CN105521997A - Method for diagnosing faults of rolling mill roller system on basis of vibration signals - Google Patents

Method for diagnosing faults of rolling mill roller system on basis of vibration signals Download PDF

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CN105521997A
CN105521997A CN201410520511.6A CN201410520511A CN105521997A CN 105521997 A CN105521997 A CN 105521997A CN 201410520511 A CN201410520511 A CN 201410520511A CN 105521997 A CN105521997 A CN 105521997A
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roll
vibration
speed
frame
rolling mill
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CN105521997B (en
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陈孝明
全基哲
李山青
尤天星
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Baoshan Iron and Steel Co Ltd
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Baoshan Iron and Steel Co Ltd
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Abstract

A method for diagnosing faults of a rolling mill roller system on the basis of vibration signals comprises the steps of (a) conducting parameter initialization including setting of the relation between machine frame alarm reference values and motor rotating speeds and setting of the machine frame reduction gearbox reduction ratio; (b) collecting signals including machine frame vibration signals, motor rotating speed signals and roller diameter information; (c) conducting data pretreatment including conversion between sensor electric signals and actual values, vibration signal offset removal, noise filtering and the like; (d) calculating a vibration waveform peak-to-peak value; (e) conducting alarm judgment, and determining that abnormal vibration occurs if the vibration waveform peak-to-peak value exceeds the alarm reference value at the corresponding rotating speed; (f) determining the vibration type, and recording the period of the abnormal vibration signals if abnormal vibration is periodic; (g) calculating the rotating periods Tj of rollers; (h) comparing the periods, and if the period of the abnormal vibration signals is equal to the rotating period of the rollers of one certain type in a corresponding machine frame, determining that abnormal vibration is possibly caused by the rollers of the type; and (i) confirming the correlation and determining the anomaly of the roller system.

