CN113447264B - Online acoustic monitoring and diagnosing method for tooth breakage fault of planetary gear box - Google Patents
Online acoustic monitoring and diagnosing method for tooth breakage fault of planetary gear box Download PDFInfo
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Abstract
An online acoustic monitoring and diagnosing method for a broken tooth fault of a planetary gear box comprises the steps of intercepting sound pressure signals of a plurality of working cycles of the planetary gear box through a shearing, filtering and normalization preprocessing method; decomposing the preprocessed sound pressure signal by using a multi-resolution singular value decomposition method, setting the optimal decomposition layer number, and obtaining a plurality of components through decomposition; calculating fault characteristic frequency of a broken tooth theory according to the structure of the planetary gearbox, constructing a reference signal based on the fault characteristic frequency, and selecting a fault component from a plurality of components by using an autoregressive model designed by the reference signal; and carrying out envelope spectrum analysis on the fault component, calculating the amplitude ratio of the fault characteristic frequency spectral line to the whole frequency spectrum spectral line, setting an amplitude ratio threshold value, and indicating that the tooth breaking fault occurs when the calculated amplitude ratio is greater than the amplitude ratio threshold value. According to the method, the state of the planetary gear box can be accurately monitored and diagnosed on line only by one sound pressure sensor, other signals do not need to be additionally measured or other monitoring devices do not need to be adopted, and the reliability of fault diagnosis is high.
Description
Technical Field
The invention relates to the technical field of acoustic monitoring and fault diagnosis of a planetary gear box, in particular to an online acoustic monitoring and diagnosis method for a broken tooth fault of the planetary gear box, which is applied to an actual engineering mechanical system.
Background
As a core device of a mechanical system, the working state of the planetary gearbox is related to the safe and stable operation of the whole mechanical system. The online monitoring and diagnosing system for the planetary gearbox can help users to find and eliminate faults in time, and plays an important role in ensuring stable and safe operation of a mechanical system. The traditional planetary gearbox monitoring technology is mainly a vibration monitoring technology, is widely applied to mechanical equipment systems such as motors, rails, automobiles, machine tools and the like, and obtains a good fault diagnosis effect, for example, in a published patent document, "a gearbox fault diagnosis method based on resonance baseband wide fourier decomposition" (CN 112539933A), a resonance baseband wide fourier decomposition method is used for monitoring and diagnosing gearbox faults by using vibration signals.
The vibration monitoring technology adopts a contact type measuring mode, however, in some practical engineering applications, the vibration monitoring technology is not suitable for being adopted when mechanical equipment is running or high corrosion, high-temperature and humid environment exist and the installation position is limited so that the accelerometer cannot be conveniently installed. At this time, a non-contact acoustic monitoring and diagnosis technology needs to be researched, for example, in a published patent document "fault diagnosis method for central transmission bevel gear of aircraft engine based on acoustic test" (CN 112284720 a), sound pressure signals are used to perform fault diagnosis for the central transmission bevel gear of aircraft engine by using order analysis, hilbert transform, envelope spectrum and cepstrum technology, however, the method needs to additionally measure rotating speed signals and introduce a sound conduit system, and the problem of endpoint effect and modal aliasing exists in an empirical mode decomposition algorithm used in hilbert transform, which affects the accuracy of fault diagnosis.
The structure of the planetary gear box is complex, the rotating speed and the load can be changed in practical engineering application, sound signals generated by gear meshing and vibration in the planetary gear box can be transmitted outwards through a complex transmission path, the sound pressure signals received by a sound pressure sensor outside the planetary gear box are weak, interference noise is high, visual and reliable sensitive characteristic information is difficult to extract from the existing acoustic monitoring and diagnosing method, and effective on-line acoustic monitoring and diagnosing can not be carried out on the running state of the planetary gear box.
Disclosure of Invention
The invention aims to provide an online acoustic monitoring and diagnosing method for a broken tooth fault of a planetary gear box, aiming at solving the technical problem of timely and accurately judging the operation state and the maintenance requirement of the planetary gear box, aiming at solving the technical problem of the existing acoustic monitoring and diagnosing technology in the process of monitoring and diagnosing the operation state of a complex planetary gear box, and providing accurate reference for the maintenance and the replacement of the planetary gear box.
