformation quantity of balls contacting the faults can be changed when the bearing is in fault, and then contact force of the balls and a raceway can be changed, and the set bearing faults are introduced into the bearing dynamic model; the basic characteristic parameters of the bearing comprise the mass, the rigidity and the damping of the inner ring of the bearing, the mass, the rigidity and the damping of the outer ring of the bearing, the mass, the rigidity and the damping of the shock absorber and the number of the balls.
The bearing fault simulation method has the beneficial effects that: the method adopts a semi-physical simulation mode to realize bearing fault simulation, wherein a rotating speed and a loading part retain physical objects, namely, the actual rotating speed and the actual load required by the bearing fault simulation are both obtained from an actual bearing experiment bench; the bearing part adopts a mathematical model, namely a bearing dynamic model is adopted to replace an actual bearing. When fault simulation is carried out, a driving device and a loading device in a bearing experiment bench and a bearing dynamic model operate simultaneously, the bearing experiment bench sends the actual rotating speed and the actual load generated by the bearing experiment bench to the bearing dynamic model in real time, so that the dynamic characteristics (such as time delay, dynamic fluctuation and the like) of the rotating speed and the load of the whole actual bench are input into the bearing dynamic model in real time, and the dynamic characteristics can truly reflect various external environment factors and the influence of the mechanical or electrical characteristics of other parts in the bearing bench on the operation of the bearing, namely the actual operation condition of the bearing, thereby improving the precision of bearing fault simulation; meanwhile, the bearing dynamic model is adopted to replace an actual bearing, fault simulation of different bearings under different fault conditions can be completed by modifying bearing characteristic parameters and fault geometric parameters such as fault positions, sizes and quantities, bearing fault simulation efficiency can be improved, and extreme faults which cannot be performed due to safety factors in an actual experiment can be simulated.
Further, in the bearing fault simulation method, the driving device outputs an actual rotating speed according to a target rotating speed input by the upper computer, and the loading device outputs an actual load according to a target load input by the upper computer.
The invention also provides a bearing fault simulation device which comprises a bearing experiment bench, a bearing dynamic model and an upper computer; the bearing experiment bench comprises a driving device and a loading device, wherein the driving device is used for generating an actual rotating speed required by bearing fault simulation, and the loading device is used for generating an actual load required by the bearing fault simulation; the upper computer is used for setting basic characteristic parameters of the bearing and setting bearing faults; the bearing dynamic model is used for outputting the bearing vibration acceleration corresponding to the introduced bearing fault according to the introduced bearing fault, the input basic characteristic parameters of the bearing and the real-time input actual rotating speed and actual load, and finishing bearing fault simulation;
the upper computer sets a bearing fault by setting a fault position, a fault size and a fault number, wherein the bearing fault is changed according to the deformation quantity of a ball contacting the fault when the bearing is in fault, and then the contact force of the ball and a raceway is changed and introduced into the bearing dynamic model; the basic characteristic parameters of the bearing comprise the mass, the rigidity and the damping of the inner ring of the bearing, the mass, the rigidity and the damping of the outer ring of the bearing, the mass, the rigidity and the damping of the shock absorber and the number of the balls.
The bearing fault simulation device has the beneficial effects that: the device realizes bearing fault simulation in a semi-physical simulation mode, wherein a rotating speed and a loading part retain physical objects, namely the actual rotating speed and the actual load required by the bearing fault simulation are both obtained from an actual bearing experiment bench; the bearing part adopts a mathematical model, namely a bearing dynamic model is adopted to replace an actual bearing. When fault simulation is carried out, a driving device and a loading device in a bearing experiment bench and a bearing dynamic model operate simultaneously, the bearing experiment bench sends the actual rotating speed and the actual load generated by the bearing experiment bench to the bearing dynamic model in real time, so that the dynamic characteristics (such as time delay, dynamic fluctuation and the like) of the rotating speed and the load of the whole actual bench are input into the bearing dynamic model in real time, and the dynamic characteristics can truly reflect various external environment factors and the influence of the mechanical or electrical characteristics of other parts in the bearing bench on the operation of the bearing, namely the actual operation condition of the bearing, thereby improving the precision of bearing fault simulation; meanwhile, the bearing dynamic model is adopted to replace an actual bearing, fault simulation of different bearings under different fault conditions can be completed by modifying bearing characteristic parameters and fault geometric parameters such as fault positions, sizes and quantities, bearing fault simulation efficiency can be improved, and extreme faults which cannot be performed due to safety factors in an actual experiment can be simulated.
