CN113386822B - Comprehensive diagnosis method, device and equipment for wheel multilateral out-of-round - Google Patents
Comprehensive diagnosis method, device and equipment for wheel multilateral out-of-round Download PDFInfo
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- CN113386822B CN113386822B CN202110611196.8A CN202110611196A CN113386822B CN 113386822 B CN113386822 B CN 113386822B CN 202110611196 A CN202110611196 A CN 202110611196A CN 113386822 B CN113386822 B CN 113386822B
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- B61K9/00—Railway vehicle profile gauges; Detecting or indicating overheating of components; Apparatus on locomotives or cars to indicate bad track sections; General design of track recording vehicles
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Abstract
The invention discloses a comprehensive diagnosis method, a device, equipment and a computer readable storage medium for wheel multilateral out-of-round, which are characterized in that a vibration acceleration signal of a wheel in a driving process is obtained, a corresponding vibration level difference value is obtained after the vibration acceleration signal is subjected to spectrum analysis and calculation, when the vibration level difference value is judged to be larger than a first preset level difference threshold value, the vibration acceleration signal is further re-integrated and a corresponding out-of-round jitter value is calculated, and when the out-of-round jitter value is judged to be larger than a preset jitter value threshold value, alarm information is output so as to reasonably guide turning repair and arrange a turning repair plan, thereby dynamically monitoring and effectively evaluating the out-of-round degree of the wheel in real time during train operation, guaranteeing safe train operation and simultaneously providing effective guide suggestions so as to reasonably arrange the turning repair plan.
Description
Technical Field
The invention relates to the technical field of rail transit, in particular to a comprehensive diagnosis method, device and equipment for wheel multi-edge out-of-round and a computer readable storage medium.
Background
In recent years, with the expanded operation of rail transit vehicles and the improvement of the running speed of railway trains in China, the problem of out-of-round wheel treads is increased continuously, and the influence caused by the problem is more and more obvious. Wheel out-of-round, i.e. the wheel radius exhibits a periodic out-of-round in the circumferential direction. Out-of-roundness of a wheel can cause a series of dynamic response changes in a vehicle-track system, which can have a serious impact on driving stability, safety, and service life of various components of the vehicle-track system. Therefore, the out-of-roundness degree of the wheel needs to be measured, and once the out-of-roundness exceeds the standard, the turning wheel is arranged for maintenance and then put into operation.
Currently, in a locomotive section and a vehicle section, a wheel tread out-of-roundness is usually measured by using an artificial wheel caliper, an out-of-roundness measuring instrument or a turning turbine to obtain a radial runout of the wheel tread, i.e., a difference between a maximum value and a minimum value of a radius at different positions on the circumference of the wheel, and these measuring methods all belong to static monitoring. However, static monitoring needs to be performed under the condition that a train is stopped or a wheel is disassembled, the turnover time of the train is occupied, the speed is low, the workload is large, the period that the jumping quantity of the wheel exceeds the standard is shortened for lines with severe working conditions, and the situation that planning is saturated and turning is not performed is frequently generated in the service sections or the vehicle sections, so that the manual investment is aggravated and the loss of the lathe is aggravated due to the extra-working point of the turning workshop.
In summary, how to dynamically monitor and effectively evaluate the out-of-roundness degree of the wheel in real time during the operation of the train is an urgent problem to be solved by those skilled in the art.
Disclosure of Invention
In order to solve the above technical problems, the present invention provides a comprehensive diagnosis method, device, equipment and computer readable storage medium for wheel multi-edge out-of-roundness, which can dynamically monitor and effectively evaluate the out-of-roundness degree of the wheel in real time during the train operation, and provide effective guidance suggestions while ensuring the safe operation of the train, so as to reasonably arrange a wheel turning plan.
The invention provides a comprehensive diagnosis method for wheel multilateral out-of-round, which comprises the following steps:
acquiring a vibration acceleration signal of a wheel in the running process of a train;
carrying out spectrum analysis on the vibration acceleration signal to obtain a corresponding multi-order vibration effective value, and calculating a vibration level difference value corresponding to the multi-order vibration effective value;
judging whether the vibration level difference value is larger than a first preset level difference threshold value or not;
if the vibration level difference value is larger than the first preset level difference threshold value, performing double integration on the vibration acceleration signal to obtain a corresponding displacement signal, and calculating a characteristic value of the displacement signal to obtain a corresponding out-of-round jitter value;
Judging whether the out-of-round jumping magnitude value is larger than a preset jumping magnitude threshold value;
and if the out-of-round jumping quantity value is larger than the preset jumping quantity threshold value, outputting alarm information.
Preferably, the performing a spectrum analysis on the vibration acceleration signal to obtain a corresponding effective value of multi-order vibration, and calculating a vibration level difference value corresponding to the effective value of multi-order vibration includes:
carrying out spectrum analysis on the vibration acceleration signal to obtain a multi-order vibration amplitude of the vibration acceleration;
calculating the multi-order vibration effective value of the vibration acceleration according to the multi-order vibration amplitude;
and calculating the vibration level difference value corresponding to the multi-order vibration effective value according to the multi-order vibration effective value.
Preferably, the calculation formula for calculating the effective value of the multi-order vibration of the vibration acceleration is as follows:
in the formula, a rms Representing the effective value of multi-step vibration, n representing the order of multi-edge out-of-round of wheel, a n Represents the nth order vibration amplitude, wherein n =1,2,3 …;
the calculation formula for calculating the vibration level difference value corresponding to the multi-order vibration effective value is as follows:
in the formula, A dB Representing the vibration level difference, N representing the rotating speed of the axle on which the wheel is positioned, and D representing the axle diameter of the axle on which the wheel is positioned.
Preferably, before the re-integrating the vibration acceleration signal to obtain a corresponding displacement signal and calculating a characteristic value of the displacement signal to obtain a corresponding out-of-roundness jitter value, the method further comprises:
judging whether the rotating speed of the wheel is smaller than a preset rotating speed threshold value or not;
if the rotating speed of the wheel is smaller than the preset rotating speed threshold value, performing the step of performing double integration on the vibration acceleration signal to obtain a corresponding displacement signal, and calculating a characteristic value of the displacement signal to obtain a corresponding out-of-round run-out value;
and if the rotating speed of the wheel is not less than the preset rotating speed threshold value, returning to the step of acquiring the vibration acceleration signal of the wheel in the running process of the train.