The technical scheme of the invention is as follows:
an online acoustic monitoring and diagnosing method for a broken tooth fault of a planetary gearbox is characterized by comprising the following steps:
s1: collecting sound pressure signals:
measuring sound pressure signal P of planetary gear box at close distance position for a period of time by using sound pressure sensor 1 ；
S2: from sound pressure signals P by window functions 1 Sound pressure signal P of middle-shear planetary gear box in t working cycle time 2 Removing the high-frequency interference signal by using a low-pass filter to obtain a filtered sound pressure signal P 3 The sound pressure signal is normalized to [ -1, +1 ] by the following equation]Obtaining a normalized sound pressure signal P 4 ：
In the formula (1), P 4 For normalized sound pressure signal, P 3max Is a sound pressure signal P 3 Maximum value of, P 3min Is a sound pressure signal P 3 Minimum value of (d);
s3: for sound pressure signal P 4 And (3) decomposing:
determining the optimal decomposition layer number based on a noise energy ratio method, wherein a calculation formula of a noise energy ratio xi is as follows:
in the formula (2), xi is the noise energy ratio, and the xi value range is [0, 0.01 ]]J is the number of decomposition layers, E J Energy of the component decomposed for the J-th layer, E t Is the total energy of the signal to be decomposed;
calculating to obtain the optimal decomposition layer number J and J +1 decomposition components;
s4: constructing a reference signal:
calculating theoretical fault characteristic frequency f when tooth breaking fault occurs according to structure of planetary gear box fd The reference signal x (t) is constructed by:
in the formula (3), f fd Phi is a theoretical fault characteristic frequency, phi is a phase, and t is a working cycle time;
s5: selecting a fault component:
i) converting the reference signal x (t) into an autoregressive model:
in the formula (4), β i Is the coefficient of the autoregressive model, k is the order of the model, ε t Is a residual error;
ii) Z-transforming equation (4) to obtain a system function h (Z) as:
in formula (5), z is a complex variable;
iii) passing J +1 decomposition components through a system function H (z), and outputting a fault component most relevant to the reference signal and recording the fault component as C 1 ；
S6: calculating the amplitude ratio:
i) calculating the envelope spectrum ES (C) 1 )：
ES(C 1 )＝FT(|C 1 +j×h|) (6)
In equation (6), FT is Fourier transform,
ii) selecting a frequency spectrum of a frequency range, and calculating the amplitude ratio by using the following formula:
in the formula (7), A is the amplitude, A all Is the sum of the amplitudes of the entire spectral lines;
q is a value between 0 and 1, when Q is close to 0, the running state of the planetary gearbox is good, and when Q is close to 1, the running state of the planetary gearbox is poor;
s7: outputting a state monitoring result:
setting a fault alarm threshold Q 0 Comparing the amplitude ratio Q and Q obtained in step S6 0 If Q is greater than or equal to Q 0 An alarm command is sent to prompt the planetary gearbox to be repaired or replaced, otherwise, the steps S1 to S6 are repeatedly executed to monitor the running state of the planetary gearbox until the planetary gearbox is repaired or replaced.
In the technical scheme, the sound pressure signal P of the planetary gear box at the close-distance position for a period of time is measured 1 The close-range position refers to a position of the sound pressure sensor 1-3cm away from the planetary gearbox; the window function is preferablyBy usingA rectangular window, hanning window or hamming window function; the t work cycle time is preferably 8-12 work cycle times of the planetary gearbox; the low-pass filter for removing the high-frequency interference signals refers to the high-frequency interference signals which are larger than or equal to 400 Hz.
Further, the optimal number of decomposition layers J obtained by calculation in step S3 is preferably 7.
Further, the frequency spectrum of the frequency range in step S5 is preferably 20-25 times the theoretical fault characteristic frequency f fd The spectrum of the range.
