CN201262588Y

CN201262588Y - Portable locomotive oscillation fault detector

Info

Publication number: CN201262588Y
Application number: CNU2008201587041U
Authority: CN
Inventors: 谭群林; 杨四清; 吴磊; 凌浩东; 袁雪姣
Original assignee: Zhuzhou CSR Times Electric Co Ltd
Current assignee: Zhuzhou CRRC Times Electric Co Ltd
Priority date: 2008-10-10
Filing date: 2008-10-10
Publication date: 2009-06-24
Anticipated expiration: 2018-10-10

Abstract

The utility model discloses a portable locomotive vibration fault detector which comprises a portable microcomputer, a vibration data acquisition unit and a sensor collecting unit, wherein, an FPGA core control unit of the vibration data collector is connected with a central processing unit, a DDS waveform synthesis unit, an SRAM high-speed data buffer unit, a signal conditioning and data acquisition unit, a pulse shaping and isolating circuit unit and a vibration sensor drive unit by an IIC bus; and a sensor collecting unit comprises a vibration sensor and a photoelectric revolution speed sensor which respectively transform vibration signals and revolution speed signals into electrical signals for being used by the vibration data collector. The portable locomotive vibration fault detector can realize the record, analysis, storage and query of acquired data of a portable machine, and carry out comprehensive analysis of the data. The fault detector can accurately detect faults of a locomotive traction motor and an axle box bearing by a crown chakra on the ground, and carry out fault positioning, thus being applicable to the diagnosis of site ground.

Description

Portable locomotive vibration fault detector

Technical field

The utility model relates to a kind of failure detector, particularly a kind of portable locomotive vibration fault detector.

Background technology

Locomotive wheel is the key component of locomotive to the bearing of axle box and traction motor, in case break down, gently then cause accident of locomotive defect, influence the railway running on time, heavy then the major accident of train overturning takes place, bring inestimable loss for the country and people's lives and properties.Along with the continuous speed-raising of train, it is particularly important that the reliability of locomotive portion out of shape becomes, and potential safety hazard is more outstanding.Using conventional methods for a long time is the artificial visually examine, knocks, and touches etc., owing to be subjected to artificial factor, its reliability is relatively poor, even can not find fault exactly.

Summary of the invention

The purpose of this utility model provides a kind of formula locomotive vibration fault detector of taking, it can in time find fault as early as possible, prevent the generation of accident to greatest extent, for realizing the safety monitoring maintenance and the scientific management of locomotive portion out of shape, increase work efficiency, improve accuracy, promote the transformation of maintenance job from the periodic maintenance to the state maintenance.

A kind of formula locomotive vibration fault detector of taking, it comprises portable microcomputer 1, vibrating data collection device 2 and sensor acquisition unit 3, and wherein said vibrating data collection device 2 comprises fpga core control module 4 and adopts unit 8, shaping pulse and buffer circuit unit 9, vibration transducer driver element 10 by iic bus with CPU (central processing unit) 5, DDS waveform synthesis unit 6, SRAM fast data buffer unit 7, signal condition and data that the corresponding port of this fpga core control module 4 links to each other; Described CPU (central processing unit) 5 comprises USB2.0 communication unit and iic bus control, and this CPU (central processing unit) 5 links to each other with the PORT COM of portable microcomputer 1 by the USB2.0 communication unit; Signal condition and data acquisition unit 8 are made of the two independent acquisition channel, and each acquisition channel is made up of channel switching circuit, programmable amplifying circuit, program control filtering circuit, four parts of AD Acquisition Circuit respectively; Described sensor acquisition unit 3 comprises respectively vibration transducer 11 and the photoelectric sensor 12 that vibration signal and tach signal are converted to electric signal and utilize for vibrating data collection device 2.

Data-signal is changed, is treated as to the rotating speed that vibration transducer 11 and photoelectric sensor 12 collect, vibration signal by vibrating data collection device 2 respectively, link to each other with the portable microcomputer that integrates data acquisition, analysis, storage diagnosis judgement reporting printing by the USB2.0 communication unit, carry out computational analysis and fault diagnosis by portable microcomputer.

