CN115046764A - Early fault diagnosis method for rolling bearing - Google Patents
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Abstract
The invention discloses a rolling bearing early fault diagnosis method, which belongs to the technical field of mechanical state monitoring, and aims to overcome the defect that the traditional evaluation index is insensitive to early faults. And then, by utilizing a continuous alarm frequency triggering mechanism, the early failure of the rolling bearing can be accurately and reliably monitored by using a smaller triggering frequency. The research result of the invention in the aspect of early fault diagnosis of the rolling bearing lays a foundation for realizing the residual life prediction of the rolling bearing.
Description
Technical Field
The invention belongs to the technical field of mechanical state monitoring, and particularly relates to an early fault diagnosis method for a rolling bearing.
Background
The rolling bearing is used as a key component in a transmission system of mechanical equipment, and is widely applied to the mechanical equipment. The working environment of the rolling bearing is often very complex, and the rolling bearing is usually continuously operated under the conditions of high rotating speed and high load, so that faults are easy to occur. When it is in a fault operation state, it has a serious influence on the health condition of the rotating mechanical equipment, and even finally leads to the failure of the equipment. In view of this, in order to ensure the safety and reliability of the equipment and avoid the occurrence of catastrophic accidents, the working state of the bearing must be strictly monitored, and preferably real-time online detection is performed to prevent accidents caused by rolling bearing failures.
Early fault monitoring and diagnosis of the rolling bearing are hot spots in research in the current industrial field, particularly, with the development of intelligent technology, the automation degree of mechanical equipment is higher and higher, and the rolling bearing is a key component of the mechanical equipment, so that higher requirements are also put forward on the running state monitoring of the rolling bearing. The fault features commonly used by engineers at present are time domain features, frequency domain features and time-frequency domain features. When the early fault occurs in the running of the rolling bearing, the fluctuation of the vibration signal is weak, and the difference between the extracted characteristic parameter value of the early fault and the characteristic parameter value in the stationary period is not large. For different bearings and different working conditions of the same type of bearings, the performance changes of the characteristics are large, and no general indicator effectively reflects the running state of the bearings in different states. If these characteristics of the signal are used directly, they are not sensitive to early failure of the rolling bearing, which can lead to missed detection of early failure, and thus detection can only be made if the rolling bearing fails significantly. Most of the characteristics are isolated and not connected with each other, and the multi-dimensional characteristic information is slightly redundant. A continuous trigger mechanism adopted in engineering is used for judging early faults of machinery, namely when M continuous indexes exceed a threshold value, the early faults are indicated. However, the value of M is generally large, and the judgment cannot be performed by using a small value of M. The above-described disadvantage may greatly affect the ability to detect an early failure time, and the discrimination accuracy thereof may be degraded.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide an accurate and rapid early fault diagnosis method for a rolling bearing.
In order to achieve the purpose, the technical scheme of the invention comprises the following steps:
1) and acquiring initial vibration data S of the whole life cycle of the rolling bearing. Selecting p pieces of history data collected initially, extracting A pieces of characteristics to form an original characteristic index set F ═ (F) 1 ,f 2 ,...,f i ) 1,2, a, wherein f i ＝(f i1 ,f i2 ,...,f ip )。
2) Performing Gaussian denoising algorithm smoothing processing on each feature in the original feature set F to obtain F ═ F' 1 ,f 2 ',...,f i ')。
Then, each feature in the feature set F' is subjected to evolution accumulation summation technology conversion processing to obtain CF ═ CF 1 ,cf 2 ,...,cf i )。
3) Calculating Pearson correlation coefficients of A-1 features of the root mean square of the evolution cumulative sum and other evolution cumulative sum transformation in the feature set, setting a preset threshold q, and reserving B features larger than the threshold q to obtain a new feature index set CF ═ (CF ═ CF 1 ,cf 2 ,...,cf B )。
4) And (4) carrying out principal component analysis calculation on the new characteristic index set CF', and selecting a difference array of the first principal component array as the health index HI. Calculating to obtain the average value of the health index by using p-1 historical data of the health index
And standard deviation sigma, calculating initial threshold
Calculating A characteristics of the new vibration signal collected in real time, adding the A characteristics into F', still utilizing the characteristic set selected from the steps 1) to 3), and having p +1 values in each characteristic. And then, performing principal component analysis and calculation on the characteristics, taking the first principal component of the characteristics, and calculating the difference number of the first principal component as a new health index HI'.
If there are consecutive 3 values of HI' m 、HI' m+1 And HI' m+2 Exceeding the threshold T indicates a time T m Early failure of the rolling bearing occurs. And if no continuous 3 values exceed the threshold value T, reading the next vibration signal, calculating A characteristics of the new vibration signal, adding the A characteristics to the last F', reusing the characteristic sets selected in the steps 1-3, then carrying out principal component analysis calculation on the characteristics, and calculating the health index until the continuous 3 health index values exceed the threshold value T. .
Further, the features in step 1) include 14 time-domain features and 4 frequency-domain features.
