WO2018050008A1 - 轴承剩余寿命的监测方法及监测装置 - Google Patents

轴承剩余寿命的监测方法及监测装置 Download PDF

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Publication number
WO2018050008A1
WO2018050008A1 PCT/CN2017/100661 CN2017100661W WO2018050008A1 WO 2018050008 A1 WO2018050008 A1 WO 2018050008A1 CN 2017100661 W CN2017100661 W CN 2017100661W WO 2018050008 A1 WO2018050008 A1 WO 2018050008A1
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Prior art keywords
bearing
defect
determining
load
time
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PCT/CN2017/100661
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English (en)
French (fr)
Inventor
郭磊
卜格非
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Schaeffler Technologies AG and Co KG
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Schaeffler Technologies AG and Co KG
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Priority to DE112017004678.5T priority Critical patent/DE112017004678T5/de
Priority to US16/318,142 priority patent/US10823638B2/en
Publication of WO2018050008A1 publication Critical patent/WO2018050008A1/zh
Anticipated expiration legal-status Critical
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M13/00—Testing of machine parts
    • G01M13/04—Bearings
    • G01M13/045—Acoustic or vibration analysis
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C19/00—Bearings with rolling contact, for exclusively rotary movement
    • F16C19/52—Bearings with rolling contact, for exclusively rotary movement with devices affected by abnormal or undesired conditions
    • F16C19/527—Bearings with rolling contact, for exclusively rotary movement with devices affected by abnormal or undesired conditions related to vibration and noise
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M13/00—Testing of machine parts
    • G01M13/04—Bearings
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2291/00—Indexing codes associated with group G01N29/00
    • G01N2291/26—Scanned objects
    • G01N2291/269—Various geometry objects
    • G01N2291/2696—Wheels, Gears, Bearings

Definitions

  • the invention relates to the field of bearings, in particular to a monitoring method and a monitoring device for remaining bearing life.
  • Bearings are an indispensable part of the mechanical field, and their operating conditions directly affect the performance of the bearing service system (ie the mechanical equipment in which the bearing is located). Therefore, when the bearing is running, it is necessary to monitor the state of the bearing and alarm when the bearing is abnormal.
  • the existing methods for monitoring whether the state of the rolling bearing is abnormal include: the first type, determining whether the bearing state is abnormal by collecting the bearing temperature, and determining that the bearing state is abnormal and alarming when the bearing temperature reaches the set threshold; By collecting the vibration parameters of the bearing, including the amplitude and frequency of the vibration, etc., it is judged whether the bearing state is abnormal. When the vibration parameter exceeds the set threshold, the state of the bearing is determined to be abnormal, and an alarm is issued.
  • the abnormal state of the bearing is usually at the end of the development of the bearing defect. In other words, the bearing is close to or has been in a failed state, and the maintenance personnel cannot rely on this method to advance. Schedule maintenance plans and countermeasures.
  • the method can judge the abnormality of the bearing early in the bearing defect.
  • this method is difficult to judge the remaining life of the bearing, so maintenance personnel cannot rely on this method. Schedule maintenance plans and countermeasures in advance.
  • the problem solved by the present invention is that the existing method of monitoring the state of the bearing cannot judge the remaining service life of the bearing, and the maintenance personnel cannot arrange the maintenance plan and the countermeasure in advance.
  • the present invention provides a method for monitoring the remaining life of a bearing, comprising: determining a position of a defect of the bearing during operation of the bearing, determining a size of the defect; and determining a position and a setting according to the defect a condition determining a failure mode of the bearing, and an expansion rate and a failure value of the defect in the failure mode, the failure value being a maximum value at which the defect can be achieved when the bearing fails;
  • the remaining size of the bearing is obtained by the size, the rate of expansion, and the failure value.
  • determining the location of the defect of the bearing includes: acquiring a vibration signal of the bearing, the vibration signal including a vibration frequency and a magnitude of the bearing; performing frequency domain analysis on the vibration signal to determine The location of the defect.
  • determining the position of the defect of the bearing includes: acquiring an acoustic emission signal of the bearing, the acoustic emission signal including a frequency and a magnitude of the acoustic wave generated by the bearing; and frequencying the acoustic emission signal Domain analysis to determine where the defect is located.
  • the determining the size of the defect comprises: determining a relative rotational speed between the rolling element of the bearing and the inner ring or the outer ring; determining a time required for the rolling element to pass the defect; The relative rotational speed and the time are calculated to calculate the size of the defect.
  • the determining the time required for the rolling body to pass the defect comprises: acquiring a vibration signal of the bearing, the vibration signal including a vibration frequency and a magnitude of the bearing; and performing time domain on the vibration signal
  • the analysis determines the time required for the rolling body to pass the defect, which is the time interval between the time when the rolling body reaches the defect and the time when the defect is released.
  • the determining the time required for the rolling body to pass the defect comprises: acquiring an acoustic emission signal of the bearing, the acoustic emission signal including a frequency of the acoustic wave generated by the bearing Rate and amplitude; performing time domain analysis on the acoustic emission signal to determine a time required for the rolling body to pass the defect, the time being the time at which the rolling body reaches the defect and the time at which the defect is detached time interval.
  • the bearing before determining the location of the defect of the bearing and the size of the defect, further comprising determining whether the bearing has a defect: during the running, obtaining an operating parameter value of the bearing, the operating parameter of the bearing includes One or more of the temperature of the bearing, the vibration frequency of the bearing, the amplitude, and the rotational speed of the bearing; when one or more of the operating parameter values are abnormal, it is determined that the bearing is defective.
  • the method before acquiring the operating parameter value of the bearing, the method further includes: detecting an operating parameter value of the bearing.
  • the method further includes: diagnosing whether the operating parameter value is abnormal: obtaining a standard value of the operating parameter; comparing the operating parameter value with a standard value of the operating parameter to obtain a difference, where the difference is When the setting range is exceeded, it is determined that the operating parameter is abnormal.
  • the bearing when the bearing is free of defects: determining a load of the bearing; and obtaining a remaining life of the bearing according to the load and the rated dynamic load of the bearing.
  • the determining the load of the bearing comprises: determining an equivalent load that the bearing receives during the operation, and using the equivalent load as the load.
  • the determining the load of the bearing comprises: determining a real-time load received by the bearing during the operation, and using the real-time load as the load.
  • the present invention also provides a monitoring device for remaining bearing life, comprising: a defect determining unit, configured to determine a position of a defect of the bearing during operation of the bearing, determine a size of the defect; and a failure determining unit for a location and a set condition of the defect, determining a failure mode of the bearing, and an expansion rate and a failure value of the defect in the failure mode, the failure value being achievable by the defect when the bearing fails a maximum value; a first calculating unit, configured to obtain, based on a size of the defect determined by the defect determining unit, the expansion rate determined by the failure determining unit, and the failure value The remaining life of the bearing.
  • a defect determining unit configured to determine a position of a defect of the bearing during operation of the bearing, determine a size of the defect
  • a failure determining unit for a location and a set condition of the defect, determining a failure mode of the bearing, and an expansion rate and a failure value of the defect in the failure mode, the failure value being achievable by the
  • the defect determining unit includes: a vibration acquiring module, configured to acquire a vibration signal of the bearing, the vibration signal includes a vibration frequency and a magnitude of the bearing; and a vibration analysis module, configured to The vibration signal acquired by the acquisition module is subjected to frequency domain analysis to determine the location of the defect.