Further, in the bearing fault simulation device, the upper computer is further configured to set a target rotation speed of the driving device and a target load of the loading device, the driving device outputs an actual rotation speed according to the target rotation speed input by the upper computer, and the loading device outputs the actual load according to the target load input by the upper computer.
Further, in the bearing fault simulation device, the driving device comprises a motor controller, a driving motor and a rotation speed sensor, wherein the motor controller is connected with the driving motor, and the driving motor is connected with the rotation speed sensor; the loading device comprises a hydraulic loading system controller, a hydraulic loading system and a force sensor, wherein the hydraulic loading system controller is connected with the hydraulic loading system, and the hydraulic loading system is connected with the force sensor.
Drawings
FIG. 1 is a schematic structural diagram of a bearing fault simulation apparatus of the present invention;
FIG. 2 is a schematic representation of a 5-degree-of-freedom bearing kinetic model of the present invention;
FIG. 3 is a schematic view of the geometry of the bearing inner race in contact with the balls in the event of a failure;
FIG. 4 is a schematic view of the geometry of the bearing outer race in contact with the balls in the event of a fault;
FIG. 5 is a schematic view of a bearing fault shape and corresponding bearing fault size and shape submodel for different fault sizes;
FIG. 6 is H>HdA time fault depth schematic;
FIG. 7 is H<HdA time fault depth schematic;
FIG. 8 is a flow chart of a bearing fault simulation method of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments.
Bearing fault analogue means embodiment:
the bearing fault simulation device of the embodiment is shown in fig. 1, and the device is composed of 3 parts, namely a bearing experiment bench, a bearing fault dynamic model part and an upper computer, wherein the parts are respectively as follows:
bearing experiment bench
The bearing experiment bench comprises a driving device and a loading device. The driving device comprises a motor controller, a driving motor and a rotating speed sensor, wherein the motor controller is connected with the driving motor, the driving motor is connected with the rotating speed sensor, the rotating speed sensor is used for acquiring the rotating speed of the driving motor in real time, and the motor controller outputs a rotating speed control instruction to the driving motor based on a target rotating speed obtained from an upper computer and the rotating speed of the driving motor obtained from the rotating speed sensor; the loading device comprises a hydraulic loading system controller, a hydraulic loading system and a force sensor, wherein the hydraulic loading system controller is connected with the hydraulic loading system, the hydraulic loading system is connected with the force sensor, the force sensor is used for acquiring axial loads and radial loads output by the hydraulic loading system in real time, and the hydraulic loading system controller outputs a load control instruction to the hydraulic loading system based on target axial loads and radial loads (hereinafter referred to as target loads) obtained from an upper computer and actual axial loads and radial loads (hereinafter referred to as actual loads) obtained from the force sensor.
The bearing in the embodiment can bear axial load and radial load at the same time, so that the hydraulic loading system can generate loads in the two directions at the same time; of course, as another embodiment, when the bearing can only bear the load in one direction, the loading system can be controlled to generate the load in one direction, and in addition, other types of loading systems can be adopted to replace the hydraulic loading system.
In the embodiment, the driving device consists of a motor controller, a driving motor and a rotating speed sensor, the loading device consists of a hydraulic loading system controller, a hydraulic loading system and a force sensor, the driving device outputs an actual rotating speed according to a target rotating speed input by an upper computer, and the loading device outputs an actual load according to a target load input by the upper computer; in another embodiment, the driving device may be a motor with a speed-shifting function, and the actual speed output by the motor is controlled by adjusting the speed-shifting function.
