CN105065639A - Resonance rupture automatic reconnoitering, identification and prevention monitoring method for gear case and transmission system - Google Patents

Abstract

The invention relates to a resonance rupture automatic reconnoitering, identification and prevention monitoring method for a gear case and transmission system. The main structure comprises a rotating speed sensor S installed on a gear shaft, vibration shock detection sensors A installed on bearing pedestals of a gear case and an on-line monitoring device JKQ. The on-line monitoring device JKQ is connected with all the sensors and acquires vibration shock signals detected by the sensors and corresponding acceleration and resonance demodulation signals in a parallel manner, and carries out rotating speed tracking, and outputs analyzed and decided control information. By employing the Resonance rupture automatic reconnoitering, identification and prevention monitoring method for the gear case and transmission system, present common faults of gear transmission systems of high-speed railways can be discovered timely, the reasons of the faults can be found out, monitoring measures can be taken in real time, the failure rate of the existing gear case and transmission system can be reduced, an improved machinery system can be obtained, and the gear case and transmission system can be guided to operate safely.

Description

Gear-box and transmission system resonance are broken automatically to scout and are identified and the precaution and controlling method

Technical field

The present invention relates to gear-box and transmission system to break automatically to scout and identify and the precaution and controlling method.Belong to movable machinery equipment safety monitoring technique field.Be mainly used in high ferro operation field gear train assembly, bearing is comprised by monitoring gear-box and transmission system in high ferro Train motion, the vibration acceleration of gear component and rotating speed, the variation relation of vibration frequency, identify the resonant frequency of gear-box and transmission system, resonance speed and synchronous vibration acceleration, thus propose to change rotating speed according to vibration acceleration limits value, avoid resonance, the strick precaution reducing vibration is resonated the control way broken, and then rigidity and resonant frequency decline send malfunction alarm with the open-close crack impact information significantly resonated caused by member bursts, application on-call maintenance, to ensure high ferro safe operation.

Technical background

Current, there is gear train assembly significant trouble in high ferro operation field, even if adopt state-of-the art external product to avoid, seriously jeopardizes high ferro security of operation in a large number.Document (on 08 11st, 2014 01:57 China Business News, 5,473 people participate in, and the iron general requirements of her specially offered high ferro gear-box of good fortune existing mass defect China is stopped using Chen Shanshan, Zhang Yaqing) is had to concentrate report to point out:

In the Fu Yite company of old brand senior strong team Germany in high ferro gear-box supply field, encounter " not acclimatized " in the business of the Chinese high ferro vehicle Component of supply recently, even face the embarrassment being required temporarily suspending operations for consolidation.

" China Business News " reporter exclusively learned yesterday, because Fu Yite supplies the gear-box of Chinese high ferro rail motor set vehicle, there is a lot of problem such as crackle, hot box trouble continuously, Chinese Railway parent company has required that vehicle manufacturers suspends the new structure gear-box using Fu Yite, and Fu Yite is in the factory of Shanghai production high ferro gear-box, be also required temporary transient suspending operations for consolidation.

The situation that root the reporter learned, the gear-box gone wrong, mainly be arranged on 380B (L) rail motor set, yesterday, management level of the vehicle manufacturers northern car of China (601299.SH) of 380B (L) rail motor set represent reporter, current company is changing the new structure gear-box of Fu Yite successively, and introduce more multi-provider to diversify risks.

(1) gear-box is out of order continuously:

Gear-box is the key equipment of high speed train motive transmission, being one of ten large supporting technologies of EMU, is also one of most important transmission link in motor train unit transmission system system, high to the requirement of precision and reliability, manufacture and design difficulty large, have much relations with traffic safety.

Before this, the high ferro gear-box supply of China is mainly monopolized by foreign-made business, and altogether, German Fu Yite is exactly the senior supplier of high ferro gear-box field old brand, has the railway gear-box knowhow of more than 40 year, and also to the European high ferro ICE supply of material.

But, this but in the process of the Chinese high ferro vehicle gear box of supply, encounters a series of trouble from the well-known supplier of " Germany manufactures ".

Since 27 days June in 2012, operate in the CRH380B BL CL rail motor set Fu Yite gear-box ， just accumulative generation casing crack fault 45 of the high speed passenger dedicated railways such as force is wide, Beijing-Shanghai, Harbin-to-Dalian.For addressing this problem, the beginning of this year starts, northern car side of China and according to the requirement of " Chinese Railway parent company fortune No. [2013] 495, a motor-car letter " file, has installed more than 100 overlapped Fu Yite new structure gear-boxes at CRH380B (L) rail motor set that dispatch from the factory.

But, the new structure gear-box just installed, went wrong again in succession in six Julies.The portion obtained according to reporter is from the analysis report of security situation weekly of Chinese Railway parent company, on June 21st, 2014, the CRH380B-6435L car group that Guangzhou Railway Corporation attaches troops to a unit, just when performing Xi Anbei-south, Guangzhou transport, 06 car report gear-bearing reached thermal limit.

Checking discovery further by putting in storage, the new structure gear-box that CRH380B-6435L car group is changed, all there is output terminal wheel side tapered roller bearing, labyrinth ring, waterproof back-up ring, labyrinth lid wear phenomenon.And before this, the new structure gear-box of Fu Yite is accumulative there is hot box trouble 7.

July 7, there is the too high problem of temperature in the gear-box of Harbin office Harbin-to-Dalian high ferro G49 rail motor set (No. CRH380B-6326) again, for guaranteeing rail motor set security of operation, changing hot standby rail motor set and taking on follow-up cross-channel after the Zhongdao of western station, G49 Harbin.These rail motor set are also just just full row 16 gear-boxes have been replaced by new structure Fu Yite gear-box June 21.

July 13, there is rail motor set new structure box bearing heating problem in Shenyang office Harbin-to-Dalian high ferro G325 rail motor set (CRH380B-6326) again.Find by decomposing fault gear-box, wheel side box bearing retainer hot melt is broken, the distortion of bearing roller overwhelming majority hot melt, and be scattered in gearwheel box body, major part roller and retainer depart from inner ring, take off to gear-box inner, broken when train high speed operation and after large and small gear scratching.

" the problem such as crackle of occurring of old gear-box before this, the geographical situation special with Chinese high ferro circuit has determines relation, such as compared with the Plains such as Europe, military wide threaded list road is many, if wind tunnel effect is not considered, just crack problem may be there is after running, " expert of a high ferro technical field tells reporter, therefore, the new structure gear-box of Fu Yite have also contemplated that more strength, but new problem produces again---cause the reason that gearbox temperature raises, may arrange unreasonable in oil-collecting and oil return with gear case body internal structure, the low on fuel of the participation bearing lubrication that oil trap is collected, cause the lubrication effect of output terminal bearing bad relevant.

" box bearing is superheated to a certain degree; the worst result is bearing failure; but due to axletree axle temperature overheated time; temperature transducer warning device can stop from command of execution high ferro; so there is no what catastrophic consequence occurs ", above-mentioned expert points out, but, no matter be stop or change trains, all affect the up-time efficiency of high ferro.

(2) northern car is anxious seeks more multi-provider

The reporter learned, due to the generation of a series of fault of Fu Yite new structure gear-box, Guangzhou office 6435 car group and Jinan office 6231 car group were once stopping reaching the standard grade, Shenyang office 6268,6263 car group is then required to gain original structure gear-box, Harbin office 6300,6326,6328 car group, road bureau also as far as possible minimizing to reach the standard grade the frequency.

And Chinese northern car ongoing Fu Yite new structure gear-box more changes jobs, also requested timeout by Chinese Railway parent company, simultaneously, iron always also requires that the Fu Yite new structure gear-box of northern car to entrucking is changed, and requires that the rail motor set being about to the to pay time-out having filled Fu Yite new structure gear-box dispatches from the factory.In addition, Fu Yite, in the factory of Shanghai production high ferro gear-box, is also required temporary transient suspending operations for consolidation.

" the total relevant punishment that this goes wrong to Fu Yite new structure gear-box of iron is still severeer "; the insider of a high ferro vehicular manufacturer states frankly; and halt the supply of Fu Yite; also a series of impact will be produced on Rail car manufacture, operation; such as; vehicular manufacturer may run into the embarrassment of replacing in time without suitable Component, and then affects vehicle delivery progress.

" we have required that Fu Yite aspect solved the problem of new structure gear-box in three months, and suspend replacing new structure gear-box.For still using the rail motor set of old gear-box, flaw detection strength grade when we also improve maintenance "; Chinese northern Che Yiwei manages and revealed reporter yesterday; and for the new rail motor set that will pay; company is mainly with the products substitution of the gear-box manufacturer Fleder of another Germany of family at present, and the rail motor set of existing assembling Fleder gear-box dispatch from the factory at present.In addition, in order to diversify risks, company also plans to increase another Germany of family gear-box manufacturer Cai Aifu becomes supplier, but, it will supply high ferro gear-box, obtains the total accreditation of iron after also needing to run through 300,000 kilometers of running experiments, and realizing batch production yet needs the time.