Preferably, before the determining whether the rotation speed of the wheel is less than a preset rotation speed threshold, the method further comprises:
judging whether the vibration level difference value is larger than a second preset level difference threshold value or not;
if the vibration level difference value is larger than the second preset level difference threshold value, directly outputting alarm information;
and if the vibration level difference value is not greater than the second preset level difference threshold value, executing the step of judging whether the rotating speed of the wheel is less than a preset rotating speed threshold value.
Preferably, the re-integrating the vibration acceleration signal to obtain a corresponding displacement signal and calculating a characteristic value of the displacement signal to obtain a corresponding out-of-round jitter value includes:
performing frequency domain re-integration on the vibration acceleration signal to obtain a corresponding displacement signal, and performing empirical mode decomposition extraction on the displacement signal;
and calculating the waveform amplitude characteristic value of the displacement signal after empirical mode decomposition extraction to obtain a corresponding out-of-round jitter value.
Preferably, the calculating the waveform amplitude characteristic value of the displacement signal after the empirical mode decomposition extraction to obtain the corresponding out-of-roundness jitter value includes:
acquiring all minimum values exceeding a preset displacement threshold value from the displacement signals extracted by empirical mode decomposition;
determining a maximum minimum value and a minimum value among all the minimum values;
and calculating the difference value between the maximum minimum value and the minimum value to obtain the corresponding out-of-roundness beating quantity value.
In another aspect, the present invention provides a wheel multi-edge out-of-round comprehensive diagnosis apparatus, including:
the signal acquisition module is used for acquiring a vibration acceleration signal of a wheel in the running process of the train;
The frequency spectrum analysis module is used for carrying out frequency spectrum analysis on the vibration acceleration signal to obtain a corresponding multi-order vibration effective value and calculating a vibration level difference value corresponding to the multi-order vibration effective value;
the level difference judging module is used for judging whether the vibration level difference value is larger than a first preset level difference threshold value or not;
the re-integration module is used for re-integrating the vibration acceleration signal to obtain a corresponding displacement signal and calculating a characteristic value of the displacement signal to obtain a corresponding out-of-roundness beating value if the vibration level difference value is greater than the first preset level difference threshold value;
the jumping amount judging module is used for judging whether the out-of-round jumping amount value is larger than a preset jumping amount threshold value;
and the alarm output module is used for outputting alarm information if the out-of-roundness jumping quantity value is greater than the preset jumping quantity threshold value.
Still another aspect of the present invention provides a wheel multi-lateral out-of-round comprehensive diagnosis apparatus, including:
a memory for storing a computer program;
and the processor is used for realizing the steps of the wheel multi-edge out-of-round comprehensive diagnosis method when the computer program is executed.
Yet another aspect of the present invention provides a computer-readable storage medium having stored thereon a computer program which, when executed by a processor, implements the steps of any one of the above-described wheel multi-lateral out-of-round comprehensive diagnosis methods.
The invention has at least the following beneficial effects:
according to the method, the vibration acceleration signal of the wheel in the driving process is obtained, the vibration acceleration signal is subjected to spectrum analysis and calculation to obtain the corresponding vibration level difference value, when the vibration level difference value is judged to be larger than a first preset level difference threshold value, the vibration acceleration signal is further subjected to reintegration and the corresponding out-of-round jitter value is calculated, and when the out-of-round jitter value is judged to be larger than a preset jitter value threshold value, alarm information is output to reasonably guide turning-round repair and arrange a turning-round repair plan, so that the out-of-round degree of the wheel is dynamically monitored and effectively evaluated in real time during train operation, the safe operation of the train is guaranteed, and effective guide suggestions are provided to reasonably arrange the turning-round repair plan of the wheel.
Drawings
In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present application, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
Fig. 1 is a schematic flow chart of a comprehensive diagnosis method for wheel multi-edge out-of-round according to an embodiment of the present invention;
fig. 2 is a schematic flow chart of another comprehensive diagnosis method for wheel multi-edge out-of-round according to an embodiment of the present invention;
FIG. 3 is a graph of absolute error variation of a displacement signal obtained by a frequency domain integration method;
FIG. 4 is a waveform diagram of an original displacement signal;
FIG. 5 is a waveform comparison diagram of a displacement signal obtained by a frequency domain integration method and an original displacement signal;
FIG. 6 is a waveform comparison diagram of a displacement signal and an original displacement signal obtained by direct integration, integration after band-pass filtering, and multiple term removal after integration;
FIG. 7 is a comparison graph of waveforms of a displacement signal obtained by the method according to the embodiment of the present invention and an original displacement signal;
FIG. 8 is an equivalent model diagram obtained by performing an equivalent process on an actual model;
FIG. 9 is a simulation experiment diagram of wheel local out-of-roundness inaccuracy;
FIG. 10 is a comparison of estimated values of out-of-round runout before and after a certain number 5 wire 1 wheel lathe;
FIG. 11 is a comparison of estimated values of out-of-round runout before and after a certain number 5 wire 2 wheel lathe;
FIG. 12 is a trend plot of estimated values of out-of-round runout before and after a 9-wire 2-bit wheel;
Fig. 13 is a schematic structural diagram of a comprehensive diagnosis apparatus for wheel multi-lateral out-of-round according to an embodiment of the present invention;
fig. 14 is a schematic structural diagram of a comprehensive diagnosis apparatus for wheel multi-edge out-of-round according to an embodiment of the present invention.
Detailed Description
The core of the invention is to provide a comprehensive diagnosis method, a device, equipment and a computer readable storage medium for wheel multi-edge out-of-round, which realize real-time dynamic monitoring and effective evaluation of the out-of-round degree of the wheels during the train operation, and provide effective guidance suggestions while ensuring the safe operation of the train so as to reasonably arrange a wheel turning plan.