Second, bearing fault dynamic model part
The bearing fault dynamic model part of the embodiment comprises a 5-degree-of-freedom normal bearing dynamic model (hereinafter referred to as a 5-degree-of-freedom bearing dynamic model) and a bearing fault model, wherein each model is as follows:
1. 5 degree of freedom bearing dynamic model
As shown in fig. 2, the bearing is composed of an inner ring, an outer ring and balls, and the following degrees of freedom are considered: the horizontal and vertical directions of the inner ring and the outer ring have one degree of freedom respectively, and the whole system forms a 5-degree-of-freedom system by adding one degree of freedom in the vertical direction of the shock absorber.
Based on Newton's second law, a 5-degree-of-freedom bearing dynamic model is obtained as shown in formula (1):
in the formula, Ms,Mp,mRThe weights of the bearing inner ring, the bearing outer ring and the shock absorber are respectively; ks,Kp,KRThe rigidity of the bearing inner ring, the rigidity of the bearing outer ring and the rigidity of the shock absorber are respectively set; rs,Rp,RRDamping of the bearing inner ring, the bearing outer ring and the shock absorber respectively; x is the number ofs,ys,
Respectively displacement, speed and acceleration of the bearing inner ring in the x direction and the y direction; x is the number ofp,yp,
Respectively displacement, speed and acceleration of the bearing outer ring in the x direction and the y direction; y isb,
Respectively displacement, speed and acceleration of the shock absorber in the y direction; fxAnd FyExternal forces in the x and y directions, respectively; f. ofx,fyThe contact forces of the balls and the raceways in the x and y directions, respectively.
Among these, from Herz's contact theory:
in the formula, kbIn order to be able to provide the rigidity of the bearing balls,jis the deformation of the jth balljAngular position of j-th ball, gammajFor the switching function, its value is determined by equation (3):
from the equations (2) and (3), the contact force f between the ball and the racewayx,fyMainly by the amount of deformation of the ballsjAnd (6) determining.
Wherein the deformation amount of each ball is determined when the bearing is not failedjIt can be calculated from the relative displacement of the inner and outer races at this position and the play of the bearing, as shown in equation (4):
j＝(xs-xp)cosφj+(ys-yp)sinφj-c (4)
when the bearing fails, only the deformation of the ball at the failure position changes, the deformation of the ball at other positions is not affected by the failure, and for the ball at the failure position, the size and the number of the failure further affect the deformation of the ball and the deformation of the ball of the failed bearing'jAs shown in equation (5):
′j＝(xs-xp)cosφj+(ys-yp)sinφj-c-βjcd(5)
wherein c is the play of the bearing, βjFor characterizing whether a fault has an effect on contact deformation, which is influenced by the fault location and can be described by a fault location submodel, cdRepresenting the amount of change in contact deformation due to a fault, which is affected by the size and shape of the fault, and which can be characterized by a fault size and shape submodel, βjAnd cdBoth together determine the current fault versus change in contact deflection.
2. Bearing fault model
The bearing fault model of the embodiment comprises a fault position sub-model, a fault size and shape sub-model and a fault quantity sub-model, wherein each model specifically comprises the following components:
1) fault location submodel
The location of a bearing failure can be classified into 3 cases, namely, a failure occurring in the inner race in the axial direction, a failure occurring in the outer race of the bearing, and a failure occurring in the bearing balls, β in these 3 casesjValues are different, and modeling is needed respectively, specifically as follows:
(1) faults occur in the inner ring or the outer ring of the bearing
β when a fault occurs in the inner race or the outer race of the bearingjCan be calculated from equation (6):
in the formula, phidIndicating the starting angle of the fault with respect to the ball, delta phidIndicating the angular range of the fault relative to the ball.
Wherein when a fault occurs in the outer ring of the bearing, since the outer ring of the bearing is usually kept static in the actual bearing stand, the fault position is fixed, and then phi isdIs constant and remains unchanged as shown in equation (7):
φd＝constant (7)
when a fault occurs in the inner race of the bearingSince the inner rings rotate coaxially, the relative position of the fault changes at that time, phidCan be calculated from equation (8).
φd＝ωst+φd0(8)
In the formula, phid0As initial fault location, ωsThe inner ring rotation speed is denoted by t, and time is denoted by t.