But, above-mentioned management level are also stated frankly, no matter are Fleder or Cai Aifu, general arrangement level by contrast and technology maturity best or Fu Yite, and northern car buying Fleder gear-box price, also exceed more than 50% than Fu Yite.

It should be noted that high ferro vehicular manufacturer domestic at present, also develop gear-box voluntarily in quickening.May in this year, by South China car (21.58,0.00,0.00%) China head cover speed per hour 380 kilometer motor vehicle group train driving device for gear box of weir, (601766.SH) relative villa Co., Ltd of rolling stock technical study institute independent development, have passed 300,000 kilometers of operation examinations, the high ferro gear-box of Science in Future in China south car is expected to be substituted by domestic.

In the face of faults such as a large amount of gear-box of occurring and associated components crackles, the MANUFACTURER of some old brands is in the world all at a loss what to do: can not automatically identify the catastrophe failure occurred, the reason of initiating failure can not be identified, more can not propose to avoid the parts such as existing gear-box to occur fast, sharply expand the countermeasure of fault.

And in order to ensure high ferro security of operation, being badly in need of in Timeliness coverage fault, finding the reason of initiating failure, taking actualizing technology in Countermeasure etc. to break through in real time.

Summary of the invention

According to inventor in multinomial art solutions, use " the mechanical fault diagnosis technology of generalized resonance and resonance and demodulation " in the railway system, apply accumulated experience, utilize the metaphysics of the dialectics of nature, first analyze the external cause of fault things and the dialectical relationships of internal cause such as the crackle that this type of high ferro train gear-box and associated components occur in a large number, confirm the faults such as the crackle that this type of mechanical system gear-box and associated components occur in a large number, remain because resonance causes crack damage.And analyze the immanent cause producing resonance crack damage, and be the natural frequency determined because itself there is low resistance mechanical resonance system, i.e. the resonant frequency of mechanical system; The natural frequency of gear-box and transmission system is in the wavelength coverage that movable machinery is easy to resonance, and this is the internal cause of things itself.The internal causes of things determine its receptance to external action, when dynamic excitation vibration frequency equals the natural frequency of gear-box and transmission system, system will produce significantly once per revolution vibration, thus initiation gear-box and transmission system occur significantly, the dynamic deformation of frequent, once dynamic deformation exceedes fatigue of materials ultimate strength, will break, this is the result that internal cause is formed under external cause action.

Therefore, a kind of gear-box of special proposition and transmission system resonance are broken automatically to scout and are identified and the precaution and controlling method.

Object of the present invention: the vibration utilizing panoramic dynamic excitation, scouting, the resonance identifying gear-box and transmission system, resonant frequency, resonance speed are the first tasks solving the multiple countermeasure of current failure; And then by taking precautions against coincideing of its endexoteric condition, preventing external cause vibration initiation gear-box and transmission system resonance from breaking is the second task solving the multiple countermeasure of current failure; And propose to identify that gear-box and transmission system resonates the identifying method of breaking, be then take precautions against gear-box and transmission system resonance initiation of breaking to jeopardize the 3rd task of safe major accident.

The present invention realizes in the following way:

A kind of gear-box and transmission system resonance are broken automatically to scout and are identified and the precaution and controlling method, and main structure contains the speed probe S be arranged on gear shaft, is arranged on the vibratory impulse detecting sensor A on each bearing support of gear-box and on-line monitoring device JKQ.On-line monitoring device JKQ is connected with each sensor, adopts rotating-speed tracking parallel mode to gather vibration and shock signal that each sensor is surveyed, and the acceleration of correspondence and resonance and demodulation signal, and exports the control information of decision-making by analysis.

This method inductive is characterised in that:

1) according to parts and this shaftgear number of teeth X of association, the key parameter of each bearing: central diameter Do, roller diameter d, roller number Z, wrapping angle α, the velocity ratio C of each gear and the rotational frequency FN of rotating speed measuring sensor corresponding gear belonging to vibratory impulse detecting sensor A, each sensor administrative bearing number B, each bearing, set up resonance multidimensional and scout the resonant frequency that matrix confirms the various parts of possibility gradual change;

2) then carrying out the continuous monitoring of full speed range for found various parts resonance bands, when finding that synchronous vibration exceeds limits value, then sending pre-alarm, and propose the rotating speed control way avoiding dangerous resonance;

3) when finding the resonant frequency of correspondence of resonant component rhegma or destruction to low drifting 2 ~ 5% and above feature, then send 1 grade or 2 grades of warning immediately, apply for on-call maintenance;

4) or just installing on-line monitoring device cannot carry out full speed range continuous monitoring for various parts resonance bands additional, but find that synchronous impact of appearance simultaneously of the violent oscillatory motion close to the resonant frequency of other homotype parts then sends 1 grade or 2 grades of warnings, application on-call maintenance immediately;

Utilize the on-stream each rank vibration inevitably produced of each type component of rotary component, by monitoring each rank vibration frequency, utilize its with rotation speed change to close to or equal the resonant frequency of gear-box and transmission system time, all inevitably excite this natural law of the judder of gear-box and transmission part resonator system and be reflected in the oscillating signal of the vibratory impulse detecting sensor A on each bearing of gear-box, rely on " the mechanical fault diagnosis technology of generalized resonance and resonance and demodulation " in the railway system, apply accumulated experience and prior art, each rank vibration of the on-stream generation of each type component of accurate perception rotary component and frequency thereof, as the input stimulus information of scouting gear-box and transmission system resonant frequency, identify that resonator system is to the resonance power gain of input stimulus information by detecting, resonant frequency, resonance speed etc., export vibration information, calculate the function relation of input and output information, the transfer function trend intrinsic with resonator system is made comparisons, thus reach the resonant frequency identifying gear-box and transmission system, quality, Oscillation Amplitude.The input stimulus of system is each rank oscillating signal of rotary component, the diagnostic alarms that system output is gear-box vibratory impulse and control information.

Gear-box and transmission system resonance are broken automatically to scout and are identified and the precaution and controlling method, input stimulus vibration source relates to this shaftgear number of teeth X of parts association described in vibratory impulse detecting sensor A, each sensor administrative bearing number B of multiple some position, each bearing, the key parameter of each bearing: central diameter Do, roller diameter d, roller number Z, wrapping angle α, the velocity ratio C of each gear and the rotational frequency FN of rotating speed measuring sensor corresponding gear.

Rotary component each rank vibration input stimulus characteristic frequency function is:

Protect outer vibration frequency $f=\frac{D_0-d\·\cos \mathrm{\α}}{2D_0}\×\mathrm{fn}\×n,n=\mathrm{1,2,3};$

Protect internal vibration frequency $f=\frac{D_0+d\·\cos \mathrm{\α}}{2D_0}\×\mathrm{fn}\×n,n=\mathrm{1,2,3};$

Outer shroud vibration frequency $f=\frac{D_0-d\·\cos \mathrm{\α}}{2D_0}\×Z\×\mathrm{fn}\×n,n=\mathrm{1,2,3};$

Inner ring vibration frequency $f=\frac{D_0+d\·\cos \mathrm{\α}}{2D_0}\×Z\×\mathrm{fn}\×n,n=\mathrm{1,2,3};$

Roll single vibration frequency $f=\frac{D_0^2-d^2\·{\cos }^2\mathrm{\α}}{2D_0\·d}\×\mathrm{fn}\×n,n=\mathrm{1,2,3};$

Roll two vibration frequency $f=\frac{D_0^2-d^2\·{\cos }^2\mathrm{\α}}{D_0\·d}\×\mathrm{fn}\×n,n=\mathrm{1,2,3};$

This tooth vibration frequency f=fn × n, n=1,2,3;

Adjacent tooth vibration frequency f=C × fn × n, n=1,2,3;

Mesh vibration frequency f=X × fn;

In formula, Do is the central diameter of bearing, and d is rolling element diameter, and α is roller contact angle, and Z is rolling element quantity, and fn is this axle speed-frequency, and C is velocity ratio, and X is this shaftgear number of teeth, and n=1,2,3 represents 1,2,3 rank of all kinds of vibration.

The frequency of each rank vibration of rotary component with rotation speed change when this frequency and gear-box and transmission part resonant frequency close or identical time, the judder of the gear-box excited or the formation of transmission part resonator system is also reflected in the oscillating signal of the vibratory impulse detecting sensor A on each bearing of gear-box.

Gear-box and transmission system resonance are broken automatically to scout and are identified and the precaution and controlling method, it is characterized in that: set up resonance multidimensional and scout the resonant frequency that matrix confirms the various parts of possibility gradual change, be utilize the frequency of each rank of any rotary component vibration with rotation speed change when this frequency and gear-box and transmission part resonant frequency close or identical time, the judder of the gear-box excited or transmission part resonator system is also reflected in the oscillating signal of the vibratory impulse detecting sensor A on each bearing of gear-box; When 3 kinds and above rotary component certain rank vibration frequency under different rotating speeds are close frequencies and excite gear-box or transmission part judder, then confirm that this frequency is the resonant frequency FG of gear-box or transmission part.The input stimulus of system is each rank vibration of rotary component, and gear-box and transmission system are resonator system, and system exports as gear-box vibration.

