CN116295796A - High-frequency acoustic wave sensing device and method for early fault detection of electromechanical system - Google Patents
High-frequency acoustic wave sensing device and method for early fault detection of electromechanical system Download PDFInfo
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Abstract
The invention discloses high-frequency acoustic wave sensing equipment and a method for early fault detection of an electromechanical system, which are applied to the field of fault detection and comprise the following steps: the sensing unit adopts a piezoelectric ceramic high-frequency sound wave transducer to convert high-frequency sound waves into electric signals; the amplitude control unit amplifies the weak electric signal; the heterodyne frequency reduction unit moves the signal from high frequency to audio frequency; the power amplification module drives the playing device to monitor the audio signal; the microcontroller collects audio, performs preprocessing and transmits the audio to the upper computer; meanwhile, controlling the digital-to-analog conversion module according to the state of the encoder to adjust the gain of the equipment and the carrier frequency; the liquid crystal display module displays information such as gain, carrier frequency, decibel value and the like. The gain and carrier frequency of the equipment are adjusted to deal with different faults of the electromechanical system, and specific early fault categories are identified through fault detection technology. The invention has the advantages of abundant fault detection types, various detection frequencies, portability and high efficiency, and can effectively determine the early fault type of the electromechanical system and realize preventive maintenance.
Description
Technical Field
The invention relates to the field of fault detection, in particular to high-frequency acoustic wave sensing equipment and a method for early fault detection of an electromechanical system.
Background
The electromechanical system is always operated under severe environments such as high load, high operation and the like, the failure occurrence rate is far higher than that of other equipment, and serious failures are possibly generated when any part of the electromechanical system is in operation, and even serious social disaster is difficult and economic loss is caused. For the fault detection of the electromechanical system, the current common method is a vibration detection method, but the technology based on vibration fault signal analysis has the problem of insufficient fault information pickup capability, and when the fault of the electromechanical system is detected through the vibration fault signal, the electromechanical system often reaches the place needing to be maintained, and preventive maintenance cannot be realized.
Common faults of electromechanical systems are typically rotary machine faults, partial discharge faults, leaks, etc. For rotating machinery, when the bearing fails early, a 24k-50kHz fault signal is generated, which is earlier than the heat and vibration signal changes; for partial discharge, when current escapes from the high-voltage line or jumps across the junction gap, air molecules around it are disturbed to generate a high-frequency acoustic signal; for leakage, when gas passes through a leakage point in a pressure state, turbulence is generated at the position of the leakage point, and a strong high-frequency sound wave signal exists in the turbulence. Therefore, the detection of the high-frequency sound wave signal can effectively detect early faults of the electromechanical system, effectively identify the fault type of the electromechanical system according to the signal characteristics, and effectively carry out preventive maintenance on the electromechanical system according to the signal change trend.
Along with the progress of scientific technology, the application of high-frequency acoustic wave technology is becoming more and more widespread. Through the search of the prior art, although corresponding high-frequency sound wave detection equipment, such as a flexible piezoelectric ultrasonic sensing system (202110829022.9) for monitoring the partial discharge of the power equipment, is provided, an ultrasonic detection method and system (200710178019.5) are provided, the problem that the fault detection is single in detection fault, huge in system and low in detection efficiency exists in the prior art by utilizing high-frequency sound waves.
Disclosure of Invention
The invention aims to provide high-frequency sound wave sensing equipment and a method for detecting early faults of an electromechanical system, which can detect high-frequency sound wave signals generated when the electromechanical system such as rotary machinery, power equipment and the like has the advantages of rich fault detection types, various detection frequencies, portability, high efficiency and the like, can effectively determine the early faults of the electromechanical system and realize preventive maintenance of the electromechanical system.
