CN115635366A - Large machine tool blade acoustic emission online monitoring system and method - Google Patents
Large machine tool blade acoustic emission online monitoring system and method Download PDFInfo
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- CN115635366A CN115635366A CN202211243562.XA CN202211243562A CN115635366A CN 115635366 A CN115635366 A CN 115635366A CN 202211243562 A CN202211243562 A CN 202211243562A CN 115635366 A CN115635366 A CN 115635366A
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- 238000012544 monitoring process Methods 0.000 title claims abstract description 51
- 238000000034 method Methods 0.000 title claims abstract description 13
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- 238000007621 cluster analysis Methods 0.000 claims description 3
- 239000000084 colloidal system Substances 0.000 claims description 3
- 238000002474 experimental method Methods 0.000 claims description 3
- 238000009434 installation Methods 0.000 claims description 3
- 238000002360 preparation method Methods 0.000 claims description 3
- 230000009466 transformation Effects 0.000 claims description 3
- UXOWGYHJODZGMF-QORCZRPOSA-N Aliskiren Chemical compound COCCCOC1=CC(C[C@@H](C[C@H](N)[C@@H](O)C[C@@H](C(C)C)C(=O)NCC(C)(C)C(N)=O)C(C)C)=CC=C1OC UXOWGYHJODZGMF-QORCZRPOSA-N 0.000 claims description 2
- 229960004601 aliskiren Drugs 0.000 claims description 2
- 230000007774 longterm Effects 0.000 abstract description 7
- 238000004804 winding Methods 0.000 abstract description 4
- 238000011161 development Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 238000012806 monitoring device Methods 0.000 description 3
- 238000010586 diagram Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 239000000956 alloy Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
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- 238000005260 corrosion Methods 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
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- 230000003068 static effect Effects 0.000 description 1
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Abstract
The invention aims to provide an online acoustic emission monitoring system and method for a large machine tool blade. The invention fixes the acoustic emission device on the rotating shaft of the large machine tool in a working state, and supplies power to the acoustic emission device through the rotating power supply device, thereby solving the problems of line winding and balance weight unbalance of the blade and power supply of a monitoring module when the machine tool blade is dynamically monitored, effectively realizing long-term dynamic monitoring of fatigue damage of the large machine tool blade, and providing an important means for monitoring the health condition of the machine tool blade.
Description
Technical Field
The invention relates to a large machine tool, in particular to a blade on-line monitoring system and a blade on-line monitoring method.
Background
With the deepening of the informatization process and the rapid development of the internet industry, the traditional backward production mode of industrial equipment seriously influences the development of the economic society, and the traditional backward production mode becomes the problem which is urgently solved in the 21 st century and meets the challenge. The acoustic emission technology is a brand-new dynamic nondestructive monitoring technology, can know the running state of equipment in real time, ensures safe and efficient production operation, and has good development prospect.
The blade is a key part for the operation of a machine tool, and the long-term operation of the machine tool blade can cause fatigue damage of different degrees under the influence of various severe working environments such as vibration, pollution, alternating load and the like. Because the blade size is less, it is difficult to discover the damage of blade in time with the naked eye to influence the performance and the life-span of blade, lead to great incident even. By monitoring the service state of the blade, the fatigue damage condition can be found in time, the maintenance cost is reduced, and the safe operation of the machine tool is ensured, so that the fatigue damage monitoring on the blade has important practical significance.
Acoustic emission is a common monitoring method, and is often used for static monitoring of structures such as bridges, rock and soil, pressure vessels and the like, while dynamic monitoring of machine tool blades in a working state is rarely reported due to problems of line winding, counterweight installation, long-term power supply and the like, and a solution is urgently needed in engineering application.
Disclosure of Invention
The invention aims to provide a system and a method for monitoring blade fatigue damage of a large machine tool on line by acoustic emission, which can realize long-term real-time health monitoring of the blade fatigue damage.
The purpose of the invention is realized as follows:
the invention relates to a large-scale machine tool blade acoustic emission on-line monitoring system, which is characterized in that: including wheel hub, lathe pivot, system even take the ware, lathe pivot and blade are installed on wheel hub, and the system is taken ware one side even and is passed through the nut and link to each other with the lathe pivot, and the system is taken the ware and is installed acoustic emission module in, and acoustic emission sensor installs at blade work area assigned position, and acoustic emission sensor connects acoustic emission module and detects the acoustic emission damage signal that the blade produced when rotating.
