A kind of gear defects rapid detection system based on vibration Frequency Analysis and method
Technical field
The present invention relates to gear defects detection technique field, more particularly, to a kind of gear based on vibration Frequency Analysis
Defect rapid detection system and method.
Background technology
Due to manufacturing fast development, gear as the basic part in mechanical manufacturing field, volume of production at home
Great scale.Due to reasons such as techniques during Gear Production, all kinds of defects, such as burr can be produced, crackle etc., but
The lossless feature of master gear is most important for the engagement of gear and transmission performance, and the detection for gear defects is current
Predominantly stay in human subjective and judge the stage, it is low to there is efficiency, the low deficiency of accuracy rate.Although there is also the side such as optics now
Formula detecting instrument, but this method complex operation, instrument cost is expensive, and detects there is no thoroughness, and it is right to be so just difficult to meet
The increasingly enhanced requirement producing precision of gear.The high efficiency that the realization of the present invention carries out 100% to the manufacturing defect of gear is online
Detection, will produce far-reaching and important impact to Gear Production industry.
Therefore, prior art has yet to be improved and developed.
Content of the invention
The technical problem to be solved in the present invention is, for the drawbacks described above of prior art, provides a kind of being based on to vibrate frequency
The gear defects rapid detection system of rate analysis and method, it is desirable to provide a kind of rational in infrastructure, low cost of manufacture, simple to operate,
The high gear testing system and method for accuracy of detection.
In order to realize above-mentioned purpose, the technical scheme that present invention solution technical problem is adopted is as follows:
A kind of gear defects method for quick based on vibration Frequency Analysis, including step:
A, fill gear to be detected, gear to be detected is shaken to a fixed position by handwheel, then takes this
Wheel locating distance adjusting is on this position, repeatedly adjusts more than three times, more locked Large Gear Shaft;
B, dress detection dedicated gear, shake steamboat to an indefinite position, takes steamboat locating distance and adjusts, adjusts for the first time
When, keep the fine rotation of gear to be detected, it is to avoid break, after being in correct position, remember pointer position, then rollback inspection
Survey dedicated gear, to not contacting at dial gauge stylus, repeat above-mentioned control method more than three times, if the percentage of more than three times represents
Number difference is to be considered as correctly installing during ± 0.01mm;
C, locked detection dedicated gear;
When D, open detection system, first drivewheel and driven pulley all at the uniform velocity start to rotate with relatively low speed, after 0.5S
Frequency analyzer automatic monitoring record data, after systematic collection to be collected to 3 data more than cycle, the automatic stall of system;
E, overall analysis system are compared analysis to 3 data more than cycle of system acquisition, to characteristic frequency
Power density carries out fuzzy principle and judges, when the power density thinking this characteristic frequency reaches user's setting value, judges this tooth
Wheel is defective.
The described gear defects method for quick based on vibration Frequency Analysis, described fuzzy principle judges to refer to existing
Set up at least one fuzzy set between some power density peaks and minima, then the power of each time domain of sub-distribution is close
Angle value is to being subordinate to set accordingly, and specifies the minima in the power density set at the gear defects that collect, works as somewhere
Power density be not less than this minima when, then judge that this gear is defective.
The described gear defects method for quick based on vibration Frequency Analysis, described detecting system further includes to use
Sensor in collection signal.
The described gear defects method for quick based on vibration Frequency Analysis, described detecting system further includes always
Controller, communication bus, interface circuit, display, electronic control unit, signal sampler, DSP, point
Analysis system;Described master controller, communication bus, interface circuit, display, electronic control unit, signal sampler, DSP number
Word signal processor, analysis system are connected with master controller by interface circuit.
The described gear defects method for quick based on vibration Frequency Analysis, described overall analysis system is further
Including:For showing the PC display of the analysis result of described frequency analyzer.
The described gear defects method for quick based on vibration Frequency Analysis, described sensor is torque sensor or turns
Fast sensor.
The described gear defects method for quick based on vibration Frequency Analysis, described DSP is
KeyStone polycaryon processor C667x.
