TWI845041B - Transmission device and transmission structure condition monitoring method thereof - Google Patents

Abstract

A transmission device comprises a transmission structure and a circuit board arranged on an input port of the transmission structure, wherein at least one sensor and a data processor are integrated on the circuit board to perform a signal measurement process.

Description

Transmission device and state monitoring method of transmission structure

The present invention relates to a monitoring mechanism, and more particularly to a state monitoring method of a transmission device and its transmission structure.

In response to the rise of Industry 4.0, many factories have transformed into digitalization to measure and quantify machine signals for subsequent diagnosis of health indicators.

Existing industrial gearboxes do not have sensing components, and multiple sensors need to be installed externally for measurement. However, external measurement requires consideration of installation space and sensor wiring path. Traditional wired accelerometers cannot achieve remote monitoring effects and require specific hardware to receive signals.

Furthermore, existing diagnostic methods involve building a fault database through experimental rules or designing parameters to calculate characteristic frequencies. However, both methods require a lot of analysis time and analysts need to have relevant technical backgrounds, so general on-site operators cannot quickly define fault phenomena.

Therefore, how to overcome the above-mentioned deficiencies in the prior art has become a difficult problem that the industry needs to overcome urgently.

In view of the above-mentioned deficiencies of the prior art, the present invention provides a transmission device, comprising: a transmission structure having an input end and an output end opposite to each other; a circuit board disposed on the input end of the transmission structure; a sensing element disposed on the circuit board; and a data processing element disposed on the circuit board and communicatively connected to the sensing element.

The present invention further provides a state monitoring method for a transmission structure, comprising: providing a transmission device as described above; sensing a plurality of vibration signals of the transmission structure by the sensing element; converting the plurality of vibration signals into a spectrum signal by the data processing element; and comparing the spectrum signal with a comparison signal to determine whether the transmission structure is abnormal, wherein the comparison signal is a normal spectrum presented by the vibration signal generated by the transmission structure in a normal state.

As can be seen from the above, in the transmission device and the state monitoring method of the transmission structure of the present invention, the sensing element is mainly installed on the input end of the transmission structure, so when performing the measurement operation, there is no need to hang an external sensor. Therefore, compared with the conventional technology, the state monitoring method of the transmission structure of the present invention does not need to consider the installation space and the sensor wiring path, and can achieve the effect of remote monitoring.

Furthermore, through the configuration of the circuit board and the data processing element, multiple vibration signals of the sensing element can be received without going through specific hardware.

The following describes the implementation of the present invention by means of specific embodiments. Those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification.

It should be noted that the structures, proportions, sizes, etc. depicted in the drawings attached to this specification are only used to match the contents disclosed in the specification for understanding and reading by people familiar with this technology, and are not used to limit the restrictive conditions for the implementation of the present invention. Therefore, they have no substantial technical significance. Any modification of the structure, change of the proportion relationship or adjustment of the size should still fall within the scope of the technical content disclosed by the present invention without affecting the effects and purposes that can be achieved by the present invention. At the same time, the terms such as "above" and "a" etc. cited in this specification are only for the convenience of description and are not used to limit the scope of the present invention. Changes or adjustments to the relative relationships shall also be regarded as the scope of the present invention without substantially changing the technical content.

FIG1 is a three-dimensional schematic diagram of a transmission device 1 of the present invention. As shown in FIG1 , the transmission device 1 comprises: a transmission structure 10, a circuit board 11, at least one sensing element 12 and a data processing element 13.

The transmission structure 10 has an input terminal 10a and an output terminal 10b opposite to each other.

In this embodiment, the transmission structure 10 is a reduction structure, such as a gear set of a reduction box or a gear box, which includes a plurality of gears 100. For example, the gear set may include a ring gear, a planetary gear, a sun gear or other gears.

Furthermore, the input end 10a of the transmission structure 10 has an input shaft 101 linked to the plurality of gears 100, and the output end 10b of the transmission structure 10 has an output shaft 102 linked to the plurality of gears 100, so that the input shaft 101 links the output shaft 102 via the plurality of gears 100. For example, the input shaft 101 can be connected to a motor such as a power source, and the output shaft 102 can be connected to a tool such as a drill.

