基于ZigBee的轴承寿命测试数据采集和分析系统
摘要
作为旋转机械中应用最为广泛的零部件之一,轴承的运行状态直接影响着整个系统的稳定性。生产厂家对轴承的质量检测都比较重视,除了常规的生产过程质量检测外,有条件的地方还需要对轴承进行全设计寿命的运行试验,本论文针对的就是这类试验系统。与对滚动轴承运行状态进行现场监控报警的系统不同,本论文涉及到的滚动轴承疲劳寿命测试系统,主要完成对滚动轴承从无损状态一直运转到损坏的整个试验过程中振动和温度的数据采集、传输,对数据进行分析,并提供在整个实验周期内所有采集点数据的数据、图形与声音的再现能力。
本论文中数据从试验台到监控主机的传输采用Zigbee无线通讯方案实现。借用了其组网和网络自愈机制,并在此基础上完成数据校验重传、对象字典定义等软件机制,简化布线、新测试节点动态加入等工程应用问题,增强了系统的灵活性。为每个试验台搭配了一块基于ARM9的嵌入式终端来完成数据的收集、监测、波形显示和传输控制,终端LCD会实时更新显示采集到的振动和温度数据,当发现数据异常时,终端将输出控制指令直接停止试验,从而避免在长期的寿命周期实验中人工安排的难题;终端将各自测试轴承的振动和温度数据上传到监控主机,上位机程序对接收到的数据进行波形显示、FFT变换、存储,并根据数据异常情况自动或手动下传控制命令到终端来控制试验进程。
在初步试验中,本系统运行稳定,在ZigBee协议栈及上层重传机制的保障下,系统无线网络能持续稳定完成数据传输任务,保证了采集终端与主控机的交互通讯。上位机程序提供了必要的交互界面,方便查看数据内容以及对终端下传控制指令。上位机程序能对被测轴承的整个寿命周期不同阶段的数据实现分析和存储以及振动声音回放,为人工分析被测轴承的失效过程,以及可能的更深层次理论研究提供数据支持。
As one of the most extensive used machine replacement parts in rotary machines, the running state of rolling bearing influences the stability of the whole system directly. Manufacturers pay great attention on bearing quality inspection. Besides conventional detection of the production process, many manufacturers would take full life running tests on rolling bearings if conditions are met. The system in this paper is designed for these tests. Different from most monitoring systems that monitor the running state of rolling bearings in real time when they are being used, a design of analytic system for fatigue test on rolling bearing is proposed in this paper. The data of the whole process of the fatigue test that causes rolling bearing changes from being fully good to damaged is collected and transferred to the monitor computer, and the program on the monitor computer will analyze and store the data. These works make it possible to reappear the whole change history of data, wave and sound in the test.
The data transfer work of the system design propose in this paper is based on ZigBee technology. Based on the convenient network self-startup and self-repair mechanism of ZigBee, retransmission mechanism and object dictionary are designed in software which make the wiring work and addition of new test node easy to achieve. All of these make the system more flexible. An embedded system terminal device based on ARM9 is assigned to each test stand to collect and check the data, and also control the transfer process. An LCD shows the vibrate wave and temperature in real time. When anomaly is discovered, the ARM processor will output a control signal to end the test process. Terminal devices upload the vibrating and temperature data of their test stand to the center monitor PC. The program on the center monitor PC figures out the wave based on the received data and its FFT wave also, then these data is stored in files on the hard disk. If needed, control signals are emitted to terminal devices through ZigBee network to control the test process. The network is started in mesh topology, and an upper protocol include auto resend mechanism is designed to ensure stability of wireless network transfer.
The preliminary test reveals that the system runs steadily. Under the work of ZigBee’s protocol stack and the retransmission mechanism, the wireless network dose a good job on transfer constantly, which provides condition for the communication between the center monitor PC and terminal device. The PC program provides a friendly interface, so it is very convenient to look over data and send control signals to the terminal devices. Data in different periods of the test is stored and can be analyzed, which provides data support to the research on bearing’s failure process and maybe deeper theory research.