  • the defect determining unit includes: an acoustic wave acquiring module, configured to acquire an acoustic emission signal of the bearing, the acoustic emission signal includes a frequency and a magnitude of an acoustic wave generated by the bearing; and an acoustic wave analysis module, configured to: Performing frequency domain analysis on the acoustic emission signal acquired by the acoustic wave acquisition module to determine a location of the defect.
  • an acoustic wave acquiring module configured to acquire an acoustic emission signal of the bearing, the acoustic emission signal includes a frequency and a magnitude of an acoustic wave generated by the bearing
  • an acoustic wave analysis module configured to: Performing frequency domain analysis on the acoustic emission signal acquired by the acoustic wave acquisition module to determine a location of the defect.
  • the defect determining unit further includes: a rotation speed determining module, configured to determine a relative rotational speed between the rolling element of the bearing and the inner ring or the outer ring; and a determining module for determining the rolling body passing through The time required for the defect; the calculation module, configured to calculate the size of the defect based on the relative rotational speed determined by the rotational speed determining module and the time determined by the use determining module.
  • a rotation speed determining module configured to determine a relative rotational speed between the rolling element of the bearing and the inner ring or the outer ring
  • a determining module for determining the rolling body passing through The time required for the defect
  • the calculation module configured to calculate the size of the defect based on the relative rotational speed determined by the rotational speed determining module and the time determined by the use determining module.
  • the time determination module includes: a first acquisition submodule, configured to acquire a vibration signal of the bearing, the vibration signal includes a vibration frequency and a magnitude of the bearing; and a first analysis submodule, configured to: Performing a time domain analysis on the vibration signal acquired by the first acquisition sub-module, determining a time required for the rolling body to pass the defect, the time being the time when the rolling body reaches the defect and the moment of leaving the defect Interval.
  • the time determination module includes: a second acquisition submodule, configured to acquire an acoustic emission signal of the bearing, the acoustic emission signal includes a frequency and a magnitude of an acoustic wave generated by the bearing; and a second analysis a module, configured to perform time domain analysis on the acoustic emission signal acquired by the second acquisition submodule, and determine a time required for the rolling body to pass the defect, where the time is when the rolling body reaches the defect The time interval from the moment when the defect is removed.
  • the method further includes: a defect determining unit, configured to determine whether the bearing has a defect; and the defect determining unit includes: a parameter obtaining module, configured to be used in the running process of the bearing Obtaining an operating parameter value of the bearing, the parameter comprising one or more of a temperature of the bearing, a vibration frequency of the bearing, an amplitude, and a rotational speed of the bearing; and a determining module for acquiring the parameter acquiring module When an abnormality occurs in one or more of the operating parameter values, it is determined that the bearing has a defect.
  • a detecting unit is further configured to detect an operating parameter value of the bearing before acquiring an operating parameter value of the bearing.
  • the defect determining unit further includes: a standard obtaining module, configured to acquire a standard value of the operating parameter; and the determining module is further configured to: use the standard acquiring module to obtain the running of the bearing The obtained operating parameter value of the bearing is compared with the standard value of the operating parameter to obtain a difference, and when the difference exceeds the set range, it is determined that the operating parameter is abnormal.
  • a standard obtaining module configured to acquire a standard value of the operating parameter
  • the determining module is further configured to: use the standard acquiring module to obtain the running of the bearing The obtained operating parameter value of the bearing is compared with the standard value of the operating parameter to obtain a difference, and when the difference exceeds the set range, it is determined that the operating parameter is abnormal.
  • the method further includes: a load determining unit, configured to determine a load of the bearing when the bearing is free from defects; a second calculating unit, configured to determine the load according to the load determining unit, and the The rated dynamic load of the bearing is obtained for the remaining life of the bearing.
  • the load determining unit is further configured to: determine an equivalent load that the bearing receives during the operation, and use the equivalent load as the load.
  • the load determining unit is further configured to: determine a real-time load that the bearing receives during the operation, and use the real-time load as the load.
  • the size of the defect is determined based on the position of the defect, and the failure mode, the failure value, and the expansion rate of the defect are determined according to the position and setting conditions of the defect, and finally The remaining life of the bearing is calculated based on the size of the defect, the expansion rate, and the failure value. Therefore, maintenance personnel can arrange maintenance plans and countermeasures in advance according to the remaining life of the monitored bearings to improve the safety of the operation of the bearing service system.
  • FIG. 1 is a schematic diagram of a monitoring method according to an embodiment of the present invention.
  • FIG. 2 is a flow chart of a monitoring method according to an embodiment of the present invention.
  • FIG. 3 is a schematic diagram of a monitoring device according to an embodiment of the present invention.
  • Fig. 4 is a schematic diagram of a monitoring apparatus in a modification of the embodiment of the present invention.
  • the invention provides a method for monitoring the remaining life of a bearing.
  • the monitoring method comprises the following steps:
  • the bearings in this embodiment are generally referred to as rolling bearings.
  • the most likely position of the bearing during the operation of the bearing is the rolling surface of the rolling contact inside the bearing, including the raceway of the inner ring of the bearing, the raceway of the outer ring, the rolling elements and the cage. Therefore, the location of the defect generally includes: inner ring, outer ring, rolling elements and cage.
  • the method of determining the remaining life of the bearing is mainly described by taking the case where the defect occurs in the inner ring and the outer ring as an example.
  • Setting conditions generally refers to the experience accumulated in the industry.
  • the data obtained by accumulating the industry experience can be used to derive the failure mode, and then the expansion rate and failure value of the defect in the failure mode are obtained.
  • the types of failure modes include: contact fatigue aging, wear failure, fracture failure, plastic deformation failure, corrosion Invalidation, etc.
  • the failure mode is different, the rate of expansion of the defect may be different, and the failure value of the defect that the bearing can withstand, that is, the maximum value of the defect.
  • the expansion rate of the defect and the failure value of the defect can be obtained according to the empirical data accumulated in the industry. For example, in the contact fatigue failure mode, when the area of the defect reaches 5% to 6% of the contact area, the bearing is considered to be in failure, and the defect area at this time is the failure value.
  • the time required for the defect to extend to the value of the failure can be calculated. Then, based on the rotational speed of the bearing and the time required for the defect to extend to the failure value, the number of turns in which the remaining bearing can be operated is calculated, thereby obtaining the remaining life of the bearing. Alternatively, the remaining life of the bearing can be measured directly based on the time required for the defect to extend to the failure value.
  • the size of the defect is determined based on the position of the defect, and the failure mode of the bearing is determined according to the position and setting conditions of the defect, The failure value and the expansion rate of the defect, and finally the remaining life of the bearing is calculated according to the size of the defect, the expansion rate, and the failure value. Therefore, maintenance personnel can arrange maintenance plans and countermeasures in advance according to the remaining life of the monitored bearings to improve the safety of the operation of the bearing service system.
  • Steps S10 to S30 are explained in detail below.
  • Step S10 During the operation of the bearing, determine the position of the bearing defect and determine the size of the defect.
  • the location of the defect can be obtained by vibration analysis, acoustic emission analysis, or other methods.
  • the vibration analysis method and the acoustic emission analysis method are taken as an example to introduce the manner of obtaining the defect position.
  • the vibration signal of the bearing is obtained, and the vibration signal includes the vibration frequency and amplitude of the bearing; then, the vibration signal is subjected to frequency domain analysis to determine the position of the defect.
  • the acoustic emission analysis method first, the acoustic emission signal of the bearing is obtained, and the acoustic emission signal contains the frequency and amplitude of the acoustic wave generated by the bearing; then, the acoustic emission signal is subjected to frequency domain analysis to determine the position of the defect.