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1, an embodiment of the present invention provides a method for comprehensively diagnosing wheel multi-lateral out-of-round, including:
And S110, acquiring a vibration acceleration signal of a wheel in the running process of the train.
In the embodiment of the invention, in the running process of the train, the vibration acceleration signals of the wheel tread can be acquired through corresponding signal acquisition equipment and are sent to the processor for subsequent processing. The signal acquisition equipment for acquiring the vibration acceleration signal is a vibration acceleration sensor which can be mounted on bearing seats of various rotating mechanical devices, and the vibration acceleration sensor is a common sensor and is commonly used for detecting vibration acceleration with some relevant characteristics. It should be noted that the selection of the signal acquisition device is only one implementation manner provided by the embodiment of the present invention, and is not unique, and the selection of the type and the corresponding model thereof is not specifically limited in the embodiment of the present invention, for example, piezoelectric, capacitive, MEMS (Micro-Electro-Mechanical Systems ) and the like may be selected. The installation position of the vibration acceleration acquisition device is not limited, and the vibration acceleration acquisition device can acquire vibration acceleration signals of the contact between the tread and the rail surface, such as the vibration acceleration acquisition device is installed on a bearing seat of an axle box, a bogie and the like.
And S120, carrying out spectrum analysis on the vibration acceleration signal to obtain a corresponding multi-order vibration effective value, and calculating a vibration level difference value corresponding to the multi-order vibration effective value.
In the embodiment of the invention, the frequency spectrum analysis is to perform FFT (Fast Fourier Transform, chinese name) transformation on the collected vibration acceleration signal to obtain the frequency spectrum of the vibration acceleration, analyze the multi-order spectrum of the wheel tread frequency in the frequency spectrum to obtain a multi-order vibration effective value, and calculate the vibration level difference value corresponding to the multi-order vibration effective value. The physical significance of the multi-order vibration effective value lies in the vibration magnitude level (the influence degree on safe operation) generated by the multi-edge out-of-round wheel in actual operation, and the multi-order vibration effective value is converted into a corresponding vibration level difference value in order to effectively evaluate the multi-edge out-of-round degree of the wheel.
S130, judging whether the vibration level difference value is larger than a first preset level difference threshold value, if so, executing a step S140.
In the embodiment of the invention, the vibration level difference (dB) is adopted to evaluate the multilateral out-of-roundness degree of the wheel, the early warning limit value (namely a first preset level difference threshold) of the vibration level difference is preset, and when the vibration level difference is judged to be greater than the preset early warning limit value, the step S140 is continuously executed; otherwise, return to step S110. Where "dB" (decibel) is a ratio, it is understood that 0dB means that the two signals compared to each other are equally large.
S140, the vibration acceleration signal is subjected to re-integration to obtain a corresponding displacement signal, and a characteristic value of the displacement signal is calculated to obtain a corresponding out-of-round jitter value.
In the embodiment of the present invention, when it is determined that the vibration level difference value is greater than the first preset level difference threshold value, the obtained vibration acceleration signal is further subjected to re-integration to obtain a corresponding displacement signal, that is, the acceleration signal is subjected to primary integration to obtain a velocity signal, and the secondary integration is to obtain a displacement signal, where the secondary integration is the re-integration, and the integration method is not limited in the embodiment of the present invention, and may be time domain integration or frequency domain integration. Further, after obtaining the displacement signal, a characteristic value of the displacement signal may be calculated to obtain a corresponding out-of-roundness jitter value, where the characteristic value may have a plurality of expression calculation manners, such as a peak-to-peak value, a maximum minimum difference value, a positive peak value, a negative peak value, and the like of the signal, and may be set according to an actual situation, which is not limited in the embodiment of the present invention.
S150, judging whether the out-of-round jumping magnitude value is larger than a preset jumping magnitude threshold value, if so, executing step S160.
In the embodiment of the invention, the radial run-out is a main reference value for evaluating the severity of the out-of-round at the multiple sides of the wheel and guiding the turning repair at present, different run-out threshold standards (namely, preset run-out threshold values) are preset, and when the out-of-round run-out is judged to be larger than the preset run-out threshold standard, the step S160 is continuously executed; otherwise, return to step S110. In specific implementation, the preset threshold value of the bounce amount may be set to 0.5mm or 0.35mm according to different application requirements.
And S160, outputting alarm information.
In the embodiment of the invention, when the out-of-round runout value is judged to be larger than the preset runout threshold value, alarm information is output to remind a driver, meanwhile, the alarm information is sent to a control center, and the turning operation specified by the standard is arranged on the wheel by a locomotive service section or a vehicle section.
As can be seen from the above, the comprehensive diagnosis method for wheel multi-lateral out-of-round provided in the embodiment of the present invention obtains the vibration acceleration signal of the wheel during driving, performs spectrum analysis and calculation on the vibration acceleration signal to obtain the corresponding vibration level difference, further performs re-integration on the vibration acceleration signal and calculates the corresponding out-of-round jitter value when it is determined that the vibration level difference is greater than the first preset level difference threshold, and outputs alarm information to reasonably guide turning and arrange a turning plan when it is determined that the out-of-round jitter value is greater than the preset jitter threshold, so as to dynamically monitor and effectively evaluate the out-of-round degree of the wheel in real time during train operation, and provide effective guidance suggestions while ensuring safe train operation, so as to reasonably arrange the turning plan.
Referring to fig. 2, a flow chart of another method for comprehensively diagnosing wheel multi-lateral out-of-round according to an embodiment of the present invention is shown, where the method includes:
S210, obtaining a vibration acceleration signal of a wheel in the running process of the train.
S220, carrying out spectrum analysis on the vibration acceleration signal to obtain a corresponding multi-order vibration effective value, and calculating a vibration level difference value corresponding to the multi-order vibration effective value.
And S230, judging whether the vibration level difference value is larger than a first preset level difference threshold value, if so, executing a step S240, and if not, returning to the step S210.