Description

A kind of method based on vibration signal diagnosis roller system of rolling mill fault
Technical field
The invention belongs to roller system of rolling mill fault diagnosis field, be specifically related to a kind of method based on vibration signal diagnosis roller system of rolling mill fault.
Background technology
Rolling mill vibration is one of ubiquitous problem in the operation of rolling, serious problem is brought to production, the most outstanding performance is the surface vibration line caused by rolling mill vibration, even causes the fractures such as band steel, bring serious adverse effect to the continuity of producing and other aspects time serious.
Because rolling mill vibration occurrence cause is comparatively complicated, the expert of countries in the world and researcher are devoted to the research of rolling mill vibration, attempt the possible cause of reasonable dismissal rolling mill vibration and propose effectively to draw up vibration measure, by up to the present, there is no special effective method or measure can fundamentally solve rolling mill vibration problem, maximum methods is used to be monitored rolling mill vibration situation by a set of rolling mill vibration monitoring system so far, by carrying out data analysis to the vibration signal monitored, judge the Vibration Condition of milling train, when rolling mill vibration value exceedes setting value, then report to the police, thus remind operating personnel to adopt corresponding measure to avoid causing batch production accident because of rolling mill vibration, but the research that the current concrete analysis application aspect of related researcher on rolling mill vibration signal is carried out is little, the method realizing roller system of rolling mill fault diagnosis based on vibration signal was not proposed.
Chinese patent CN103115668A discloses " the fault signature extracting method of milling train oscillation mark vibration signal and recognition methods ", it is the demodulation method based on second-order cyclic auto-correlation function, frequency demodulation is carried out to the oscillation mark vibration signal of non-stationary and carries out time domain section, improve the degree of accuracy that oscillation mark vibration signal fault signature extracts, and propose to adopt the form of power spectral information entropy to carry out alarm decision, but do not propose the identification recognition methods of concrete fault in patent, more cannot diagnose roller system fault accurately.
Chinese patent CN201179527Y discloses a kind of tandem-mill strip-steel vibration marks monitoring warning device, by the acquisition process to signals such as rolling mill vibration, rotating speed, roller footpath, coil of strip information, realize the early warning that vibration line phenomenon is produced, but in patent, do not propose the method for vibration signal on Research on failure diagnosis of rolling mill.
Chinese patent CN200710176052.4 proposes a kind of expert system being applicable to rotating machinery vibrating failure diagnosis, but does not provide the concrete diagnostic method of vibration signal on rotating machinery fault.
In sum, still lacking the roller system fault of effective means to milling train carries out quick diagnosis at present, therefore, be badly in need of a kind of diagnostic method for roller system of rolling mill fault, not only to realize the on-line monitoring of roller system of rolling mill state, and warning can be provided in time when roller system is abnormal, avoid because roller system of rolling mill is abnormal and cause batch production accident.
Summary of the invention
The object of the present invention is to provide a kind of method based on vibration signal diagnosis roller system of rolling mill fault, by calculating the rotation period of each roll in the analyzing and processing of rolling mill vibration signal and roller system, realizing the diagnosis of roller system of rolling mill fault.
For achieving the above object, technical scheme of the present invention is:
Based on a method for vibration signal diagnosis roller system of rolling mill fault, it is characterized in that, comprise the steps:
A) parameter initialization
Comprise corresponding relation G between each rack alarm reference value and motor speed i(v) setting, each frame reduction gear box speed reducing ratio n isetting, wherein v is motor speed, and i is shelf number;
B) signals collecting
Comprise each frame vibration signal X i(t), each gantry motor tach signal v i(t), each breast roll footpath information D ijcollection, wherein, D ijrepresent the diameter of the jth roll in No. i-th frame;
C) data prediction
Comprise the conversion between each sensor electrical signal and actual value, the biased removal, noise filtering etc. of vibration signal, the average of motor speed signal solves, and obtains each frame vibration waveform X ' after having processed i(t), each frame average motor rotating speed
D) vibrational waveform peak-to-peak value F icalculate
Comprise each frame process complete after vibrational waveform X ' it () peak-to-peak value calculates, namely calculate maximum X ' in this scope internal vibration waveform i (max)with minimum of a value X ' i (min)between difference, F i=X ' i (max)-X ' i (min);
E) alarm decision
If vibrational waveform peak-to-peak value exceedes the warning reference value under corresponding rotating speed, namely then think and carry out vibration alarming by generation abnormal vibrations; Otherwise ignore;
Wherein, according to each frame average motor rotating speed and the corresponding relation G between each rack alarm reference value and motor speed iv () obtains;
F) oscillatory type judges
According to alarm, checking vibrational waveform, whether be periodically, if periodicity abnormal vibrations, then remember that its cycle is T if observing abnormal vibrations;
G) all types of roll rotation cycle T in corresponding breast roll system is calculated j
Calculate working roll rotating speed according to motor speed and milling train reduction gear box speed reducing ratio, thus calculate working roll rotation period T a, namely
T a = 60 v i ‾ n i
Wherein, for motor speed, unit: rpm;
N ifor the speed reducing ratio of corresponding milling train;
Again, according to roll surface speed principle and roller footpath information, roll surface speed can be known:
v ′ = π D a T a = π D b T b
That is, T b = T a D b D a
Wherein, v ' is roll surface speed, unit: mm/s;
D a, D bbe respectively the diameter of working roll, other types roll, unit: mm;
T a, T bbe respectively the rotation period of working roll, other types roll, unit: s;
H) period ratio comparatively
If a certain type roll rotation cycle T in abnormal transient vibration signal cycle T and corresponding frame jequal, then think that abnormal vibrations may be caused by the type roll;
I) correlation confirms and the unusual determination of roller system
Observe T and T jcorrelation under different mill speed, if both cycles are all relevant to motor speed, and still keeps equal between the two, then can confirm that abnormal vibrations is caused by this roll.
In the methods of the invention:
Described step a) in warning reference value G iv () refers to the setting value judged for milling train abnormal vibrations, consider the increase along with stand motor rotating speed v, Mill chattering amplitude also can increase, therefore for improving abnormal vibrations warning accuracy rate, therefore, under different rotating speeds v, need to be set in different warning reference values.
Warning reference value G ithe numerical values recited of (v) determine mainly according to milling train when no exceptions is vibrated, its maximum vibration acceleration at various speeds and the difference G ' of minimum vibration acceleration iv the corresponding relation between () and rotating speed v carries out determining, consider the impact of random noise simultaneously, and ensure warning accuracy rate, usual G i(v)=(2 ~ 3) G ' i(v).
Described step a) middle speed reducing ratio by searching the mechanical drawing of each milling train, can obtain its speed reducing ratio, thus can obtain the corresponding relation between the rotating speed of working roll and motor speed.