  • the initially obtained vibration signal or acoustic emission signal is generally a time domain signal, which reflects the state of the vibration or sound wave amplitude with respect to time.
  • the time domain signal needs to be converted into a vibration spectrum or an acoustic emission spectrum, and the fault frequency is analyzed according to the converted spectrum: if the characteristic frequency of a component is close to the fault frequency, the component is defective.
  • vibration analysis and acoustic emission analysis are used to analyze the position of bearing defects, it is a relatively mature technology in the field, and will not be elaborated here.
  • the determination of the defect size can be performed by the following steps S11 to S13.
  • step S11 when determining the relative rotational speed, one is to determine the revolution speed of the rolling element, that is, the speed at which the rolling element rotates around the central axis of the bearing, and the second is to determine the rotational speed of the component in which the defect is located, such as the inner ring and the outer ring. The speed of the circle. The relative rotational speed between the rolling element and the component in which the defect is located is then determined based on the rotational speed of the rolling element and the rotational speed of the component in which the defect is located.
  • step S12 the time required for the rolling elements to pass the defect can be determined by vibration analysis, acoustic emission analysis or other analysis methods.
  • the vibration analysis method first, the vibration signal of the bearing is obtained, and the vibration signal includes the vibration frequency and the amplitude of the bearing; then, the time domain analysis of the vibration signal is performed to determine the time required for the rolling element to pass the defect, and the time is the arrival of the rolling element. The time interval between the moment of the defect and the moment of departure from the defect.
  • the initially obtained vibration signal is the time domain signal, ie the amplitude of the vibration is about The distribution of time.
  • Time domain analysis of the time domain signal When the rolling element does not pass through the defect area, the time domain signal of the vibration changes substantially in a regular state; when the rolling element passes through the defect area, the time domain signal is abruptly changed. Conversely, during this period of time when the time domain signal is abrupt, the rolling element passes through a defective portion. Then, the time period is the time required for the rolling elements to pass through the defect.
  • the acoustic emission signal of the bearing is first obtained, and the acoustic emission signal includes the frequency and amplitude of the acoustic wave generated by the bearing; then, the time domain analysis of the acoustic emission signal is performed to determine the time required for the rolling element to pass the defect, The time is the time interval between the moment when the rolling element reaches the defect and the moment when the defect is released.
  • the initially obtained acoustic emission signal is a time domain signal, ie the distribution of the amplitude of the acoustic wave with respect to time.
  • the acoustic signal is small; when the rolling element does not pass through the defective area, the acoustic signal is abrupt. Then, the period of time during which the mutation occurs is the time required for the rolling element to pass through the defect.
  • step S10 further comprising step S100: determining whether the bearing has a defect. If it is judged that there is a defect in the bearing, steps S10 to S30 are performed.
  • step S100 the process of determining whether the bearing has a defect includes:
  • S110 obtaining an operating parameter value of the bearing during operation, the operating parameter of the bearing includes one or more of a bearing temperature, a bearing vibration frequency, an amplitude, and a bearing rotation speed;
  • the step of detecting the running parameter value of the bearing is also included.
  • a temperature sensor can be used to detect the temperature of the bearing
  • a vibration acceleration sensor can be used to detect the vibration frequency and amplitude of the bearing
  • a rotational speed sensor can be used to detect the bearing. Speed.
  • step S120 a process of diagnosing whether an abnormality occurs in the running parameter value includes:
  • the standard value generally refers to the value of each operating parameter obtained when the bearing is in normal operation. In general, when the bearing is just put into use, or just after the end of maintenance, it is considered that the bearing is in normal operation.
  • S122 Comparing the running parameter value with the standard value of the running parameter to obtain a difference, and determining that the running parameter is abnormal when the difference exceeds the set range.
  • step S100 if it is determined that there is no defect in the bearing, the remaining life of the bearing is calculated according to the following steps S40 to S50.
  • S50 Obtain the remaining life of the bearing according to the load and the rated dynamic load of the bearing.
  • the rated dynamic load can be obtained according to the method specified in ISO 281 Rolling Bearings, Dynamic Load Rating and Rated Life (hereinafter referred to as ISO 281).
  • the load may be an equivalent load or a real-time load.
  • the equivalent load also called the equivalent dynamic load, generally refers to the actual load acting on the bearing is converted into the same imaginary load as the basic dynamic load direction.
  • Real-time load refers to the actual load that the bearing receives at each moment during operation.
  • step S40 further includes determining the equivalent load that the bearing is subjected to during operation, and using the equivalent load as the load.
  • step S40 further includes determining the real-time load that the bearing is subjected to during operation, and using the real-time load as the load.
  • step S50 the fatigue life of the bearing needs to be calculated before calculating the remaining life of the bearing.
  • Bearing fatigue life can be calculated according to the general formula in current industry standards.
  • the bearing life of the bearing is determined by the ISO 281
  • the general formula to get, the general formula is:
  • L nm is the fatigue life of the bearing
  • a 1 is the life-correction coefficient based on reliability
  • a ISO is the life correction coefficient based on factors such as lubrication, environment, pollutant particles and installation
  • C u is the fatigue load limit
  • e C For the pollution factor
  • ⁇ is the viscosity ratio of the lubricant
  • P is the load to which the bearing is subjected, such as the equivalent dynamic load (ie equivalent load) or real-time load
  • ⁇ is the index determined according to the type of rolling element of the bearing.
  • the remaining life of the bearing can be obtained according to the number of running rings that the bearing has passed.
  • Figure 2 shows a flow chart of the method of the present embodiment.
  • the bearing when the bearing starts to operate, it is first determined whether the bearing has a defect; if there is a defect, the remaining life of the bearing is obtained according to the size of the defect, the expansion rate and the failure value, that is, Step S10 to step S30 to obtain the remaining life; if there is no defect, the remaining life of the bearing is obtained according to the equivalent load or the real-time load, that is, the remaining life is obtained by step S40 to step S50.
  • step S40 to step S50 may be omitted.
  • the embodiment further provides a monitoring device for the remaining life of the bearing.
  • the monitoring device includes:
  • the defect determining unit 10 is configured to determine a position of the bearing defect during the operation of the bearing, and determine the size of the defect;
  • the failure determining unit 20 is configured to determine, according to the position and setting conditions of the defect, the failure mode of the bearing under the operating condition of the operating process, and the expansion of the defect in the failure mode Explosion rate and failure value, the failure value is the maximum value that the defect can reach when the bearing fails;
  • the first calculating unit 30 is configured to obtain a bearing remaining life based on the size of the defect determined by the defect determining unit 10, the expansion rate determined by the failure determining unit 20, and the failure value.
  • bearing remaining operation time (failure value - defect size) / expansion rate.
  • the position and size of the defect can be determined by vibration analysis, acoustic emission analysis, and the like.
  • the defect determining unit 10 in order to determine the position of the defect, includes:
  • the vibration acquiring module 11 is configured to obtain a vibration signal of the bearing, and the vibration signal includes a vibration frequency and a magnitude of the bearing;
  • the vibration analysis module 12 is configured to perform frequency domain analysis on the vibration signal acquired by the vibration acquisition module 11 to determine the location of the defect.
  • the defect determining unit 10 further includes:
  • a rotation speed determining module 13 for determining a relative rotational speed between the rolling element of the bearing and the inner ring or the outer ring;
  • a time determination module 14 for determining the time required for the rolling elements to pass the defect
  • the calculation module 15 is configured to calculate the size of the defect based on the relative rotational speed determined by the rotational speed determining module 13 and the time determined by the time determining module 14.