A kind of system of the gear defects method for quick based on vibration Frequency Analysis as above, including:
Including driving shaft 1, handwheel 2, mobile work platform 3, transmission case 4, connecting shaft 5, dial gauge 8, projecting shaft 9, belt 10,
The gear testing platform of the scalable locating distance of driven shaft 11, wherein dial gauge 8 are used for adjusting gear 6 to be detected and detection is special
Centre-to-centre spacing between gear 7;
Can provide at the uniform velocity or the power plant system that rotates of uniform speed change, for providing motive force to gear 6 to be detected;
Fixing device system, for reducing the described collection letter of the gear defects rapid detection system based on vibration Frequency Analysis
Number interference;
Including the automatic vibration frequency analyses system of frequency analyzer 14 and PC display 15, for gathering gear to be detected
6 measurement data and institute's gathered data is analyzed;
Automatic detection module, for according to described automatic vibration frequency analyses systematic analysiss data to described to be detected
Gear 6 carries out defect automatic detection;
Wherein;Gear 6 to be detected is installed on driving shaft 1, and detection dedicated gear 7 is installed on driven shaft 11, or to be checked
Survey gear 6 be installed on driven shaft, detection dedicated gear 7 be installed on driving shaft 1, transmission case 4 be placed in mobile work platform 3 it
On, driving shaft 1, transmission case 4, connecting shaft 5 are sequentially connected.
The system of the described gear defects method for quick based on vibration Frequency Analysis, described handwheel 2 is two, respectively
For fixing described gear to be detected 6, detection dedicated gear 7.
The system of the described gear defects method for quick based on vibration Frequency Analysis, described power plant system enters
One step is made up of servomotor, Synchromous machine drive system.
The system of the described gear defects method for quick based on vibration Frequency Analysis, described fixing device system
Further include fixed station 16, projecting shaft 9, sensor 13, described fixed station 16 is followed driven shaft 11 and rotated, described fixation
Described sensor 13 is fixed on the end of described detection dedicated gear 7 projecting shaft 9 by platform 16.
The system of the described gear defects method for quick based on vibration Frequency Analysis, described automatic vibration frequency is divided
Analysis system further includes master controller, communication bus, interface circuit, display, electronic control unit, signal sampler, DSP
Digital signal processor, analysis system;Described master controller, communication bus, interface circuit, display, electronic control unit,
Signal sampler, DSP, analysis system are connected with master controller by interface circuit.
The system of the described gear defects method for quick based on vibration Frequency Analysis, described automatic detection module is examined
Survey the data of described vibration Frequency Analysis system, and the power density of characteristic frequency is judged according to fuzzy principle, when
When thinking that the power density of this characteristic frequency reaches the standard set by user, described automatic detection module is reported to the police, and judges
Described gear to be detected(6)Defective.
The system of the described gear defects method for quick based on vibration Frequency Analysis, described sensor 13 is moment of torsion
Sensor or speed probe.
The system of the described gear defects method for quick based on vibration Frequency Analysis, at described DSP digital signal
Reason device is KeyStone polycaryon processor C667x.
Gear defects rapid detection system based on vibration Frequency Analysis provided by the present invention and method, its advantage
It is:Detection of gear defects efficiency high, precision high detection standard consistency is good, simple to operate, and detection gear-type is wide.
Brief description
The gear defects method for quick flow chart based on vibration Frequency Analysis of Fig. 1 present invention;
The gear defects method for quick preferred application embodiment flow process based on vibration Frequency Analysis of Fig. 2 present invention
Figure;
The membership function of the gear defects method for quick fuzzy set based on vibration Frequency Analysis of Fig. 3 present invention
Figure;
Fig. 4 is the gear defects rapid detection system structural representation based on vibration Frequency Analysis of the present invention;
Fig. 5 is the gear defects rapid detection system hand wheel type gear testing peace based on vibration Frequency Analysis of the present invention
Assembling platform;
Fig. 6 is the gear defects rapid detection system motor control formula gear inspection based on vibration Frequency Analysis of the present invention
Survey mounting platform.
In figure, 1- driving shaft;2- handwheel;3- mobile work platform;4- transmission case;5- connecting shaft;6- gear to be detected;7- examines
Survey dedicated gear;8- dial gauge;9- projecting shaft;10- belt;11- driven shaft;12- power plant system;13- sensor;14-
Frequency analyzer;15-PC display;16- fixed station.