The 14 time domain features include 10 dimensional time domain features, which are respectively root mean square, maximum value, minimum value, average value, peak-to-peak value, absolute average value, variance, standard deviation, kurtosis and skewness, and the specific expression is as follows:
root mean square value
Maximum value F 2 ＝max(x(i))；
Minimum value F 3 Min (x (i)); mean value
Peak to peak value F 5 Max (x (i)) -min (x (i)); absolute mean value
Variance (variance)
Standard deviation of
Kurtosis
Deflection degree
The 4 dimensionless time domain characteristics are a form factor, a peak factor, a pulse factor and a margin factor respectively, and the specific expression is as follows:
form factor
Crest factor
Pulse factor
Margin factor
Among these characteristic parameters are those that are sensitive to early bearing failure, such as kurtosis, peaks, margin factors, and impulse factors, but are primarily directed to impact-type failures. There are also characteristic parameters that change more steadily during the overall degradation process, such as root mean square values, which change correspondingly as the degree of bearing wear increases. Therefore, these indexes are generally used in combination in consideration of both sensitivity and stability.
The 4 frequency domain features include the mean frequency, center of gravity frequency, root mean square frequency, and frequency standard deviation. In order to obtain the frequency domain characteristics of the vibration signal, the time domain signal may be subjected to a fourier transform FFT to obtain a frequency domain signal. The specific expression is as follows:
mean frequency
Frequency of center of gravity
Root mean square frequency
Standard deviation of frequency
Wherein f is k And s (k) is the frequency value corresponding to the k-th spectral line, and s (k) is the corresponding frequency amplitude.
k＝1,2,...,N fft ，N fft Is the length of the spectral signal.
Frequency characteristic F 15 Reflecting the magnitude of the frequency vibration energy, F 16 ～F 17 Reflecting the change of the position of the main frequency band, F 18 Reflecting the degree of spectral dispersion.
Further, in the step 2), smoothing is performed by using a gaussian denoising algorithm, that is, a gaussian weighted moving average filter, and the process is as follows:
let the sliding window length be n. When n is even or odd:
where G is a weight vector satisfying a Gaussian distribution, f i ' is the feature of the ith feature after the smoothing of the Gaussian weighted moving average filter. The expression of the gaussian weight vector G is:
where A is the normalized coefficient, a is the width of the Gaussian denoising window,
and the formula of the evolution cumulative sum algorithm is as follows:
wherein
The average value of the ith characteristic of the bearing in the initial operation period is taken;
further, the formula of the pearson correlation coefficient in step 3) is as follows:
where k is the length of the feature x (i),
and
are the mean values of x (i) and y (i), respectively. The Pearson correlation coefficient has a value range of [ -1,1 [)]. The closer the absolute value of the correlation coefficient is to 1, the higher the correlation degree of x and y is; the closer the absolute value of the correlation coefficient is to 0, the lower the correlation of x with y.
The invention has the advantages that: firstly, smoothing noisy signals by using a Gaussian weighted moving average filter, secondly, transforming the characteristics by using an evolution accumulation addition and transformation technology, overcoming the defect that the traditional evaluation index is insensitive to early faults, secondly, converting multidimensional characteristics into single-dimensional characteristics by using a principal component analysis method in order to fully fuse characteristic information of a time domain and a frequency domain, and taking a difference array as a health index, wherein the change of early degradation of the rolling bearing can be represented to the maximum extent. And finally, a continuous alarm frequency triggering mechanism is utilized, and the early failure of the rolling bearing can be accurately and reliably monitored only by using a small triggering frequency, so that the interference of external factors such as noise and the like is overcome, and the early failure can be rapidly judged.
Drawings
FIG. 1 is a flow chart of the method of the present invention;
FIG. 2 is a graph of vibration signals monitored by two sets of test bearings according to an embodiment;
FIG. 3 is a diagram showing the result of the judgment of the bearing early failure occurrence time by the method of the present invention in the bearing 1 according to the embodiment of the present invention;
FIG. 4 is a diagram showing the result of the judgment of the bearing early failure occurrence time by the method of the present invention in the bearing 2 of the embodiment.
Detailed description of the invention
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be described in further detail with reference to the accompanying drawings.
The general flow chart of the method for diagnosing the early failure of the rolling bearing is shown in figure 1, and the technical scheme and the implementation steps of the method are as follows:
and 4, constructing a new health index by utilizing a principal component analysis technology, calculating a threshold value, and monitoring early faults of the rolling bearing in real time by utilizing a continuous alarm frequency triggering mechanism.
The respective steps are explained in detail one by one below.
Step 1: data are derived from PHM 2012PRONOSTIA rolling bearing accelerated life test rig. In the full-life accelerated life experiment, the sampling frequency of the acceleration sensor is 25.6kHz, the sampling time is 0.1s, the sampling interval is 10s, and 2560 points are sampled each time. The shaft speed was 1800rmp and the bearing radial load was 4000N.