It should be understood that there are many types of transmission structures 10, as long as they can transmit power, and they are not limited to the above.

The circuit board 11 is disposed on the input end 10a of the transmission structure 10. In this embodiment, the circuit board 11 is annular to surround the input shaft 101. It should be understood that the shape of the circuit board 11 can be designed according to demand, as long as it can be disposed on the input end 10a, and there is no special limitation.

The sensing element 12 is disposed on the circuit board 11. In this embodiment, the sensing element 12 is an accelerometer or a temperature sensor.

The data processing element 13 is disposed on the circuit board 11 and is communicatively connected to the sensing element 12 .

In this embodiment, the data processing element 13 is a microcontroller unit (MCU).

Furthermore, the transmission device 1 further comprises a data transmission element 14 which is communicatively connected to the data processing element 13. For example, the data transmission element 14 is in the form of an antenna to transmit the processing result of the data processing element 13 to an electronic device such as a computer (not shown).

Furthermore, the data transmission element 14 is disposed on the circuit board 11, so that the circuit board 11, the sensing element 12, the data processing element 13 and the data transmission element 14 are integrated into an electronic module 1a, i.e. modularization. It should be understood that the power required by the electronic module 1a can be provided by installing a battery on the circuit board 11 or connecting an external power supply device.

Therefore, the transmission device 1 of the present invention integrates the circuit board 11, the sensing element 12 (accelerometer and/or temperature sensor), the data processing element 13, the data transmission element 14 (such as a WIFI antenna), and even the power supply into a single electronic module 1a, and places it in the input end 10a of the transmission structure 10, so that the required data can be effectively obtained and the service life of the electronic module 1a can be improved. Specifically, since the rotation speed at the input end 10a is higher, the vibration signal is the strongest and is far away from the high temperature of the transmission structure 10 (such as the multiple gears 100 and the output end 10b), so a better vibration signal can be obtained and the life of the circuit board 11 can be extended.

FIG2 is a block flow chart of the state monitoring method of the transmission structure of the present invention. In this embodiment, the state monitoring method monitors whether the transmission structure 10 of the transmission device 1 is abnormal.

In step S20, a pre-process is performed to connect the circuit board 11 to an electronic device such as a computer through the data transmission element 14.

In this embodiment, the circuit board 11 and the computer are set to the same network domain using Wi-Fi.

In step S21, the vibration signal is measured to sense the multiple vibration signals of the transmission structure 10 through the sensing element 12 and remove the noise.

In this embodiment, the vibration signal is a time domain signal, so the complex vibration signal can be used as vibration time domain data.

In step S22, the complex vibration signal is converted into a first spectrum signal (as shown in FIG. 3A) by the data processing element 13.

In this embodiment, the time domain signal is converted into a frequency domain signal using a Fourier transform method such as Fast Fourier Transform (FFT) to display the vibration spectrum.

In step S23, the data processing element 13 performs a data volume simplification operation to obtain a second spectrum signal (as shown in FIG. 3B ).

In this embodiment, the frequency range is first rounded to an integer, and then the amplitude of the frequency repeater is averaged to define the frequency range as 0 to 5000 Hz. For example, the data volume is set to 10000 Hz because the sampling rate is set to 10000 Hz, that is, 10000 data per second, but the frequency calculation does not need to be so precise, so the frequency is rounded to an integer, and then the same integer frequency is averaged, so that the original data of 360000 (first spectrum signal) shown in FIG3A can be reduced to 5000 (second spectrum signal) as shown in FIG3B, which is about 86% reduction, so as to reduce the storage capacity.

Therefore, integerizing and averaging the frequency can reduce the amount of data and retain the frequency signal at the full bandwidth.

In step S24, a judgment operation is performed to determine whether the transmission structure 10 is abnormal.