The technical scheme adopted for solving the technical problems is as follows:
in a first aspect, a high frequency acoustic wave sensing apparatus for detecting early failure of an electromechanical system, comprising: the device comprises a signal sensing unit, an amplitude control unit, a heterodyne frequency reduction unit, a power amplification module, a playing device, an embedded microcontroller, a digital-to-analog conversion module, a rotary encoder module, a liquid crystal display module and an upper computer module;
the signal sensing unit is used for converting a micro-amplitude high-frequency sound wave signal generated by the early failure of the electromechanical system into an electric signal;
the amplitude control unit is used for amplifying the weak high-frequency sound wave induction electric signal output by the signal sensing unit without distortion;
the heterodyne frequency reduction unit is used for moving the induction electric signal amplified by the amplitude control unit to an audio frequency range from high frequency;
the power amplifying module is used for amplifying the power of the audio signal and driving the playing device;
the embedded microcontroller is used for collecting the high-frequency acoustic wave electric signals subjected to frequency reduction by the heterodyne frequency reduction unit, preprocessing and extracting the characteristics of the collected audio signals, transmitting the audio signals to the upper computer, detecting the state of the rotary encoder module in real time, controlling the digital-to-analog conversion module according to the state of the rotary encoder module, and adjusting the gain of the amplitude control unit and the carrier frequency of the mixer module;
the liquid crystal display module is used for displaying the current signal gain state, carrier frequency information and current high-frequency sound wave signal decibel value information. The device is further improved in that the signal sensing unit adopts a piezoelectric ceramic high-frequency sound wave transducer, and the design is divided into a contact type transducer and a scanning type transducer. The contact type transducer adopts a metal rod-shaped design, the front end of the contact type transducer is provided with a contact rod, and the contact rod is a tip rod and is used for reducing the contact area with an electromechanical system to be tested and enhancing the signal measurement directivity of the sensor; the scanning sensor adopts a microphone type design and is used for receiving high-frequency sound wave signals propagated in air, such as high-frequency sound wave signals generated by pressure leakage or electric discharge. The UV-level high-frequency sound wave signal can be converted into an electric signal by directly contacting or approaching the electromechanical system to be tested to acquire the high-frequency sound wave signal, the center frequency of the signal sensing unit is 40kHz, and the working bandwidth is 20kHz-100kHz. The piezoelectric ceramic high-frequency sound wave transducer is connected with equipment through a connector, so that the volume of the equipment is reduced, and the equipment is convenient to carry.
The device is further improved in that the amplitude control unit is connected with the signal sensing unit and comprises a primary amplifying module, a voltage-controlled amplifying module and a secondary amplifying module, and the amplitude of the high-frequency sound wave sensing signal can be adjusted according to requirements. In order to solve the problem that the high-frequency sound wave sensing signals acquired by the signal sensing unit are weak and the industrial field environment is severe, the interference signals are relatively large, the primary amplifying module adopts a charge amplifier, so that the influence of cable capacitance can be effectively avoided; the voltage-controlled amplification module can further amplify or attenuate the high-frequency sound wave induction signal amplified and output by the primary amplification module according to the magnitude of the control voltage; the secondary amplifying module is a voltage amplifier, adopts a multi-stage amplifying circuit structure, and can effectively amplify weak high-frequency sound wave induction electric signals without distortion.
The device is further improved in that the heterodyne down-conversion unit is connected with the amplitude control unit and comprises a mixer module and a low-pass filter module. Because the audible sound range of the human ear is 20-15kHz, if the human ear is expected to hear the high-frequency sound wave signal generated by the early failure of the electromechanical system, the high-frequency sound wave signal generated by the early stage of the electromechanical system needs to be subjected to frequency reduction treatment; the heterodyne frequency-reducing unit adopts heterodyne frequency reduction, the mixer module multiplies the input high-frequency sound wave induction signal with the local oscillation source, and the output signal contains both sum frequency components and difference frequency components. The cut-off frequency of the low-pass filter is set at 8kHz, the output signal of the mixer module is input into the low-pass filter module, namely, the sum frequency component is filtered, and the difference frequency component which can be heard by human ears, namely, the audio frequency component is reserved.
The device is further improved in that the power amplification module is connected with the heterodyne frequency reduction unit and used for amplifying the power of the audio component output by the low-pass filter, driving the playing device and facilitating staff to monitor high-frequency sound wave induction signals generated by early faults of the electromechanical system.
The device is further improved in that the embedded microcontroller is connected with the heterodyne frequency reduction unit, and the embedded microcontroller internally comprises an analog-to-digital conversion module, a central processing unit and a wireless transmission module. The analog-to-digital conversion module is connected with the low-pass filter module and used for collecting high-frequency acoustic wave electric signals after frequency reduction; the central processing unit performs preprocessing and feature extraction on the collected audio signals so as to obtain early fault features of the electromechanical system; the wireless transmission module can wirelessly transmit the audio signals acquired by the analog-to-digital conversion module and the characteristic values extracted by the central processing unit for processing the audio signals to an upper computer;
the device is further improved in that the digital-to-analog conversion module is connected with the embedded microcontroller, and the embedded microcontroller controls the digital-to-analog conversion module to output two paths of control voltage signals through the GPIO port. One path of voltage signal is input to the amplitude control unit and used for controlling the gain of the high-frequency sound wave induction signal; the other voltage signal is input to the mixer module of the heterodyne frequency reduction unit and used for controlling the oscillation frequency of the local oscillation source in the mixer module, so that the oscillation frequency of the local oscillation source can be adjusted within the range of 20kHz-100kHz.