In order to scout the vibration of vibration source, the all types of each rank vibration of on-line monitoring device identification rotary component, record and preserve frequency, rotating speed, the accekeration information vibrated, vibration source is expressed with multi-dimensional matrix, to set up the multi-dimensional matrix information of vibration source, and then set up the resonant frequency that resonance multidimensional scouts the various parts of matrix confirmation possibility gradual change.Concrete grammar is as follows:

This matrix is utilized to set up network type searching method, the accekeration of all kinds of vibration source each rank vibration under full rotating speed is scouted in search, under certain frequency, amplification phenomenon is had when gear-box resonator system exports vibration acceleration, there is maximum, then the possible condition of resonator system generation " resonance " as external cause vibrational excitation.When 3 kinds and above rotary component certain rank vibration frequency under different rotating speeds are close frequencies and excite gear-box or transmission part judder, then confirm that this frequency is the necessary condition of the resonant frequency FG of gear-box or transmission part.

According to kinematical theory, when the eigen vibration frequency of certain, each rotary component of each vibrations of rotating components source Oscillation Amplitude S is f, the acceleration of vibration source is a=-(2 π f) ²ssin (2 π ft); By input stimulus characteristic frequency function, f and fn is proportional relation, so acceleration a's and rotating speed fn is square proportional; Using the feature of mechanical second order resonator system as the theoretical foundation identifying resonance and resonant frequency: when scouting the vibration of gear-box resonator system with acceleration, the Oscillation Amplitude S in input stimulus source _m, scout the vibration acceleration a obtained _out, when there is not resonator system and affecting, S _mwith a _outtransfer function a=-(2 π f) should be met ²ssin (2 π ft).A kind of gear-box and transmission system resonance are broken automatically to scout and are identified and the precaution and controlling method, it is characterized in that: if the acceleration a that system exports _outbe greater than the acceleration a of transfer function _outmore than 3 times time, namely think " gear-box and transmission part judder "; Frequency f corresponding to this acceleration maximum is the resonant frequency FG of resonator system, if 3 kinds and above rotary component and different vibration source can evoke " gear-box and the transmission part judder " of this FG, then prove that gear-box and transmission part resonate in frequency FG.

Gear-box and transmission system resonance are broken automatically to scout and are identified and the precaution and controlling method, it is characterized in that: accelerate to prevent gear-box and transmission part from strongly resonating to occur tired or crackle, the continuous monitoring of full speed range is carried out for found various parts resonance bands, when finding that synchronous vibration exceeds limits value AX (such as 8 ~ 12g the peak value) that this mechanical component design specifies, then send pre-alarm; And send out and avoid the rotating speed control way of dangerous resonance to be: increase or reduce rotating speed 3 ~ 5% or more, to the vibration avoiding resonating be reduced to limits value 1/2 and following.That is, by taking precautions against coincideing of endexoteric condition, prevent external cause vibration initiation gear-box and transmission system resonance from breaking, as the rotating speed control way avoiding dangerous resonance.

Gear-box and transmission system resonance are broken automatically to scout and are identified and the precaution and controlling method, in order to take precautions against gear-box and transmission system resonance break cause jeopardize safe major accident, judge to identify whether gear-box and transmission part occur fatigue or crackle, make alarm condition: when there is the resonant frequency of correspondence of resonant component rhegma or destruction to low drifting 2 ~ 5% and above feature, then send 1 grade or 2 grades of warnings immediately, application on-call maintenance; For the parts of gear housing one class consolidated structures, resonant frequency to low drifting 2 ~ 3% time, send 1 grade of warning, when resonant frequency to low skew 3 ~ 5% and above time, send 2 grades of warnings; Pull bar, Flexible Rotating etc. are become to the parts of resonant frequency, when resonant frequency relative to lowest resonance frequency FGL to low offset 2 ~ 3% time, send 1 grade of warning, when the relative lowest resonance frequency FGL of resonant frequency to low drifting 3 ~ 5% and above time, send 2 grades of warnings.

In order to take precautions against gear-box and transmission system resonance break cause jeopardize safe major accident, a kind of gear-box and transmission system resonance are broken automatically to scout and are identified and the precaution and controlling method, carry out long-term rotating-speed tracking monitor the drift identifying resonant frequency continuously for various parts resonance bands full speed range.In order to identify whether gear-box and transmission part occur fatigue or crackle, just to install additional on-line monitoring device cannot for various parts resonance bands carry out full speed range carry out for a long time rotating-speed tracking monitor the drift identifying resonant frequency continuously time, then vibration acceleration and resonance and demodulation are asked definitely relative long-pending, that is: the vibration acceleration [g] equaling energizing frequency be multiplied with resonance and demodulation [SV] waveform that frequency equals this energizing frequency integral multiple and ask absolute value, being defined as " definitely relatively long-pending "; Finding that vibration acceleration exceedes the definitely relatively long-pending of the same frequency of appearance simultaneously of acceleration limits value AX=8 ~ 12g or its vibration of half, then send 1 grade or 2 grades of warnings, application on-call maintenance; Wherein, if only find that vibration acceleration 1 rank are more than AX/2 and definitely relative with 1 rank of vibration acceleration same frequency long-pending more than 9kgSV, then send 1 grade of warning for gear-box; If also find, vibration acceleration 1 rank are greater than 2 times of 1 rank more than AX and long-pending amplitude definitely relative to 2 rank of 1 order frequency 2 overtones band of vibration acceleration and more than 20kgSV, then send 2 grades of warnings.

External vibration excitation certainly exists and is difficult to reduce, accelerate the failure to prevent gear-box and transmission part under the external vibration incentive action being also difficult to reduction certainly existed, strong resonance occurring because of low resistance, a kind of gear-box and transmission system resonance are broken automatically to scout and are identified and the precaution and controlling method, it is characterized in that: identify that the method for resonance low resistance is that the output vibration carrying out the full speed range that certain vibrational excitation factor excites is carried out measurement statistics and obtained A (F), to far below resonant frequency FG's (as 1/5 ~ 1/3) and higher than resonant frequency FG (as 1.2FG and more than) the vibration performance acceleration spectrum A (F) of frequency range, make and meet B (F)=A (F) (assembly average) and B (F) ∝ F ²magnitude reference matched curve B (F), the K=A (FG) during calculated rate FG/B (FG), as " resonance power gain " K, if this resonance power gain K is greater than 3, then advise increasing damping to resonance section.Such as: to macromolecule, the low-gravity coating of the external coated high cohesion of gear-box, when it vibrates with gear-box local buckling, vibrational energy is converted into heat and scatters and disappears, effectively reduce synchronous vibration by increasing damping.

" a kind of gear-box and transmission system resonance are broken automatically to scout and identified and the precaution and controlling method " proposed by the invention can realize Timeliness coverage fault to the current multiple fault of high ferro gear train assembly, finds the reason of initiating failure, take the aspect actualizing technology such as Countermeasure to break through in real time.The high ferro technology of taking its place in the front ranks of the world for China develops more healthily, run and create the economic benefit promoted in the whole world more reliably escorts.

Accompanying drawing illustrates:

Accompanying drawing 1-1 is that gear-box and transmission system resonance are broken automatically to scout and identified and the precaution and controlling method structural representation;

Accompanying drawing 1-2 is that gear-box and transmission system resonance are broken automatically to scout and identified and the precaution and controlling method information schematic diagram;

Accompanying drawing 2-0 is the acceleration responsive that the search of multi-dimensional matrix network type obtains 4 all kinds of Bearing gear part 1 ~ 3 of car 24 measuring point rank vibration relative rotation speeds and frequency;

Accompanying drawing 2-1 is 2 car, 24 gearbox input shaft outer race 2 rank oscillating curves;

Accompanying drawing 2-2 is 2 car, 22 gear-box mesh vibration curves;

Accompanying drawing 2-3 is 2 car, 22 gearbox output shaft bearing inner ring 3 rank oscillating curves;

Accompanying drawing 3-1 is that 4 car, 24 gearbox input shaft bearings roll single 1 rank oscillating curve;

Accompanying drawing 3-2 is 4 car, 24 gearbox input shaft small gear 2 rank oscillating curves;

Accompanying drawing 3-3 is that 4 car, 22 gearbox output shaft bearings roll single 1 rank oscillating curve;

Accompanying drawing 4-1 is that outer 2 rank oscillating curves protected by 8 car, 24 gearbox input shaft bearings;

Accompanying drawing 4-2 is 8 car, 34 gearbox input shaft gearwheel 2 rank oscillating curves;

Accompanying drawing 4-3 is 8 car, 34 gearbox input shaft small gear 1 rank oscillating curves;