The present invention may further comprise:
1. the system is even carried the ware and is connected electrically conductive sliding ring, electrically conductive sliding ring includes that sliding ring main part, sliding ring spline screens, sliding ring flange dish, sliding ring spline device, sliding ring spline fixing device, and the sliding ring main part is connected to the sliding ring flange dish, and the sliding ring spline screens is installed on the sliding ring flange dish, and the outer loop installation sliding ring spline device of sliding ring main part, the sliding ring spline fixing device includes the screens stationary blade, splines the fixed station, and the screens stationary blade is connected and is spline the fixed station, sets up the sliding ring on the screens stationary blade and splines the device preformed hole, and the sliding ring spline device and sliding ring spline the device preformed hole and cooperate.
2. The interface of the acoustic emission sensor is coated with high-strength glue.
The invention relates to a large-scale machine tool blade acoustic emission online monitoring method, which is characterized in that:
(1) Preparation before experiment: smearing a special couplant for sound emission on a designated position of a blade working area, sleeving a sound emission sensor in a sensor protection die, smearing a layer of high-strength colloid on the periphery of the die, fixing the blade, rotationally fixing a system connector and a machine tool rotating shaft through a circular nut, placing a sound emission module in the system connector, connecting the sound emission sensor with a sound emission module, sleeving a conductive sliding ring on the circular nut at one end of the system connector, screwing a sliding ring rotation-stopping clamp position, fastening the sliding ring on the system connector, fastening a sliding ring rotation-stopping device with a sliding ring rotation-stopping fixing device through a bolt, connecting an inner ring lead corresponding to the conductive sliding ring with a power line of the sound emission module, and connecting an outer ring lead with a power supply;
(2) Setting instrument parameters: starting an acoustic emission module, setting monitoring parameters of the acoustic emission module, including parameters of an early warning system including a threshold value, a gain amplitude value, a noise judgment value, an amplitude value and a ringing count, wherein the instrument comprises red, green and blue prompting lamps, the red indicates that an early warning signal is generated, the green indicates that an acoustic emission signal is generated, the blue indicates that the instrument is connected with a network, waiting for the acoustic emission module to light the blue lamp, connecting the blue lamp with Aliskiren cloud, and preparing to start monitoring;
(3) And (3) damage monitoring: the method comprises the steps of starting a machine tool, enabling a blade to rotate, enabling an acoustic emission probe to monitor the state of the blade in real time, enabling the acoustic emission probe to send an acoustic emission signal to an acoustic emission module in real time when the blade is damaged, enabling the acoustic emission module to display a green light to prompt damage when the acoustic emission module receives the acoustic emission signal and upload data to Aliskiu in real time, enabling the acoustic emission module to display a red light prompt alarm when the amplitude of the acoustic emission signal exceeds a preset alarm value, carrying out cluster analysis and wavelet packet transformation on the monitored acoustic emission data, obtaining frequency band characteristics of different damage modes, identifying the damage mode of the blade, and obtaining a damage evolution rule of the blade.
The invention has the advantages that: the invention fixes the acoustic emission device on the rotating shaft of the large machine tool in a working state, and supplies power to the acoustic emission device through the rotary power supply device, thereby solving the problems of line winding and balance weight unbalance of the blade and power supply of a monitoring module when the machine tool blade is dynamically monitored, effectively realizing long-term dynamic monitoring of the fatigue damage of the large machine tool blade, and providing an important means for monitoring the health condition of the machine tool blade.
Drawings
FIG. 1 is a schematic structural view of the present invention;
FIG. 2 is a front view of a sensor protection die structure;
FIG. 3 is a top view of a sensor protection die structure;
FIG. 4 is a schematic diagram of a system connector;
FIG. 5 is a schematic view of a conductive slip ring structure;
FIG. 6 is a left side view of the conductive slip ring;
FIG. 7 is a right side view of the conductive slip ring;
FIG. 8 is a side view of the slip ring anti-rotation fixture;
fig. 9 is a front view of the slip ring anti-rotation fixing device.