In this embodiment, the user manually compares the second spectrum signal (as shown in FIG. 3B ) presented by the computer with a comparison signal (as shown in FIG. 3C ) to determine whether the transmission structure 10 is abnormal, wherein the comparison signal is a normal spectrum presented by the vibration signal generated by the transmission structure 10 in a normal state. For example, the signal of the normal spectrum may be first stored (or built-in) in the database of the computer, and the content items accessed by the database may include frequency, amplitude, average amplitude, the number of frequencies exceeding the average amplitude, or other items. In another embodiment, the user can also store the "initial operation spectrum" in a computer to an initial database, so that at the end of each operation, the transmission device 1 automatically performs a subtraction operation with the "initial operation spectrum" in the computer, and stores the spectrum dense group band and the average amplitude threshold result, and automatically performs the abnormal judgment operation. It should be understood that the judgment operation performed in step S24 can be performed in many ways, and can be performed manually, automatically or in other appropriate ways, and is not limited to the above .

Furthermore, based on the reference signal (signal of normal frequency spectrum), the user can judge whether a dense signal group appears on the computer, and thus know whether the transmission structure 10 is abnormal. Therefore, whether the transmission structure 10 is abnormal can be known by human judgment or automatic judgment.

In step S25, when a dense signal group band appears, it is determined to be abnormal. If no dense signal group band appears, it is determined to be normal.

In this embodiment, when the number N of frequencies exceeding the average amplitude of the spectrum signal (second spectrum signal) is greater than 1.5 times the number M of frequencies exceeding the average amplitude of the normal spectrum signal (N>1.5M), a densely packed signal band (i.e., defined as an abnormal spectrum signal) will appear.

In step S26, a subtraction operation is performed. When it is determined to be abnormal, the computer can subtract the spectrum signal from the reference signal to calculate the cause of the abnormality of the transmission structure 10.

In this embodiment, the abnormal frequency spectrum (such as the second frequency spectrum signal shown in FIG. 3B ) is subtracted from the normal frequency spectrum (such as the control signal shown in FIG. 3C ) to obtain a target frequency spectrum P, as shown in FIG. 4 , and then the amplitudes corresponding to the frequencies of 0 to 5000 Hz in the target frequency spectrum P are averaged, and the value of the average amplitude is used as the threshold value Q (such as 0.5 x 10 ^-5 g as shown in FIG. 4 ). Next, the theoretical blending frequency is used as the reference L (251Hz as shown in the figure), and it is observed whether there are multiple (at least 2) identical intervals (20Hz as shown in Figure 4) between the peak values F0, F1, F2, F3, and F4 on the left and right sides that are higher than the threshold value Q. By using the interval as the target factor, the cause of the fault (or abnormality) can be compared to the gear 100 at the input terminal 10a.

Furthermore, the correlation between the fault cause and the target factor (pitch) is built into the computer's database, so as long as the pitch is known, the abnormal cause of the transmission structure 10 can be known. For example, the target factor (pitch) is 20 Hz, and the corresponding abnormal cause is defined as "wear of the input gear".

Furthermore, the reference L can also use the frequency position of the maximum amplitude, but the judgment efficiency of using the theoretical fusion frequency is higher.

Therefore, the frequency subtraction method is used, that is, the signal of the healthy frequency is subtracted from the signal of the abnormal frequency to obtain the difference, and the difference can be quantified by the spacing and amplitude. That is, the combined frequency (or the highest response frequency) is first used as the reference L, and then multiple equal spacings are searched to the left and right of the reference L to define the fault phenomenon or component. Therefore, this subtraction operation is applicable to all types of transmission mechanisms.

In step S27, the state monitoring method of the transmission structure 10 is terminated. In this embodiment, the calculation result can be stored in the computer database for subsequent reference by users. For example, when the input condition of the transmission structure 10 is 1200rpm/80Nm, the input gear is damaged, and it can be found that the target factor will appear 3 times of 20Hz interval near the meshing frequency (216Hz). This interval can be used to define the fault item and store it in the computer database.

