CN114235951A - Crack fault acoustic diagnosis method and device for engine air inlet casing support plate - Google Patents
Crack fault acoustic diagnosis method and device for engine air inlet casing support plate Download PDFInfo
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Abstract
The application provides a crack fault acoustic diagnosis method for an engine air inlet casing support plate, which comprises the following steps: impacting an engine air inlet casing fixing support plate to generate an acoustic signal; collecting a force signal impacting an engine air inlet casing fixing support plate and an acoustic signal generated by the engine air inlet casing fixing support plate, and processing the force signal and the acoustic signal by a transfer function method to obtain an acoustic frequency response signal; and comparing the acoustic frequency response signal of the engine air inlet casing fixing support plate with the acoustic frequency response signal of the engine air inlet casing fixing support plate in the database, if the frequency difference value of the first peak value of the two acoustic frequency response signals exceeds a threshold value, judging that the engine air inlet casing fixing support plate has cracks, otherwise, judging that the engine air inlet casing fixing support plate has no cracks. Compared with the traditional fault diagnosis method, the crack fault acoustic diagnosis method is simpler and more efficient, and can effectively identify the crack fault in the support plate and at the structural joint surface.
Description
Technical Field
The application belongs to the technical field of automatic control, and particularly relates to a method and a device for identifying characteristic parameters of a gap link on line based on line segment fitting.
Background
The air inlet casing is used as a main bearing and air inlet part at the front end of the aircraft engine, and has the functions of rectifying incoming air flow, ensuring that the air flow can meet the use requirement of the air compressor, and enabling the air flow to flow through the bent flow channel with the minimum total pressure loss and the minimum aerodynamic resistance. The engine air inlet casing faces the problems of large load and light weight, and meanwhile, the air inlet casing works under the working conditions of high pressure, high speed and various loads for a long time, so that the air inlet casing is easy to corrode and vibrate, a fixed support plate of the air inlet casing is easy to crack, and further, the crack is evolved into the fracture of the support plate, and a flight accident is caused.
Because the structure of the aircraft engine is complex, and the crack forms of the inlet casing support plate are various, the traditional detection methods such as hole detection, fluorescence, vibration, noise monitoring, ultrasonic flaw detection and the like have several problems when the crack fault of the inlet casing support plate is diagnosed:
1) the nondestructive inspection detection methods of hole detection, fluorescence and the like are common methods for detecting structural cracks, corrosion, tearing and other faults and defects in the engineering field, are also common detection means for the structural state of an aero-engine, but the application of the nondestructive inspection detection methods to the detection of the cracks of an engine air inlet casing support plate has the following problems:
1.1) the accuracy of nondestructive flaw detection such as hole detection, fluorescence and the like is limited by the operation correctness and judgment capability of inspectors, so that diagnosis errors can be caused by human factors, and the detection reliability is reduced;
1.2) nondestructive flaw detection such as hole detection, fluorescence and the like can only detect the crack state of the surface of the support plate and cannot identify the crack state in the structure and at the joint surface of the structure;
2) vibration and noise monitoring is also a common fault diagnosis method for large-scale equipment. The equipment fault diagnosis can be realized by identifying the vibration and noise characteristic signals generated in the equipment operation process, and extracting and separating the equipment state information in the characteristic signals. However, the application of the method to the detection of cracks of the engine intake casing support plate has the following problems:
2.1) the whole structure of the aircraft engine is complex, the test condition is severe, and potential safety hazards of the test can exist when vibration and noise points are added in the test state;
2.2) the characteristics of the vibration and noise signals of the whole aircraft engine are complex, the structure of the supporting plate of the air inlet casing is small, the energy of the generated vibration and noise signals is weak, and the characteristic signals of the supporting plate of the air inlet casing are difficult to identify from the vibration and noise signals of the whole aircraft;
3) structural modal analysis is also a common tool in structural fault diagnosis. The modal information of the structure is obtained based on the modal identification and analysis method, and the diagnosis of the structural fault can be realized by comparing the modal information of the structure in the initial state. However, the application of the method to the detection of cracks of the engine inlet casing support plate has the following problems:
3.1) the number of the engine air inlet casing support plates is large, vibration measuring points need to be arranged on each support plate to obtain the state information of all the support plates, modal tests are carried out on each support plate, and the test process and method are complex;
3.2) the whole structure of the aircraft engine is complex, and the difficulty in arranging vibration measuring points on all support plates is high in the whole state;
4) ultrasonic inspection is also a common method used in structural fault diagnosis. However, the application of the method to the detection of cracks of the engine intake casing support plate has the following problems:
4.1) the ultrasonic flaw detection needs to determine flaw detection sensitivity and a flaw judgment standard in advance, and the crack state of the surface of the support plate cannot be effectively identified when the sensitivity is too high or too low;
4.2) under the complete machine state, the ultrasonic flaw detection can only detect the surface crack state of the support plate, and cannot identify the crack characteristics in the structure and at the structure joint surface;
5) fast fourier transform and short-time fourier transform are common experimental data processing means in signal processing, and the characteristic information of a signal is acquired by decomposing a time domain signal into components with different frequencies. In the test scheme, the applied excitation has randomness, and the acoustic response signal of the support plate has weak energy and short duration, so that the traditional Fourier transform analysis method cannot effectively identify the characteristic signal of the support plate.