  • the time determination module 14 includes:
  • a first acquisition sub-module 141 configured to acquire a vibration signal of the bearing, where the vibration signal includes a vibration frequency and a magnitude of the bearing;
  • the first analysis sub-module 142 is configured to perform time domain analysis on the vibration signal acquired by the first acquisition sub-module 141, and determine the time required for the rolling element to pass the defect, and the time is the rolling body to The time interval between the moment of the defect and the moment of the defect.
  • the defect determining unit 10 when determining the position and size of the defect of the bearing by the acoustic emission analysis method, in order to determine the position of the defect, the defect determining unit 10 includes:
  • the sound wave acquiring module 11' is configured to obtain an acoustic emission signal of the bearing, and the sound emission signal includes a frequency and a magnitude of the sound wave generated by the bearing;
  • the acoustic wave analysis module 12' is configured to perform frequency domain analysis on the acoustic emission signal acquired by the acoustic wave acquisition module to determine the location of the defect.
  • the time determination module 14 includes:
  • a second acquisition sub-module 141' for acquiring an acoustic emission signal of the bearing, the acoustic emission signal comprising a frequency and a magnitude of the acoustic wave generated by the bearing;
  • the second analysis sub-module 142 ′ is configured to perform time domain analysis on the acoustic emission signal acquired by the second acquisition sub-module 141 ′, and determine a time required for the rolling element to pass the defect, and the time is the time when the rolling element reaches the defect and the defect is removed. The time interval of the moment.
  • the monitoring device further includes a defect judging unit 100 for judging whether the bearing has a defect.
  • the defect determining unit 100 includes:
  • the parameter obtaining module 101 is configured to obtain a running parameter value of the bearing during operation of the bearing, the parameter comprising one or more of a bearing temperature, a bearing vibration frequency, an amplitude, and a bearing rotational speed;
  • the determining module 102 is configured to determine that the bearing has a defect when one or more abnormalities of the operating parameter values acquired by the parameter acquiring module 101 occur.
  • the monitoring device further comprises a detection unit T for detecting the operating parameter values of the bearing before acquiring the operating parameter values of the bearing.
  • the detecting unit T may include a temperature sensor and a vibration acceleration sensor The speed sensor, the vibration frequency of the bearing, the amplitude, and the rotational speed of the bearing are detected, and the detected signal is transmitted to the parameter acquisition module 101.
  • the defect determining unit 100 further includes a standard obtaining module 103 for obtaining a standard value of the operating parameter.
  • the determining module 102 is further configured to compare the operating parameter value of the bearing obtained during the running process of the bearing acquired by the standard obtaining module 103 with the standard value of the operating parameter to obtain a difference, and when the difference exceeds the set range, determine An exception occurred in this run parameter.