Detailed Description
The invention will now be described in more detail by way of example with reference to the accompanying drawings in which:
with reference to fig. 1-9, the present invention provides an on-line monitoring system for acoustic emission of large machine tool blade, comprising: the large-scale lathe body device, sound emission device, rotatory power supply unit. The large machine tool body device is used for building a main body structure of the large machine tool; the acoustic emission device is fixed in the system connector 404, is connected with the machine tool rotating shaft 2 through the system connector 404 and is used for monitoring the damage condition of the machine tool blade in a rotating state in real time; the rotary power supply device is fixed on the other side of the system connector 404 and is used for supplying power to the acoustic emission device for long-term monitoring.
The large machine tool body device includes: wheel hub 301, lathe pivot 2, lathe organism 1. Hub 301 is for securing blades; the machine tool rotating shaft 2 is arranged in the center of the hub and rotates along with the blade; the front machine body 1 of the machine tool is fixed on the rotating shaft 2 of the machine tool, and the gravity center of the machine tool is kept.
The acoustic emission monitoring device includes: an acoustic emission sensor 402, an acoustic emission monitoring module 403. The acoustic emission sensor 402 is fixed at a position where the blade is easy to damage, is connected with an acoustic emission monitoring module 403, and is used for detecting an acoustic emission damage signal generated when the machine tool blade rotates; the acoustic emission monitoring module 403 is fixed in the system connector 404, and is configured to receive the damage signal transmitted by the acoustic emission sensor 402 in real time.
The acoustic emission on-line monitoring device still includes: the sensor protects the mold 401, system connector 404. The sensor protection die 401 effectively protects the acoustic emission sensor 402 and is fixed on the blade 302 by high-strength glue; the system connector 404 is used for fixing the acoustic emission online monitoring module 403, and one side of the system connector is connected with the machine tool rotating shaft 2 through a nut.
The rotary power supply device includes: conductive slip ring 60, slip ring anti-rotation fixture 605. One end of the conductive slip ring 60 is connected with the system carrier 404 and is fixed by a round nut 405; slip ring anti-rotation fixtures 605 are attached to the conductive slip ring 60.
The conductive slip ring 60 further comprises rotor stator leads, a slip ring rotation stopping clamp 601, a slip ring flange 602, a slip ring main body 603, a slip ring rotation stopping device 604: the slip ring main body 603 is fixedly connected with the slip ring flange 602.
The slip ring rotation stopping clamp 601 is connected 602 with the slip ring flange plate and fixed on the circular nut 405: the slip ring rotation stopping device 604 is connected with a slip ring rotation stopping fixing device 605.
The slip ring rotation stop fixture 605 includes: a clamping fixing piece 6051 and a rotation stopping fixing table 6054. The power line of the conductive slip ring passes through a power line preformed hole 6053 in the clamping fixed plate 6051 to be led out, and the slip ring rotation stopping device 604 and a slip ring rotation stopping device preformed hole 6052 in the clamping fixed plate 6051 are connected through bolts; the rotation stopping fixing table 6054 is positioned at the center of the clamping fixing piece and used for fixing the conductive slip ring.
As shown in fig. 1, the structural schematic diagram of the large machine tool blade acoustic emission online monitoring system of the present invention includes a large machine tool body device for building a main body structure of the large machine tool; the acoustic emission online monitoring device is fixed in the system connector 404, is connected with the machine tool rotating shaft 2 through the system connector 404 and is used for monitoring the damage condition of the machine tool blade in a rotating state in real time; and the rotary power supply device is fixed on the other side of the system connector 404 and is used for supplying power to the acoustic emission device for long-term monitoring.
The large machine tool body device comprises a hub 301, a fixing device and a control device, wherein the hub 301 is mainly used for fixing a rotating component through a fastening bolt 303; the machine tool rotating shaft 2 is arranged in the center of the hub and rotates along with the blade 302; and the machine tool front body 2 is fixed on the machine tool rotating shaft 2 and keeps the center of gravity of the machine tool.
The acoustic emission device comprises an acoustic emission sensor 402, a sound emission module 403 and a control module, wherein the acoustic emission sensor 402 is fixed at a position where the blade is easy to damage and connected with the acoustic emission module 403 and is used for detecting an acoustic emission damage signal generated when the machine tool blade rotates; and the acoustic emission module 403 is fixed in the system carrier 404 and is configured to receive the fatigue damage signal transmitted by the acoustic emission sensor 402 in real time.