Disclosure of Invention
The present application is directed to a method and apparatus for acoustically diagnosing crack faults in an engine inlet casing support plate that solves or reduces at least one of the problems set forth above.
In one aspect, the present application provides a method of crack fault acoustic diagnosis of an engine inlet case plate, the method comprising:
impacting an engine air inlet casing fixing support plate to generate an acoustic signal;
collecting a force signal impacting an engine air inlet casing fixing support plate and an acoustic signal generated by the engine air inlet casing fixing support plate, and processing the force signal and the acoustic signal by a transfer function method to obtain an acoustic frequency response signal;
and comparing the acoustic frequency response signal of the engine air inlet casing fixing support plate with the acoustic frequency response signal of the engine air inlet casing fixing support plate in the database, if the frequency difference value of the first peak value of the two acoustic frequency response signals exceeds a threshold value, judging that the engine air inlet casing fixing support plate has cracks, otherwise, judging that the engine air inlet casing fixing support plate has no cracks.
Further, before striking the engine intake casing fixing support plate to generate the acoustic signal, the method further comprises the following steps: and collecting the background noise of the environment.
Further, after an acoustic signal generated by an engine air inlet casing fixing support plate is collected, the acoustic signal is compared with the background noise, and the acoustic signal higher than the preset value of the background noise is an effective signal within a certain frequency range.
Further, the frequency range is 0-1000 Hz.
Further, the predetermined value is not less than 3 dB.
Further, the process of processing the force signal and the acoustic signal by a transfer function method to obtain an acoustic frequency response signal includes:
positioning the time of occurrence of the acoustic response signal of the fixed support plate based on the time domain analysis of the force signal;
selecting analysis time with a certain length based on the duration of the acoustic response signal;
based on a transfer function method, the collected force signals are subjected to normalization processing on the acoustic response signals of the support plate, the influence of random excitation on the acoustic response signals of the support plate is eliminated, and the characteristic signals of the support plate are obtained.
Further, the transfer function is expressed as follows:
in the formula, Pxy(f) Is the self-spectrum of the input terminal, Pxx(f) Is the cross-spectrum of the output.
In another aspect, the present application provides an apparatus for implementing the crack fault acoustic diagnosis method for an engine intake casing support plate as described in any one of the above, the apparatus comprising:
an acoustic sensor for acquiring an acoustic signal;
the force hammer is used for impacting the fixed support plate to enable the fixed support plate to generate an acoustic signal;
the acquisition system is used for processing the acoustic signals acquired by the acoustic sensor and the force signals impacting the fixed support plate;
the handheld support is connected with the acoustic sensor and the force hammer respectively, and the handheld support sends the acoustic sensor and the force hammer to the positions near the fixed support plate through the outside of the engine; and
and the sensor fixing support is fixedly connected with the fixing support plate and is used for supporting and fixedly connecting an acoustic sensor and a force hammering point handheld support.