Specific embodiment
For making the objects, technical solutions and advantages of the present invention clearer, clear and definite, develop simultaneously embodiment pair referring to the drawings
The present invention further describes.It should be appreciated that specific embodiment described herein is only in order to explain the present invention, and without
In the restriction present invention.
Refer to Fig. 1, be the gear defects method for quick flow chart based on vibration Frequency Analysis of the present invention.At this
Before the method for quick of invention starts, need User Defined criterion of acceptability, and select judgment criteria.Methods described bag
Include following steps:
S100, fill gear to be detected, gear to be detected is shaken to a fixed position by handwheel, then takes this wheel locating distance
And adjust and be on this position, repeatedly adjust more than three times, more locked Large Gear Shaft.
S200, dress detection dedicated gear, shake steamboat, to an indefinite position, takes steamboat locating distance and adjusts, for the first time
During regulation, keep the fine rotation of gear to be detected, it is to avoid break, after being in correct position, remember pointer position, then return
Move back detection dedicated gear, to not contacting at dial gauge stylus, repeat above-mentioned control method more than three times, if the percentage of more than three times
Represent that number difference is to be considered as correctly installing during ± 0.01mm.
S300, locked detection dedicated gear.
When S400, open detection system, first drivewheel and driven pulley all at the uniform velocity start to rotate with relatively low speed, 0.5S
Frequency analyzer automatic monitoring record data afterwards, after systematic collection to be collected to 3 data more than cycle, system is stopped automatically
Turn.
S500, overall analysis system are compared analysis to 3 data more than cycle of system acquisition, to specific frequency
The power density of rate carries out fuzzy principle and judges, when the power density thinking this characteristic frequency reaches user's setting value, judges
This gear is defective.
Refer to Fig. 2, be that the gear defects method for quick preferred application based on vibration Frequency Analysis of the present invention is real
Apply a flow chart;As shown in Fig. 2 comprising the following steps:
Autotest starts;Fuzzy judgement initializes;Wait input signal, be prepared to enter into next stage;Automatically divide
Join membership function;Qualification is judged;If system is not in one of six incremental fuzzy sets T, N, S, M, B, VB,
Then system alarm, otherwise result transmission mastery routine, autotest terminates.Input result of determination again, output result of determination is simultaneously
Point out the phase place of the defect of unqualified gear, subsequently into next gear testing, auto-returned cycle detection.Enter next
Detection process, system start-up, system uniform rotation more than three weeks, the time-frequency of three cycle doctors of collection turns torsional wave and moves data,
Time frequency signal is converted, set specific frequency signal is scanned for.Without searching qualified signal, then system
Uniform rotation more than three weeks;If having searched out qualified signal, it is prepared to enter into signal power density fuzzy Judgment program,
Output result simultaneously points out the phase place of unqualified gear.
Refer to Fig. 3, be the gear defects method for quick fuzzy set based on vibration Frequency Analysis of the present invention
The figure of membership function.The fuzzy set of initialization regulation six incremented by successivelies of T, N, S, M, B, VB, for different gears
Purposes and detection Stringency, this autotest can set up different gear defects judgment criteria as requested, you can
Tally with the actual situation give a definition arbitrary initial fuzzy set be gear defects at minimum power density set, this set
In minimum power density value be gear defects and intact marginal value;Set according to oneself requirement when assuming that user is actually detected
Determine X(X refers to any one in initialized 5 fuzzy sets)For the minimum power density set at gear defects, if inspection
The power density measuring is under the jurisdiction of the incremental fuzzy set after X or X, then its corresponding detected gear, judges that it is not
Qualified gear, that is, this gear is defective, if the power density detecting be under the jurisdiction of X before fuzzy set of successively decreasing, its institute right
The detected gear answered, judges that it is qualified gear, i.e. this gear zero defect.