Accompanying drawing 5-0 is that gear-box is subject to the resonance of gears meshing vibrational excitation closely to cause the simulation model of crackle and open-close crack impact;

Accompanying drawing 5-1 is resonant frequency, the amplification factor mensuration of gear-box;

Accompanying drawing 5-2 is that gear 100Hzlum vibration does not excite gear-box to resonate but amplifies 0.107dB, gear-box vibration acceleration 0.0407g;

Accompanying drawing 5-3 is the information waveform that simulated measurement obtains as gear mesh frequency F=900Hz, FG=900Hz, G=10;

Accompanying drawing 5-4 is the information frequency spectrum that simulated measurement obtains as gear mesh frequency F=900Hz, FG=900Hz, G=10;

Accompanying drawing 5-5 is the information waveform that simulated measurement obtains as gear mesh frequency F=700Hz, FG=900Hz, G=10;

Accompanying drawing 5-6 is the information frequency spectrum that simulated measurement obtains as gear mesh frequency F=700Hz, FG=900Hz, G=10;

Accompanying drawing 5-7 is the information waveform that simulated measurement obtains as gear mesh frequency F=950Hz, FG=900Hz, G=10;

Accompanying drawing 5-8 is the information frequency spectrum that simulated measurement obtains as gear mesh frequency F=950Hz, FG=900Hz, G=10;

Accompanying drawing 5-9 is the information waveform that simulated measurement obtains as gear mesh frequency F=990Hz, FG=900Hz, G=10;

Accompanying drawing 5-10 is the information frequency spectrum that simulated measurement obtains as gear mesh frequency F=990Hz, FG=900Hz, G=10;

Accompanying drawing 5-11 is the information waveform that simulated measurement obtains as gear mesh frequency F=990Hz, FG=900Hz, G=10;

Accompanying drawing 5-12 is the information frequency spectrum that simulated measurement obtains as gear mesh frequency F=990Hz, FG=900Hz, G=10;

Accompanying drawing 5-13 is the information waveform and frequency spectrum that simulated measurement obtains as gear mesh frequency F=700Hz, FG=900Hz, G=5;

Accompanying drawing 5-14 is the information waveform and frequency spectrum that simulated measurement obtains as gear mesh frequency F=810Hz, FG=900Hz, G=5;

Accompanying drawing 5-15 is the information waveform and frequency spectrum that simulated measurement obtains as gear mesh frequency F=900Hz, FG=900Hz, G=5;

Accompanying drawing 5-16 is the information waveform and frequency spectrum that simulated measurement obtains as gear mesh frequency F=950Hz, FG=900Hz, G=5;

Accompanying drawing 5-17 is the information waveform and frequency spectrum that simulated measurement obtains as gear mesh frequency F=990Hz, FG=900Hz, G=5.

Embodiment

Below in conjunction with drawings and Examples, the present invention will be further described.

With reference to accompanying drawing 1-1 and Fig. 1-2, the present embodiment main structure contains the speed probe be arranged on gear shaft, be arranged on the vibratory impulse detecting sensor on each bearing support of gear-box, and on-line monitoring device, on-line monitoring device is connected with each sensor, adopts rotating-speed tracking parallel mode to gather vibration and shock signal that each sensor is surveyed, and the acceleration of correspondence and resonance and demodulation signal, and export the on-line monitoring device of the control information of decision-making by analysis

(1) according to parts and this shaftgear number of teeth X of association, the key parameter of each bearing: central diameter Do, roller diameter d, roller number Z, wrapping angle a, the velocity ratio C of each gear and the rotational frequency FN of rotating speed measuring sensor corresponding gear belonging to vibratory impulse detecting sensor A, each sensor administrative bearing number B, each bearing, set up resonance multidimensional and scout the resonant frequency that matrix confirms the various parts of possibility gradual change;

(2) then carrying out the continuous monitoring of full speed range for found various parts resonance bands, when finding that synchronous vibration exceeds limits value, then sending pre-alarm, and propose the rotating speed control way avoiding dangerous resonance;

(3) when finding the resonant frequency of correspondence of resonant component rhegma or destruction to low drifting 2 ~ 5% and above feature, then send 1 grade or 2 grades of warning immediately, apply for on-call maintenance; Or just installing on-line monitoring device cannot carry out full speed range continuous monitoring for various parts resonance bands additional (4), but find that synchronous impact of appearance simultaneously of the violent oscillatory motion close to the resonant frequency of other homotype parts then sends 1 grade or 2 grades of warnings, application on-call maintenance immediately.

The method of matrix is scouted by setting up resonance multidimensional, confirm the resonant frequency of the various parts of possibility gradual change, its principle be utilize the frequency of each rank of any rotary component vibration with rotation speed change when this frequency and gear-box and transmission part resonant frequency close or identical time, the judder of the gear-box excited or transmission part resonator system is also reflected in the oscillating signal of the vibratory impulse detecting sensor A on each bearing of gear-box; When 3 kinds and above rotary component certain rank vibration frequency under different rotating speeds are close frequencies and excite gear-box or transmission part judder, then confirm that this frequency is the resonant frequency FG of gear-box or transmission part, the input stimulus of system is each rank vibration information of rotary component, gear-box and transmission system are resonator system, system export for gear-box vibration information,

Rotary component each rank vibration input stimulus characteristic frequency function is:

Protect outer vibration frequency $f=\frac{D_0-d\·\cos \mathrm{\α}}{2D_0}\×\mathrm{fn}\×n,n=\mathrm{1,2,3};$

Protect internal vibration frequency $f=\frac{D_0+d\·\cos \mathrm{\α}}{2D_0}\×\mathrm{fn}\×n,n=\mathrm{1,2,3};$

Outer shroud vibration frequency $f=\frac{D_0-d\·\cos \mathrm{\α}}{2D_0}\×Z\×\mathrm{fn}\×n,n=\mathrm{1,2,3};$

Inner ring vibration frequency $f=\frac{D_0+d\·\cos \mathrm{\α}}{2D_0}\×Z\×\mathrm{fn}\×n,n=\mathrm{1,2,3};$

Roll single vibration frequency $f=\frac{D_0^2-d^2\·{\cos }^2\mathrm{\α}}{2D_0\·d}\×\mathrm{fn}\×n,n=\mathrm{1,2,3};$

Roll two vibration frequency $f=\frac{D_0^2-d^2\·{\cos }^2\mathrm{\α}}{D_0\·d}\×\mathrm{fn}\×n,n=\mathrm{1,2,3};$

This tooth vibration frequency f=fn × n, n=1,2,3;

Adjacent tooth vibration frequency f=C × fn × n, n=1,2,3;

Mesh vibration frequency f=X × fn;

In formula, Do is the central diameter of bearing, and d is rolling element diameter, and α is roller contact angle, and Z is rolling element quantity, and fn is this axle speed-frequency, and C is velocity ratio, and X is this shaftgear number of teeth, and n=1,2,3 represents 1,2,3 rank of all kinds of vibration.

According to kinematical theory, when the eigen vibration frequency of certain, each rotary component of each vibrations of rotating components source Oscillation Amplitude S is f, the acceleration of vibration source is a=-(2 π f) ²ssin (2 π ft); By formula content according to claim 2, f and fn is proportional relation, so acceleration a's and rotating speed fn is square proportional; Using the feature of mechanical second order resonator system as the theoretical foundation identifying resonance and resonant frequency: when scouting the vibration of gear-box resonator system with acceleration, the Oscillation Amplitude S in input stimulus source _m, scout the vibration acceleration a obtained _out, when there is not resonator system and affecting, S _mwith a _outtransfer function a=-(2 π f) should be met ²ssin (2 π ft), is characterized in that: if the acceleration a that system exports _outbe greater than the acceleration a of transfer function _outmore than 3 times time, namely think " gear-box or transmission part judder "; Frequency f corresponding to this acceleration maximum is the resonant frequency FG of resonator system, if 3 kinds and above rotary component and different vibration source can evoke " gear-box or the transmission part judder " of this FG, then prove that gear-box or transmission part resonate in frequency FG.

Carrying out the continuous monitoring of full speed range for found various parts resonance bands, when finding that synchronous vibration exceeds limits value AX (such as 8 ~ 12g the peak value) that this mechanical component design specifies, then sending pre-alarm; And send out and avoid the rotating speed control way of dangerous resonance to be: increase or reduce rotating speed 3 ~ 5% or more, to the vibration avoiding resonating be reduced to limits value AX 1/2 and following.

When finding the resonant frequency of the correspondence of resonant component rhegma or destruction to low drifting 2 ~ 5% and above feature, then send 1 grade or 2 grades of warnings immediately, application on-call maintenance; For the parts of gear housing one class consolidated structures, resonant frequency sends 1 grade of warning to low drifting 2 ~ 3%, and resonant frequency is to low drifting 3 ~ 5% and send 2 grades of warnings above; Pull bar, Flexible Rotating etc. are become to the parts of resonant frequency, the relative lowest resonance frequency FGL of resonant frequency sends 1 grade of warning to low drifting 2 ~ 3%, and the relative lowest resonance frequency FGL of resonant frequency is to low drifting 3 ~ 5% and send 2 grades of warnings above.