S240, determining whether the vibration level difference is greater than a second preset level difference threshold, if so, performing step S280, otherwise, performing step S250.
In the embodiment of the invention, a primary fault alarm limit value (namely a second preset level difference threshold value) of the vibration level difference is preset, when the vibration level difference value is judged to be larger than the preset primary fault alarm limit value, the step S280 is directly executed, alarm information is output to remind a driver, meanwhile, the alarm information is sent to a control center, and a turning-round operation specified by a standard is arranged on a wheel by a locomotive section or a vehicle section; otherwise, the step S250 is continuously executed.
And S250, judging whether the rotating speed of the wheel is less than a preset rotating speed threshold value, if so, executing S260, otherwise, returning to the step S210.
In the embodiment of the invention, the flying phenomenon of the local out-of-round of the wheel is considered, and when the rotating speed of the wheel exceeds a certain threshold value, the amplitude output of the displacement signal obtained by performing the re-integration on the vibration acceleration signal is obviously smaller than the actual out-of-round size of the wheel, namely the situation of inaccurate measurement occurs. Therefore, a soaring critical condition value (i.e., a preset rotation speed threshold value) of the wheel rotation speed is preset, when it is determined that the vibration level difference value is greater than the first preset level difference threshold value and not greater than the second preset level difference threshold value, it is further determined whether the wheel rotation speed is less than the preset rotation speed threshold value at this time, and if so, the step S260 is continuously executed; otherwise, return to step S210.
And S260, re-integrating the vibration acceleration signal to obtain a corresponding displacement signal, and calculating a characteristic value of the displacement signal to obtain a corresponding out-of-roundness jitter value.
S270, judging whether the out-of-round jumping magnitude value is larger than a preset jumping magnitude threshold value, if so, executing the step S280, otherwise, returning to the step S210.
And S280, outputting alarm information.
Specifically, in the foregoing embodiment, step S220 includes:
carrying out spectrum analysis on the vibration acceleration signal to obtain a multi-order vibration amplitude of the vibration acceleration;
calculating the multi-order vibration effective value of the vibration acceleration according to the multi-order vibration amplitude;
and calculating the vibration level difference value corresponding to the multi-order vibration effective value according to the multi-order vibration effective value.
Further, in the above embodiment, the calculation formula for calculating the effective value of the multi-step vibration of the vibration acceleration is as follows:
in the formula, a rms Representing the effective value of multi-step vibration, n representing the number of steps of wheel multi-edge out-of-round, a n Represents the nth order vibration amplitude, wherein n =1,2,3 …;
the calculation formula for calculating the vibration level difference value corresponding to the multi-order vibration effective value is as follows:
in the formula, A dB Representing the vibration level difference, N representing the rotating speed of the axle on which the wheel is positioned, and D representing the axle diameter of the axle on which the wheel is positioned.
In the embodiment of the invention, the FFT conversion is carried out on the collected vibration acceleration signal to obtain the frequency spectrum of the vibration acceleration, the multi-order spectrum (for example, the spectrum of 1 to 20 orders) of the wheel tread frequency in the frequency spectrum is analyzed to obtain the multi-order vibration amplitude (for example, the vibration amplitude of 1 to 20 orders) of the vibration acceleration, then the multi-order vibration effective value of the vibration acceleration is obtained through the formula calculation, and the multi-order vibration effective value is converted into the vibration level difference value.
Optionally, in some embodiments of the present invention, step S260 includes:
performing frequency domain re-integration on the vibration acceleration signal to obtain a corresponding displacement signal, and performing empirical mode decomposition extraction on the displacement signal;
and calculating the waveform amplitude characteristic value of the displacement signal after empirical mode decomposition extraction to obtain a corresponding out-of-round jitter value.
The fundamental principle of the frequency domain integration method is to perform fourier transform on a signal to be integrated, perform signal integration in the frequency domain, and then convert the signal into the time domain by using fourier inversion operation. According to the Fourier expression:
a(ω)＝Ae jωt ；
in the formula, a (ω) represents a component of the vibration acceleration signal at the frequency ω, a represents an amplitude of the component, and j represents an imaginary number.
If the initial displacement is not considered, the vibration acceleration signal is subjected to secondary integration to obtain the expression of the corresponding displacement signal in the frequency domain:
In the formula, x (ω) represents a component of the displacement signal at the frequency ω.
Therefore, the vibration acceleration signal and the displacement signal are shown as phase reversal in the frequency domain, and the amplitude is A/omega 2 Therefore, a convenient way is provided for realizing the conversion from the acceleration signal to the displacement signal through frequency domain integration. However, this integration method often adds a band-pass filtering step, for example, full-band direct integration is adopted, and a step of removing dc components is added before and after integration, but this method has a problem that a trend term is generated in the integration process, and the quadratic productDue to the influence of signal noise and a first-time integration trend term, the signal after integration is often seriously distorted.
The existing solutions mainly have two kinds: firstly, low-pass or band-pass filtering is adopted to reduce noise of signals before integration, so that the low-frequency component is not considered, and the noise reduction method has a good effect in application occasions; secondly, the trend term removing processing is carried out after each integration, the method has certain effect on the condition of large signal-to-noise ratio, however, the trend term generated when the noise is large is not approximate to a simple quadratic term any more, and the method is difficult to apply. Meanwhile, in practical applications, noise components are often unknown, and in some cases, low-frequency components or high-frequency components in signals are probably the most useful signal features, so that any preprocessing of signals can also be actually a kind of 'damage' to the signals.
In order to analyze and propose the sensitivity of the full frequency domain integration to the frequency, the absolute error of the conversion of a single frequency signal at different frequencies is firstly studied, and the absolute error δ is defined as:
in the formula (di) 2 (i) Represents the frequency domain integrated displacement signal and dis (i) represents the original displacement signal.
Simulating a displacement signal dis (t) of a single frequency:
dis(t)＝sin(2πft)；
the corresponding vibration acceleration signal dis (t) is then:
acc(t)＝-(2πf) 2 sin(2πft)；
the sampling frequency is 1000Hz, the sampling time is 50s, the change frequency f is changed from 0.02Hz to 500Hz, and the absolute error change of the displacement signal obtained by adopting a frequency domain integration method is shown in figure 3.