Further, the failure alarm threshold Q in step S7 0 The value range of (A) is preferably 0.8-0.9 times of the amplitude ratio Q when the tooth breaking fault occurs.
Compared with the prior art, the invention has the following advantages and prominent technical effects: the online acoustic monitoring and diagnosing method provided by the invention can effectively monitor the running state of the planetary gear box in real time only by one sound pressure sensor, can early warn possible faults, does not need to additionally measure other signals or adopt other monitoring devices, and can timely and accurately judge the technical problems of the running state and the maintenance requirement of the planetary gear box, thereby providing accurate reference for the maintenance and the replacement of the planetary gear box. The acoustic monitoring and diagnosing method provided by the invention has no end effect and modal aliasing problems in an empirical mode decomposition algorithm, can accurately extract fault components and has high fault diagnosis reliability; the sound pressure sensor adopted by the invention can be arranged under the working state of the planetary gear box, is convenient and reliable to install, can greatly improve the convenience of online monitoring and diagnosis of the planetary gear box, and is suitable for practical engineering application.
Drawings
FIG. 1 is a flow chart of an online acoustic monitoring and diagnosing method for a planetary gearbox in an embodiment.
FIG. 2 shows the fault component C in the example 1 The time domain waveform of (a).
FIG. 3 shows the fault component C in the embodiment 1 The envelope spectrum of (a).
Detailed Description
The principles and operation of the present invention will be further described with reference to the drawings and examples, which are provided for illustration only and are not intended to limit the scope of the present invention.
The invention provides an online acoustic monitoring method for the operating state of a planetary gearbox, which specifically comprises the following steps:
s1: collecting sound pressure signals:
measuring sound pressure signal P of planetary gear box at close distance position for a period of time by using sound pressure sensor 1 (ii) a The close-up position is generally at the position of 1-3cm of the planetary gearbox;
s2: from sound pressure signals P by window functions 1 Sound pressure signal P of middle shear output planetary gear box in t working cycle time 2 Removing the high-frequency interference signal by using a low-pass filter to obtain a filtered sound pressure signal P 3 The sound pressure signal is normalized to [ -1, +1 ] by the following equation]Obtaining a normalized sound pressure signal P 4 ：
In the formula (1), P 4 For normalized sound pressure signal, P 3max Is a sound pressure signal P 3 Maximum value of, P 3min Is a sound pressure signal P 3 Minimum value of (d);
the window function is used for intercepting a sound pressure signal P of the planetary gear box in t working cycle time 2 Typically a rectangular window, a hanning window or a hamming window function. The t duty cycle times are preferably 8-12 duty cycle times for the planetary gearbox. And the low-pass filter is used for removing the high-frequency interference signals with the frequency of more than or equal to 400 Hz.
S3: sound pressure signal P by using multi-resolution singular value decomposition method 4 And (3) decomposing:
sound pressure signal P by multiresolution singular value decomposition method 4 The number of the components obtained after decomposition is determined by the number of decomposition layers, if the number of the decomposition layers is large, the calculated amount is large, and if the number of the decomposition layers is small, the decomposition components contain more interference noise components to influence the monitoring and diagnosis effect; determining the optimal decomposition layer number based on a noise energy ratio method, wherein a calculation formula of a noise energy ratio xi is as follows:
in the formula (2), xi is the noise energy ratio, J is the number of decomposition layers, and E J Energy of the component decomposed for the J-th layer, E t Is the total energy of the signal to be decomposed;