In order to identify whether gear-box and transmission part occur fatigue or crackle, just install on-line monitoring device additional and cannot for various parts resonance bands carry out full speed range carry out for a long time rotating-speed tracking monitor the drift identifying resonant frequency continuously time, then vibration acceleration and resonance and demodulation are asked definitely relative long-pending, that is: the vibration acceleration [g] equaling energizing frequency f be multiplied with resonance and demodulation [SV] waveform that frequency equals this energizing frequency integral multiple and ask absolute value, being defined as " definitely relatively long-pending "; Finding that vibration acceleration exceedes the definitely relatively long-pending of the same frequency of appearance simultaneously of the vibration of acceleration limits value AX=8 ~ 12g, then send 1 grade or 2 grades of warnings, application on-call maintenance; Wherein, if only find that vibration acceleration 1 rank are more than AX/2 and definitely relative with 1 rank of vibration acceleration same frequency long-pending more than 1 grade of warning limits value JXDJ1=9kgSV, then send 1 grade of warning for gear-box; If also find, vibration acceleration 1 rank are greater than 2 times of 1 rank more than AX and long-pending amplitude definitely relative to 2 rank of 1 order frequency 2 overtones band of vibration acceleration and more than 2 grades of warning limits value JXDJ2=20kgSV, then send 2 grades of warnings;

The general formula of definitely relatively long-pending warning restriction value function is:

1 grade of warning limits value:

JXDJ1＝(0.0402[g]*8*F/100) ²*40.2[SV/g]*F/100*3；

2 grades of warning limits values:

JXDJ2＝(0.0402[g]*12*F/100) ²*40.2[SV/g]*F/100*3；

In formula, 0.0402g is the acceleration of 1um amplitude when 100Hz, and 8,12 is 1,2 grade of acceleration limits value of reporting to the police, and F is current vibration frequency [Hz], 40.2SV is the impact resonance and demodulation impact value [SV] that 0.0402g acceleration is corresponding, and 3 is engineering experience correction factor.

Accelerate the failure to prevent gear-box and transmission part under the external vibration incentive action being also difficult to reduction certainly existed, strong resonance occurring because of low resistance, identify that the method for resonance low resistance is that the output vibration carrying out the full speed range that certain vibrational excitation factor excites is carried out measurement statistics and obtained A (F), to far below resonant frequency FG's (as 1/5 ~ 1/3) and higher than resonant frequency FG (as 1.2FG and more than) the vibration performance acceleration spectrum A (F) of frequency range, make and meet B (F)=A (F) (assembly average) and B (F) ∝ F ²magnitude reference matched curve B (F), the K=A (FG) during calculated rate FG/B (FG), as " resonance power gain " K, if this resonance power gain K is greater than 3, then advise increasing damping to resonance section.Such as: to macromolecule, the low-gravity coating of the external coated high cohesion of gear-box, when it vibrates with gear-box local buckling, vibrational energy is converted into heat and scatters and disappears, effectively reduce synchronous vibration by increasing damping.

As:

Step 1: multi-dimensional matrix search confirms that gear-box exists FG1=950Hz, FG2=1450Hz synchronous vibration;

On-line measuring device sets up multi-dimensional matrix network type way of search, obtain the acceleration responsive of different vehicle, different measuring points, all kinds of part, 1 ~ 3 rank vibration relative rotation speed and frequency, such as accompanying drawing 2-0 is the acceleration responsive that the search of multi-dimensional matrix network type obtains 4 all kinds of Bearing gear part 1 ~ 3 of car 24 measuring point rank vibration relative rotation speeds and frequency.

As accompanying drawing 2, accompanying drawing 3, accompanying drawing 4, when 3 kinds and above rotary component and different vibration source can evoke " gear-box and the transmission part judder " of FG, then prove that gear-box and transmission part resonate in frequency FG.Fig. 2-1 is the outer race 2 rank oscillating curve of 24,2 car (gearbox input shaft measuring point), namely to drive a vehicle the gearbox input shaft outer race 2 rank vibration acceleration information of automatically catching, visible when frequency 950Hz, 1450Hz (speed of a motor vehicle 160km/h, 240km/h) outer shroud 2 rank vibration have amplification phenomenon, there is maximum, during 950Hz, vibration reaches 5g, during 1450Hz, vibration reaches 4.5g, and namely 950Hz, 1450Hz are judged as " resonance " frequency of doubtful gear-box.

Fig. 2-2 is the gears meshing oscillating curve of 22,2 car (gearbox output shaft gearwheel side measuring point), namely to drive a vehicle the gears meshing vibration acceleration information of automatically catching, visible when frequency 950Hz, 1450Hz (speed of a motor vehicle 160km/h, 240km/h) gears meshing vibration have amplification phenomenon, there is maximum, during 950Hz, vibration reaches 3.5g, during 1450Hz, vibration reaches 3g, and namely 950Hz, 1450Hz are judged as doubtful " resonance " frequency of gear-box.

Fig. 2-3 is the bearing inner ring 3 rank oscillating curve of 22,2 car (gearbox output shaft gearwheel side measuring point), namely to drive a vehicle the gearbox output shaft bearing inner ring 3 rank vibration acceleration information of automatically catching, visible when frequency 950Hz (speed of a motor vehicle 160km/h) and 1450Hz (speed of a motor vehicle 250km/h) inner ring 3 rank vibration have amplification phenomenon, there is maximum, reach 0.3g when vibration reaches 0.35g, 1450Hz during 950Hz, namely 950Hz, 1450Hz are judged as doubtful " resonance " frequency of gear-box.

3 kinds of rotary components such as the vibration of gearbox input shaft outer race 2 rank, the vibration of gearbox output shaft bearing inner ring 3 rank, gears meshing vibration and different vibration source all evoke " gear-box and the transmission part judder " of 950Hz, 1450Hz under different rotating speeds (speed of a motor vehicle), prove that gear-box and transmission part resonate in frequency FG1=950Hz, FG2=1450Hz.Think that this frequency is the resonant frequency of gear case body.

Step 2: multi-dimensional matrix search confirms that gearbox drive shaft exists FG1=72Hz, FG2=95Hz lateral resonance.

Fig. 3-1 is that the bearing of 24,4 car (gearbox input shaft measuring point) rolls single 1 rank oscillating curve, namely the gearbox input shaft bearing of automatically catching of driving a vehicle rolls single 1 rank vibration acceleration information, roll single 1 rank vibration when frequency 72Hz, 95Hz (speed of a motor vehicle 160km/h, 208km/h) and have amplification phenomenon as seen, there is maximum, during 72Hz, vibration reaches 1.1g, during 95Hz, vibration reaches 0.7g, and namely 72Hz, 95Hz are judged as doubtful " resonance " frequency of gearbox drive shaft.Fig. 3-2 is the small gear 2 rank oscillating curve of 24,4 car (gearbox input shaft measuring point), namely to drive a vehicle the gearbox input shaft small gear 2 rank vibration acceleration information of automatically catching, visible when frequency 72Hz, 95Hz (speed of a motor vehicle 160km/h, 208km/h) small gear 2 rank vibration have amplification phenomenon, there is maximum, during 72Hz, vibration reaches 1g, during 95Hz, vibration reaches 0.7g, and namely 72Hz, 95Hz are judged as doubtful " resonance " frequency of gearbox drive shaft.

Fig. 3-3 is that the bearing of 22,4 car (gearbox output shaft measuring point) rolls single 1 rank oscillating curve, namely the gearbox output shaft bearing of automatically catching of driving a vehicle rolls single 1 rank vibration acceleration information, roll single 1 rank vibration when frequency 72Hz, 95Hz (speed of a motor vehicle 160km/h, 208km/h) and have amplification phenomenon as seen, there is maximum, during 72Hz, vibration reaches 3.5g, during 95Hz, vibration reaches 2g, and namely 72Hz, 95Hz are judged as doubtful " resonance " frequency of gearbox drive shaft.

Gearbox input shaft bearing rolls single 1 rank vibration, the vibration of small gear 2 rank, gearbox output shaft bearing roll 3 kinds of rotary components such as single 1 rank and different vibration source all evokes " the strong transverse vibration of gearbox drive shaft " of 72H, 95Hz under different rotating speeds, proves that gear-box and transmission part and gearbox drive shaft resonate in frequency FG1=72Hz, FG2=95Hz.The transverse resonance frequency that this frequency is input shaft is proved in modal analysis.