  • the determination module 102 determines that there is a defect in the bearing, the remaining life of the bearing is calculated by the defect determination unit 10, the failure determination unit 20, and the first calculation unit 30. If the determination unit 102 determines that there is no defect in the bearing, the remaining life is calculated by the load of the bearing.
  • the monitoring device further includes a load determining unit 40 and a second calculating unit 50 for calculating the remaining life of the bearing when no defect occurs.
  • the load determining unit 40 is configured to determine the load of the bearing when there is no defect in the bearing.
  • the second calculating unit 50 is for determining the load according to the load determining unit 40 and the rated dynamic load of the bearing to obtain the remaining life of the bearing.
  • the load can be an equivalent load or a real-time load. Therefore, if the equivalent load is used as the load for calculating the remaining life, the load determining unit 40 is used to: determine the equivalent load that the bearing receives during operation, and use the equivalent load as the load.
  • the load determining unit 40 is further configured to: determine the real-time load that the bearing is subjected to during operation, and use the real-time load as the load.

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  • General Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
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Abstract

一种轴承剩余寿命的监测方法及监测装置，其中监测方法包括：在轴承运行过程中，确定轴承的缺陷所在的位置，确定缺陷的大小（S10）；根据缺陷所在的位置和设定条件，确定轴承的失效模式，以及在失效模式下缺陷的扩展速率和失效值（S20），失效值为轴承失效时缺陷能够达到的最大值；基于缺陷的大小、扩展速率以及失效值，获得轴承剩余寿命（S30）。该监测方法和监测装置能够判断轴承的剩余使用寿命，以便维护人员提前安排维护计划和应对措施。

Description

轴承剩余寿命的监测方法及监测装置
本申请要求于2016年09月19日提交中国专利局、申请号为201610833422.6、发明名称为“轴承剩余寿命的监测方法及监测装置”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本发明涉及轴承领域，具体涉及一种轴承剩余寿命的监测方法及监测装置。
背景技术
轴承是机械领域不可或缺的重要位置，其运行状况直接影响到轴承服役系统(即轴承所在机械设备)的性能。因此，在轴承运行时，需要对轴承的状态进行监测，并在轴承出现异常时报警。
现有监测滚动轴承的状态是否出现异常的方法包括：第一种，通过采集轴承温度来判断轴承状态是否异常，在轴承温度达到设定阈值时，认定轴承的状态异常，并进行报警；第二种，通过采集轴承的振动参数，包括振动的幅值和频率等来判断轴承状态是否异常，在振动参数超过设定阈值时，认定轴承的状态异常，并进行报警。
上述方法的缺点在于：
对于第一种方法，当轴承温度达到设定阈值时，此时轴承的异常状态通常已处于轴承缺陷发展的末期，换言之，轴承已接近或已处于失效状态，导致维护人员无法依靠此方法来事先安排维护计划和应对措施。
对于第二种方法，由于振动对轴承缺陷的敏感度要高于温度，因此该方法能够在轴承缺陷产生的早期判断出轴承的异常。但是，该方法难以判断轴承的剩余使用寿命，因此维护人员也无法依靠此方法来 提前安排维护计划和应对措施。
发明内容
本发明解决的问题是现有监测轴承状态的方法无法判断轴承的剩余使用寿命，导致维护人员无法提前安排维护计划和应对措施。
为解决上述问题，本发明提供一种轴承剩余寿命的监测方法，包括：在轴承运行过程中，确定轴承的缺陷所在的位置，确定所述缺陷的大小；根据所述缺陷所在的位置和设定条件，确定所述轴承的失效模式，以及在所述失效模式下所述缺陷的扩展速率和失效值，所述失效值为所述轴承失效时所述缺陷能够达到的最大值；基于所述缺陷的大小、所述扩展速率以及所述失效值，获得所述轴承剩余寿命。
可选的，所述确定轴承的缺陷所在的位置包括：获取所述轴承的振动信号，所述振动信号包含所述轴承的振动频率和幅值；对所述振动信号进行频域分析，以确定所述缺陷所在的位置。
可选的，所述确定轴承的缺陷所在的位置包括：获取所述轴承的声发射信号，所述声发射信号包含所述轴承产生的声波的频率和幅值；对所述声发射信号进行频域分析，以确定所述缺陷所在的位置。
可选的，所述确定所述缺陷的大小包括：确定所述轴承的滚动体与内圈或外圈之间的相对转速；确定所述滚动体经过所述缺陷所需的时间；根据所述相对转速以及所述时间，计算得到所述缺陷的大小。
可选的，所述确定所述滚动体经过缺陷所需的时间包括：获取所述轴承的振动信号，所述振动信号包含所述轴承的振动频率和幅值；对所述振动信号进行时域分析，确定所述滚动体经过缺陷所需的时间，所述时间为所述滚动体到达所述缺陷的时刻与脱离所述缺陷的时刻的时间间隔。
可选的，所述确定所述滚动体经过缺陷所需的时间包括：获取所述轴承的声发射信号，所述声发射信号包含所述轴承产生的声波的频 率和幅值；对所述声发射信号进行时域分析，确定所述滚动体经过缺陷所需的时间，所述时间为所述滚动体到达所述缺陷的时刻与脱离所述缺陷的时刻的时间间隔。
可选的，在确定所述轴承的缺陷所在位置，以及缺陷大小之前，还包括判断所述轴承是否存在缺陷：在所述运行过程中，获取所述轴承的运行参数值，轴承的运行参数包括轴承的温度、轴承的振动频率、振幅、轴承的转速中的一个或多个；所述运行参数值的一个或多个发生异常时，判定所述轴承存在缺陷。
可选的，在获取所述轴承的运行参数值之前，还包括：对所述轴承的运行参数值进行检测。
可选的，还包括诊断所述运行参数值是否发生异常：获取所述运行参数的标准值；将所述运行参数值和该运行参数的标准值进行比较，得到差值，在所述差值超出设定范围时，认定该运行参数发生异常。
可选的，当所述轴承不存在缺陷时：确定所述轴承的载荷；根据所述载荷，以及所述轴承的额定动载荷，获得轴承的剩余寿命。
可选的，所述确定所述轴承的载荷包括：确定所述轴承在所述运行过程中受到的等效载荷，将所述等效载荷作为所述载荷。
可选的，所述确定所述轴承的载荷包括：确定所述轴承在所述运行过程中受到的实时载荷，将所述实时载荷作为所述载荷。