The crack fault diagnosis method and device provided by the application realize effective, quick and accurate identification of the crack fault of the engine air inlet casing fixing support plate, and have the main advantages that:
1) when the traditional fault diagnosis method is applied to diagnosis of crack faults of a fixed support plate of an air inlet casing of an aircraft engine, the problems of poor diagnosis reliability, incapability of identifying crack characteristics in the structure and at the structural joint surface, complexity of the diagnosis method and the like exist, and compared with the traditional fault diagnosis method, the crack fault acoustic diagnosis method is simpler and more efficient, and can effectively identify the crack faults in the support plate and at the structural joint surface;
2) due to the fact that excitation is random, the acoustic response signal of the support plate is weak in energy and short in duration, the traditional Fourier transform analysis method cannot effectively identify the characteristic signal of the support plate, and the method of the application can effectively identify the characteristic signal of the support plate by processing the characteristic of the acoustic response signal of the support plate;
3) the fault diagnosis device can realize simple and efficient diagnosis of the crack fault of the engine air inlet casing support plate under the condition of an external field test.
Drawings
In order to more clearly illustrate the technical solutions provided by the present application, the following briefly introduces the accompanying drawings. It is to be expressly understood that the drawings described below are only illustrative of some embodiments of the invention.
FIG. 1 is a schematic diagram of a crack fault diagnosis method for an engine inlet casing support plate according to the present application.
FIG. 2 is a schematic view of the crack fault diagnosis device for the engine inlet casing support plate according to the present application.
Fig. 3 is a graph of the acoustic frequency of a plate obtained by a conventional fourier transform method.
Fig. 4 is a graph of the acoustic frequency of the plate obtained by the acoustic diagnostic method of the present application.
Detailed Description
In order to make the implementation objects, technical solutions and advantages of the present application clearer, the technical solutions in the embodiments of the present application will be described in more detail below with reference to the drawings in the embodiments of the present application.
The crack fault acoustic diagnosis method and the crack fault acoustic diagnosis device are provided for crack fault diagnosis of a fixed support plate of an air inlet casing of an aero-engine, and can be used for effectively, accurately and quickly identifying the crack fault of the support plate of the air inlet casing.
In the process of endurance test of the aero-engine, the support plate can generate fatigue cracks due to the fact that the air inlet casing works under the test working condition of high speed and high load for a long time, and the test safety and the reliability of the aero-engine are seriously affected. The acoustic signal is used as a signal capable of reflecting structural characteristic state information, when the support plate has a crack fault, the structural characteristics of the fixed support plate can change, and further the acoustic signal characteristics generated by the stress of the fixed support plate change along with the change. According to the characteristic, the acoustic diagnosis method for the crack fault of the fixing support plate of the air inlet casing of the aircraft engine is provided, and the crack fault of the support plate of the air inlet casing of the engine can be effectively identified.
As shown in fig. 1 and fig. 2, before the test, a test database of a brand-new inlet casing support plate is established, and the crack fault of the fixed support plate is diagnosed by comparing the test data characteristics.
The testing system mainly comprises an acoustic sensor 11, a force hammer 13 and an acoustic data acquisition system 12. Before the test, the power hammer 13 and the acoustic sensor are synchronously connected into a data acquisition system, and the system can be ensured to stably and effectively acquire acoustic signals. Before the formal test of the application is carried out, the background noise of the test environment is recorded.
In the test, the acoustic sensor 11 is first fixed, and each support plate is sequentially tapped by the power hammer 13. An acoustic response signal generated by knocking the fixed support plate is collected by the acoustic data collection system 12 and compared with a background noise signal, acoustic signal data which is at least 3dB higher than the background noise is valid data within the frequency range of 0-1000 Hz, and invalid data needs to be tested again.
And comparing the screened effective data with the frequency of the sound response signal of the intact fixed support plate with the first peak, judging that the fixed support plate is intact if the difference value of the two is within a certain frequency range (determined according to a test database of a brand-new casing support plate), and otherwise, judging that the fixed support plate has a crack fault. In the application, the diagnosis of the crack fault of the support plate can be effectively realized by comparing the frequency of the first peak of the acoustic response signals of the target support plate and the intact support plate.