(2) Failure occurs in the bearing ball
Therefore, when a fault occurs on the balls, the fault will alternately contact the inner ring and the outer ring along with the rotation of the balls, and because the curvatures of the inner ring and the outer ring are different, the influence on the deformation of the balls when the fault contacts the inner ring and the outer ring is different (as shown in fig. 3 and 4), at this time βjCan be calculated by equation (9):
wherein:
in the formula, phisIs the ball failure position, k is the position number of the failed ball, B is failedWidth, Δ φbo、ΔφbiAngular ranges of the fault with respect to the outer and inner rings, respectively, Db、DoAnd DiThe diameter of the ball, the outer diameter of the bearing and the inner diameter of the bearing are respectively.
2) Sub-model for fault size and shape
The size of the fault is closely related to the shape of the fault, where two parameters η are definedbdAnd ηdTo construct the fault size and shape submodel, the calculation formulas of the two parameters are respectively as follows:
where L is the length of the fault and B is the width of the fault.
Readily known, ηbdThe ball size versus the fault size is described, ηdThe relative size of the fault itself length and width is described ηbdAnd ηdTaking different values, the geometry of the ball-to-failure interface will be different.
Therefore, based on ηbdAnd ηdCan use 4 different functions to describe the shape of the fault, as shown in equation (12):
wherein H1、H2、H3And H4The mathematical models of (2) are as follows, and a diagram of each model is shown in fig. 5.
H1＝cd′ (13)
Wherein phi represents the angle between the fault starting point and the ball center of the ball1And phi2Respectively representing the angle values of the middle two dividing points of the bearing fault shape piecewise function.
Where cd' can be calculated from equation (17) and equation (18), and the graph of equation (18) is shown in fig. 6 and 7.
cd′＝min(H,Hd) (17)
3) Fault number submodel
The fault number submodel is mainly used for defining how many faults of the bearing are respectively arranged on the inner ring, the outer ring and the ball bearing and the angle position of each fault.
After the position, the fault size and the fault number of the fault are set, the corresponding fault position submodel and the corresponding fault size and shape submodel are called to respectively calculate the change of the ball shape variable and the change of the contact force brought by the fault at each fault position, and then the fault is introduced into a 5-freedom-degree bearing dynamic model by means of the change of the contact force, so that the simulation of multiple faults of the bearing is realized.
Third, upper computer
In order to facilitate the setting of experiment parameters and the reading of experiment results by experimenters, the upper computer interface is developed based on the dSPACEControldesk software in the embodiment, and as other embodiments, the upper computer interface can also be developed based on the Labview software. The upper computer interface mainly comprises a working condition setting module, a bearing and fault parameter configuration module and a result display and analysis module.
(1) And the working condition setting module is used for setting the target rotating speed and the target load of the bearing experiment bench by experimenters, the set target rotating speed and the set target load are respectively sent to the motor controller and the hydraulic loading system controller through serial port communication or CAN communication, and meanwhile, the actual rotating speed and the actual load of the bearing experiment bench are directly fed back to the upper computer through the rotating speed sensor and the force sensor.
(2) The bearing and fault parameter configuration module is mainly used for setting basic characteristic parameters and fault geometric parameters of the bearing by experimenters. The basic characteristic parameters of the bearing comprise the mass, the rigidity, the damping, the number of bearing balls and the like of an inner ring and an outer ring of the bearing and a shock absorber; the fault geometry parameters include the number of faults, the location of the fault, the width and length of the fault (i.e., the size of the fault), etc.
(3) And the result display and analysis module is responsible for directly acquiring the bearing x-axis and y-axis transient acceleration output by the 5-degree-of-freedom bearing dynamic model through A/D (analog/digital) acquisition, extracting time domain and frequency domain characteristics and calculating envelope spectrum based on the acquired acceleration, and displaying the result in a chart form.