Tell step b) in vibration signal can gather the vibration signal of milling train by arranging an acceleration transducer on mill housing, rolling mill vibration signal is mainly used in follow-up vibration and judges.
Described step b) in motor speed signal can directly collect from mill control system, the size of motor speed can affect the size of warning reference value.
Described step b) in roller footpath information milling train shut down roll change time carry out record.
Described step c) in signal length choose should try one's best shorter, avoid two abnormal vibrations waveforms to be added up within the scope of one as far as possible simultaneously, but too short signal length declines to the susceptibility of low-frequency vibration signal, the data length being generally used for analyzing is between 0.1 ~ 0.5s.
Described step c) in each sensor electrical signal and actual value between conversion, refer to the demarcation of corresponding relation between the signal of telecommunication result of sensor measurement and actual value, the biased removal of vibration signal, noise filtering are conventional digital signal processing methods, for DC-offset correction component and high-frequency noise, it is that tachometer value by this segment length is averaged that the average of motor speed signal solves, thus obtain a mean speed, thus for determining the vibration alarming reference value corresponding to this section of vibration data;
Described step c) in tach signal pretreatment mainly refer to that carrying out average to the rate signal of gathered certain length solves, thus determine the warning reference value corresponding to this segment data.
Described step g) in other types roll generally refer to intermediate calender rolls, backing roll in milling train except working roll.
Further, described step g) in be the calculating carrying out the various roll rotation cycle for the milling train of working roll actuation types, for the milling train of other types roll transmission, also can calculate the rotation period of each roll by similar principle.
The invention has the beneficial effects as follows:
1., by the gather and analysis to each frame vibration, tach signal, achieve the on-line monitoring of roll running status.
2. by the monitoring of the inventive method breaker roll running status, provide warning in time when roll exists abnormal, thus avoid because roller system of rolling mill is abnormal and cause batch production accident.
3., by gather and analysis to each frame vibration, tach signal, give a kind of roller system fault diagnosis method, thus can the frame at the abnormal roll place of quick position and roll type.
4. orient frame and the roll type at abnormal roll place according to the inventive method, guidance can be provided for mill roll.
5. because the inventive method is to the Real-Time Monitoring of rolling mill vibration signal, by analyzing the vibrational waveform characteristic monitored, can as a kind of milling train mechanical fault diagnosis householder method, for searching other failure causes beyond roller system fault.
Accompanying drawing explanation
Fig. 1 is the flow chart that the present invention is based on vibration signal diagnosis roller system of rolling mill fault method.
Fig. 2 is the motor speed of certain milling train in the embodiment of the present invention one when being about the 355rpm vibrational waveform figure of continuous five seconds.
Fig. 3 is the motor speed of certain milling train in the embodiment of the present invention one when being about the 451rpm vibrational waveform figure of continuous five seconds.
Detailed description of the invention
See Fig. 1, roller system of rolling mill method for diagnosing faults of the present invention comprises the following steps:
A) corresponding relation G between each rack alarm reference value and motor speed is set i(v), each frame gearratio n i.
B) the vibration signal X of each frame vertical direction is gathered i(t), motor speed signal v i(t), each breast roll footpath information D ij.
C) each frame gets the signal of certain length respectively, carries out pretreatment to gathered data, obtains each frame vibration waveform X ' after having processed i(t) and tach signal
D) peak-to-peak value within the scope of this sampling period is calculated, i.e. maximum X ' in vibrational waveform i (max)with minimum of a value X ' i (min)between difference, F i=X ' i (max)-X ' i (min).
E) F is compared iwith size, if then think and carry out generation abnormal vibrations vibration alarming, otherwise ignore.
F) according to alarm, checking vibrational waveform, whether be periodically, if periodicity abnormal vibrations, then remember that its cycle is T if observing abnormal vibrations.
G) calculate working roll rotating speed according to motor speed and milling train reduction gear box speed reducing ratio, thus calculate working roll rotation period T a, namely
T a = 60 v i ‾ n i
Wherein, for motor speed, unit: rpm;
N ifor the speed reducing ratio of corresponding milling train;
Again, according to roll surface speed principle and roller footpath information, roll surface speed can be known:
v ′ = π D a T a = π D b T b
That is, T b = T a D b D a
Wherein, v ' is roll surface speed, unit: mm/s;
D a, D bbe respectively the diameter of working roll, other types roll, unit: mm;
T a, T bbe respectively the rotation period of working roll, other types roll, unit: s;
Other types milling train can calculate the swing circle of all types of roll according to similar principles.
H) abnormal transient vibration signal cycle T and each roll rotation cycle T in corresponding breast roll system is compared jif there is a certain roll rotation cycle T jconsistent with abnormal transient vibration signal cycle T, then think that abnormal vibrations may be caused by this roll.
I) T and T is observed further jcorrelation under different mill speed, if both cycles are all relevant to motor speed, and relation between the two still remains unchanged, then can confirm that abnormal vibrations is caused by this roll.
Enumerate following examples below again to be described further the inventive method:
The work roll diameter d of certain six-high cluster mill 1be about 450mm, intermediate calender rolls diameter d 2be about 530mm, backing roll diameter d 3be about 1350mm, gearbox speed reduction ratio is 0.77, and when producing, milling train exists abnormal sound, is analyzed rolling mill vibration signal by following steps, successfully diagnoses roller system of rolling mill failure cause.
Parameter initialization sets, and the warning reference value setting this frame is 0.2g, speed reducing ratio is 0.77, according to parameters such as sensor calibration result setting sensor sensitivity.
Rolling mill vibration signal, motor speed signal is gathered with the frequency acquisition of 2048Hz.
Rolling mill vibration signal, the motor speed signal got 0.5 second carry out data prediction, and motor speed is 355rpm.
Peak-to-peak value F=0.31g is calculated to the vibrational waveform processed.
Peak-to-peak value result of calculation exceeds alarm setting value, therefore it is determined that the presence of abnormal vibrations.
Vibrational waveform data in 5 seconds are observed, as shown in Figure 2, finds that this abnormal vibrations has obvious periodicity.
Therefrom can observe abnormal vibrations cycle T is 0.66 second, according to motor speed and speed reducing ratio, calculates working roll cycle T 1=60/ (355 × 0.77)=0.22 second, intermediate calender rolls cycle T 2=0.22 × 0.53/0.45=0.26 second, roller cycle T between support 3=0.22 × 1.35/0.45=0.66 second.
Find that the cycle of backing roll and abnormal vibrations is equal through comparing, this frame backing roll of preliminary judgement exists abnormal.
After motor speed is raised to 451rpm, the abnormal vibrations cycle becomes 0.52s, as Fig. 3, recalculates working roll cycle T 1=60/ (451 × 0.77)=0.17 second, intermediate calender rolls cycle T 2=0.17 × 0.53/0.45=0.2 second, backing roll cycle T 3=0.17 × 1.35/0.45=0.51 second, be still consistent with the abnormal vibrations cycle, therefore judge that backing roll exists abnormal.
Carry out lower machine check to this frame backing roll, find that peeling off appears in backing roll roll surface, the method judgment accuracy is verified.

