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旋转机械易损关键零部件故障诊断方法研究
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摘要
在各类机械设备中,由于旋转机械的特殊地位,其故障理论和诊断方法历来是各国专家和学者的研究热点之一。旋转机械中转子及其相关组件是设备产生故障的主要来源,其振动信号的表现形式大都是非平稳的、动态的和随机的。特别是当旋转设备工作在变转速时,故障信号变得越加复杂,特征提取和故障识别十分困难。本文将信号处理技术和模式识别技术中的一些新方法引入到旋转机械故障诊断中来,对故障易发的滚动轴承、齿轮及转子故障诊断方法进行了一些有益的研究和探索。
     (1)针对滚动轴承恒转速条件下故障引发的共振信号信噪比较高但非平稳的特点,利用EMD将其分解并提取包含故障信息的平稳信号,经包络解调后构建了反映轴承故障状态的特征矢量。研究了DHMM多样本训练方法并对轴承状态进行了识别。试验结果表明所提出的方法对单一故障和同时存在多种故障的轴承诊断都取得了良好的识别效果。
     (2)指出了滚动轴承故障引发的轴承共振信号并非简单的偏置调幅信号,利用所建的故障模型试验了CAF的解调效果。通过研究、对比和分析,证明了CAF的形貌特征能够反映轴承的故障状态,结合CHMM对动态信号识别能力,提出了一种滚动轴承故障识别方法,并通过试验验证了方法的有效性。
     (3)对于滚动轴承必须经历的启动过程,由于转速的变化,故障特征频率不复存在。利用小波分析方法提取故障共振信号,采用瞬时频率估计、阶比跟踪技术对轴承故障振动信号进行分析,给出了故障特征阶比系数的概念和算法,试验了算法在轴承故障诊断中的可行性。
     (4)变转速更贴近旋转机械应用中的实际情况,本文指出了变转速滚动轴承故障信号的双变频调制特性并建立了故障模型。给出了OCAF的计算公式,研究了其对双变频信号的解调性能。利用特定转速下的故障动态信息构建特征向量,提出了基于OCAF-CHMM的滚动轴承故障诊断方法,并通过试验对该方法进行了检验。
     (5)通过DCS获取齿轮特征信息,并采用DHMM模型对齿轮进行了故障识别。试验表明所提出的方法能够很好地识别断齿、点蚀等齿轮状态。这种方法结合了DCS解调信噪比高、表达相对简单和DHMM运算量相对较小的特点,有利于提高诊断速度。
     (6)充分利用HMM和SVM在序列行为分类和小样本方面的优势,提出了基于SVM-HMM模型的旋转机械故障诊断方法。该模型在转子启动过程故障诊断试验中,与以往提出的基于SOM-HMM模型的诊断方法相比,减少了量化过程的信息损失及模型训练所需样本数量,提高了故障识别率并减少了模型训练时间。将该模型用于滚动轴承损伤类故障诊断中,也获得了较满意的效果,验证了SVM-HMM模型在滚动轴承故障诊断中的可行性。
Due to the special status of rotating machine in various types of mechanical equipment. Fault theories and diagnosis methods has always been a research focus of experts and scholars home and broad. In rotating machinery equipment, the rotor and its related components are the major fault sources, and the most of its vibration signal appears unstable, dynamic and random, and the fault signal becomes more complex when the rotating equipment works in the variable speed. So the signal extraction and fault recognition method has always been a complex and interesting subject. With the continual emergence of new technologies and methods of a variety of signal processing and pattern recognition, new vitality has been injected in solving these problems. This paper aims to introduce some new methods of signal processing and pattern recognition technology in fault diagnosis of rotating machine, and some useful researches and explorations of fault diagnosis methods for fault-prone bearings, gears and rotor.
     (1) For the high noise ratio but unstable characteristics of resonance signal caused by rolling bearing fault at the constant speed conditions, EMD method is employed so that the resonance signal can be decomposed and fault information that contains smooth signal can be extracted, after demodulation by envelope the characteristics in reflecting the bearing fault state vector is constructed. Diverse training methods of DHMM are researched and the status of the bearing is also identified. Experimental result shows that the proposed method is capable in carrying out satisfactory result in testing both single and multiple faults.
     (2) Pointing out that the resonance signal of the bearing caused by the failure of the antifriction bearing is not a simple bias AM signal, utilizing the fault models to test the outcome after demodulated by CAF. It is proved that the morphology of CAF could report the failure status of the bearing based on research, comparison and analysis. Combining the ability of CHMM to recognize the dynamic signal, a method of antifriction bearing fault detection is proposed, and the validity of the method has been verified.
     (3) The fault characteristic frequency disappears during the starting procedure of the antifriction bearing due to the change of the rotate speed. The fault resonance signal is figured out by the method of wavelet analysis, the vibration signals of the antifriction bearing are analyzed by the method of estimation of instantaneous frequency and ratio tracking, so that the concept and algorithm of the fault characteristics and ratio coefficient are raised, and the feasibility of the algorithm has been verified.
     (4) The change of the rotate speed is closer to real situation of the application of the rotating machinery. This article indicates the dual frequency conversion characteristics of variable speed antifriction bearing fault signal. Computational formula of OCAF is proposed, and research on the demodulation capability on dual-frequency signal has been done. A method of fault diagnosis on the rolling bearing is carried out based on OCAF-CHMM and the characteristic rector of the.multidate information under the specific rotate speed, and the method has been verified to be effective.
     (5) The feature information of the gear is obtained via DCS, and the failure of the gear has been identified via DHMM model. The experiment indicates that the proposed method can recognize the broken tooth, corrosive pitting and sort of status correctly. The specific method is the combination of the three features, such as the high demodulation SNR of DCS, simplicity of expression and the reduced quantity of computation, which can improve the diagnostic rate.
     (6) Fully taking the advantage of HMM model and SVM model on the sequence behavior classification and small sample, a rotating machine faults diagnosis method is proposed based on SVM-HMM model. Comparing with the SOM-HMM method, SVM-HMM method reduces the sample numbers of the information loss and model training, decreases the time of model training and increases the rate of identification. A satisfactory outcome on the test of diagnosis on the damage of rolling bearing has been obtained, and the feasibility of SVM-HMM model on the diagnosis of the rolling bearing has been verified.
引文
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