It can be seen that the full frequency domain integration has smaller errors except when the frequency approaches 0 (which is actually equivalent to a long enough sampling time to satisfy the requirement of acquiring a complete cycle, but not the problem caused by the algorithm itself), and the frequency starts at more than 0.12Hz, and the relative error is below 0.1 mm.
The simulated displacement signal dis (t) is a sinusoidal signal of three frequency components (5 Hz, 40Hz, 200 Hz), the signal expression of which is:
dis(t)＝sin(2πf 1 t)+sin(2πf 2 t)+sin(2πf 3 t)；
the sampling frequency is 1000Hz and the waveform of the original displacement signal dis (t) is shown in fig. 4.
According to the integral relation, the vibration acceleration signal acc (t) corresponding to the original displacement signal dis (t) should be:
acc(t)＝-(2πf 1 ) 2 sin(2πf 1 t)-(2πf 2 ) 2 sin(2πf 2 t)-(2πf 3 ) 2 sin(2πf 3 t)；
Calculating a displacement signal for the vibration acceleration signal acc (t) by using the proposed full frequency domain integral, and a recovered displacement signal dis 2 The waveform pair of (t) and the original displacement signal dis (t) is shown in fig. 5.
After eliminating boundary part data points to eliminate boundary effects, the corresponding relative error δ =0.006mm is calculated.
Further adding random noise to the vibration acceleration signal acc (t) to obtain a vibration acceleration signal containing noise, wherein the vibration acceleration signal containing noise is as follows:
acc 2 (t)＝acc(t)+0.001×4π 2 (f 1 2 +f 2 2 +f 3 2 )randn(t)；
the comparison between the displacement signal obtained by directly performing quadratic integration, respectively performing integration after traditional band-pass filtering (3 Hz to 210 Hz), and removing polynomial (20 th-order polynomial) after integration and the original displacement signal is shown in fig. 6.
It can be seen that the relative errors after direct integration and band-pass filtering are δ =10.4mm, 1.6mm and 1.85mm respectively (the boundary effect is eliminated), while full-frequency-domain integration still has a large error for noisy signals, and the effect of the traditional method of band-pass filtering and removing multiple terms is not ideal.
In the embodiment of the present invention, the obtained vibration acceleration signal is not subjected to any noise reduction processing, but is subjected to frequency domain re-integration to obtain a corresponding displacement signal, and the displacement signal is subjected to empirical mode decomposition extraction, and the number of the extracted vibration acceleration signal is the number of frequencies included in the frequencies (which can be predicted in monitoring of a rotating machine, and only the first layer is taken for wheel tread surface out-of-round), for example, the first 3 layers are extracted. And further calculating the waveform amplitude characteristic value of the displacement signal after empirical mode decomposition extraction to obtain a corresponding out-of-round jitter value.
Among them, EMD (english name: empical Mode Decomposition, chinese name: empirical Mode Decomposition extraction) belongs to a data-driven adaptive analysis method, whose essence is to decompose a signal into a series of intrinsic Mode function components, which must satisfy two conditions: firstly, the number of extreme points of all components and the number of zero-crossing points of the components are required to be equal or have a difference of not more than 1, and only one extreme value exists in two adjacent zero-crossing point ranges; secondly, at all the moments, the upper and lower envelopes of the components are symmetrical, and the average value is zero. In the embodiment of the invention, the method is used for solving the problem of signal distortion caused by frequency domain integration, and meanwhile, the method of directly removing the data of the boundary part is adopted to avoid the problem of boundary effect caused by EMD. In addition, the main reasons for choosing this method are: EMD is adopted to decompose according to an intrinsic mode, and compared with high-pass filtering, the method is more suitable for the application requirement; the usual method of removing the trend term (integration of noisy signals necessarily yields a quadratic term); the effects of interfering or anomalous data points may be partially eliminated.
The ratio of the displacement signal obtained by the method provided by the embodiment of the invention and the original displacement signal is shown in fig. 7.
It can be seen that the effect of direct integration and bandpass filtering is greatly improved, and the calculation of the corresponding relative error delta =0.1mm illustrates the effectiveness of the method.
Further, in some embodiments of the present invention, the calculating the waveform amplitude characteristic value of the displacement signal after the empirical mode decomposition extraction to obtain the corresponding out-of-roundness jitter value includes:
acquiring all minimum values exceeding a preset displacement threshold value from the displacement signals extracted by empirical mode decomposition;
determining a maximum minimum value and a minimum value among all minimum values;
and calculating the difference value between the maximum minimum value and the minimum value to obtain the corresponding out-of-roundness beating quantity value.
In the embodiment of the present invention, the waveform amplitude characteristic value is represented by a maximum minimum difference value, and a calculation process thereof is as follows: acquiring all minimum values exceeding a first threshold value from the displacement signals extracted by empirical mode decomposition, wherein the first threshold value can be set according to actual experience and is not unique; further, in all the minimum values, the maximum minimum value and the minimum value are determined, and the difference between the maximum minimum value and the minimum value is calculated to obtain the maximum minimum difference value, namely the corresponding out-of-round jitter value.
In specific implementation, in order to determine the sizes of the first preset level difference threshold and the second preset level difference threshold, it is verified whether the "vibration level difference value dB" can accurately evaluate out-of-roundness at different degrees. And selecting a plurality of case data of different lines, different out-of-round degrees and the front and the back of the turning wheel to ensure the accuracy and the objectivity of the verification result, wherein the selected case data are shown in table 1.
TABLE 1
The three ways of transverse comparison, longitudinal comparison and self-comparison are adopted, and the cases (case data) and expected results of the three comparisons are shown in table 2.