Step 3, multi-dimensional matrix search confirms that gearbox drive shaft exists FG=45Hz torsional resonance:

Fig. 4-1 is that outer 2 rank oscillating curves protected by the bearing of 24,8 car (gearbox input shaft measuring point), namely outer 2 rank vibration acceleration information protected by the gearbox input shaft bearing of automatically catching of driving a vehicle, protect outer 2 rank vibrations when frequency 45Hz (speed of a motor vehicle 230km/h) and have amplification phenomenon as seen, there is maximum, during 45Hz, vibration reaches 0.5g, and namely 45Hz is judged to be doubtful " resonance " frequency that gearbox drive shaft reverses.

Fig. 4-2 is adjacent tooth and the gearwheel 2 rank oscillating curve of 24,8 car (gearbox input shaft measuring point), namely to drive a vehicle the gear-box gearwheel 2 rank vibration acceleration information of automatically catching, visible when frequency 45Hz (speed of a motor vehicle 245km/h) gearwheel 2 rank vibration have amplification phenomenon, there is maximum, during 45Hz, vibration reaches 0.26g, and namely 45Hz is judged as doubtful " resonance " frequency that gearbox drive shaft reverses.

Fig. 4-3 is this tooth i.e. small gear 1 rank oscillating curve of 24,8 car (gearbox input shaft measuring point), namely to drive a vehicle the gearbox input shaft small gear 1 rank vibration acceleration information of automatically catching, visible when frequency 45Hz (speed of a motor vehicle 200km/h) small gear 1 rank vibration have amplification phenomenon, there is maximum, during 45Hz, vibration reaches 0.6g, and namely 45Hz is judged as doubtful " resonance " frequency that gearbox drive shaft reverses.

3 kinds of rotary components such as gearbox input shaft bearing guarantor outer 2 rank, gearwheel 2 rank, small gear 1 rank vibration and different vibration source all evoke " gear-box drives strong torsional vibration " of 45Hz under different rotating speeds, prove that gear-box and transmission part and gearbox drive shaft resonate in frequency FG=45Hz.The torsional resonance frequency that this frequency is input shaft is proved in modal analysis.

Step 4, the resonance of gears meshing vibrational excitation gear-box and crack initiation, the identification closing impact and warning

In order to identify whether gear-box and transmission part occur fatigue or crackle, just to install additional on-line monitoring device cannot for various parts resonance bands carry out full speed range carry out for a long time rotating-speed tracking monitor the drift identifying resonant frequency continuously time, then vibration acceleration and resonance and demodulation are asked definitely relative long-pending, that is: the vibration acceleration [g] equaling energizing frequency be multiplied with resonance and demodulation [SV] waveform that frequency equals this energizing frequency integral multiple and ask absolute value, being defined as " definitely relatively long-pending "; Finding that vibration acceleration exceedes the definitely relatively long-pending of the same frequency of appearance simultaneously of acceleration limits value AX=8 ~ 12g or its vibration of half, then send 1 grade or 2 grades of warnings, application on-call maintenance; Wherein, for the resonance of the F=FG=900Hz of gear-box, if only find, vibration acceleration 1 rank are more than AX/2 and definitely relative with 1 rank of vibration acceleration same frequency long-pending more than 1 grade of warning limits value JXDJ1=9kgSV, then send 1 grade of warning; If also find, vibration acceleration 1 rank are greater than 2 times of 1 rank more than AX and long-pending amplitude definitely relative to 2 rank of 1 order frequency 2 overtones band of vibration acceleration and more than 2 grades of warning limits value JXDJ2=20kgSV, then send 2 grades of warnings.

The general formula of definitely relatively long-pending warning restriction value function is:

1 grade of warning limits value:

JXDJ1＝(0.0402[g]*8*F/100) ²*40.2[SV/g]*F/100*3，

Work as F=900Hz, JXDJ1=9.090kgSV ≈ 9kgSV

2 grades of warning limits values:

JXDJ2＝(0.0402[g]*12*F/100) ²*40.2[SV/g]*F/100*3，

Work as F=900Hz, JXDJ2=20.459kgSV ≈ 20kgSV;

In formula, 0.0402g is the acceleration of 1um amplitude when 100Hz, and 8,12 is 1,2 grade of acceleration limits value of reporting to the police, and F is current vibration frequency [Hz], 40.2SV is the impact resonance and demodulation impact value [SV] that 0.0402g acceleration is corresponding, and 3 is engineering experience correction factor.

Specification of a model is in accompanying drawing 5-0.

If gears meshing vibration is resonated with gear-box natural frequency FG caused the crackle of gear-box.

If gears meshing Oscillation Amplitude is 1um, gear-box resonant frequency FG=900Hz, dynamic magnifier G=10;

If when gear-box amplitude is greater than 5um, causes gear-box crackle and to ftracture further impacts, when negative amplitude is less than-0.5um, cause existing crack closure impact.These impact to be superimposed upon respectively in gears meshing vibration and act on gear-box.

The synthesis oscillation acceleration of measuring gear case, carries out lower pass-filter to the synthesis oscillation acceleration signal of gear-box and obtains gear phase low-frequency vibration acceleration signal; Whether the synthesis oscillation acceleration signal of gear-box is existed to the resonance and demodulation impulse detection of impact; That asks gear-box low-frequency vibration and resonance and demodulation to impact is absolute relative long-pending.Theoretical rule is:

If gear-box only exists the closed impact of crackle, then definitely relatively long-pending frequency spectrum is N*F, wherein N=1,2,3

If gear-box exists the closed of crackle and cracking impacts, then definitely relatively long-pending frequency spectrum is 2N*F, wherein N=1,2,3

Obviously, due to gear-box resonant frequency FG=900Hz, dynamic magnifier G=10, therefore when F=FG or F is close to FG, the most easily there is violent oscillatory motion and cause gear-box occurring that the cracking of crackle impacts and has the closed impact of crackle.

Theoretical according to vibration: amplitude x=X*sin (2p*F) m of sinusoidal vibration, then vibration velocity v=-X* (2p*F) cos (2p*F) [m/s], then the acceleration of sinusoidal vibration is a=-X* (2p*F) ^2sin (2p*F) [m/s^2]

As amplitude X=1um, during F=100,

Vibration acceleration is AO=0.3948m/s/s=0.0402g

Measure because Fig. 5-2 emulates: during F=100Hz, gear-box resonance amplifies 0.107dB, is converted into G=10 ^(0.107/20)=1.0124 times, the acceleration of output is A=AO*G=0.0407g, coincide with the simulation result of Fig. 5-2.

Because the amplitude of gear-box is less than 5um, do not cause cracking impact, closed impact, resonance and demodulation exports and definitely relative amassing exports.

In order to identify peak value [SV] corresponding relation of the impact that gear-box vibration acceleration [g] and resonance and demodulation detect, the amplitude [g*SV] and the frequency spectrum thereof that have employed " definitely relative long-pending " of being expressed with the long-pending absolute value of resonance and demodulation impact by vibration acceleration describe.

Measure because Fig. 5-3 emulates: as gear mesh frequency F=900Hz, excite the gear-box resonance that resonant frequency is FG=900Hz, power gain is 10, in addition the gear-box that there is crackle makes amplitude increase because large amplitude generation crack initiation reduces rigidity, therefore the apparent amplitude of gear-box reaches 13.7um; And vibrating the impact of posivtive spike appearance on opportunity cracking, closing in the appearance on opportunity of vibration negative peak and impact; Although almost can't see the feature that open-close crack is impacted in the amplitude waveform and Acceleration pulse of gear-box, but the resonance and demodulation of acceleration is detected in the resonance and demodulation waveform having found to correspond to open-close crack impact, and the absolute value of this resonance and demodulation signal and gear-box low frequency acceleration signal product, namely, in definitely relatively long-pending waveform, all there is the pulse of corresponding opening and closing 2 Secondary Shocks of each gear cycle.Particularly, in the frequency analysis of the waveform of Fig. 5-4 couples of Fig. 5-3, show brightly: the frequency spectrum of the effect of gears meshing amplitude, the limited resonance amplitude of gear-box, the comprehensive acceleration of gear-box, gear-box low frequency acceleration is 900Hz, and resonance and demodulation is 1800=2*900Hz with definitely relative long-pending dominant frequency spectrum, both embody gear-box crackle and there is open and close impact, and definitely relatively long-pending wave-shape amplitude reaches 84.5 [kgSV], 2 rank spectrums reach 10*2.83 [kgSV].