Claims (2)

1., based on a method for vibration signal diagnosis roller system of rolling mill fault, it is characterized in that, comprise the steps:
A) parameter initialization
Comprise corresponding relation G between each rack alarm reference value and motor speed i(v) setting, each frame reduction gear box speed reducing ratio n isetting, wherein v is motor speed, and i is shelf number;
B) signals collecting
Comprise each frame vibration signal X i(t), each gantry motor tach signal v i(t), each breast roll footpath information D ijcollection, wherein, D ijrepresent the diameter of the jth roll in No. i-th frame;
C) data prediction
Comprise the conversion between each sensor electrical signal and actual value, the biased removal, noise filtering etc. of vibration signal, the average of motor speed signal solves, and obtains each frame vibration waveform X ' after having processed i(t), each frame average motor rotating speed
D) vibrational waveform peak-to-peak value F icalculate
Comprise each frame process complete after vibrational waveform X ' it () peak-to-peak value calculates, namely calculate maximum X ' in this scope internal vibration waveform i (max)with minimum of a value X ' i (min)between difference, F i=X ' i (max)-X ' i (min);
E) alarm decision
If vibrational waveform peak-to-peak value exceedes the warning reference value under corresponding rotating speed, namely then think and carry out vibration alarming by generation abnormal vibrations; Otherwise ignore;
Wherein, according to each frame average motor rotating speed and the corresponding relation G between each rack alarm reference value and motor speed iv () obtains;
F) oscillatory type judges
According to alarm, checking vibrational waveform, whether be periodically, if periodicity abnormal vibrations, then remember that its cycle is T, unit: second if observing abnormal vibrations;
G) all types of roll rotation cycle T in corresponding breast roll system is calculated j
Calculate working roll rotating speed according to motor speed and milling train reduction gear box speed reducing ratio, thus calculate working roll rotation period T a, namely
T a = 60 v i n i
Wherein, v ifor motor speed, unit: rpm;
N ifor the speed reducing ratio of corresponding milling train;
Again according to roll surface speed principle and roller footpath information, roll surface speed can be known:
v ′ = πD a T a = πb b T b
Namely T b = T a D b D a
Wherein, v ' is roll surface speed, unit: mm/s;
D a, D bbe respectively the diameter of working roll, other types roll, unit: mm;
T a, T bbe respectively the rotation period of working roll, other types roll, unit: s;
H) period ratio comparatively
If a certain type roll rotation cycle T in abnormal transient vibration signal cycle T and corresponding frame jequal, then think that abnormal vibrations may be caused by the type roll;
I) correlation confirms and the unusual determination of roller system
Observe T and T jcorrelation under different mill speed, if both cycles are all relevant to motor speed, and still keeps equal between the two, then can confirm that abnormal vibrations is caused by this roll.
2. as claimed in claim 1 based on the method for vibration signal diagnosis roller system of rolling mill fault, it is characterized in that, described step g) in be carry out various roll rotation computation of Period for the milling train of working roll actuation types, for the milling train of other types roll transmission, similar computational methods also can be adopted to obtain the rotation period of each roll.
CN201410520511.6A 2014-09-30 2014-09-30 A kind of method based on vibration signal diagnosis roller system of rolling mill failure Active CN105521997B (en)