TABLE 2
By using the lateral comparison, the following verification conclusion can be obtained by performing the statistical analysis of the trend of the "vibration level difference dB" on the three wheel out-of-round cases (data) of 21 # line, 0.71mm,0.58mm and 0.24mm of a certain city: out-of-round more than 0.7mm, the vibration level difference dB exceeds 60dB and does not exceed 66dB; out-of-round more than 0.5mm and less than 0.7mm, the vibration level difference value dB exceeds 60dB; out-of-round below 0.5mm, the vibration level difference dB does not exceed 60dB.
By using longitudinal comparison, a verification conclusion can be obtained by performing statistical analysis on the trend of the vibration level difference value dB on two wheel out-of-roundness cases (data) of a wheel with the line of 0.71mm and a wheel with the line of 1.31mm of the line of 21: and out-of-roundness of more than 0.7mm, wherein the dB value of the vibration level difference exceeds 60dB, and the dB value of the part exceeds 66dB. The verification conclusion can be obtained by performing statistical analysis on the trend of the vibration level difference value dB on two wheel out-of-roundness cases (data) of a wheel with the line of 0.58mm and a wheel with the line of 0.52mm, which are the 21 st line, and the 9 th line, which is the 0.52 mm: out-of-round more than 0.5mm and less than 0.7mm, the vibration level difference dB exceeds 60dB. By performing statistical analysis on the tendency of 'vibration level difference dB' of two wheel out-of-roundness cases (data) with the line of 0.24mm and the line of 0.13mm of the line of 9, the verification conclusion of the out-of-roundness below 0.5mm can be obtained, and the vibration level difference dB does not exceed 60dB (the 0.13mm wheel with the line of 9 slightly exceeds).
By using self-comparison, the following verification conclusions can be obtained by performing statistical analysis of the "vibration level difference dB" trend for three out-of-roundness cases (data) of wheels with line 21 of 0.71mm, line 9 of 0.52mm and line 21 of 0.24 mm: after the wheel is turned, the trend of the vibration level difference dB is obviously reduced to be below 54dB, and the vibration level difference dB gradually shows a rising trend along with the increase of the operating mileage; out-of-round more than 0.5mm and less than 0.7mm, after turning the wheel, the vibration level difference dB trend is obviously reduced to less than 54dB, and the vibration level difference dB gradually shows a rising trend along with the increase of the operation mileage; and out-of-round below 0.5mm, and the dB trend of the vibration level difference value before and after turning the wheel is not obviously changed below 54 dB.
From the verification of the actual case data, when the out-of-round runout amount of the wheel exceeds 0.5mm, the vibration level difference value dB trend is generally over 60dB, after turning the wheel, the vibration level difference value dB trend is obviously reduced to be below 54dB, and the vibration level difference value dB gradually shows an increasing trend along with the increase of the operation mileage. Therefore, in the embodiment of the present invention, the first preset level difference threshold may be set to 54dB, and the second preset level difference threshold may be set to 60dB.
Further, in order to determine the soaring critical condition value (i.e. the preset rotation speed threshold value) of the wheel rotation speed, the actual model is subjected to an equivalent processing, and the model after the equivalent processing is shown in fig. 8.
Simulation software is utilized to carry out simulation analysis on displacement and acceleration signals of different out-of-roundness of wheels of a certain vehicle model at different rotating speeds. Wherein, the technical parameters of the vehicle type are shown in table 3.
TABLE 3
| Parameter item | Parameter value |
| Axle weight t | 23/25 |
| Weight t of bogie | 20 |
| Weight kg of the motor | 20 |
| Unsprung weight kg | 4572.5 |
| Wheel diameter mm | 1250 |
| Maximum speed km/h | 120 |
| Linear static deflection mm | 38 |
| Damping coefficient kN.s/m of primary shock absorber | 42.5 |
| Stiffness per axis in the vertical direction of 10 6 N/m | 6.45 |
The simulation single local out-of-roundness is set to be 1mm, the calculated rotating speed is within the variation range of 30r/min-520r/min, and the out-of-roundness situation is estimated through the negative peak value of the displacement signal, as shown in fig. 9.
It can be seen that the local out-of-round has obvious flying phenomenon, when the rotating speed exceeds 100r/min, the amplitude output of the displacement signal is obviously less than the out-of-round. Therefore, in the embodiment of the invention, the preset rotation speed threshold value can be set to be 100r/min.
And continuously performing theoretical analysis on the soaring phenomenon, and adding downward elastic force and damping force of a spring system when the wheel falls to force the wheel not to be separated from the wheel track compared with the situation that only a free falling body is considered, wherein the damping C and the damping x' are smaller and are temporarily ignored, so that the original soaring critical condition is calculated as follows:
In general, the out-of-roundness a is smaller than the initial compression amount Δ x of the spring, and therefore, the spring force can be regarded as constant in a short time, regardless of the change in the elongation of the spring during the fall, that is:
K△x＝Mg；
the flight condition can be estimated by the above formula, namely:
simplification is made by M/M =5,g =9.8, i.e.:
and estimating according to the wheel diameter of 1250mm after the out-of-round wheel of 1mm, wherein the rotating speed is more than 1.58Hz, namely 95r/min, and the rotating speed accords with the preset rotating speed threshold value of 100r/min obtained from the simulation result.
In the following, the comprehensive diagnosis method for wheel multi-edge out-of-round provided by the embodiment of the invention is verified by combining specific cases.
Case 1: a certain wire No. 5 1 wheel was located in a 3-12-th-turn wheel in 2014, and the radial runout of the wheel was measured by lathe contact at 1.37mm until 27-th in 2014, which was measured at 0.74mm. The wheel maintenance history data is shown in table 4.
TABLE 4
The comprehensive diagnosis method for out-of-roundness at multiple sides of the wheel provided by the embodiment of the invention is adopted to estimate the out-of-roundness jumping amount of the wheel, and the estimated values of the out-of-roundness jumping amount before and after the wheel turning are shown in figure 10.
It can be seen that the estimated values of out-of-round runout before and after the wheel turning are smaller than the actual out-of-round size. This is because the rotation speed of the wheel is usually greater than 100r/min during actual driving, and the result is consistent with the above theoretical simulation.
Case 2: table 5 shows maintenance history data of a certain 5 th line 2-bit wheel.