Measure because Fig. 5-5 emulates: as gear mesh frequency F=700Hz, although do not excite the gear-box resonance that resonant frequency is FG=900Hz, power gain is 10, the 1um mesh vibration of gear is still amplified to 2.4um; Because gear-box vibrates the posivtive spike of 2.4um is less than the 5um threshold value that causes and opened and does not occur that cracking impacts, but at the vibration negative peak of-2.4um lower than closed impact threshold value-0.5um, so that there is closed impact; Although almost can't see the feature that open-close crack is impacted in the amplitude waveform and Acceleration pulse of gear-box, but the resonance and demodulation of acceleration is detected to the resonance and demodulation waveform having found to correspond to crack closure impact, the absolute value of this resonance and demodulation signal and gear-box low frequency acceleration signal product, namely, in definitely relatively long-pending waveform, all there is corresponding 1 the closed pulse impacted of each gear cycle.Particularly, in the frequency analysis of the waveform of Fig. 5-6 couples of Fig. 5-5, show brightly: the frequency spectrum of the effect of gears meshing amplitude, the limited resonance amplitude of gear-box, the comprehensive acceleration of gear-box, gear-box low frequency acceleration is 700Hz, and resonance and demodulation is also 700Hz with definitely relative long-pending dominant frequency spectrum, only embody gear-box crackle and there is closed impact, and definitely relatively long-pending waveforms amplitude reaches 1.76 [kgSV], 1 rank spectrum only reaches 10*0.052 [kgSV].

Verify that the synchronous vibration of Real time identification crackle under above-mentioned resonance condition and open-close crack impact definitely relative emulation statistics that is long-pending and frequency spectrum discerning method as follows:

Conclude thus and obtain:

Synchronous vibration and the open-close crack of Real time identification crackle impact definitely relative long-pending and frequency spectrum discerning method:

In order to identify whether gear-box and transmission part occur fatigue or crackle, monitor the drift identifying resonant frequency continuously just installing the rotating-speed tracking that carries out for a long time that on-line monitoring device cannot carry out full speed range for various parts resonance bands additional, then vibration acceleration and resonance and demodulation are asked definitely relative long-pending; Finding that vibration acceleration exceedes the definitely relatively long-pending of the same frequency of appearance simultaneously of acceleration limits value AX=8g or its vibration of half, then send 1 grade or 2 grades of warnings immediately, application on-call maintenance; Wherein, if only find, vibration acceleration is more than AX/2 and definitely relative with 1 rank of vibration acceleration same frequency long-pending more than 9kgSV, then send 1 grade of warning; If also find, vibration acceleration 1 rank are greater than 2 times of 1 rank more than AX and long-pending amplitude definitely relative to 2 rank of 1 order frequency 2 overtones band of vibration acceleration and more than 20kgSV, then send 2 grades of warnings.

Measure because Fig. 5-7 emulates: as gear mesh frequency F=950Hz, although higher than the gear-box resonance that resonant frequency FG=900Hz, power gain are less than 10, but the 1um mesh vibration of gear is still amplified to 7.28um, and the Amplitude & Phase of the amplitude fish gears meshing vibration of gear-box is contrary; The posivtive spike of 7.16um due to gear-box vibration is greater than the 5um threshold value that causes cracking and occurs that cracking impacts, and the vibration negative peak of-7.4um lower than closed impact threshold value-0.5um, so that occurs closed impact; Although almost can't see the feature that open-close crack is impacted in the amplitude waveform and Acceleration pulse of gear-box, but the resonance and demodulation of acceleration is detected and has found to correspond to crack initiation, the closed resonance and demodulation waveform impacted, the absolute value of this resonance and demodulation signal and gear-box low frequency acceleration signal product, namely, in definitely relatively long-pending waveform, all there is the pulse that corresponding 2 opening and closings of each gear cycle are impacted.Particularly, in the frequency analysis of the waveform of Fig. 5-8 couples of Fig. 5-7, show brightly: the frequency spectrum of the effect of gears meshing amplitude, the limited resonance amplitude of gear-box, the comprehensive acceleration of gear-box, gear-box low frequency acceleration is 950Hz, and resonance and demodulation is 1900Hz with definitely relative long-pending dominant frequency spectrum, only embody gear-box crackle and there is cracking, closed impact, and definitely relatively long-pending wave-shape amplitude reaches 39.4 [kgSV], 2 rank spectrums only reach 10*1.25 [kgSV].

Data statistics and warning decision-making as follows:

Measure because Fig. 5-9 emulates: as gear mesh frequency F=990Hz, although higher than the gear-box resonance that resonant frequency FG=900Hz, power gain are less than 10, but the 1um mesh vibration of gear is still amplified to 4.5um, and the amplitude of gear-box is contrary with the Amplitude & Phase that gears meshing vibrates; Posivtive spike due to the 4.46um of gear-box vibration is less than the 5um threshold value and impact of not ftractureing that cause cracking, and the vibration negative peak of-4.54um lower than closed impact threshold value-0.5um, so that occurs closed impact; Although almost can't see the feature that open-close crack is impacted in the amplitude waveform and Acceleration pulse of gear-box, but the resonance and demodulation of acceleration is detected and has found to correspond to crack initiation, the closed resonance and demodulation waveform impacted, the absolute value of this resonance and demodulation signal and gear-box low frequency acceleration signal product, namely, in definitely relatively long-pending waveform, all there is corresponding 1 the closed pulse impacted of each gear cycle.Particularly, in the frequency analysis of the waveform of Fig. 5-10 couples of Fig. 5-9, show brightly: the frequency spectrum of the effect of gears meshing amplitude, the limited resonance amplitude of gear-box, the comprehensive acceleration of gear-box, gear-box low frequency acceleration is 990Hz, and resonance and demodulation is also still 990Hz with definitely relative long-pending dominant frequency spectrum, only embody gear-box crackle and only there is closed impact, and definitely relatively long-pending wave-shape amplitude reaches 13.22 [kgSV], 1 rank spectrum only reaches 10*0.367 [kgSV].

Data statistics and warning decision-making as follows:

Measure because Fig. 5-11 emulates: as gear mesh frequency F=810Hz, although higher than the gear-box resonance that resonant frequency FG=900Hz, power gain are less than 10, but the 1um mesh vibration of gear is still amplified to 4.74um, and the amplitude of gear-box is identical with the Amplitude & Phase that gears meshing vibrates; Posivtive spike due to the 4.68um of gear-box vibration is less than the 5um threshold value and impact of not ftractureing that cause cracking, and the vibration negative peak of-4.79um lower than closed impact threshold value-0.5um, so that occurs closed impact; Although almost can't see the feature that open-close crack is impacted in the amplitude waveform and Acceleration pulse of gear-box, but the resonance and demodulation of acceleration is detected to the resonance and demodulation waveform having found to correspond to crack closure impact, the absolute value of this resonance and demodulation signal and gear-box low frequency acceleration signal product, namely, in definitely relatively long-pending waveform, all there is corresponding 1 the closed pulse impacted of each gear cycle.Particularly, in the frequency analysis of the waveform of Fig. 5-12 couples of Fig. 5-11, show brightly: the frequency spectrum of the effect of gears meshing amplitude, the limited resonance amplitude of gear-box, the comprehensive acceleration of gear-box, gear-box low frequency acceleration is 810Hz, and resonance and demodulation is also still 810Hz with definitely relative long-pending dominant frequency spectrum, only embody gear-box crackle and only there is closed impact, and definitely relatively long-pending wave-shape amplitude reaches 9.02 [kgSV], 1 rank spectrum only reaches 10*0.246 [kgSV].

Data statistics and warning decision-making as follows:

Step 5, increases the checking that resonance damping reduction resonance amplitude is reported to the police with minimizing Crack Extension;

When gear-box resonance FG=900Hz amplification factor is G=10, vibration, crackle warning message by constant amplitude (1um) vibrational excitation generation: (see accompanying drawing 5-1 ~ 5-12)

When gear-box resonance FG=900Hz amplification factor is G=5, vibration, crackle warning message by constant amplitude (1um) vibrational excitation generation: (see accompanying drawing 5-13 ~ 5-17)

More above-mentioned data:

As the dynamic magnifier G=10 of gear-box, be similar to and report to the police from F=0.9 ~ 1.1FG (risk range 0.2FG);

As the dynamic magnifier G=5 of gear-box, be similar to and report to the police from F=1.0 ~ 1.056FG (risk range 0.056FG).

Claims (7)

1. gear-box and transmission system resonance are broken automatically to scout and are identified and the precaution and controlling method, main structure contains the speed probe be arranged on gear shaft, be arranged on the vibratory impulse detecting sensor on each bearing support of gear-box, and on-line monitoring device, on-line monitoring device is connected with each sensor, rotating-speed tracking parallel mode is adopted to gather vibration and shock signal that each sensor is surveyed, with acceleration and the resonance and demodulation signal of correspondence, and export the on-line monitoring device of the control information of decision-making by analysis, it is characterized in that:

1) according to parts and this shaftgear number of teeth X of association, the key parameter of each bearing: central diameter Do, roller diameter d, roller number Z, wrapping angle a, the velocity ratio C of each gear and the rotational frequency FN of rotating speed measuring sensor corresponding gear belonging to vibratory impulse detecting sensor A, each sensor administrative bearing number B, each bearing, set up resonance multidimensional and scout the resonant frequency that matrix confirms the various parts of possibility gradual change;

2) then carrying out the continuous monitoring of full speed range for found various parts resonance bands, when finding that synchronous vibration exceeds limits value, then sending pre-alarm, and propose the rotating speed control way avoiding dangerous resonance;

3) when finding the resonant frequency of correspondence of resonant component rhegma or destruction to low drifting 2 ~ 5% and above feature, then send 1 grade or 2 grades of warning immediately, apply for on-call maintenance;

4) or just installing on-line monitoring device cannot carry out full speed range continuous monitoring for various parts resonance bands additional, but find that synchronous impact of appearance simultaneously of the violent oscillatory motion close to the resonant frequency of other homotype parts then sends 1 grade or 2 grades of warnings, application on-call maintenance immediately.