The acoustic emission device further includes: the sensor protection mold 401 is fixed at a position where the blade is easy to be damaged as shown in fig. 2 and 3, and a layer of high-strength glue needs to be coated at an interface of the sensor protection mold before the acoustic emission sensor 402 is placed so that the sensor protection mold can be fixed at a specified position of a blade working area. The system carrier 404, as shown in fig. 4, is used to fix the acoustic emission module 403 and ensure that the acoustic emission module rotates when the machine tool blade rotates. The system is even carried ware 404, and formula framework as an organic whole, the main part is formed by the corrosion resistant plate welding, and its limit is the chamfer component, and acoustic emission module fixing bolt 4011 is fixed in acoustic emission module back face, the system even carry ware one side through the nut 405 at curb plate center with lathe pivot 2 links to each other.
The rotary power supply device includes: a conductive slip ring 60, one side of which is connected with the system carrier 404 and fixed by a circular nut 405; and a slip ring rotation stopping fixing device 605 connected to the conductive slip ring 60.
The conductive slip ring 60 comprises a rotor stator lead, a slip ring rotation stopping position clamp 601, a slip ring flange plate 602, a slip ring main body 603 and a slip ring rotation stopping device 604. As shown in fig. 5 to 7, the slip ring flange 602 is connected to the slip ring main body 603, and the slip ring flange 602 is fixed to the circular nut 405 by the slip ring stopper 601. Further optionally, the power line of the acoustic emission module is 10A, and may be connected to the rotor lead of the inner ring of the conductive slip ring through special processing, and the outer ring of the conductive slip ring is fixed to the slip ring rotation stopping fixing device 605 through the slip ring rotation stopping device 604 by using two alloy bolts.
The slip ring rotation stop fixture 605 includes: a clamping fixed piece 6051 and a rotation stopping fixed table 6054. As shown in fig. 8 and 9, the power line of the conductive slip ring is led out through a power line preformed hole 6053 in the clamping fixed piece 6051, the slip ring rotation stopping device 604 and the slip ring rotation stopping device preformed hole 6052 in the clamping fixed piece 6051 are connected through bolts, and the rotation stopping fixed table 6054 is positioned at the center of the clamping fixed piece and fixes the stator end of the conductive slip ring.
The invention discloses an online monitoring method for fatigue damage of a large machine tool blade in a working state, which is used for monitoring by using the monitoring system provided by the invention.
The monitoring method comprises the following steps:
(1) Preparation before experiment: smearing the acoustic emission special couplant PXUAC at a designated position of a blade working area, sleeving the acoustic emission sensor 402 in a sensor protection mold 401, and smearing a layer of high-strength 502 colloid on the periphery of the mold to fix the blade. The system connector 404 and the machine tool rotating shaft 2 are fixed in a rotating mode through a circular nut, the acoustic emission module 403 is placed in the system connector 404, the acoustic emission module fixing bolt 4011 is used for screwing and fixing, and the acoustic emission sensor 402 is connected with the acoustic emission module 403. The conductive slip ring 60 is sleeved on a round nut 405 at one end of the system connector, and a slip ring rotation stopping clamping position 601 is screwed down to fasten the slip ring on the system connector 404, so that the slip ring rotation stopping device and the slip ring rotation stopping fixing device are fastened through bolts. And the corresponding inner ring lead of the conductive slip ring 60 is connected with a power line of the acoustic emission module, and the outer ring lead is connected with a power supply.
(2) Setting instrument parameters: the acoustic emission module 403 is turned on, and monitoring parameters thereof, including threshold, gain amplitude, noise determination value, and parameters of the warning system such as amplitude and ringing count, are set. The instrument comprises three types of prompting lamps, namely red, green and blue, wherein the red represents the generation of an early warning signal, the green represents the generation of an audible emission signal, and the blue represents the connection of the instrument with a network. And waiting for the sound emission module to light up the blue lamp and connect with Aliyun to prepare for starting monitoring.
(3) And (3) damage monitoring: the large-scale machine tool is started, the machine tool blade rotates, the acoustic emission probe monitors the state of the blade in real time, when the blade is damaged, the acoustic emission probe sends an acoustic emission signal to the acoustic emission module in real time, and the acoustic emission module displays a green light to prompt the damage when receiving the acoustic emission signal and uploads data to Aliyun in real time. When the amplitude of the acoustic emission signal exceeds a preset alarm value, the acoustic emission module displays a red light prompt alarm. And performing cluster analysis and wavelet packet transformation on the monitored acoustic emission data to acquire frequency band characteristics of different damage modes, identifying the damage mode of the blade and acquiring a damage evolution rule of the blade.