The improvement of the device is further that the rotary encoder module is connected with the embedded microcontroller, and the rotary encoder module has the functions of left rotation, right rotation and buttons. The embedded microcontroller can detect the state of the encoder module in real time, and the embedded microcontroller controls the digital-to-analog conversion module according to the state of the encoder module, so that the purposes of adjustable gain of the amplitude control unit and adjustable carrier frequency of the mixer module are achieved.
The improvement of the device is that the liquid crystal display module is connected with the embedded microcontroller, and the embedded microcontroller can display the information such as the current signal gain state, the carrier frequency information, the current high-frequency sound wave signal decibel value and the like through the liquid crystal display module, so that man-machine interaction is realized.
In a second aspect, a high frequency acoustic wave sensing method includes the steps of:
the scanning type sensor or the contact type sensor is selected according to different fault detection environments of the electromechanical system, a high-frequency sound wave signal generated by early faults of the electromechanical system is converted into an electric signal, the weak electric signal generated by the sensor is amplified through an amplitude control unit, a heterodyne frequency reduction unit carries out frequency spectrum movement on the electric signal amplified by the amplitude control unit, the electric signal is moved to a low frequency (an audible frequency range of human ears) through a high frequency, the low-frequency electric signal output by the heterodyne frequency reduction unit is input to a power amplification module, the power amplification module carries out power amplification on the low-frequency electric signal and outputs the low-frequency electric signal to a playing device, and therefore the high-frequency sound wave signal generated by the early faults of the electromechanical system can be monitored in real time in the industrial inspection process, during the period, the gain and the carrier frequency of the high-frequency sound wave sensing device are adjusted through a rotary encoder by sound heard by the playing device and indication of a liquid crystal display screen, and the high-frequency sound wave signal is amplified and reduced through the amplitude control unit and the heterodyne frequency reduction unit until the sound of the electromechanical device running clearly heard and the liquid crystal display screen shows the maximum decibel value of the high-frequency sound wave signal.
The method is further improved in that if a scanning type sensor is selected for confirming leakage faults and is connected with detection equipment through a connector, the scanning type sensor points to a detection area, if the electromechanical system has leakage faults, the scanning type sensor can convert high-frequency sound wave signals in turbulence generated by the electromechanical system due to leakage into electric signals, initially, the amplitude control unit gain of the high-frequency sound wave sensing equipment is adjusted to be the highest through adjusting a rotary encoder, the carrier frequency of a heterodyne frequency reducing unit is adjusted, the amplitude control unit gain is gradually reduced, the suspected leakage points are approached and slightly move back and forth in all directions, if the leakage points are at the positions, the electric signals sensed by the scanning type sensor are enhanced, and a liquid crystal display screen displays ultrasonic decibel values to be increased; when the display device is moved away from the leakage position, the intensity of the sound signal output by the display device can be reduced, and the liquid crystal display screen displays the reduction of the high-frequency sound wave decibel value. The amplitude control unit gain may be continually reduced and the device moved closer to the suspected leak until the leak can be determined;
if the partial discharge fault is to be detected, the method is similar to the leakage detection method, and is different from the method that the playing device hears not an impact sound but a crack or a buzzing sound.
The method is further improved in that if a contact type sensor is selected for detecting bearing faults and is connected with detection equipment through a connector, the contact type sensor contacts a bearing seat, the contact type sensor can convert high-frequency sound wave signals generated by the operation of an electromechanical system bearing into electric signals, the amplitude control unit gain of the high-frequency sound wave sensing equipment is adjusted to be the highest through an adjusting rotary encoder, the carrier frequency of a heterodyne frequency reducing unit is adjusted, the amplitude control unit gain is gradually adjusted, the carrier frequency of the heterodyne frequency reducing unit is adjusted, and a playing device is used for monitoring the quality of bearing sound signals to make proper judgment; firstly, collecting normal bearing running signals to establish bearing fault early warning baseline standards; secondly, observing a high-frequency sound wave decibel value displayed by a liquid crystal display screen in an actual detection process, and if the high-frequency sound wave decibel value exceeds a certain threshold value, indicating that the bearing has early faults (for example, if the high-frequency sound wave decibel value exceeds a base line by 8dB, indicating that the bearing has pre-failure or under lubrication, and if the high-frequency sound wave decibel value exceeds the base line by 12dB, determining that the bearing has early faults); in order to determine the fault type, the high-frequency acoustic wave sensing device can be connected with an upper computer for wireless communication, the upper computer is used for collecting operation data of an electromechanical system, and further fault analysis is carried out through a mechanical fault diagnosis technology to judge the specific fault types of the rotating machinery such as under lubrication, over lubrication, lubrication pollution and micro wear damage.