2. gear-box according to claim 1 and transmission system resonance are broken automatically to scout and are identified and the precaution and controlling method, it is characterized in that: the method for scouting matrix by setting up resonance multidimensional, confirm the resonant frequency of the various parts of possibility gradual change, its principle is that the frequency of each rank vibration utilizing any rotary component is with rotation speed change, and when this frequency and gear-box and transmission part resonant frequency close to or identical time, the judder of the gear-box excited or transmission part resonator system, and be reflected in the oscillating signal of the vibratory impulse detecting sensor A on each bearing of gear-box, when 3 kinds and above rotary component certain rank vibration frequency under different rotating speeds are close frequencies and excite gear-box or transmission part judder, then confirm that this frequency is the resonant frequency FG of gear-box or transmission part, the input stimulus of system is each rank vibration information of rotary component, gear-box and transmission system are resonator system, system exports as gear-box vibration information

Rotary component each rank vibration input stimulus characteristic frequency function is:

Protect outer vibration frequency $f=\frac{D_0-d\·\cos \mathrm{\α}}{{2D}_0}\×\mathrm{fn}\×n,n=\mathrm{1,2,3};$

Protect internal vibration frequency $f=\frac{D_0+d\·\cos \mathrm{\α}}{{2D}_0}\×\mathrm{fn}\×n,n=\mathrm{1,2,3};$

Outer shroud vibration frequency $f=\frac{D_0-d\·\cos \mathrm{\α}}{{2D}_0}\×Z\×\mathrm{fn}\×n,n=\mathrm{1,2,3};$

Inner ring vibration frequency $f=\frac{D_0+d\·\cos \mathrm{\α}}{{2D}_a}\×Z\×\mathrm{fn}\×n,n=\mathrm{1,2,3};$

Roll single vibration frequency $f=\frac{D_0^2-d^2\·{\cos }^2\mathrm{\α}}{{2D}_0\·d}\×\mathrm{fn}\×n,n=\mathrm{1,2,3};$

Roll two vibration frequency $f=\frac{D_0^2-d^2\·{\cos }^2\mathrm{\α}}{D_0\·d}\×\mathrm{fn}\×n,n=\mathrm{1,2,3};$

This tooth vibration frequency f=fn × n, n=1,2,3;

Adjacent tooth vibration frequency f=C × fn × n, n=1,2,3;

Mesh vibration frequency f=X × fn;

In formula, Do is the central diameter of bearing, and d is rolling element diameter, and α is roller contact angle, and Z is rolling element quantity, and fn is this axle speed-frequency, and C is velocity ratio, and X is this shaftgear number of teeth, and n=1,2,3 represents 1,2,3 rank of all kinds of vibration.

3. gear-box according to claim 2 and transmission system resonance are broken automatically to scout and are identified and the precaution and controlling method, according to kinematical theory, when the eigen vibration frequency of certain, each rotary component of each vibrations of rotating components source Oscillation Amplitude S is f, the acceleration of vibration source is a=-(2 π f) ²ssin (2 π ft); By formula content according to claim 2, f and fn is proportional relation, so acceleration a's and rotating speed fn is square proportional; Using the feature of mechanical second order resonator system as the theoretical foundation identifying resonance and resonant frequency: when scouting the vibration of gear-box resonator system with acceleration, the Oscillation Amplitude S in input stimulus source _m, scout the vibration acceleration a obtained _out, when there is not resonator system and affecting, S _mwith a _outtransfer function a=-(2 π f) should be met ²ssin (2 π ft), is characterized in that: if the acceleration a ' that system exports _outbe greater than the acceleration a of transfer function _outmore than 3 times time, namely think " gear-box or transmission part judder "; Frequency f corresponding to this acceleration maximum is the resonant frequency FG of resonator system, if 3 kinds and above rotary component and different vibration source can evoke " gear-box or the transmission part judder " of this FG, then prove that gear-box or transmission part resonate in frequency FG.

4. gear-box according to claim 1 and transmission system resonance are broken automatically to scout and are identified and the precaution and controlling method, it is characterized in that: the continuous monitoring carrying out full speed range for found various parts resonance bands, when finding that synchronous vibration exceeds limits value AX (such as 8 ~ 12g the peak value) that this mechanical component design specifies, then send pre-alarm; And send out and avoid the rotating speed control way of dangerous resonance to be: increase or reduce rotating speed 3 ~ 5% or more, to the vibration avoiding resonating be reduced to limits value AX 1/2 and following.

5. a kind of gear-box according to claim 1 and transmission system resonance are broken automatically to scout and are identified and the precaution and controlling method, it is characterized in that: when finding the resonant frequency of the correspondence of resonant component rhegma or destruction to low drifting 2 ~ 5% and above feature, then send 1 grade or 2 grades of warnings immediately, application on-call maintenance; For the parts of gear housing one class consolidated structures, resonant frequency sends 1 grade of warning to low drifting 2 ~ 3%, and resonant frequency is to low drifting 3 ~ 5% and send 2 grades of warnings above; Pull bar, Flexible Rotating etc. are become to the parts of resonant frequency, the relative lowest resonance frequency FGL of resonant frequency sends 1 grade of warning to low drifting 2 ~ 3%, and the relative lower resonant frequency FGL of resonant frequency is to low drifting 3 ~ 5% and send 2 grades of warnings above.

6. gear-box according to claim 1 and transmission system resonance are broken automatically to scout and are identified and the precaution and controlling method, it is characterized in that: in order to identify whether gear-box and transmission part occur fatigue or crackle, just install on-line monitoring device additional and cannot for various parts resonance bands carry out full speed range carry out for a long time rotating-speed tracking monitor the drift identifying resonant frequency continuously time, then vibration acceleration and resonance and demodulation are asked definitely relative long-pending, that is: the vibration acceleration [g] equaling energizing frequency f is multiplied with resonance and demodulation [SV] waveform that frequency equals this energizing frequency integral multiple and asks absolute value, be defined as " definitely relatively long-pending ", finding that vibration acceleration exceedes the definitely relatively long-pending of the same frequency of appearance simultaneously of the vibration of acceleration limits value AX=8 ~ 12g, then send 1 grade or 2 grades of warnings, application on-call maintenance, wherein, if only find that vibration acceleration 1 rank are more than AX/2 and definitely relative with 1 rank of vibration acceleration same frequency long-pending more than 1 grade of warning limits value JXDJ1=9kgSV, then send 1 grade of warning for gear-box, if also find, vibration acceleration 1 rank are greater than 2 times of 1 rank more than AX and long-pending amplitude definitely relative to 2 rank of 1 order frequency 2 overtones band of vibration acceleration and more than 2 grades of warning limits value JXDJ2=20kgSV, then send 2 grades of warnings,

The general formula of definitely relatively long-pending warning restriction value function is:

1 grade of warning limits value:

JXDJ1＝(0.0402[g]*8*F/100) ²*40.2[SV/g]*F/100*3；

2 grades of warning limits values:

JXDJ2＝(0.0402[g]*12*F/100) ²*40.2[SV/g]*F/100*3；

In formula, 0.0402g is the acceleration of 1um amplitude when 100Hz, and 8,12 is 1,2 grade of acceleration limits value of reporting to the police, and F is current vibration frequency [Hz], 40.2SV is the impact resonance and demodulation impact value [SV] that 0.0402g acceleration is corresponding, and 3 is engineering experience correction factor.

7. gear-box according to claim 1 and transmission system resonance are broken automatically to scout and are identified and the precaution and controlling method, accelerate the failure to prevent gear-box and transmission part under the external vibration incentive action being also difficult to reduction certainly existed, strong resonance occurring because of low resistance, it is characterized in that: identify that the method for resonance low resistance is that the output vibration carrying out the full speed range that certain vibrational excitation factor excites is carried out measurement statistics and obtained A (F), to far below resonant frequency FG's (as 1/5 ~ 1/3) and higher than resonant frequency FG (as 1.2FG and more than) the vibration performance acceleration spectrum A (F) of frequency range, make and meet B (F)=A (F) (assembly average) and B (F) ∝ F ²magnitude reference matched curve B (F), the K=A (FG) during calculated rate FG/B (FG), as " resonance power gain " K, if this resonance power gain K is greater than 3, then advise increasing damping to resonance section.Such as: to macromolecule, the low-gravity coating of the external coated high cohesion of gear-box, when it vibrates with gear-box local buckling, vibrational energy is converted into heat and scatters and disappears, effectively reduce synchronous vibration by increasing damping.