In conclusion, the online acoustic emission monitoring system for the large machine tool blade effectively solves the problems of line winding, balance weight unbalance and monitoring module power supply of the blade when the machine tool blade is dynamically monitored, can dynamically monitor the working state of the machine tool blade for a long time, and provides an important means for monitoring the health condition of the machine tool blade.
Claims (4)
1. A large-scale lathe blade acoustic emission on-line monitoring system, characterized by: including wheel hub, lathe pivot, system even take the ware, lathe pivot and blade are installed on wheel hub, and the system is taken ware one side and is passed through the nut and link to each other with the lathe pivot, and the system is taken the ware and is installed acoustic emission module in, and acoustic emission sensor installs at blade work area assigned position, and acoustic emission sensor connects acoustic emission module and detects the acoustic emission damage signal that the blade produced when rotating.
2. The large machine tool blade acoustic emission online monitoring system according to claim 1, characterized in that: the system is even carried the ware and is connected electrically conductive sliding ring, electrically conductive sliding ring includes that sliding ring main part, sliding ring spline screens, sliding ring flange, sliding ring spline device, sliding ring spline fixing device, and the sliding ring main part is connected to the sliding ring flange, and the sliding ring spline screens is installed on the sliding ring flange, and the outer loop installation sliding ring of sliding ring main part splines the device, the sliding ring spline fixing device includes the screens stationary blade, splines the fixed station, and the screens stationary blade is connected and is splines the fixed station, sets up the sliding ring on the screens stationary blade and splines the device preformed hole that splines, and the sliding ring splines the device and the sliding ring spline the device preformed hole and cooperate.
3. The large machine tool blade acoustic emission online monitoring system according to claim 1, characterized in that: the interface of the acoustic emission sensor is coated with high-strength glue.
4. A method for monitoring the blade sound emission of a large machine tool on line is characterized in that:
(1) Preparation before experiment: smearing a special couplant for sound emission on a designated position of a blade working area, sleeving a sound emission sensor in a sensor protection die, smearing a layer of high-strength colloid on the periphery of the die, fixing the blade, rotationally fixing a system connector and a machine tool rotating shaft through a circular nut, placing a sound emission module in the system connector, connecting the sound emission sensor with a sound emission module, sleeving a conductive sliding ring on the circular nut at one end of the system connector, screwing a sliding ring rotation-stopping clamp position, fastening the sliding ring on the system connector, fastening a sliding ring rotation-stopping device with a sliding ring rotation-stopping fixing device through a bolt, connecting an inner ring lead corresponding to the conductive sliding ring with a power line of the sound emission module, and connecting an outer ring lead with a power supply;
(2) Setting instrument parameters: starting an acoustic emission module, setting monitoring parameters of the acoustic emission module, including parameters of an early warning system including a threshold value, a gain amplitude value, a noise judgment value, an amplitude value and a ringing count, wherein the instrument comprises red, green and blue prompting lamps, the red indicates that an early warning signal is generated, the green indicates that an acoustic emission signal is generated, the blue indicates that the instrument is connected with a network, waiting for the acoustic emission module to light the blue lamp, connecting the blue lamp with Aliskiren cloud, and preparing to start monitoring;
(3) And (3) damage monitoring: the method comprises the steps of starting a machine tool, enabling a blade to rotate, enabling an acoustic emission probe to monitor the state of the blade in real time, enabling the acoustic emission probe to send an acoustic emission signal to an acoustic emission module in real time when the blade is damaged, enabling the acoustic emission module to display a green light to prompt damage when the acoustic emission module receives the acoustic emission signal and upload data to Aliskiu in real time, enabling the acoustic emission module to display a red light prompt alarm when the amplitude of the acoustic emission signal exceeds a preset alarm value, carrying out cluster analysis and wavelet packet transformation on the monitored acoustic emission data, obtaining frequency band characteristics of different damage modes, identifying the damage mode of the blade, and obtaining a damage evolution rule of the blade.
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| CN202211243562.XA CN115635366A (en) | 2022-10-12 | 2022-10-12 | Large machine tool blade acoustic emission online monitoring system and method |
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| CN202211243562.XA CN115635366A (en) | 2022-10-12 | 2022-10-12 | Large machine tool blade acoustic emission online monitoring system and method |
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