In the above scheme, the fault analysis of the upper computer on the electromechanical system mainly comprises the following steps:
s1: the upper computer performs seven-point three-time smoothing filtering on the acquired data, and solves a three-time polynomial coefficient approximating the input data by using a least square method so as to reduce the influence of noise on the subsequent feature extraction and classification, and the method comprises the following specific calculation steps of
Wherein y is n For filtering the data before smoothing, Y N For filtering the smoothed data.
S2: frame division processing, setting the length m of each frame, dividing the data n into n/m frames, and extracting the characteristics of each frame of data to reduce the calculation time;
s3: the main component analysis reduces the dimension, extracts the main characteristic component of the data, reduces the dimension of the data after framing, and reduces the calculation time;
s4: EMD decomposition, namely calculating and selecting N groups of IMF components with higher energy value information in the obtained eigenmode functions (IMF components), and improving the local feature analysis effect.
S5: and calculating an entropy value, namely calculating approximate entropy, sample entropy, permutation entropy and wavelet entropy value for each group of IMF components of each frame signal.
S6: and (5) classifying the support vector machine, and performing fault classification and discrimination on the processed signals.
In the above scheme, in S2, the length m of each frame is set to be greater than 200.
In the above scheme, in the step S6, the support vector machine sets the function as a radial basis function, and sets the gamma and c super parameters as optimal states during classification.
By adopting the technical scheme, the invention has the following technical progress:
the high-frequency acoustic wave sensing device provided by the invention is small in size, convenient to carry, various in detection frequency, suitable for industrial inspection, high in environmental noise interference resistance, and capable of integrating the modern mechanical fault diagnosis technology and retaining the traditional auscultation technology, so that early fault discrimination of an electromechanical system is more accurate and efficient, and preventive maintenance of the electromechanical system is facilitated.
The high-frequency acoustic wave sensing equipment provided by the invention has the advantages of high sensitivity, good directivity, high detection speed and the like, is provided with the scanning type and contact type high-frequency acoustic wave transducer, can cope with various electromechanical system fault detection environments, and has the advantages of simple detection process and wide application scene.
The high-frequency acoustic wave sensing method solves the problems of poor local characteristic analysis effect and low classification accuracy of the traditional fault diagnosis analysis method, provides a fault diagnosis method based on multi-entropy fusion of principal component analysis and EMD decomposition, effectively shortens calculation time and improves fault discrimination accuracy.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are required to be used in the embodiments will be briefly described below.
FIG. 1 is a block diagram of the structure of a high frequency acoustic wave sensing apparatus of the present invention;
FIG. 2 is a schematic illustration of an application of the high frequency acoustic wave sensing apparatus of the present invention;
FIG. 3 is a schematic diagram of a high frequency acoustic wave sensing device of the present invention detecting a partial discharge failure of an electromechanical system;
FIG. 4 is a schematic diagram of a high frequency acoustic wave sensing device of the present invention detecting electromechanical system rotary machine faults;
FIG. 5 is a schematic diagram of the operation of the upper computer module of the high frequency acoustic wave sensor apparatus of the present invention;
wherein, 1, a signal sensing unit, 2, an amplitude control unit, 21, a primary amplifying module, 22, a voltage-controlled amplifying module, 23, a secondary amplifying module, 3, a heterodyne down-conversion unit, 31, a mixer module, 32, a low-pass filter module, 4, a power amplifying module, 5, a playing device, 6, an embedded microprocessor, 61, a wireless transmission module, 62, a central processing unit, 63, an analog-to-digital conversion module, 7, a digital-to-analog conversion module, 8, a rotary encoder module, 9, a liquid crystal display module, 10 and an upper computer.
Detailed Description
The following detailed description of embodiments of the invention is, therefore, to be taken in conjunction with the accompanying drawings, and it is to be understood that the scope of the invention is not limited to the specific embodiments.
Throughout the specification and claims, unless explicitly stated otherwise, the term "comprise" or "comprises" and the like will be understood to include the stated element or component without excluding other elements or components.