In addition, the fourier transform analysis method is a data processing analysis means commonly used in fault signal processing, mainly including fast fourier transform and short-time fourier transform, and the principle is to decompose time domain data of a period of time into sinusoidal components of different frequencies. In the application, because the duration of the acoustic signal generated by the knocking of the fixed support plate is short, the energy of the acoustic response signal is weak, and the applied excitation is random, the following problems can be encountered when the fault signal is processed by applying the fast fourier transform or the short time fourier transform: 1) when the time length of the selected and analyzed data is long, the crack fault signals of the support plate cannot be accurately identified under certain excitation conditions; 2) when the time for selecting and analyzing the data is short, the analysis precision is poor.
Under the background, the method further provides effective extraction of the characteristic signals of the support plate, and the specific process comprises the following steps:
firstly, the time of the acoustic response signal of the support plate is analyzed and positioned based on the time domain of the force signal;
secondly, selecting a proper analysis duration based on the duration of the acoustic response signal, wherein the analysis duration can be usually 0.2s or 0.5 s;
and finally, based on a transfer function method, carrying out normalization processing on the acoustic response signals of the support plate by the collected force signals, eliminating the influence of random excitation on the acoustic response signals of the support plate, acquiring characteristic signals of the support plate, and further realizing the diagnosis of the crack faults of the support plate.
Wherein, the expression form of the transfer function is as follows:
wherein: pxy(f) Is the self-spectrum of the input terminal, Pxx(f) Is the cross-spectrum of the output.
As shown in FIGS. 3 and 4, under random excitation, the characteristic signals of the support plate cannot be effectively identified by the traditional Fourier transform analysis method, and the characteristic signals of the support plate appear around 250Hz obviously by applying the method of the application.
Finally, comparing the frequency curve in fig. 4 with the data in the database, a change occurs, i.e. a crack is generated, but usually it is lower.
In the complete state of the aircraft engine, the air inlet casing is positioned inside the air inlet channel, the conventional means is that a tester drills into the air inlet channel to diagnose the crack state of the support plate, and the test method is complex and has low efficiency. Therefore, the present application further provides a diagnosis device suitable for the method based on the diagnosis method, so that the diagnosis scheme is simpler and more convenient, and the diagnosis efficiency is improved.
As shown in fig. 1 and 4, the diagnostic apparatus provided by the present application is mainly composed of an acoustic sensor 11, an acquisition system 12 (not shown in fig. 4), a power hammer 13, a sensor fixing bracket 14, and a handheld bracket 15. The sensor fixing support is a fixing device of an acoustic sensor and a handheld support, so that the microphone is ensured to be stable in state and not to shake during a diagnostic test; the handheld support is used for fixing the power hammer and the sensor respectively, and the power hammer and the sensor can be extended into the supporting plate by the aid of the handheld support, so that the crack state of the supporting plate can be detected without the need of drilling a tester into the air inlet channel, a diagnosis scheme is simpler and more convenient, and diagnosis efficiency can be improved.
The crack fault diagnosis method and device provided by the application realize effective, quick and accurate identification of the crack fault of the engine air inlet casing fixing support plate, and have the main advantages that:
1) when the traditional fault diagnosis method is applied to diagnosis of crack faults of a fixed support plate of an air inlet casing of an aircraft engine, the problems of poor diagnosis reliability, incapability of identifying crack characteristics in the structure and at the structural joint surface, complexity of the diagnosis method and the like exist, and compared with the traditional fault diagnosis method, the crack fault acoustic diagnosis method is simpler and more efficient, and can effectively identify the crack faults in the support plate and at the structural joint surface;
2) due to the fact that excitation is random, the acoustic response signal of the support plate is weak in energy and short in duration, the traditional Fourier transform analysis method cannot effectively identify the characteristic signal of the support plate, and the method of the application can effectively identify the characteristic signal of the support plate by processing the characteristic of the acoustic response signal of the support plate;
3) the fault diagnosis device can realize simple and efficient diagnosis of the crack fault of the engine air inlet casing support plate under the condition of an external field test.