本论文中数据从试验台到监控主机的传输采用Zigbee无线通讯方案实现。借用了其组网和网络自愈机制,并在此基础上完成数据校验重传、对象字典定义等软件机制,简化布线、新测试节点动态加入等工程应用问题,增强了系统的灵活性。为每个试验台搭配了一块基于ARM9的嵌入式终端来完成数据的收集、监测、波形显示和传输控制,终端LCD会实时更新显示采集到的振动和温度数据,当发现数据异常时,终端将输出控制指令直接停止试验,从而避免在长期的寿命周期实验中人工安排的难题;终端将各自测试轴承的振动和温度数据上传到监控主机,上位机程序对接收到的数据进行波形显示、FFT变换、存储,并根据数据异常情况自动或手动下传控制命令到终端来控制试验进程。
在初步试验中,本系统运行稳定,在ZigBee协议栈及上层重传机制的保障下,系统无线网络能持续稳定完成数据传输任务,保证了采集终端与主控机的交互通讯。上位机程序提供了必要的交互界面,方便查看数据内容以及对终端下传控制指令。上位机程序能对被测轴承的整个寿命周期不同阶段的数据实现分析和存储以及振动声音回放,为人工分析被测轴承的失效过程,以及可能的更深层次理论研究提供数据支持。
As one of the most extensive used machine replacement parts in rotary machines, the running state of rolling bearing influences the stability of the whole system directly. Manufacturers pay great attention on bearing quality inspection. Besides conventional detection of the production process, many manufacturers would take full life running tests on rolling bearings if conditions are met. The system in this paper is designed for these tests. Different from most monitoring systems that monitor the running state of rolling bearings in real time when they are being used, a design of analytic system for fatigue test on rolling bearing is proposed in this paper. The data of the whole process of the fatigue test that causes rolling bearing changes from being fully good to damaged is collected and transferred to the monitor computer, and the program on the monitor computer will analyze and store the data. These works make it possible to reappear the whole change history of data, wave and sound in the test.
The data transfer work of the system design propose in this paper is based on ZigBee technology. Based on the convenient network self-startup and self-repair mechanism of ZigBee, retransmission mechanism and object dictionary are designed in software which make the wiring work and addition of new test node easy to achieve. All of these make the system more flexible. An embedded system terminal device based on ARM9 is assigned to each test stand to collect and check the data, and also control the transfer process. An LCD shows the vibrate wave and temperature in real time. When anomaly is discovered, the ARM processor will output a control signal to end the test process. Terminal devices upload the vibrating and temperature data of their test stand to the center monitor PC. The program on the center monitor PC figures out the wave based on the received data and its FFT wave also, then these data is stored in files on the hard disk. If needed, control signals are emitted to terminal devices through ZigBee network to control the test process. The network is started in mesh topology, and an upper protocol include auto resend mechanism is designed to ensure stability of wireless network transfer.
The preliminary test reveals that the system runs steadily. Under the work of ZigBee’s protocol stack and the retransmission mechanism, the wireless network dose a good job on transfer constantly, which provides condition for the communication between the center monitor PC and terminal device. The PC program provides a friendly interface, so it is very convenient to look over data and send control signals to the terminal devices. Data in different periods of the test is stored and can be analyzed, which provides data support to the research on bearing’s failure process and maybe deeper theory research.
引文
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[6]武和雷,朱善安,林瑞仲,郑剑锋.滚动轴承故障诊断虚拟仪器系统[J].轴承. 2002(12):34-39.
[7]王卓,田振华,赵丁选.滚动轴承的振动监测与故障诊断系统研究[J].机电工程. 2001,18(6):52-54.
[8]刘永斌,刘志刚等.基于嵌入式传感器的滚动轴承状态监测系统的研究[J].机械制造. 2003,41(472):55-57.
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[10]高保禄,冯秀芳,等.基于无线传感器网络数据融合的滚动轴承故障诊断[J].中北大学学报. 2010,31(3):248-252.
[11]吕琛,宋希庚,邹积斌.振动、噪声信号的阶比分析与DSP实现[J].数据采集与处理. 2001,16(4):478-482.
[12]苏宝定.滚动轴承振动检测与智能诊断系统研究[D].大连理工大学,2008.
[13]单明芳.基于DSP的滚动轴承振动信号采集系统的研制[D].东北大学,2005.
[14]刘传明,赵学智,黄礼荣,李兴林.滚动轴承振动信号采集与数据处理系统[J].轴承. 2000(6):26-30.
[15]吴晨霞.基于ZigBee技术的轴承温度监控系统[D].大连理工大学,2009.
[16]姜玉龙,汪庆年,刘夏,武和雷.基于DSP的滚动轴承故障诊断系统的设计[J].南昌大学学报. 2007,37:263-268.
[17]刘亚娟,乔亚敏.基于软件共振解调分析的滚动轴承故障诊断系统开发[J].仪器仪表与检测技术. 2004,23(11):64-66.
[18]陈爱戎.基于Fourier变换的滑动轴承故障诊断技术[J].轴承. 2009(6):56-60.
[19]马家驹,梁文梅.滚动轴承振动统计特性分析[J].轴承. 1994(1):33-37.
[20]刘宗政,陈恳,陈振华,陈雁,黄元林.滚动轴承的振动特性分析及典型故障诊断[J].机械设计与制造. 2009(3):103-105.
[21]李百栋.滚动轴承故障诊断技术与应用[J].设备管理与维修. 2007(5):43-45.
[22]牛竣峰,郑斌,侯文.基于小波包分析的滚动轴承故障诊断方法的研究[J].机械工程与自动化.2009(3):107-109.
[23]杨振友,彭涛.基于振动信号分析和支持向量机的滚动轴承故障诊断[J].湖南工业大学学报. 2009,23(1):96-99.
[24]胡继昌.滚动轴承故障诊断技术研究现状及发展趋势研究[J].大众科学. 2008(16):25-29.
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