The vehicle section of advancing aftercarriage is carried out the top wheel, can be implemented in the indoor finer detection of carrying out, like this can get rid of the noise jamming in the vehicle operating by it.Can accurately detect locomotive traction motor, axle box bearing failure and carry out localization of fault by the top wheel on ground, as: (bearing outer ring, inner ring, rolling body, retainer, gear) realizes the puzzled health check-up survey of bearing fault.Principal feature: the portable machine record, analyze, storage and inquiry image data, and do comprehensive data analysis.Be applicable to the diagnosis of field ground.

Description of drawings

Fig. 1 is the utility model electrical block diagram;

Fig. 2 is the utility model circuit theory diagrams;

Fig. 3 is USB communication data flow process figure;

Fig. 4 is portable microcomputer analysis process figure.

Embodiment

As shown in Figure 1, Figure 2, Figure 3 and Figure 4, a kind of formula locomotive vibration fault detector of taking, it comprises portable microcomputer 1, vibrating data collection device 2 and sensor acquisition unit 3, and wherein said vibrating data collection device 2 comprises fpga core control module 4 and adopts unit 8, shaping pulse and buffer circuit unit 9, vibration transducer driver element 10 by iic bus with CPU (central processing unit) 5, DDS waveform synthesis unit 6, SRAM fast data buffer unit 7, signal condition and data that the corresponding port of this fpga core control module 4 links to each other; Described fpga core control module 4 is closely connected other six unit of vibrating data collection device 2 together, makes their co-ordinations.Described CPU (central processing unit) 5 comprises USB2.0 communication unit and iic bus control, and this CPU (central processing unit) 5 links to each other with the PORT COM of portable microcomputer 1 by the USB2.0 communication unit; The USB2.0 communication unit is responsible for the data transmission of data acquisition unit is analyzed to host computer, and CPU (central processing unit) 5 realizes program control amplification and filtering by the instruction and data that the USB2.0 communication receives host computer simultaneously; Signal condition and data acquisition unit 8 are made of the two independent acquisition channel, and each acquisition channel is made up of channel switching circuit, programmable amplifying circuit, program control filtering circuit, four parts of AD Acquisition Circuit respectively; Described sensor acquisition unit 3 comprises respectively vibration transducer 11 and the photoelectric sensor 12 that vibration signal and tach signal are converted to electric signal and utilize for vibrating data collection device 2.

Described vibration transducer 11 comprises two 4 road vibrating data collection sensors, and photoelectric sensor 12 comprises one of photoelectricity rotating speed pick-up transducers.

To the judgement of the current state of the machinery and equipment moved, differentiating him is normal operation or misoperation.By inferring whole by the part and judging essential method, the character of failure judgement and reason by phenomenon.The one side of diagnosis is prediction, is exactly by now forecast future.Judge its whether normally operation by recognition techniques, derive its serviceable life by prediction.For locomotive, it can be the identification initial failure service of utilization department, improves the reliability of locomotive operation, helps the transformation that promotes that the maintenance job periodic maintenance is repaiied to state, reduces maintenance cost; The research improvement that designs and make for express locomotive provides foundation, for motorcycle safety provides advanced means.

It is the integrated circuit of ISSI25616 that SRAM fast data buffer unit 7 adopts model, the A/D change-over circuit of fpga core control module 4 employing model is that 16 bit parallel AD integrated circuit, the program filtering employing model of AD7671 is the integrated circuit of MAX262, it is the integrated circuit of PGA205 that model is adopted in program control amplification, and it is the integrated circuit of MAX308 that channel selecting adopts model; It is the integrated circuit of PCF8574T that model is adopted in 8 IO controls.

The USB2.0 transfer rate, sampling rate 500K/S, 16, eight tunnels analogy amount inputs, ± 5 volts analog quantity input range.The programmable amplifier gain is 1,2,4,8 times, is selected by software entirely.Programmable filter adopts two-way 8 rank Design of Filter, filter type (low pass, band logical), centre frequency, quality factor, entirely by software design.