The above description is only for the specific embodiments of the present application, but the scope of the present application is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present application should be covered within the scope of the present application. Therefore, the protection scope of the present application shall be subject to the protection scope of the claims.
Claims (8)
1. A method for acoustically diagnosing a crack fault in an engine inlet case support plate, the method comprising:
impacting an engine air inlet casing fixing support plate to generate an acoustic signal;
collecting a force signal impacting an engine air inlet casing fixing support plate and an acoustic signal generated by the engine air inlet casing fixing support plate, and processing the force signal and the acoustic signal by a transfer function method to obtain an acoustic frequency response signal;
and comparing the acoustic frequency response signal of the engine air inlet casing fixing support plate with the acoustic frequency response signal of the engine air inlet casing fixing support plate in the database, if the frequency difference value of the first peak value of the two acoustic frequency response signals exceeds a threshold value, judging that the engine air inlet casing fixing support plate has cracks, otherwise, judging that the engine air inlet casing fixing support plate has no cracks.
2. The method of acoustically diagnosing a crack fault in an engine inlet casing support plate of claim 1 further comprising, prior to impacting the engine inlet casing support plate to generate the acoustic signal: and collecting the background noise of the environment.
3. The method as claimed in claim 2, wherein the acoustic signal generated by the engine inlet casing fixing support plate is collected and compared with the background noise, and the acoustic signal higher than the predetermined value of the background noise is a valid signal in a certain frequency range.
4. The method of claim 3, wherein the frequency range is 0 to 1000 Hz.
5. The method of acoustic diagnosis of crack failure of an engine inlet casing plate according to claim 3, characterized in that said predetermined value is not less than 3 dB.
6. The method of claim 1, wherein the step of processing the force signal and the acoustic signal by a transfer function method to obtain an acoustic frequency response signal comprises:
positioning the time of occurrence of the acoustic response signal of the fixed support plate based on the time domain analysis of the force signal;
selecting analysis time with a certain length based on the duration of the acoustic response signal;
based on a transfer function method, the collected force signals are subjected to normalization processing on the acoustic response signals of the support plate, the influence of random excitation on the acoustic response signals of the support plate is eliminated, and the characteristic signals of the support plate are obtained.
7. An acoustic method for crack fault diagnosis of an engine inlet casing plate as set forth in claim 6, characterized in that the transfer function is expressed as follows:
in the formula, Pxy(f) Is the self-spectrum of the input terminal, Pxx(f) Is the cross-spectrum of the output.
8. An apparatus for implementing a crack fault acoustic diagnostic method for an engine inlet casing strip as claimed in any one of claims 1 to 7, characterized in that it comprises:
an acoustic sensor (11) for acquiring an acoustic signal;
a power hammer (13) for striking the fixed plate to generate an acoustic signal;
an acquisition system (12) for processing the acoustic signals acquired by the acoustic sensor and the force signals impacting the fixed support plate;
the handheld support (15) is respectively connected with the acoustic sensor (11) and the force hammer (13), and the handheld support (15) sends the acoustic sensor (11) and the force hammer (13) to the vicinity of the fixed support plate through the outside of the engine; and
the sensor fixing support (14) is fixedly connected with the fixing support plate, and the sensor fixing support (14) is used for supporting and fixedly connecting an acoustic sensor (11) and a force hammer (13) point handheld support (15).
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- 2021-11-29 CN CN202111432805.XA patent/CN114235951B/en active Active
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|---|---|---|---|---|
| GB201103520D0 (en) * | 2011-03-02 | 2011-04-13 | Score Group Plc | Impact detection and monitoring system |
| CN104870969A (en) * | 2012-12-13 | 2015-08-26 | 斯奈克玛 | Method and device for acoustically detecting a malfunction of a motor having an active noise control |
| CN107631877A (en) * | 2017-08-11 | 2018-01-26 | 南京航空航天大学 | A kind of rolling bearing fault collaborative diagnosis method for casing vibration signal |
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| Title |
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| 樊高瞻 等: "基于改进形态-小波阈值降噪的轴承复合故障声学诊断", 《振动与冲击》, vol. 39, no. 12, 31 December 2020 (2020-12-31), pages 221 - 226 * |
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