Refer to Fig. 4, be the gear defects rapid detection system structural representation based on vibration Frequency Analysis of the present invention
Figure.As shown in figure 4, in the gear defects rapid detection system based on vibration Frequency Analysis that the present invention provides, at least wrapping
Include:
Including driving shaft 1, handwheel 2, mobile work platform 3, transmission case 4, connecting shaft 5, dial gauge 8, projecting shaft 9, belt 10,
The gear testing platform of the scalable locating distance of driven shaft 11, wherein dial gauge 8 are used for adjusting gear 6 to be detected and detection is special
Centre-to-centre spacing between gear 7;
Can provide at the uniform velocity or the power plant system that rotates of uniform speed change, for providing motive force to gear 6 to be detected;
Fixing device system, for reducing the described collection letter of the gear defects rapid detection system based on vibration Frequency Analysis
Number interference;
Including the automatic vibration frequency analyses system of frequency analyzer 14 and PC display 15, for gathering gear to be detected
6 measurement data and institute's gathered data is analyzed;
Automatic detection module, for according to described automatic vibration frequency analyses systematic analysiss data to described to be detected
Gear 6 carries out defect automatic detection;
Wherein;Gear 6 to be detected is installed on driving shaft 1, and detection dedicated gear 7 is installed on driven shaft(11)On, or treat
Detection gear 6 be installed on driven shaft, detection dedicated gear 7 be installed on driving shaft 1, transmission case 4 be placed in mobile work platform 3 it
On, driving shaft 1, transmission case 4, connecting shaft 5 are sequentially connected.
Preferably, described handwheel 2 is two, is respectively used to fixing described gear to be detected 6, detection dedicated gear 7.
Preferably, described power plant system is made up of servomotor, Synchromous machine drive system further.
Preferably, described fixing device system further includes fixed station 16, projecting shaft 9, sensor 13, and described consolidates
Determine platform 16 and follow driven shaft 11 to rotate, described sensor 13 is fixed on described detection dedicated gear by described fixed station 16
7 stretch out the tip of the axis.
Preferably, described automatic vibration frequency analyses system further includes master controller, communication bus, interface electricity
Road, display, electronic control unit, signal sampler, DSP, analysis system;Described master controller,
Communication bus, interface circuit, display, electronic control unit, signal sampler, DSP, analysis system are led to
Cross interface circuit to be connected with master controller.
Preferably, the data of the described vibration Frequency Analysis system of described automatic detection module detection, and to specific frequency
The power density of rate is judged, when the power density thinking this characteristic frequency reaches set by user according to fuzzy principle
During standard, described automatic detection module is reported to the police, and judges that described gear to be detected 6 is defective.
Preferably, described sensor 13 is torque sensor or speed probe.
Preferably, described DSP is KeyStone polycaryon processor C667x.
Refer to Fig. 5, be the gear defects rapid detection system hand wheel type gear based on vibration Frequency Analysis of the present invention
Detection mounting platform.As shown in figure 5, in order to be able to accurately judge whether locating distance meets the requirements, devising a gear of working good
The dial gauge 8 installed, is in this system other end, zeroing during general gauge outfit contact mobile work platform end face;When for quick peace
When dress is with type gear, handwheel 2 can be substituted for motor control automatic station-keeping system.
Refer to Fig. 6, be the gear defects rapid detection system motor control formula based on vibration Frequency Analysis of the present invention
Gear testing mounting platform.As shown in fig. 6, motor control automatic station-keeping system includes motor and motor control assembly, motor control
Device processed, for the real-time control to motor in the case of the different locating distances of realization setting, meets the needs automatically looking for position, fast quick-mounting
Press from both sides a pair of mate gear.Power plant system 12 can be replaced by servomotor, and this power set is supplied to driving shaft rotational power;
In order that sensor 13 can reach a preferable collection effect, power source is typically required to provide a low speed and uniform turn
Dynamic.In order to allow projecting shaft avoid the interference of other signals, be specifically designed play reduce external interference effect follow driven shaft
The fixed station 16 rotating;Signal in order to meet in each of meshed transmission gear process tooth engagement can gather
Require, sensor 13 must be high accurancy and precision, the high torque sensor of collecting efficiency or speed probe.
Gear defects rapid detection system based on vibration Frequency Analysis provided by the present invention and method, detection gear lacks
Sunken efficiency high, precision high detection standard consistency is good, simple to operate, and detection gear-type is wide.
It should be appreciated that the application of the present invention is not limited to above-mentioned citing, for those of ordinary skills, can
To be improved according to the above description or to convert, all these modifications and variations all should belong to the guarantor of claims of the present invention
Shield scope.