本发明还一种轴承剩余寿命的监测装置，包括：缺陷确定单元，用于在轴承运行过程中，确定轴承的缺陷所在的位置，确定所述缺陷的大小；失效确定单元，用于根据所述缺陷所在的位置和设定条件，确定所述轴承的失效模式，以及在所述失效模式下所述缺陷的扩展速率和失效值，所述失效值为所述轴承失效时所述缺陷能够达到的最大值；第一计算单元，用于基于所述缺陷确定单元确定的所述缺陷的大小、所述失效确定单元确定的所述扩展速率以及所述失效值，获得所 述轴承剩余寿命。
可选的，所述缺陷确定单元包括：振动获取模块，用于获取所述轴承的振动信号，所述振动信号包含所述轴承的振动频率和幅值；振动分析模块，用于对所述振动获取模块获取的所述振动信号进行频域分析，以确定所述缺陷所在的位置。
可选的，所述缺陷确定单元包括：声波获取模块，用于获取所述轴承的声发射信号，所述声发射信号包含所述轴承产生的声波的频率和幅值；声波分析模块，用于对所述声波获取模块获取的所述声发射信号进行频域分析，以确定所述缺陷所在的位置。
可选的，所述缺陷确定单元还包括：转速确定模块，用于确定所述轴承的滚动体与内圈或外圈之间的相对转速；用时确定模块，用于确定所述滚动体经过所述缺陷所需的时间；计算模块，用于基于所述转速确定模块确定的相对转速，以及所述用时确定模块确定的所述时间，计算得到所述缺陷的大小。
可选的，所述用时确定模块包括：第一获取子模块，用于获取所述轴承的振动信号，所述振动信号包含所述轴承的振动频率和幅值；第一分析子模块，用于对第一获取子模块获取的所述振动信号进行时域分析，确定所述滚动体经过缺陷所需的时间，所述时间为所述滚动体到达所述缺陷的时刻与脱离所述缺陷的时刻的时间间隔。
可选的，所述用时确定模块包括：第二获取子模块，用于获取所述轴承的声发射信号，所述声发射信号包含所述轴承产生的声波的频率和幅值；第二分析子模块，用于对所述第二获取子模块获取的所述声发射信号进行时域分析，确定所述滚动体经过缺陷所需的时间，所述时间为所述滚动体到达所述缺陷的时刻与脱离所述缺陷的时刻的时间间隔。
可选的，还包括缺陷判断单元，用于判断所述轴承是否存在缺陷；所述缺陷判断单元包括：参数获取模块，用于在所述轴承的运行过程 中，获取所述轴承的运行参数值，所述参数包括轴承的温度、轴承的振动频率、振幅、轴承的转速中的一个或多个；判定模块，用于在所述参数获取模块获取的所述运行参数值的一个或多个发生异常时，判定所述轴承存在缺陷。
可选的，还包括检测单元，用于在获取所述轴承的运行参数值之前，对所述轴承的运行参数值进行检测。
可选的，所述缺陷判断单元还包括：标准获取模块，用于获取所述运行参数的标准值；所述判定模块还用于：将所述标准获取模块获取的所述轴承的运行过程中获取的所述轴承的运行参数值和该运行参数的标准值进行比较，得到差值，在所述差值超出设定范围时，认定该运行参数发生异常。
可选的，还包括：载荷确定单元，用于当所述轴承不存在缺陷时，确定所述轴承的载荷；第二计算单元，用于根据所述载荷确定单元确定所述载荷，以及所述轴承的额定动载荷，获得轴承的剩余寿命。
可选的，所述载荷确定单元还用于：确定所述轴承在所述运行过程中受到的等效载荷，将所述等效载荷作为所述载荷。
可选的，所述载荷确定单元还用于：确定所述轴承在所述运行过程中受到的实时载荷，将所述实时载荷作为所述载荷。
与现有技术相比，本发明的技术方案具有以下优点：
在轴承运行过程中，如果轴承存在缺陷，基于缺陷的位置确定缺陷的大小，并根据所述缺陷所在的位置和设定条件，确定轴承的失效模式、失效值以及所述缺陷的扩展速率，最后根据所述缺陷的大小、扩展速率和失效值来计算得到轴承的剩余寿命。由此，维护人员可以根据监测得到的轴承的剩余寿命来提前安排维护计划和应对措施，提高轴承服役系统运行的安全性。
附图说明
图1是本发明实施例的监测方法的原理图；
图2是本发明实施例的监测方法的流程图；
图3是本发明实施例的监测装置的原理图；
图4是本发明实施例的变形例中监测装置的原理图。
具体实施方式
为使本发明的上述目的、特征和优点能够更为明显易懂，下面结合附图对本发明的具体实施例做详细的说明。
本发明提供一种轴承剩余寿命的监测方法，参照图1所示，该监测方法包括以下步骤：
S10：在轴承运行过程中，确定轴承的缺陷所在的位置，确定缺陷的大小；
S20：根据缺陷所在的位置和设定条件，确定在运行过程所处的工况下，轴承的失效模式，以及在失效模式下缺陷的扩展速率和失效值，失效值为轴承失效时缺陷能够达到的最大值；
S30：基于缺陷的大小、扩展速率以及失效值，获得轴承剩余寿命。
需要注意，本实施例中的轴承一般指滚动轴承。对于滚动轴承而言，在轴承运行的过程中，最有可能出现缺陷的位置就是轴承内部滚动接触的滚动表面，包括轴承的内圈的滚道、外圈的滚道、滚动体以及保持架。因此，缺陷所在的位置一般包括：内圈、外圈、滚动体和保持架。本实施例中，主要以缺陷发生于内圈、外圈时为例，阐述轴承的剩余寿命的确定方法。
设定条件，一般指行业中积累的经验。在实际中，一般而言，缺陷的位置一旦确定，对照行业经验积累获得的数据，可以推得失效模式，然后得到该失效模式下缺陷的扩展速率和失效值。失效模式的种类包括：接触疲劳时效、磨损失效、断裂失效、塑性变形失效、腐蚀 失效等。
失效模式不同，缺陷的扩展速率可能不同，轴承能够承受的缺陷的失效值，即缺陷的最大值也不同。实际中，在具体的失效模式下，可以根据业内积累的经验数据得到缺陷的扩展速率以及缺陷的失效值。例如，在接触疲失效模式下，当缺陷的面积达到接触面积5％至6％时，认为轴承失效，此时的缺陷面积即为失效值。
当缺陷的大小确定、扩展速率以及失效值确定，则可以计算出缺陷扩展至失效值所需要的时间。然后，根据轴承的转速以及缺陷扩展至失效值所需的时间，算出轴承剩余能够运转的圈数，从而得到轴承的剩余寿命。或者，也可以直接以缺陷扩展至失效值所需要的时间为依据，来衡量轴承的剩余寿命。
由此可见，本方案中，在轴承运行过程中，在轴承存在缺陷的情况下，基于缺陷的位置确定缺陷的大小，并根据所述缺陷所在的位置和设定条件，确定轴承的失效模式、失效值以及所述缺陷的扩展速率，最后根据所述缺陷的大小、扩展速率和失效值来计算得到轴承的剩余寿命。由此，维护人员可以根据监测得到的轴承的剩余寿命来提前安排维护计划和应对措施，提高轴承服役系统运行的安全性。
下面对步骤S10至S30作详细的阐述。
步骤S10：在轴承运行过程中，确定轴承的缺陷所在的位置，确定缺陷的大小。
(1)确定轴承的缺陷所在的位置。
该步骤中，缺陷所在的位置可以通过振动分析法、声发射分析法，或者其他方法获取。本实施例中以振动分析法和声发射分析法为例，介绍缺陷位置获取的方式。
在振动分析法中，首先，获取轴承的振动信号，振动信号包含轴承的振动频率和幅值；然后，对振动信号进行频域分析，以确定缺陷所在的位置。
在声发射分析法中，首先，获取轴承的声发射信号，声发射信号包含轴承产生的声波的频率和幅值；然后，对声发射信号进行频域分析，以确定缺陷所在的位置。
对于振动分析法还是声发射分析法而言，初始获得的振动信号或声发射信号一般为时域信号，体现的是振动或声波的幅值关于时间的变化状态。为了确定缺陷的位置，需要把时域信号转化为振动频谱或者声发射频谱，根据转化后的频谱来分析故障频率：如果某个部件的特征频率与故障频率接近，则该部件出现缺陷。
由于振动分析法、声发射分析法用于分析轴承缺陷的位置已经是本领域中比较成熟的技术，在此不作过多阐述。
(2)确定缺陷的大小。缺陷大小的确定可以通过以下步骤S11至S13进行。
S11：确定轴承的滚动体与内圈或外圈之间的相对转速；
S12：确定滚动体经过缺陷所需的时间；
S13：根据相对转速以及时间，计算得到缺陷的大小。
在步骤S11中，在确定所述相对转速时，一是要确定滚动体的公转转速，即滚动体围绕轴承的中心轴转动的速度，二是要确定缺陷所在部件的转速，例如内圈、外圈的转速。然后根据滚动体的转速、缺陷所在部件的转速来确定滚动体和缺陷所在部件之间的相对转速。
在步骤S12中，滚动体经过缺陷所需的时间，可以通过振动分析法、声发射分析法或者其他分析方法来确定。
在振动分析法中，首先，获取轴承的振动信号，振动信号包含轴承的振动频率和幅值；然后，对振动信号进行时域分析，确定滚动体经过缺陷所需的时间，时间为滚动体到达缺陷的时刻与脱离缺陷的时刻的时间间隔。
如前所述，初始获得的振动信号为时域信号，即振动的幅值关于 时间的分布。对该时域信号进行时域分析。当滚动体未经过缺陷区时，振动的时域信号基本呈规律变化的状态；当滚动体经过缺陷区时，时域信号会出现突变。反过来说，时域信号发生突变的这个时间段内，滚动体经过的部位存在缺陷的。那么，该时间段即为滚动体经过缺陷所需的时间。