When the bearing fault simulation device of the embodiment is used for bearing fault simulation, the 5-degree-of-freedom bearing dynamic model is put into a dSPACE real-time simulation system to operate, and the following connections are completed simultaneously:
(1) the output of a rotating speed sensor and the output of a force sensor in a bearing experiment bench are respectively input into a 5-degree-of-freedom bearing dynamic model in a dSPACE real-time simulation system through Hall signals and AD signals;
(2) 3 CAN lines are connected between the upper computer and the motor controller, between the upper computer and the hydraulic loading system controller and between the upper computer and the dSPACE real-time simulation system, the target rotating speed of the bearing experiment bench is sent to the motor controller through CAN communication, the target load of the bearing experiment bench is sent to the hydraulic loading system controller, and the basic characteristic parameters and the fault geometric parameters of the bearing are sent to a 5-freedom degree bearing dynamic model in the dSPACE real-time simulation system;
(3) and inputting the actual rotating speed detected by the rotating speed sensor, the actual load detected by the force sensor and the x-axis acceleration and the y-axis acceleration generated by the 5-degree-of-freedom bearing dynamic model into an upper computer by using Hall signals and AD signals respectively.
After the connection is completed, a bearing fault simulation experiment can be performed by using a bearing fault simulation method, which specifically comprises the following steps:
firstly, setting a target rotating speed of a driving motor in a bearing experiment rack, a target load of a hydraulic loading system, basic characteristic parameters and fault geometric parameters of a bearing through an upper computer;
the target rotating speed and the target load which are set by the upper computer generate an actual rotating speed and an actual load after passing through a driving device and a loading device in the bearing experiment bench, and the actual rotating speed and the actual load are input into a 5-freedom-degree bearing dynamic model in real time, wherein the actual rotating speed corresponds to an inner ring rotating speed omegasThe actual load corresponds to Fx and Fy in the bearing dynamic model;
basic characteristic parameters of the bearing set by the upper computer are input into the 5-degree-of-freedom bearing dynamic model and used for fixing the 5-degree-of-freedom bearing dynamic model into a specific bearing;
calculating the ball deformation quantity by combining a corresponding fault model according to the fault geometric parameters set by the upper computer'jWill of'jSubstituting the contact force formula to calculate the contact force, and substituting the calculated contact force into a 5-degree-of-freedom bearing dynamic model to complete fault introduction;
and finally, solving a 5-degree-of-freedom bearing dynamic model to obtain the bearing vibration acceleration corresponding to the introduced fault, so as to realize bearing fault simulation.
The embodiment of the bearing fault simulation method comprises the following steps:
as shown in fig. 8, the bearing fault simulation method of the present embodiment includes the following steps:
1) introducing the set bearing fault into a bearing dynamic model which is constructed in advance, and inputting basic characteristic parameters of the bearing into the bearing dynamic model;
2) inputting the actual rotating speed output by the driving device on the bearing experiment bench and the actual load output by the loading device into a bearing dynamic model in real time;
3) solving a bearing dynamic model to obtain a bearing vibration acceleration corresponding to the set bearing fault, and completing bearing fault simulation;
the set bearing fault is determined according to the set fault position, the set fault size and the set fault number, and the set bearing fault is introduced into a bearing dynamic model according to the fact that when the bearing is in fault, deformation of a ball which is in contact with the fault changes, and further contact force of the ball and a raceway changes; the basic characteristic parameters of the bearing comprise the mass, the rigidity and the damping of the inner ring of the bearing, the mass, the rigidity and the damping of the outer ring of the bearing, the mass, the rigidity and the damping of the shock absorber and the number of the balls.
The specific implementation manner of the bearing fault simulation method of this embodiment has been described in detail in the embodiment of the bearing fault simulation apparatus, and is not described herein again. In addition, it should be noted that the serial numbers in the bearing fault simulation method of the present embodiment are added only for convenience of description, and do not limit the order of inputting information into the dynamic model of the counter bearing, and in practical applications, the order among the introduction of the fault, the input of the basic characteristic parameters of the bearing, and the input of the actual rotating speed and the actual load can be flexibly adjusted according to the actual needs.