As shown in fig. 1, a high frequency acoustic wave sensing apparatus according to an embodiment of the present invention includes: the device comprises a signal sensing unit 1, an amplitude control unit 2, a heterodyne frequency reduction unit 3, a power amplification module 4, a playing device 5, an embedded microcontroller 6, a digital-to-analog conversion module 7, a rotary encoder module 8, a liquid crystal display module 9 and an upper computer module 10.
The signal sensing unit 1 adopts a piezoelectric ceramic high-frequency acoustic wave transducer, the design of the signal sensing unit is divided into a contact type transducer and a scanning type transducer, the contact type transducer adopts a metal rod-shaped design, the front end of the contact type transducer is provided with a contact rod, and the contact rod is a tip rod and is used for reducing the contact area with an electromechanical system to be measured and enhancing the signal measurement directivity of the sensor; the scanning sensor adopts a microphone type design and is used for receiving high-frequency sound wave signals propagated in air, such as high-frequency sound wave signals generated by pressure leakage or electric discharge. The center frequency of the piezoelectric ceramic high-frequency sound wave transducer is 40kHz, the working bandwidth is 20kHz-100kHz, and the piezoelectric ceramic high-frequency sound wave transducer is connected with equipment through an RCA lotus head, so that the volume of the equipment is reduced, and the piezoelectric ceramic high-frequency sound wave transducer is convenient to carry.
The amplitude control unit 2 is connected with the signal sensing unit 1, and comprises a primary amplification module 21, a voltage-controlled amplification module 22 and a secondary amplification module 23, and can adjust the amplitude of the high-frequency sound wave induction signal according to requirements. In order to solve the problem that the high-frequency acoustic wave sensing signals acquired by the signal sensing unit 1 are weak and the industrial field environment is severe, which causes a large interference signal, the primary amplifying module 21 adopts a charge amplifier, so that the influence of the wire capacitance can be effectively avoided; the voltage-controlled amplifying module 22 can further amplify or attenuate the high-frequency acoustic wave induction signal amplified and output by the primary amplifying module 21 according to the magnitude of the control voltage; the secondary amplifying module 23 is a voltage amplifier, and adopts a multi-stage amplifying circuit structure, so that the weak high-frequency sound wave induction signal can be effectively amplified without distortion.
The heterodyne frequency reducing unit 3 is connected to the amplitude control unit 2, and includes a mixer module 31 and a low-pass filter module 32, and uses heterodyne frequency reducing, the mixer module 31 multiplies the input high-frequency acoustic wave induction signal by the local oscillation source, the output signal includes both sum frequency components and difference frequency components, the cut-off frequency of the low-pass filter 32 is set at 8kHz, the output signal of the mixer module 31 is input into the low-pass filter module 32, and the sum frequency components can be filtered, so that the difference frequency components audible to the human ear, i.e., the audio frequency components, are retained.
The power amplification module 4 is connected with the heterodyne frequency reduction unit 3 and is used for amplifying the power of the audio output by the low-pass filter 32, driving the playing device 5 and facilitating the staff to monitor the high-frequency sound wave induction signal generated by the early failure of the electromechanical system.
The embedded microcontroller 6 is connected with the heterodyne down conversion unit 3, and the embedded microcontroller 6 internally comprises an analog-to-digital conversion module 61, a central processing unit 62 and a wireless transmission module 63. The analog-to-digital conversion module 61 is connected with the low-pass filter module 32 and collects the audio signal after frequency reduction; the central processing unit 62 performs preprocessing and feature extraction on the collected audio signals, so as to obtain early fault features of the electromechanical system; the wireless transmission module 63 may wirelessly transmit the audio signal collected by the analog-to-digital conversion module and the feature value extracted by the processing of the audio signal by the central processing unit 62 to an upper computer. The embedded microcontroller may be a single-chip microcomputer or other similar module capable of implementing a micro-control function.
The digital-to-analog conversion module 7 is connected with the embedded microcontroller 6, and the embedded microcontroller controls the digital-to-analog conversion module 7 to output two paths of control voltage signals through the GPIO port. One path of voltage signal is input to the amplitude control unit 2 and used for controlling the gain of the high-frequency sound wave induction signal; the other voltage signal is input to the mixer module 31 of the heterodyne frequency reducing unit 3, so as to control the oscillation frequency of the local oscillation source in the mixer module 31, and the oscillation frequency of the local oscillation source can be adjusted within the range of 20kHz-100kHz.