when the noise energy ratio xi is less than or equal to 1%, the interference noise component contained in the decomposed component does not affect the monitoring and diagnosis effect, and the value range of the noise energy ratio xi is set to be [0, 0.01 ]]Calculating to obtain the optimal decomposition layer number J of 7, and performing multi-resolution singular value decomposition on the normalized sound pressure signal P 4 After decomposition, 8 decomposition components can be obtained;
s4: constructing a reference signal:
calculating theoretical fault characteristic frequency f when tooth breaking fault occurs according to structure of planetary gear box fd Then, thenThe reference signal x (t) is constructed by:
in the formula (3), f fd Phi is the theoretical fault characteristic frequency and phi is the phase;
s5: selecting a fault component:
i) converting the reference signal x (t) into an autoregressive model:
in the formula (4), β i Is the coefficient of the autoregressive model, k is the order of the model, ε t Is a residual error;
ii) Z-transforming equation (4) to obtain a system function h (Z) as:
in formula (5), z is a complex variable;
iii) passing J +1 decomposition components through a system function H (z), and outputting a fault component most relevant to the reference signal and recording the fault component as C 1 ；
S6: calculating an amplitude ratio:
i) calculating the envelope spectrum ES (C) 1 )：
ES(C 1 )＝FT(|C 1 +j×h|) (6)
In equation (6), FT is Fourier transform,
ii) selecting a frequency spectrum of a frequency range, namely extracting 20-25 times of theoretical fault characteristic frequency f fd The following frequency spectrum, benefitThe amplitude ratio is calculated using the following equation:
in the formula (7), A is the amplitude, A all Is the sum of the amplitudes of the entire spectral lines;
q is a value between 0 and 1, when Q is close to 0, the running state of the planetary gearbox is good, and when Q is close to 1, the running state of the planetary gearbox is poor;
s7: outputting a state monitoring result:
setting a fault alarm threshold Q 0 Threshold value Q of fault alarm 0 The value range of (A) is generally 0.8-0.9 times of the amplitude ratio Q when the tooth breaking fault occurs. Comparing the amplitude ratio Q and Q obtained in step S6 0 If Q is greater than or equal to Q 0 If so, sending an alarm command to prompt the planetary gearbox to be maintained or replaced; otherwise, the steps S1 to S6 are repeatedly performed to monitor the planetary gearbox operation state until the planetary gearbox is repaired or replaced.
Example (b):
the embodiment of the invention takes a three-stage planetary gearbox in practical engineering application as an example, and the method provided by the invention is adopted to carry out online acoustic monitoring diagnosis on the three-stage planetary gearbox, and the method specifically comprises the following steps:
s1: collecting sound pressure signals:
measuring sound pressure signal P at a position 1cm away from the three-stage planetary gear box by using 1 sound pressure sensor 1 The sampling frequency is set to be 25.6kHz, the sensitivity of the sound pressure sensor is-25.8 dB (0dB ═ 1V/Pa, at 1kHz), and because the amount of the collected test data is large, only part of the data is shown in table 1;
TABLE 1 Sound pressure Signal P 1
| Data points | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 |
| P 1 (mV) | 0.0397 | 0.0306 | 0.0200 | 0.0167 | 0.0186 | 0.0203 | 0.0208 | 0.0181 | 0.0116 |
| Data points | 10 | 11 | 12 | 13 | 14 | 15 | 16 | 17 | 18 |
| P 1 (mV) | 0.0007 | -0.0068 | -0.0093 | -0.0104 | -0.0084 | -0.0054 | -0.0013 | 0.0042 | 0.0026 |
S2: using rectangular windows to derive the sound pressure signal P 1 Acoustic pressure signal P of 10 working cycles of three-stage planetary gear box is cut out in middle 2 Removing high-frequency interference signals larger than or equal to 400Hz by using a 6-order Butterworth low-pass filter to obtain a filtered sound pressure signal P 3 The sound pressure signal is normalized to [ -1, +1 ] by the following equation]Obtaining a normalized sound pressure signal P 4 ：