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107461342A (en) * 2017-08-16 2017-12-12 江苏大学 A kind of centrifugal pump fault inline diagnosis method and system
CN107618922A (en) * 2017-07-21 2018-01-23 东莞建晖纸业有限公司 Paper machine changes roll speed scaling method
CN109883688A (en) * 2017-12-06 2019-06-14 上海金艺检测技术有限公司 The Fault Locating Method of cold rolling tension roll gearbox output shaft system impact vibration
CN111922095A (en) * 2020-07-14 2020-11-13 上海数深智能科技有限公司 Vibration diagnosis method for abnormal torsional vibration fault of roller of cold rolling mill
CN114088192A (en) * 2021-10-12 2022-02-25 向量传感科技(宁波)有限公司 Vibration monitoring protection system and method and storage medium

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CN201179527Y (en) * 2007-12-04 2009-01-14 上海宝钢工业检测公司 Continuous rolling mill strip steel vibrating vein monitoring early warning apparatus
CN103115668A (en) * 2013-01-22 2013-05-22 重庆大学 Fault feature extraction method and fault feature recognition method of vibration signal of rolling mill chatter mark
CN103331310A (en) * 2013-07-13 2013-10-02 吉林大学 Magnesium alloy plate rolling parameter monitoring and fault diagnosing system and method

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH1112977A (en) * 1997-06-25 1999-01-19 Dr Seisakusho:Kk Doctor device with function to detect sticking of foreign material
TW462900B (en) * 2000-10-11 2001-11-11 China Steel Corp Vibration diagnosis method for abnormality or malfunctions of roller of hot rolling machine for steel strip
CN101135601A (en) * 2007-10-18 2008-03-05 北京英华达电力电子工程科技有限公司 Rotating machinery vibrating failure diagnosis device and method
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CN103115668A (en) * 2013-01-22 2013-05-22 重庆大学 Fault feature extraction method and fault feature recognition method of vibration signal of rolling mill chatter mark
CN103331310A (en) * 2013-07-13 2013-10-02 吉林大学 Magnesium alloy plate rolling parameter monitoring and fault diagnosing system and method

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107618922A (en) * 2017-07-21 2018-01-23 东莞建晖纸业有限公司 Paper machine changes roll speed scaling method
CN107461342A (en) * 2017-08-16 2017-12-12 江苏大学 A kind of centrifugal pump fault inline diagnosis method and system
CN107461342B (en) * 2017-08-16 2019-05-31 江苏大学 A kind of centrifugal pump fault inline diagnosis method and system
CN109883688A (en) * 2017-12-06 2019-06-14 上海金艺检测技术有限公司 The Fault Locating Method of cold rolling tension roll gearbox output shaft system impact vibration
CN109883688B (en) * 2017-12-06 2021-12-07 上海金艺检测技术有限公司 Fault positioning method for cold rolling tension roller gear box output shaft system impact vibration
CN111922095A (en) * 2020-07-14 2020-11-13 上海数深智能科技有限公司 Vibration diagnosis method for abnormal torsional vibration fault of roller of cold rolling mill
CN114088192A (en) * 2021-10-12 2022-02-25 向量传感科技(宁波)有限公司 Vibration monitoring protection system and method and storage medium

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