The rotary encoder module 8 is connected to the embedded microcontroller 6, and the rotary encoder module 8 has functions of left rotation, right rotation and buttons. The embedded microcontroller 6 can detect the state of the encoder module 8 in real time, and the embedded microcontroller 6 controls the digital-to-analog conversion module 7 according to the state of the encoder module, so as to achieve the purposes of adjustable gain of the amplitude control unit 2 and adjustable carrier frequency of the mixer module 31.
The liquid crystal display module 9 is connected with the embedded microcontroller 6, and the embedded microcontroller 6 can display the information such as the current signal gain state, carrier frequency information, current high-frequency sound wave signal decibel value and the like through the liquid crystal display module 9, so that man-machine interaction is realized.
In summary, the embodiment of the invention can detect the high-frequency sound wave signals generated by the faults of the electromechanical system for early fault detection, has the advantages of rich fault detection types, high precision, multiple detection frequencies, portability, high efficiency and the like, and can effectively carry out preventive maintenance on the electromechanical system.
The high-frequency sound wave sensing method is as shown in fig. 2, a scanning sensor or a contact sensor is selected according to different fault detection environments of the electromechanical system, and a playing device (such as an earphone) is connected; in the process of inspection, the encoder is rotated through the sound heard by the earphone and the indication of the liquid crystal display screen to adjust the gain and the carrier frequency of the high-frequency sound wave sensing device, and the high-frequency sound wave detection device amplifies and reduces the frequency of the received high-frequency sound wave signal through the amplitude control unit and the heterodyne frequency reduction unit; and observing the decibel value of the high-frequency sound wave signal of the liquid crystal display screen and monitoring the audio signal in the earphone until the sound of clear operation of the electromechanical equipment is heard.
Specifically, referring to fig. 3, for early partial discharge or micro leakage failure of the electromechanical system, the high-frequency acoustic wave sensing method is as follows:
firstly, a scanning sensor is installed on high-frequency sound wave sensing equipment, an earphone is connected and worn, the gain of the equipment is adjusted to be the lowest, and the carrier frequency is adjusted to be 40kHz. The scanning type sensor is directed to the electromechanical system to be detected, passive high-frequency sound waves generated by early faults of the electromechanical system are effectively amplified and reduced in frequency by the high-frequency sound wave detection equipment through the amplitude control unit and the heterodyne frequency reduction unit, the gain of the equipment is gradually increased, a liquid crystal display screen is observed, audio signals in the earphone are monitored, when abnormal sounds are heard, the approximate direction of the early faults of the electromechanical system can be known, the sounds are followed to the highest point, and the decibel value of the high-frequency sound wave signals in the liquid crystal display screen also displays higher values, so that the early partial discharge or the tiny leakage fault position of the electromechanical system is determined.
Specifically, referring to fig. 4, for early rotation mechanical failure of the electromechanical system, the high-frequency acoustic wave sensing method is as follows:
firstly, a contact sensor is replaced on high-frequency sound wave sensing equipment, an earphone is connected and worn, network address information of the high-frequency sound wave sensing equipment is configured through the upper computer, the gain of the equipment is initially adjusted to be the lowest, and the carrier frequency is adjusted to be 40kHz. The touch sensor is propped against the base of the shell of the rotary machine, passive high-frequency sound waves are generated by early faults of the electromechanical system, the high-frequency sound wave detection equipment effectively amplifies and reduces the frequency of the received high-frequency sound wave signals through the amplitude control unit and the heterodyne frequency reduction unit, the gain of the equipment is gradually improved, a liquid crystal display screen is observed, audio signals in the earphone are monitored, and the quality of sound signals monitored by the earphone is used as a standard for proper judgment. Aiming at abnormal fault points, the high-frequency acoustic wave sensing equipment is in wireless communication with an upper computer, the operation data of an electromechanical system is collected through the upper computer, further fault analysis is carried out through a modern mechanical fault diagnosis technology, and specific fault categories of under lubrication, over lubrication, lubrication pollution and micro wear damage are judged;
as shown in fig. 4, in the above embodiment, the fault analysis of the electromechanical system by the upper computer is mainly divided into the following steps:
s1: the upper computer performs seven-point three-time smoothing filtering on the acquired data, solves a three-time polynomial coefficient approximating the input data by using a least square method, reduces the influence of noise on subsequent feature extraction and classification, and specifically calculates as follows:
wherein y is n For filtering the data before smoothing, Y N For filtering the smoothed data.