In conclusion, the bearing fault simulation is realized in a semi-physical simulation mode, wherein the rotating speed and the loading part retain physical objects, namely the actual rotating speed and the actual load required by the bearing fault simulation are both obtained from an actual bearing experiment bench; the bearing part adopts a mathematical model, namely a bearing dynamic model is adopted to replace an actual bearing. When fault simulation is carried out, a driving device and a loading device in a bearing experiment bench and a bearing dynamic model operate simultaneously, the bearing experiment bench sends the actual rotating speed and the actual load generated by the bearing experiment bench to the bearing dynamic model in real time, so that the dynamic characteristics (such as time delay, dynamic fluctuation and the like) of the rotating speed and the load of the whole actual bench are input into the bearing dynamic model in real time, and the dynamic characteristics can truly reflect various external environment factors and the influence of the mechanical or electrical characteristics of other parts in the bearing bench on the operation of the bearing, namely the actual operation condition of the bearing, thereby improving the precision of bearing fault simulation; meanwhile, the bearing dynamic model is adopted to replace an actual bearing, fault simulation of different bearings under different fault conditions can be completed by modifying bearing characteristic parameters and fault geometric parameters such as fault positions, sizes and quantities, bearing fault simulation efficiency can be improved, and extreme faults which cannot be performed due to safety factors in an actual experiment can be simulated.
Claims (5)
1. A bearing fault simulation method is characterized by comprising the following steps:
1) introducing a set bearing fault into a bearing dynamic model which is constructed in advance, and inputting basic characteristic parameters of a bearing into the bearing dynamic model;
2) inputting the actual rotating speed output by a driving device on a bearing experiment bench and the actual load output by a loading device into the bearing dynamic model in real time;
3) solving the bearing dynamic model to obtain the bearing vibration acceleration corresponding to the set bearing fault, and completing bearing fault simulation;
the set bearing faults are determined according to set fault positions, fault sizes and fault numbers, deformation quantity of balls contacting the faults can be changed when the bearing is in fault, and then contact force of the balls and a raceway can be changed, and the set bearing faults are introduced into the bearing dynamic model; the basic characteristic parameters of the bearing comprise the mass, the rigidity and the damping of the inner ring of the bearing, the mass, the rigidity and the damping of the outer ring of the bearing, the mass, the rigidity and the damping of the shock absorber and the number of the balls.
2. The bearing fault simulation method according to claim 1, wherein the driving device outputs an actual rotational speed according to a target rotational speed input by an upper computer, and the loading device outputs an actual load according to a target load input by the upper computer.
3. A bearing fault simulation device is characterized by comprising a bearing experiment bench, a bearing dynamic model and an upper computer; the bearing experiment bench comprises a driving device and a loading device, wherein the driving device is used for generating an actual rotating speed required by bearing fault simulation, and the loading device is used for generating an actual load required by the bearing fault simulation; the upper computer is used for setting basic characteristic parameters of the bearing and setting bearing faults; the bearing dynamic model is used for outputting the bearing vibration acceleration corresponding to the introduced bearing fault according to the introduced bearing fault, the input basic characteristic parameters of the bearing and the real-time input actual rotating speed and actual load, and finishing bearing fault simulation;
the upper computer sets a bearing fault by setting a fault position, a fault size and a fault number, wherein the bearing fault is changed according to the deformation quantity of a ball contacting the fault when the bearing is in fault, and then the contact force of the ball and a raceway is changed and introduced into the bearing dynamic model; the basic characteristic parameters of the bearing comprise the mass, the rigidity and the damping of the inner ring of the bearing, the mass, the rigidity and the damping of the outer ring of the bearing, the mass, the rigidity and the damping of the shock absorber and the number of the balls.
4. The bearing fault simulation device according to claim 3, wherein the upper computer is further configured to set a target rotation speed of the driving device and a target load of the loading device, the driving device outputs an actual rotation speed according to the target rotation speed input by the upper computer, and the loading device outputs the actual load according to the target load input by the upper computer.
5. The bearing fault simulation device according to claim 3 or 4, wherein the driving device comprises a motor controller, a driving motor and a rotation speed sensor, the motor controller is connected with the driving motor, and the driving motor is connected with the rotation speed sensor; the loading device comprises a hydraulic loading system controller, a hydraulic loading system and a force sensor, wherein the hydraulic loading system controller is connected with the hydraulic loading system, and the hydraulic loading system is connected with the force sensor.
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