TABLE 5
The estimated value of the out-of-round runout before and after the wheel turning is shown in fig. 11.
It can be seen that a certain 5 th line 2-position wheel also shows a similar situation to a certain 5 th line 1-position wheel.
Case 3: for a 2-bit wheel of 9 gauge wire with a runout of 1.74mm measured in front of the wheel, we require a vehicle section to perform vibration acceleration signal acquisition on the wheel at a running speed of less than 100r/min on the test wire before turning. The comprehensive diagnosis method for out-of-round at multiple sides of the wheel provided by the embodiment of the invention is adopted to estimate the out-of-round jumping quantity of the wheel, and the estimated values of the out-of-round jumping quantities before and after the wheel-turning wheel are shown in fig. 12.
It can be seen that, except that the calculation fails due to abnormal signal acquisition for several times, the integral calculation results of other samples are close to the actual out-of-round size. Therefore, the comprehensive diagnosis method for the wheel multi-edge out-of-roundness can effectively evaluate the out-of-roundness degree of the wheel.
In another aspect, embodiments of the present invention provide a comprehensive diagnosis apparatus for wheel multi-lateral out-of-round, which may be referred to in correspondence with the above-described method.
Referring to fig. 13, the apparatus includes:
the signal acquisition module 1310 is used for acquiring a vibration acceleration signal of a wheel in the running process of the train;
a spectrum analysis module 1320, configured to perform spectrum analysis on the vibration acceleration signal to obtain a corresponding multi-order vibration effective value, and calculate a vibration level difference value corresponding to the multi-order vibration effective value;
a level difference determining module 1330 configured to determine whether the vibration level difference value is greater than a first preset level difference threshold;
the re-integration module 1340 is configured to re-integrate the vibration acceleration signal to obtain a corresponding displacement signal and calculate a characteristic value of the displacement signal to obtain a corresponding out-of-roundness beating value if the vibration level difference value is greater than a first preset level difference threshold value;
a run-out amount judging module 1350, configured to judge whether the out-of-roundness run-out amount value is greater than a preset run-out amount threshold;
and an alarm output module 1360, configured to output alarm information if the out-of-round jitter value is greater than the preset jitter amount threshold.
For the description of the relevant parts in the device for comprehensive diagnosis of out-of-round multiple edges of wheels provided by the embodiment of the present invention, please refer to the detailed description of the corresponding parts in the method for comprehensive diagnosis of out-of-round multiple edges of wheels provided by the embodiment of the present invention, and all have the corresponding effects of the method for comprehensive diagnosis of out-of-round multiple edges of wheels provided by the embodiment of the present invention, which are not repeated herein.
The wheel multi-lateral out-of-round comprehensive diagnosis device mentioned above is described from the perspective of a functional module, and further, according to another aspect of the embodiments of the present invention, a wheel multi-lateral out-of-round comprehensive diagnosis apparatus is provided, which is described from the perspective of hardware.
Referring to fig. 14, the apparatus includes:
a memory 1410 for storing a computer program;
a processor 1420, configured to implement the steps of any one of the above-mentioned wheel multi-lateral out-of-round comprehensive diagnosis methods when executing the computer program.
Processor 1420 may include one or more processing cores, such as 4-core processors, 8-core processors, and so on, among others. The processor 1420 may be implemented in at least one hardware form of a DSP (Digital Signal Processing), an FPGA (Field-Programmable Gate Array), and a PLA (Programmable Logic Array). Processor 1420 may also include a main processor, which is a processor for processing data in an awake state, also called a Central Processing Unit (CPU); a coprocessor is a low power processor for processing data in a standby state. In some embodiments, the processor 1420 may be integrated with a GPU (Graphics Processing Unit), which is responsible for rendering and rendering content that the display screen needs to display. In some embodiments, processor 1420 may also include an AI (Artificial Intelligence) processor for processing computational operations related to machine learning.
Memory 1410 may include one or more computer-readable storage media, which may be non-transitory. The memory 1410 may also include high-speed random access memory, as well as non-volatile memory, such as one or more magnetic disk storage devices, flash memory storage devices. In this embodiment, the memory 1410 is at least used for storing a computer program, wherein the computer program can realize the relevant steps of the wheel multi-lateral out-of-round comprehensive diagnosis method disclosed in any one of the foregoing embodiments after being loaded and executed by the processor. In addition, the resources stored in the memory 1410 may also include an operating system, data, and the like, and the storage manner may be a transient storage or a permanent storage. The operating system may include Windows, unix, linux, and the like, and the data may include, but is not limited to, data corresponding to the test result, and the like.
It is to be understood that, if the wheel multi-edge out-of-round comprehensive diagnosis method provided in any of the above embodiments is implemented in the form of a software functional unit and sold or used as a separate product, it may be stored in a computer-readable storage medium. Based on such understanding, the technical solutions of the present application may be substantially or partially implemented in the form of a software product, which is stored in a storage medium and executes all or part of the steps of the methods of the embodiments of the present application, or all or part of the technical solutions. And the aforementioned storage medium includes: a U disk, a removable hard disk, a Read-Only Memory (ROM), a Random Access Memory (RAM), an electrically erasable programmable ROM, a register, a hard disk, a removable magnetic disk, a CD-ROM, a magnetic or optical disk, and other various media capable of storing program codes.
In view of the above, a further aspect of the embodiments of the present invention provides a computer-readable storage medium, on which a computer program is stored, where the computer program, when executed by a processor, implements the steps of the wheel multi-edge out-of-round comprehensive diagnosis method provided in any of the above embodiments.
The functions of the functional modules of the computer-readable storage medium provided in the embodiment of the present invention may be specifically implemented according to the method in any of the method embodiments, and the specific implementation process may refer to the description related to any of the method embodiments, which is not described herein again.