S2: the framing processing reduces the data quantity, sets the length m of each frame, divides the data n into n/m frames, and extracts the data characteristics of each frame so as to greatly reduce the calculation time;
s3: the main component analysis is used for reducing the dimension, and a large amount of time is still needed for calculation after framing due to large data volume and complex entropy calculation, so that the main component analysis is used for reducing the dimension, extracting main characteristic components of the data, reducing the dimension of the data after framing and reducing the calculation time;
s4: and (3) EMD decomposition, namely selecting 7 groups of IMF components with higher energy value information from the obtained finite eigen-mode functions, namely IMF components, and performing entropy calculation to improve the local feature analysis effect.
S5: feature extraction, which calculates approximate entropy, sample entropy, permutation entropy and wavelet entropy values for each set of IMF components of each frame signal.
S6: and (5) classifying the support vector machine, and performing fault classification and discrimination on the processed signals.
In the above scheme, in S2, the length m of each frame is set to be greater than 200.
In the above scheme, in the step S6, the support vector machine sets the function as a radial basis function, and sets the gamma and c super parameters as optimal states during classification.
The above embodiments are merely illustrative of the preferred embodiments of the present invention and not intended to limit the scope of the present invention, and various modifications and improvements made by those skilled in the art to which the present invention pertains should fall within the scope of the present invention as defined in the appended claims without departing from the spirit of the present invention.
Claims (10)
1. A high frequency acoustic wave sensing device for early failure detection of an electromechanical system, comprising: the device comprises a signal sensing unit, an amplitude control unit, a heterodyne frequency reduction unit, a power amplification module, a playing device, an embedded microcontroller, a digital-to-analog conversion module, a rotary encoder module, a liquid crystal display module and an upper computer module;
the signal sensing unit is used for converting a micro-amplitude high-frequency sound wave signal generated by the early failure of the electromechanical system into an electric signal;
the amplitude control unit is used for amplifying the weak high-frequency sound wave induction electric signal output by the signal sensing unit without distortion;
the heterodyne frequency reduction unit is used for moving the induction electric signal amplified by the amplitude control unit to an audio frequency range from high frequency;
the power amplifying module is used for amplifying the power of the audio signal and driving the playing device;
the embedded microcontroller is used for collecting the high-frequency acoustic wave electric signals subjected to frequency reduction by the heterodyne frequency reduction unit, preprocessing and extracting the characteristics of the collected audio signals, transmitting the audio signals to the upper computer, detecting the state of the rotary encoder module in real time, controlling the digital-to-analog conversion module according to the state of the rotary encoder module, and adjusting the gain of the amplitude control unit and the carrier frequency of the mixer module;
the liquid crystal display module is used for displaying the current signal gain state, carrier frequency information and current high-frequency sound wave signal decibel value information.
2. The high-frequency acoustic wave sensing device for early failure detection of an electromechanical system according to claim 1, wherein the signal sensing unit includes a contact transducer having a contact bar, which is a tip bar, and a scanning transducer for reducing a contact area and enhancing sensor signal measurement directivity; the scanning sensor adopts a microphone type; the high-frequency sound wave signals are collected by contacting or approaching the electromechanical system to be tested.
3. The high-frequency acoustic wave sensing apparatus for early failure detection of an electromechanical system according to claim 1, wherein the amplitude control unit adopts a multi-stage amplifying circuit structure including a primary amplifying module, a voltage-controlled amplifying module, and a secondary amplifying module.
4. The high-frequency acoustic wave sensing device for early failure detection of an electromechanical system according to claim 1, wherein the heterodyne frequency reducing unit adopts heterodyne frequency reduction, comprises a mixer module and a low-pass filter module, wherein the mixer module multiplies an input high-frequency acoustic wave induction signal with a local oscillation source, an output signal comprises a sum frequency component and a difference frequency component of the sum frequency component, and the output signal of the mixer module is input into the low-pass filter module to filter the sum frequency component.