In the formula (1), P 4 For normalized sound pressure signal, P 3max Is a sound pressure signal P 3 Maximum value of, P 3min Is a sound pressure signal P 3 Minimum value of (d);
due to the sound pressure signal P 4 The data volume is large, and only part of the data is shown in table 2;
TABLE 2 Sound pressure Signal P 4
| Data points | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 |
| P 4 (mV) | -0.0580 | -0.0547 | -0.0513 | -0.0478 | -0.0443 | -0.0407 | -0.0371 | -0.0334 | -0.0298 |
| Data points | 10 | 11 | 12 | 13 | 14 | 15 | 16 | 17 | 18 |
| P 4 (mV) | -0.0261 | -0.0224 | -0.0187 | -0.0151 | -0.0114 | -0.0078 | -0.0042 | -0.0006 | 0.0030 |
S3: sound pressure signal P by using multi-resolution singular value decomposition method 4 And (3) decomposing:
determining the optimal decomposition layer number based on a noise energy ratio method, wherein a calculation formula of a noise energy ratio xi is as follows:
in the formula (2), xi is the noise energy ratio, J is the number of decomposition layers, and E J Energy of the component decomposed for the J-th layer, E t Is the total energy of the signal to be decomposed;
when the noise energy ratio xi is less than or equal to 1%, the interference noise component contained in the decomposed component does not affect the monitoring and diagnosis effect, and the value range of the noise energy ratio xi is set to be [0, 0.01 ]]Calculating to obtain the optimal decomposition layer number J of 7, and decomposing the sound pressure signal P by using a multi-resolution singular value decomposition method 4 8 decomposition components are obtained after decomposition;
s4: constructing a reference signal:
by calculatingTheoretical fault characteristic frequency f when tooth breaking fault occurs to the outer gear ring of the three-stage planetary gear box fd At 0.13Hz, and phase phi is set to 0, the constructed reference signal is:
s5: selecting a fault component:
i) converting the reference signal x (t) into an autoregressive model:
in the formula (4), β i Is the coefficient of the autoregressive model, k is the order of the model, ε t Is a residual error;
ii) Z-transforming equation (4) to obtain a system function h (Z) as:
in formula (5), z is a complex variable;
iii) passing 8 decomposition components through a system function H (z), and outputting a fault component most relevant to the reference signal, and recording the fault component as C 1 ；
In this embodiment, the order k of the autoregressive model is 5, and the coefficients of the 5-order autoregressive model obtained by calculation are [ -2.02567, 1.0843, -0.0999, 0.0494, -0.0082]The mean square error values obtained by passing 8 decomposition components through a system function H (z) are respectively [4.5880e-12, 7.5273e-13, 4.2112e-13, 3.1127e-13, 2.5798e-13, 2.2672e-13, 2.0618e-13, 5.3462e-08]Wherein the minimum mean square error value of the 7 th decomposition component indicates that the 7 th decomposition component is a fault component, which is denoted as C 1 The time domain waveform is shown in fig. 2;
s6: calculating an amplitude ratio:
i) calculating the envelope spectrum ES (C) using the following equation 1 )：
ES(C 1 )＝FT(|C 1 +j×h|) (6)
In equation (6), FT is Fourier transform,
ii) in this embodiment, the spectrum below 2Hz is extracted and analyzed, and the amplitude ratio is calculated by the following formula:
in the formula (7), A is the amplitude, A all Is the sum of the amplitudes of the entire spectral lines;
q is a value between 0 and 1, when Q is close to 0, the operation state of the three-stage planetary gearbox is good, when Q is close to 1, the operation state of the three-stage planetary gearbox is poor, and a fault component C is obtained through calculation 1 The envelope spectrum of (a) is as shown in fig. 3, and the amplitude ratio Q when a tooth breakage fault occurs is 0.1089;
s7: sending alarm information:
setting a fault alarm threshold Q 0 Comparing the amplitude ratio Q and Q obtained at S6 as 0.0926 0 After the size of the (B) is more than or equal to Q 0 And sending alarm information to prompt that the three-stage planetary gear box has a tooth breaking fault and needs to be maintained or replaced.