At a high speed, the design of high-accuracy data acquisition system and fault analysis algorithm is the key point of this system, analytical algorithm comprising hyperchannel vibrating data collection technology, USB2.0 high speed data transfer technology, software filtering technology, hardware filtering technical application level software, mainly adopt resonance and demodulation, wavelet analysis that the fault signature signal is extracted, adopted existing comprehensive more intense time-domain and frequency-domain analytic approach that fault is accurately located simultaneously.This is that the major technique of Mechanical Failure Analysis and localization of fault is used for the application in vibration analysis of resonance and demodulation, Wavelet Analysis Theory, to realize the bearing fault intelligent diagnostics.

Its real-time monitoring vibration signal, vibration detection and analysis are based on wavelet analysis, and spectrum analysis is conceived to find initial failure.By taking all factors into consideration vibratory impulse and temperature variations, utilize fault diagnosis technology, judge the pit that exists on rolling (or meshing) workplace of bearing and gear, grind skin, scratch is burnt attachedly, corrodes, whether indenture, rhegma, fault such as damage reach more than the C class standard that the Ministry of Railways issues.

Based on 16 high precision vibrating data collections of 8 passages of USB2.0 and FPGA, realize to signal software and hardware filtering, by the kurtosis coefficient, acceleration mean value is determined fault degree, by resonance and demodulation and Time-Frequency Analysis Method fault-signal is extracted and analyzes, carry out localization of fault, on data management function, possess storage, the printing of data, the query function of historical data in addition, with the management that realizes that computing machine detects bearing fault.Can analyze and preserve data, set up historical archives,, obtain the curve of fault progression, be the identification initial failure service of utilization department, for repair and maintenance provides the foundation of science, for design and the research of making provide improved foundation by analysis to corresponding data.

System can also operate in the generating plant at a high speed for a long time, and refinery carries out the fault detect of bearing and gear on the key equipment of industries such as steel plant.

It provides 1 analog quantity output.The dynamic link library that data analysis software, system driver and LabView and Vc call under the complete WINDOWST system is provided.Analysis software is applicable on operating system 2000 or the XP.Can in the industrial temperature scope, use.

Analog acquisition: sampling rate 500K/S, 16 bit synchronization collection and accesses; The data storage degree of depth of two-way 256K*16; Positive and negative 5V input range; Eight passage mould passages switch, 1,2,4,8 program control amplifications; 8 rank low passes, the logical program control filtering of band; The input of one road photoelectricity rotating speed, the output of one tunnel simulating signal.

The USB communication interface adopts USB2.0480M transmission interface, CY7C68013 USB2.0 main control chip; Enhancement mode 8051 cores, the setting of the coordination of responsible data and amplification, filtering chip.

Claims

1, a kind of formula locomotive vibration fault detector of taking, it is characterized in that it comprises portable microcomputer (1), vibrating data collection device (2) and sensor acquisition unit (3), wherein said vibrating data collection device (2) comprises fpga core control module (4), and by the iic bus CPU (central processing unit) (5) continuous with the corresponding port of this fpga core control module (4), DDS waveform synthesis unit (6), SRAM fast data buffer unit (7), signal condition and data are adopted unit (8), shaping pulse and buffer circuit unit (9), vibration transducer driver element (10); Described CPU (central processing unit) (5) comprises USB2.0 communication unit and iic bus control, and this CPU (central processing unit) (5) links to each other with the PORT COM of portable microcomputer (1) by the USB2.0 communication unit; Signal condition and data acquisition unit (8) are made of the two independent acquisition channel, and each acquisition channel is made up of channel switching circuit, programmable amplifying circuit, program control filtering circuit, four parts of AD Acquisition Circuit respectively; Described sensor acquisition unit (3) comprises respectively vibration transducer (11) and the photoelectric sensor (12) that vibration signal and tach signal are converted to electric signal and utilize for vibrating data collection device (2).