在分析时，需要根据时域信号计算出现突变的时间段中的起始时间点以及结束时间点，然后获得起始时间点和结束时间点之间的时间差，即滚动体经过缺陷所经过的时间。
在声发射分析法中，首先获取轴承的声发射信号，声发射信号包含轴承产生的声波的频率和幅值；然后，对声发射信号进行时域分析，确定滚动体经过缺陷所需的时间，时间为滚动体到达缺陷的时刻与脱离缺陷的时刻的时间间隔。
如前所述，初始获得的声发射信号为时域信号，即声波的幅值关于时间的分布。当滚动体未经过缺陷区时，声波信号较小；当滚动体未经过缺陷区时，声波信号会产生突变。那么，产生突变的这一时间段即为滚动体经过缺陷所需的时间。
进一步的，本实施例中，在步骤S10之前，还包括步骤S100：判断轴承是否存在缺陷。如果判断得到轴承存在缺陷，则执行步骤S10至S30。
具体地，步骤S100中，判断轴承是否存在缺陷的过程包括：
S110：在运行过程中，获取轴承的运行参数值，轴承的运行参数包括轴承的温度、轴承的振动频率、振幅、轴承的转速中的一个或多个；
S120：运行参数值的一个或多个发生异常时，判定轴承存在缺陷。
其中，在获取轴承的运行参数值之前，还包括对轴承的运行参数值进行检测的步骤。例如可以用温度传感器检测轴承的温度，用振动加速度传感器检测轴承的振动频率、振幅，用转速传感器来检测轴承 的转速。
在步骤S120中，还包括诊断运行参数值是否发生异常的过程，该过程包括：
S121：获取运行参数的标准值。标准值一般指用轴承正常运行的时候，获取的各个运行参数的值。一般情况下，将轴承刚投入使用的时候，或者刚维护结束的一段时间视为轴承正常运行的时候。
S122：将运行参数值和该运行参数的标准值进行比较，得到差值，在差值超出设定范围时，认定该运行参数发生异常。
进一步的，在步骤S100中，如果判断得到轴承不存在缺陷时，则依据以下步骤S40至S50计算轴承的剩余寿命。
S40：确定轴承的载荷。
S50：根据载荷，以及轴承的额定动载荷，获得轴承的剩余寿命。其中，额定动载荷可以依照《ISO 281滚动轴承.额定动载荷和额定寿命》(以下简称《ISO 281》)中指定的方法来获得。
在步骤S40中，载荷可以是等效载荷或者实时载荷。其中，等效载荷，也称当量动载荷，一般指把实际作用在轴承上的载荷折算成与基本额定动载荷方向相同的假想载荷。实时载荷，指的是轴承在运行过程中每个时刻实际受到的载荷。
当用等效载荷作为步骤S40中的载荷时，则步骤S40还包括：确定轴承在运行过程中受到的等效载荷，将等效载荷作为载荷。
当用实时载荷作为步骤S40中的载荷时，则步骤S40还包括：确定轴承在运行过程中受到的实时载荷，将实时载荷作为载荷。
在步骤S50中，在计算轴承的剩余寿命之前，需要先计算轴承的疲劳寿命。轴承疲劳寿命的可以按照现行的行业标准中的通用公式来计算。
本实施例中，轴承的疲劳寿命通过《ISO 281》)制定的轴承寿命 的通用公式来得到，该通用公式为：
Figure PCTCN2017100661-appb-000001
其中
Figure PCTCN2017100661-appb-000002
其中，Lnm为轴承的疲劳寿命，a1为基于可靠度的寿命修正系数，aISO为基于润滑、环境、污染物颗粒以及安装等因素的寿命修正系数，Cu为疲劳载荷极限，eC为污染系数，κ为润滑剂的粘度比，P为轴承所受的载荷，例如当量动载荷(即等效载荷)或者实时载荷，ε为根据轴承的滚动体的类型确定的指数。根据《ISO 281滚动轴承.额定动载荷和额定寿命》，当滚动体为滚珠时，ε＝3，当滚动体为滚柱时，
Figure PCTCN2017100661-appb-000003
在计算出轴承的疲劳寿命后，根据轴承已经经过的运转圈数，即可获得轴承的剩余寿命。
综上，参照图2所示，图2示出了本实施例的方法的流程图。
从流程图中可以看到，本实施例中，当轴承开始运行时，先确定轴承是否存在缺陷；如果有缺陷，则根据缺陷的大小、扩展速率和失效值，获得轴承的剩余寿命，即通过步骤S10至步骤S30来获得剩余寿命；如果没有缺陷，则根据等效载荷或实时载荷，获得轴承的剩余寿命，即通过步骤S40至步骤S50来获得剩余寿命。
在其他实施例中，如果需要将本实施例的方法用于确定轴承在缺陷状态下的剩余寿命，则可以省略步骤S40至步骤S50。
本实施例还提供一种轴承剩余寿命的监测装置，参照图3所示，该监测装置包括：
缺陷确定单元10，用于在轴承运行过程中，确定轴承的缺陷所在的位置，确定缺陷的大小；
失效确定单元20，用于根据缺陷所在的位置和设定条件，确定在运行过程的工况下，轴承的失效模式，以及在失效模式下缺陷的扩 展速率和失效值，失效值为轴承失效时缺陷能够达到的最大值；
第一计算单元30，用于基于缺陷确定单元10确定的缺陷的大小、失效确定单元20确定的扩展速率以及失效值，获得轴承剩余寿命。
其中，第一计算单元30包括以下计算公式：轴承剩余运转时间＝(失效值-缺陷大小)/扩展速率。然后可以根据剩余运转时间，以及轴承的转速，计算得到轴承的剩余寿命，即轴承能够运转的剩余圈数。
如前所述，缺陷的位置和大小可以通过振动分析法、声发射分析法等方法确定。在采用振动分析法时，为了确定缺陷的位置，缺陷确定单元10包括：
振动获取模块11，用于获取轴承的振动信号，振动信号包含轴承的振动频率和幅值；
振动分析模块12，用于对振动获取模块11获取的振动信号进行频域分析，以确定缺陷所在的位置。
进一步，为了确定缺陷的大小，缺陷确定单元10还包括：
转速确定模块13，用于确定轴承的滚动体与内圈或外圈之间的相对转速；
用时确定模块14，用于确定滚动体经过缺陷所需的时间；
计算模块15，用于基于转速确定模块13确定的相对转速，以及用时确定模块14确定的时间，计算得到缺陷的大小。
在采用振动分析法时，为了确定缺陷的大小，用时确定模块14包括：
第一获取子模块141，用于获取轴承的振动信号，振动信号包含轴承的振动频率和幅值；
第一分析子模块142，用于对第一获取子模块141获取的振动信号进行时域分析，确定滚动体经过缺陷所需的时间，时间为滚动体到 达缺陷的时刻与脱离缺陷的时刻的时间间隔。
在另一些实施例中，参照图4，在采用声发射分析法确定轴承的缺陷的位置和大小时，为了确定缺陷的位置，缺陷确定单元10包括：
声波获取模块11＇，用于获取轴承的声发射信号，声发射信号包含轴承产生的声波的频率和幅值；
声波分析模块12＇，用于对声波获取模块获取的声发射信号进行频域分析，以确定缺陷所在的位置。
在采用声发射分析法时，如图4，为了确定缺陷的大小，用时确定模块14包括：
第二获取子模块141＇，用于获取轴承的声发射信号，声发射信号包含轴承产生的声波的频率和幅值；
第二分析子模块142＇，用于对第二获取子模块141＇获取的声发射信号进行时域分析，确定滚动体经过缺陷所需的时间，时间为滚动体到达缺陷的时刻与脱离缺陷的时刻的时间间隔。
继续参照图3，在轴承运行过程中，如果事先并不知晓轴承是否已经产生缺陷，那么，监测装置还包括缺陷判断单元100，用于判断轴承是否存在缺陷。
其中，缺陷判断单元100包括：
参数获取模块101，用于在轴承的运行过程中，获取轴承的运行参数值，参数包括轴承的温度、轴承的振动频率、振幅、轴承的转速中的一个或多个；
判定模块102，用于在参数获取模块101获取的运行参数值的一个或多个发生异常时，判定轴承存在缺陷。
为了得到在轴承的运行过程中时的各项运行参数值，监测装置还包括检测单元T，用于在获取轴承的运行参数值之前，对轴承的运行参数值进行检测。检测单元T可以包括温度传感器、振动加速度传感 器、转速传感器等，以对轴承的温度、轴承的振动频率、振幅、轴承的转速进行检测，并将检测到的信号传输给参数获取模块101。
为了得到在轴承的各项运行参数的标准值，以判断各项运行参数值是否异常，缺陷判断单元100还包括标准获取模块103，用于获取运行参数的标准值。
判定模块102还用于：将标准获取模块103获取的轴承的运行过程中获取的轴承的运行参数值和该运行参数的标准值进行比较，得到差值，在差值超出设定范围时，认定该运行参数发生异常。
如果判定模块102判断得到轴承存在缺陷时，则通过缺陷确定单元10、失效确定单元20以及第一计算单元30来计算轴承的剩余寿命。如果判定单元102判断得到轴承不存在缺陷时，则通过轴承的载荷来计算剩余寿命。
具体地，监测装置还包括：载荷确定单元40和第二计算单元50，用于在未出现缺陷时计算轴承的剩余寿命。
其中载荷确定单元40用于当轴承不存在缺陷时，确定轴承的载荷。第二计算单元50用于根据载荷确定单元40确定载荷，以及轴承的额定动载荷，获得轴承的剩余寿命。