Claims (8)
1. An online acoustic monitoring and diagnosing method for a broken tooth fault of a planetary gearbox is characterized by comprising the following steps:
s1: collecting sound pressure signals:
measuring sound pressure signal P of planetary gear box at close distance position for a period of time by using sound pressure sensor 1 ；
S2: from sound pressure signals P by window functions 1 Sound pressure signal P of middle-shear planetary gear box in t working cycle time 2 Using low-pass filtersRemoving the high-frequency interference signal to obtain a filtered sound pressure signal P 3 The sound pressure signal is normalized to [ -1, +1 ] by the following equation]Obtaining a normalized sound pressure signal P 4 ：
In the formula (1), P 4 For normalized sound pressure signal, P 3max Is a sound pressure signal P 3 Maximum value of, P 3min Is a sound pressure signal P 3 Minimum value of (d);
s3: sound pressure signal P by using multi-resolution singular value decomposition method 4 And (3) decomposing:
determining the optimal decomposition layer number based on a noise energy ratio method, wherein a calculation formula of a noise energy ratio xi is as follows:
in the formula (2), xi is the noise energy ratio, and the xi value range is [0, 0.01 ]]J is the number of decomposition layers, E i Energy of the decomposed component for the ith layer, E t Is the total energy of the signal to be decomposed;
calculating to obtain the optimal decomposition layer number J and J +1 decomposition components;
s4: constructing a reference signal:
calculating theoretical fault characteristic frequency f when tooth breaking fault occurs according to structure of planetary gear box fd The reference signal x (t) is constructed by:
in the formula (3), f fd Phi is a theoretical fault characteristic frequency, phi is a phase, and t is a working cycle time;
s5: selecting a fault component:
converting the reference signal x (t) into an autoregressive model:
in the formula (4), β i Is the coefficient of the autoregressive model, k is the order of the model, ε t Is a residual error;
ii) Z-transforming equation (4) to obtain a system function h (Z) as:
in formula (5), z is a complex variable;
iii) passing J +1 decomposition components through a system function H (z), and outputting a fault component most relevant to the reference signal and recording the fault component as C 1 ；
S6: calculating an amplitude ratio:
i) calculating the envelope spectrum ES (C) 1 )：
ES(C 1 )＝FT(|C 1 +j×h|) (6)
In equation (6), FT is Fourier transform,
ii) selecting a frequency spectrum of a frequency range, and calculating the amplitude ratio Q by using the following formula:
in the formula (7), A is the amplitude, A all Is the sum of the amplitudes of the entire spectral lines;
q is a value between 0 and 1, when Q is close to 0, the running state of the planetary gearbox is good, and when Q is close to 1, the running state of the planetary gearbox is poor;
s7: outputting a state monitoring result:
is provided withFailure alarm threshold Q 0 Comparing the amplitude ratio Q and Q obtained in step S6 0 If Q is greater than or equal to Q 0 And sending an alarm command to prompt the planetary gearbox to be repaired or replaced, otherwise, repeatedly executing the steps S1 to S6 until the planetary gearbox is repaired or replaced.
2. The on-line acoustic monitoring and diagnosing method for the broken tooth fault of the planetary gearbox as claimed in claim 1, wherein: the close-range position refers to a position where the sound pressure sensor is 1-3cm away from the planetary gear box.
3. The on-line acoustic monitoring and diagnosing method for the broken tooth fault of the planetary gearbox as claimed in claim 1, wherein the method comprises the following steps: the window function is a rectangular window, a hanning window or a hamming window.
4. The on-line acoustic monitoring and diagnosing method for the broken tooth fault of the planetary gearbox as claimed in claim 1, wherein the method comprises the following steps: the t work cycle time is 8-12 work cycle times of the planetary gearbox.
5. The on-line acoustic monitoring and diagnosing method for the broken tooth fault of the planetary gearbox as claimed in claim 1, wherein the method comprises the following steps: the high-frequency interference signal is a signal greater than or equal to 400 Hz.
6. The on-line acoustic monitoring and diagnosing method for the broken tooth fault of the planetary gearbox as claimed in claim 1, wherein the method comprises the following steps: the optimal number of decomposition layers J is 7.
7. The on-line acoustic monitoring and diagnosing method for the broken tooth fault of the planetary gearbox as claimed in claim 1, wherein the method comprises the following steps: the frequency spectrum of the frequency range is 20-25 times of theoretical fault characteristic frequency f fd The spectrum of the range.
8. The on-line acoustic monitoring and diagnosing method for the broken tooth fault of the planetary gearbox as claimed in claim 1, wherein the method comprises the following steps: the failure alarm thresholdValue Q 0 The value range of (A) is 0.8-0.9 times of the amplitude ratio Q when the tooth breaking fault occurs.
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