The embodiments in the present description are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other. It is further noted that, in the present specification, relational terms such as first and second, and the like are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising a … …" does not exclude the presence of another identical element in a process, method, article, or apparatus that comprises the element.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (10)
1. A comprehensive diagnosis method for wheel multi-edge out-of-round is characterized by comprising the following steps:
acquiring a vibration acceleration signal of a wheel in the running process of a train;
carrying out spectrum analysis on the vibration acceleration signal to obtain a corresponding multi-order vibration effective value, and calculating a vibration level difference value corresponding to the multi-order vibration effective value;
judging whether the vibration level difference value is larger than a first preset level difference threshold value or not;
if the vibration level difference value is larger than the first preset level difference threshold value, performing double integration on the vibration acceleration signal to obtain a corresponding displacement signal, and calculating a characteristic value of the displacement signal to obtain a corresponding out-of-round jitter value;
Judging whether the out-of-roundness jitter magnitude is larger than a preset jitter threshold value or not;
and if the out-of-roundness jumping quantity value is larger than the preset jumping quantity threshold value, outputting alarm information.
2. The method for comprehensively diagnosing multilateral out-of-round of a wheel according to claim 1, wherein the performing a spectrum analysis on the vibration acceleration signal to obtain a corresponding multi-step vibration effective value and calculating a vibration level difference value corresponding to the multi-step vibration effective value comprises:
carrying out spectrum analysis on the vibration acceleration signal to obtain a multi-order vibration amplitude of the vibration acceleration;
calculating the multi-order vibration effective value of the vibration acceleration according to the multi-order vibration amplitude;
and calculating the vibration level difference value corresponding to the multi-order vibration effective value according to the multi-order vibration effective value.
3. The method for comprehensively diagnosing multilateral out-of-round of a wheel according to claim 2, wherein the calculation formula for calculating the multi-step vibration effective value of the vibration acceleration is as follows:
in the formula, a rms Representing the effective value of multi-step vibration, n representing the number of steps of wheel multi-edge out-of-round, a n Represents the nth order vibration amplitude, wherein n =1,2,3 …;
the calculation formula for calculating the vibration level difference value corresponding to the multi-order vibration effective value is as follows:
In the formula, A dB Representing the vibration level difference, N representing the rotating speed of the axle on which the wheel is positioned, and D representing the axle diameter of the axle on which the wheel is positioned.
4. The method for comprehensively diagnosing multilateral out-of-round in a vehicle wheel according to claim 1, wherein before the step of re-integrating the vibration acceleration signal to obtain a corresponding displacement signal and calculating a characteristic value of the displacement signal to obtain a corresponding out-of-round runout value, the method further comprises:
judging whether the rotating speed of the wheel is smaller than a preset rotating speed threshold value or not;
if the rotating speed of the wheel is smaller than the preset rotating speed threshold value, performing the step of performing double integration on the vibration acceleration signal to obtain a corresponding displacement signal, and calculating a characteristic value of the displacement signal to obtain a corresponding out-of-round run-out value;
and if the rotating speed of the wheel is not less than the preset rotating speed threshold value, returning to the step of acquiring the vibration acceleration signal of the wheel in the running process of the train.
5. The wheel multi-lateral out-of-round comprehensive diagnostic method according to claim 4, wherein before the determining whether the rotational speed of the wheel is less than a preset rotational speed threshold, the method further comprises:
judging whether the vibration level difference value is larger than a second preset level difference threshold value or not;
If the vibration level difference value is larger than the second preset level difference threshold value, directly outputting alarm information;
and if the vibration level difference value is not greater than the second preset level difference threshold value, executing the step of judging whether the rotating speed of the wheel is less than a preset rotating speed threshold value.
6. The method for comprehensively diagnosing multilateral out-of-round of a wheel according to claim 1, wherein the re-integrating the vibration acceleration signal to obtain a corresponding displacement signal and calculating the characteristic value of the displacement signal to obtain a corresponding out-of-round runout value comprises:
performing frequency domain re-integration on the vibration acceleration signal to obtain a corresponding displacement signal, and performing empirical mode decomposition extraction on the displacement signal;
and calculating the waveform amplitude characteristic value of the displacement signal after empirical mode decomposition extraction to obtain a corresponding out-of-round jitter value.
7. The method for comprehensively diagnosing wheel multi-lateral out-of-round according to claim 6, wherein the calculating the waveform amplitude characteristic value of the displacement signal after the empirical mode decomposition extraction to obtain the corresponding out-of-round run-out value comprises:
acquiring all minimum values exceeding a preset displacement threshold value from the displacement signals extracted by empirical mode decomposition;
Determining a maximum minimum value and a minimum value among all the minimum values;
and calculating the difference value between the maximum minimum value and the minimum value to obtain the corresponding out-of-roundness beating quantity value.
8. A wheel multi-edge out-of-round comprehensive diagnostic apparatus, characterized by comprising:
the signal acquisition module is used for acquiring a vibration acceleration signal of a wheel in the running process of the train;
the frequency spectrum analysis module is used for carrying out frequency spectrum analysis on the vibration acceleration signal to obtain a corresponding multi-order vibration effective value and calculating a vibration level difference value corresponding to the multi-order vibration effective value;
the level difference judging module is used for judging whether the vibration level difference value is larger than a first preset level difference threshold value or not;
the re-integration module is used for re-integrating the vibration acceleration signal to obtain a corresponding displacement signal and calculating a characteristic value of the displacement signal to obtain a corresponding out-of-round jitter value if the vibration level difference value is greater than the first preset level difference threshold value;
the jumping amount judging module is used for judging whether the out-of-round jumping amount value is larger than a preset jumping amount threshold value;
and the alarm output module is used for outputting alarm information if the out-of-round jumping quantity value is greater than the preset jumping quantity threshold value.
9. A wheel multi-lateral out-of-round comprehensive diagnostic apparatus, characterized by comprising:
a memory for storing a computer program;
a processor for implementing the steps of the wheel multi-lateral out-of-round comprehensive diagnosis method according to any one of claims 1 to 7 when executing the computer program.
10. A computer-readable storage medium, characterized in that the computer-readable storage medium has stored thereon a computer program which, when being executed by a processor, realizes the steps of the wheel multi-lateral out-of-round comprehensive diagnosis method according to any one of claims 1 to 7.
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