5. The high-frequency sound wave sensing method for early fault detection of the electromechanical system is characterized by comprising the steps of selecting a scanning type sensor and a contact type sensor in response to different fault detection environments of the electromechanical system, converting a high-frequency sound wave signal generated by the early fault of the electromechanical system into an electric signal, amplifying a weak electric signal generated by the sensor through an amplitude control unit, carrying out frequency spectrum shifting on the electric signal amplified by the amplitude control unit by a heterodyne frequency-reducing unit, carrying out frequency spectrum shifting on the electric signal amplified by the amplitude control unit to a low frequency (a frequency range audible to human ears), inputting the low-frequency electric signal output by the heterodyne frequency-reducing unit into a power amplification module, carrying out power amplification on the low-frequency electric signal by the power amplification module, and outputting the power amplification module to a playing device, thereby monitoring the early fault of the electromechanical system in real time to generate the high-frequency sound wave signal, and adjusting the gain and the carrier frequency of a high-frequency sound wave sensing device through sound heard by the playing device and the indication of a liquid crystal display screen in the industrial inspection process, and amplifying and reducing the received high-frequency sound wave signal to the maximum decibel sound wave value of the high-frequency sound wave sensing device heard by the amplitude control unit and the heterodyne frequency-reducing unit.
6. The method according to claim 5, wherein if a scanning sensor is selected for confirming the leakage fault and is connected with the detecting device through a connector, the scanning sensor is directed to the detecting area, if the leakage fault occurs in the electromechanical system, the scanning sensor converts the high-frequency sound wave signal in the turbulence generated by the leakage of the electromechanical system into an electric signal, initially, the amplitude control unit gain of the high-frequency sound wave sensing device is adjusted to be the highest by adjusting the rotary encoder, the carrier frequency of the heterodyne frequency reducing unit is adjusted, the amplitude control unit gain is gradually adjusted to be close to the suspected leakage point and slightly moves back and forth in all directions, and if the leakage point is at the position, the electric signal sensed by the scanning sensor is enhanced, and the liquid crystal display screen displays the ultrasonic decibel value; when the display device is moved away from the leakage position, the intensity of the sound signal output by the display device is reduced, and the liquid crystal display screen displays the reduction of the high-frequency sound wave decibel value; the amplitude control unit gain may be continually reduced and the device moved closer to the suspected leak until the leak can be determined;
if the partial discharge failure is to be detected, the same method as the leakage detection method is used, but the difference is that not the impact sound but the crack or the buzzing sound is heard from the playing device.
7. The method according to claim 5, wherein if a contact sensor is selected for detecting the bearing failure, the contact sensor is connected with a detecting device through a connector, the contact sensor contacts a bearing seat, the contact sensor converts a high-frequency sound wave signal generated by the operation of the electromechanical system bearing into an electric signal, the amplitude control unit gain of the high-frequency sound wave sensing device is adjusted to be the highest through adjusting a rotary encoder, the carrier frequency of a heterodyne frequency reducing unit is adjusted, the amplitude control unit gain is gradually reduced, the carrier frequency of the heterodyne frequency reducing unit is adjusted, and the quality of the bearing sound signal is monitored by a playing device to make a proper judgment; firstly, collecting normal bearing running signals to establish bearing fault early warning baseline standards; secondly, observing a high-frequency sound wave decibel value displayed by a liquid crystal display screen in an actual detection process, and indicating that the bearing has early failure if the high-frequency sound wave decibel value exceeds a certain threshold value; in order to determine the fault type, the high-frequency acoustic wave sensing device can be connected with an upper computer for wireless communication, the upper computer is used for collecting operation data of an electromechanical system, and further fault analysis is carried out through a mechanical fault diagnosis technology to judge the specific fault types of the rotating machinery such as under lubrication, over lubrication, lubrication pollution and micro wear damage.
8. The high-frequency acoustic wave sensing method for early failure detection of an electromechanical system according to claim 5, wherein the step of performing the failure analysis of the electromechanical system by the upper computer includes: firstly, carrying out seven-point three-time smoothing filtering on acquired data, and solving a three-time polynomial coefficient approximating to input data by using a least square method; secondly, framing, namely setting the length m of each frame, dividing the data n into n/m frames, and extracting the characteristics of each frame of data; then, main component analysis reduces the dimension, extracts the main characteristic component of the data, and reduces the dimension of the data after framing; then, EMD decomposition is carried out, N groups of IMF components with higher energy value information are calculated and selected in the obtained eigen-mode functions (IMF components), and the local feature analysis effect is improved; then, calculating approximate entropy, sample entropy, permutation entropy and wavelet entropy value for each group of IMF components of each frame signal to perform feature extraction; and finally, carrying out fault classification and discrimination on the processed signals through a support vector machine.
9. The method of claim 8, wherein in the framing process, the length m of each frame is set to be greater than 200.
10. The method for detecting early failure of an electromechanical system according to claim 8, wherein the support vector machine is configured to set the function as a radial basis function, and to set both gamma and c super-parameters to an optimal state during classification.
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