其中，载荷可以是等效载荷或者实时载荷。因此，如果将等效载荷作为计算剩余寿命的载荷，则载荷确定单元40用于：确定轴承在运行过程中受到的等效载荷，将等效载荷作为载荷。
如果将实时载荷作为计算剩余寿命的载荷，则载荷确定单元40还用于：确定轴承在运行过程中受到的实时载荷，将实时载荷作为载荷。
虽然本发明披露如上，但本发明并非限定于此。任何本领域技术人员，在不脱离本发明的精神和范围内，均可作各种更动与修改，因此本发明的保护范围应当以权利要求所限定的范围为准。

Claims (24)

  1. 一种轴承剩余寿命的监测方法，其特征在于，包括：
    在轴承运行过程中，确定轴承的缺陷所在的位置，确定所述缺陷的大小；
    根据所述缺陷所在的位置和设定条件，确定所述轴承的失效模式，以及在所述失效模式下所述缺陷的扩展速率和失效值，所述失效值为所述轴承失效时所述缺陷能够达到的最大值；
    基于所述缺陷的大小、所述扩展速率以及所述失效值，获得所述轴承剩余寿命。
  2. 如权利要求1所述的监测方法，其特征在于，所述确定轴承的缺陷所在的位置包括：
    获取所述轴承的振动信号，所述振动信号包含所述轴承的振动频率和幅值；
    对所述振动信号进行频域分析，以确定所述缺陷所在的位置。
  3. 如权利要求1所述的监测方法，其特征在于，所述确定轴承的缺陷所在的位置包括：
    获取所述轴承的声发射信号，所述声发射信号包含所述轴承产生的声波的频率和幅值；
    对所述声发射信号进行频域分析，以确定所述缺陷所在的位置。
  4. 如权利要求1所述的监测方法，其特征在于，所述确定所述缺陷的大小包括：
    确定所述轴承的滚动体与内圈或外圈之间的相对转速；
    确定所述滚动体经过所述缺陷所需的时间；
    根据所述相对转速以及所述时间，计算得到所述缺陷的大小。
  5. 如权利要求4所述的监测方法，其特征在于，所述确定所述滚动体经过缺陷所需的时间包括：
    获取所述轴承的振动信号，所述振动信号包含所述轴承的振动频率和幅值；
    对所述振动信号进行时域分析，确定所述滚动体经过缺陷所需的时间，所述时间为所述滚动体到达所述缺陷的时刻与脱离所述缺陷的时刻的时间间隔。
  6. 如权利要求4所述的监测方法，其特征在于，所述确定所述滚动体经过缺陷所需的时间包括：
    获取所述轴承的声发射信号，所述声发射信号包含所述轴承产生的声波的频率和幅值；
    对所述声发射信号进行时域分析，确定所述滚动体经过缺陷所需的时间，所述时间为所述滚动体到达所述缺陷的时刻与脱离所述缺陷的时刻的时间间隔。
  7. 如权利要求1所述的监测方法，其特征在于，在确定所述轴承的缺陷所在位置，以及缺陷大小之前，还包括判断所述轴承是否存在缺陷：
    在所述运行过程中，获取所述轴承的运行参数值，轴承的运行参数包括轴承的温度、轴承的振动频率、振幅、轴承的转速中的一个或多个；
    所述运行参数值的一个或多个发生异常时，判定所述轴承存在缺陷。
  8. 如权利要求7所述的监测方法，其特征在于，在获取所述轴承的运行参数值之前，还包括：对所述轴承的运行参数值进行检测。
  9. 如权利要求7所述的监测方法，其特征在于，还包括诊断所述运行参数值是否发生异常：
    获取所述运行参数的标准值；
    将所述运行参数值和该运行参数的标准值进行比较，得到差值，在所述差值超出设定范围时，认定该运行参数发生异常。
  10. 如权利要求7所述的监测方法，其特征在于，当所述轴承不存在缺陷时：
    确定所述轴承的载荷；
    根据所述载荷，以及所述轴承的额定动载荷，获得轴承的剩余寿 命。
  11. 如权利要求10所述的监测方法，其特征在于，所述确定所述轴承的载荷包括：确定所述轴承在所述运行过程中受到的等效载荷，将所述等效载荷作为所述载荷。
  12. 如权利要求10所述的监测方法，其特征在于，所述确定所述轴承的载荷包括：确定所述轴承在所述运行过程中受到的实时载荷，将所述实时载荷作为所述载荷。
  13. 一种轴承剩余寿命的监测装置，其特征在于，包括：
    缺陷确定单元，用于在轴承运行过程中，确定轴承的缺陷所在的位置，确定所述缺陷的大小；
    失效确定单元，用于根据所述缺陷所在的位置和设定条件，确定所述轴承的失效模式，以及在所述失效模式下所述缺陷的扩展速率和失效值，所述失效值为所述轴承失效时所述缺陷能够达到的最大值；
    第一计算单元，用于基于所述缺陷确定单元确定的所述缺陷的大小、所述失效确定单元确定的所述扩展速率以及所述失效值，获得所述轴承剩余寿命。
  14. 如权利要求13所述的监测装置，其特征在于，所述缺陷确定单元包括：
    振动获取模块，用于获取所述轴承的振动信号，所述振动信号包含所述轴承的振动频率和幅值；
    振动分析模块，用于对所述振动获取模块获取的所述振动信号进行频域分析，以确定所述缺陷所在的位置。
  15. 如权利要求13所述的监测装置，其特征在于，所述缺陷确定单元包括：
    声波获取模块，用于获取所述轴承的声发射信号，所述声发射信号包含所述轴承产生的声波的频率和幅值；
    声波分析模块，用于对所述声波获取模块获取的所述声发射信号进行频域分析，以确定所述缺陷所在的位置。
  16. 如权利要求13所述的监测装置，其特征在于，所述缺陷确定单元还包括：
    转速确定模块，用于确定所述轴承的滚动体与内圈或外圈之间的相对转速；
    用时确定模块，用于确定所述滚动体经过所述缺陷所需的时间；
    计算模块，用于基于所述转速确定模块确定的相对转速，以及所述用时确定模块确定的所述时间，计算得到所述缺陷的大小。
  17. 如权利要求16所述的监测装置，其特征在于，所述用时确定模块包括：
    第一获取子模块，用于获取所述轴承的振动信号，所述振动信号包含所述轴承的振动频率和幅值；
    第一分析子模块，用于对第一获取子模块获取的所述振动信号进行时域分析，确定所述滚动体经过缺陷所需的时间，所述时间为所述滚动体到达所述缺陷的时刻与脱离所述缺陷的时刻的时间间隔。
  18. 如权利要求16所述的监测装置，其特征在于，所述用时确定模块包括：
    第二获取子模块，用于获取所述轴承的声发射信号，所述声发射信号包含所述轴承产生的声波的频率和幅值；
    第二分析子模块，用于对所述第二获取子模块获取的所述声发射信号进行时域分析，确定所述滚动体经过缺陷所需的时间，所述时间为所述滚动体到达所述缺陷的时刻与脱离所述缺陷的时刻的时间间隔。
  19. 如权利要求13所述的监测装置，其特征在于，还包括缺陷判断单元，用于判断所述轴承是否存在缺陷；
    所述缺陷判断单元包括：
    参数获取模块，用于在所述轴承的运行过程中，获取所述轴承的运行参数值，所述参数包括轴承的温度、轴承的振动频率、振幅、轴承的转速中的一个或多个；
    判定模块，用于在所述参数获取模块获取的所述运行参数值的一个或多个发生异常时，判定所述轴承存在缺陷。
  20. 如权利要求19所述的监测装置，其特征在于，还包括检测 单元，用于在获取所述轴承的运行参数值之前，对所述轴承的运行参数值进行检测。
  21. 如权利要求19所述的监测装置，其特征在于，所述缺陷判断单元还包括：
    标准获取模块，用于获取所述运行参数的标准值；
    所述判定模块还用于：将所述标准获取模块获取的所述轴承的运行过程中获取的所述轴承的运行参数值和该运行参数的标准值进行比较，得到差值，在所述差值超出设定范围时，认定该运行参数发生异常。
  22. 如权利要求19所述的监测装置，其特征在于，还包括：
    载荷确定单元，用于当所述轴承不存在缺陷时，确定所述轴承的载荷；
    第二计算单元，用于根据所述载荷确定单元确定所述载荷，以及所述轴承的额定动载荷，获得轴承的剩余寿命。
  23. 如权利要求22所述的监测装置，其特征在于，所述载荷确定单元还用于：确定所述轴承在所述运行过程中受到的等效载荷，将所述等效载荷作为所述载荷。
  24. 如权利要求22所述的监测装置，其特征在于，所述载荷确定单元还用于：确定所述轴承在所述运行过程中受到的实时载荷，将所述实时载荷作为所述载荷。
PCT/CN2017/100661 2016-09-19 2017-09-06 轴承剩余寿命的监测方法及监测装置 Ceased WO2018050008A1 (zh)

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