Therefore, the state monitoring method of the transmission structure 10 of the present invention mainly uses a sensing element 12 such as a three-axis accelerometer or other sensors to be configured at the high-speed input end 10a, so that when performing measurement operations, no external sensors are required, and the interference of environmental vibration can be reduced. Then, through the configuration of the circuit board 11 and the data processing element 13, the multiple vibration signals of the sensing element 12 can be received without using specific hardware to define the fault item by spectrum calculation. Therefore, compared with the prior art, the state monitoring method of the transmission structure 10 of the present invention does not need to consider the installation space and the sensor wiring path, and can achieve the effect of remote monitoring through the cooperation of the computer and the data transmission element 14.

In summary, in the transmission device and the state monitoring method of the transmission structure of the present invention, the sensing element is installed on the input end of the transmission structure to facilitate the state monitoring method of the transmission structure.

The above embodiments are used to illustrate the principle and effect of the present invention, but not to limit the present invention. Anyone skilled in the art can modify the above embodiments without violating the spirit and scope of the present invention. Therefore, the scope of protection of the present invention should be as listed in the scope of the patent application described below.

1: Transmission device 1a: Electronic module 10: Transmission structure 10a: Input end 10b: Output end 100: Gear 101: Input shaft 102: Output shaft 11: Circuit board 12: Sensing element 13: Data processing element 14: Data transmission element F0~F4: Peak value L: Baseline P: Target spectrum Q: Threshold value S20~S27: Steps

FIG. 1 is a three-dimensional schematic diagram of the transmission device of the present invention.

FIG. 2 is a flow chart of the state monitoring method of the transmission structure of the present invention.

FIG. 3A is a curve diagram of the first spectrum signal of the state monitoring method of the transmission structure of the present invention before simplification.

FIG. 3B is a curve diagram of the simplified second spectrum signal of the state monitoring method of the transmission structure of the present invention.

FIG. 3C is a curve diagram of a control signal used in the state monitoring method of the transmission structure of the present invention.

FIG. 4 is a curve diagram of the target frequency spectrum obtained by the state monitoring method of the transmission structure of the present invention.

1: Transmission device

1a: Electronic module

10: Transmission structure

10a: Input terminal

10b: Output terminal

100: Gear

101: Input shaft

102: Output shaft

11: Circuit board

12: Sensing element

13: Data processing components

14: Data transmission components

Claims (10)

A transmission device includes: a transmission structure having an input end and an output end opposite to each other, wherein the input end of the transmission structure has an input shaft, and the output end of the transmission structure has an output shaft; a circuit board disposed on the input end of the transmission structure; a sensing element disposed on the circuit board for sensing a plurality of vibration signals of the transmission structure; and a data processing element disposed on the circuit board. The sensor element is communicatively connected to convert the complex vibration signal into a first spectrum signal, and integerize and average the first spectrum signal to obtain a second spectrum signal, wherein the integerization is to round the frequency range to an integer, and the averaging is to average the amplitude of the frequency repeater; wherein the circuit board, the data processing element and the sensor element are integrated into an electronic module. A transmission device as described in claim 1, wherein the transmission structure is a deceleration structure. A transmission device as described in claim 2, wherein the speed reduction structure is in the form of a gear set. A transmission device as described in claim 1, wherein the sensing element is an accelerometer or a temperature sensor. A transmission device as described in claim 1, wherein the data processing element is a microcontroller. The transmission device as described in claim 1 further includes a data transmission element that is communicatively connected to the data processing element. A transmission device as described in claim 6, wherein the data transmission element is in the form of an antenna. The transmission device as described in claim 6, wherein the data transmission element is disposed on the circuit board, so that the circuit board, the data processing element, the sensing element and the data transmission element are integrated into the electronic module. A state monitoring method for a transmission structure comprises: providing a transmission device as described in any one of claims 1 to 8; sensing a plurality of vibration signals of the transmission structure by the sensing element; converting the plurality of vibration signals into the second spectrum signal by the data processing element; and comparing the second spectrum signal with a comparison signal to determine whether the transmission structure is abnormal, wherein the comparison signal is a normal spectrum presented by the vibration signal generated by the transmission structure in a normal state. The state monitoring method of the transmission structure as described in claim 9, wherein the second spectrum signal is subtracted from the reference signal to determine the cause of the abnormality of the transmission structure.

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