We use two degradation trends for the bearing embodiment, one is slow degradation and one is sudden degradation, as shown in fig. 2 for bearing 1 and bearing 2 respectively. As can be seen from the figure, when the bearing initially runs, the vibration signal is stable and is in a normal running state; over time, the amplitude of the vibration signal is gradually increased or suddenly increased, and at the moment, the rolling bearing is in a failure state and is in a degradation state.
Selecting 150 pieces of history data collected initially, extracting 18 pieces of characteristics to form an original characteristic index set F ═ (F) 1 ,f 2 ,...,f i ) 1,2, 18, wherein f i ＝(f i1 ,f i2 ,...,f i150 )。
The 18 features include 14 time domain features and 4 frequency domain features.
The 14 time domain features include 10 dimensional time domain features, which are respectively root mean square, maximum value, minimum value, average value, peak-to-peak value, absolute average value, variance, standard deviation, kurtosis and bias, and the specific expression is as follows:
root mean square value
Maximum value F 2 ＝max(x(i))；
Minimum value F 3 Min (x (i)); mean value
Peak to peak value F 5 Max (x (i)) -min (x (i)); absolute mean value
Variance (variance)
Standard deviation of
Kurtosis
Deflection degree
The 4 dimensionless time domain characteristics are a form factor, a peak factor, a pulse factor and a margin factor respectively, and the specific expression is as follows:
form factor
Crest factor
Pulse factor
Margin factor
Among these characteristic parameters are those that are sensitive to early bearing failure, such as kurtosis, peaks, margin factors, and impulse factors, but are primarily directed to impact-type failures. There are also characteristic parameters that change more steadily during the overall degradation process, such as root mean square values, which change correspondingly as the degree of bearing wear increases. Therefore, these indexes are generally used in combination in consideration of both sensitivity and stability.
The 4 frequency domain features include the mean frequency, center of gravity frequency, root mean square frequency, and frequency standard deviation. In order to obtain the frequency domain characteristics of the vibration signal, the time domain signal may be subjected to a fourier transform FFT to obtain a frequency domain signal. The specific expression is as follows:
mean frequency
Frequency of center of gravity
Root mean square frequency
Standard deviation of frequency
Wherein f is k And s (k) is the frequency value corresponding to the k-th spectral line, and s (k) is the corresponding frequency amplitude value.
k＝1,2,...,N fft ，N fft Is the length of the spectral signal.
Frequency characteristic F 15 Reflecting the magnitude of the frequency vibration energy, F 16 ～F 17 Reflecting the change of the position of the main frequency band, F 18 Reflecting the degree of spectral dispersion.
And 2, step: performing Gaussian denoising algorithm smoothing processing, namely Gaussian weighted moving average filtering, on each feature in the original feature set F to obtain F ═ (F' 1 ,f 2 ',...,f i ') the procedure is as follows:
let the sliding window length be 45.
Where G is a weight vector satisfying a Gaussian distribution, f i ' is the feature of the ith feature after the smoothing of the Gaussian weighted moving average filter. The expression of the gaussian weight vector G is:
wherein A is 1, a is 45,
then, each feature in the feature set F' is subjected to evolution accumulation summation technology conversion processing to obtain CF ═ CF 1 ,cf 2 ,...,cf i )。
The formula of the evolution cumulative summation algorithm is as follows:
wherein
The method is characterized in that the ith characteristic of the bearing in the initial operation period is taken as an average value;
and step 3: calculating Pearson correlation coefficients of the root-mean-square cumulative sum in the feature set and A-1 features of cumulative sum conversion of other root-mean-square cumulative sums, setting a preset threshold value of 0.98, and reserving B features larger than the threshold value of 0.98 to obtain a new feature index set CF' ═ (CF) 1 ,cf 2 ,...,cf B )。
The formula for the pearson correlation coefficient is as follows:
where k is the length of the feature x (i),
and
are the mean values of x (i) and y (i), respectively. The Pearson correlation coefficient has a value range of [ -1,1 [)]. The closer the absolute value of the correlation coefficient is to 1, the higher the correlation degree of x and y is; the closer the absolute value of the correlation coefficient is to 0, the lower the correlation of x with y.
And 4, step 4: and (4) carrying out principal component analysis calculation on the new characteristic index set CF', and selecting a difference array of the first principal component array as the health index HI. The average value of the health index is calculated by using 149 initial historical data of the health index
And standard deviation sigma, calculating initial threshold
Calculating 18 characteristics of the new vibration signal acquired in real time, adding the characteristics into F', still using the characteristic sets selected from the steps 1) to 3), wherein each characteristic has 151 values. And then, performing principal component analysis and calculation on the characteristics, taking the first principal component of the characteristics, and calculating the difference number of the first principal component as a new health index HI'.
If there are consecutive 3 values of HI' m 、HI' m+1 And HI' m+2 Exceeding the threshold T indicates a time T m Early failure of the rolling bearing occurs. And if no continuous 3 values exceed the threshold value T, reading the next vibration signal, calculating 18 characteristics of the new vibration signal, adding the characteristics into the last F', reusing the characteristic sets selected in the steps 1-3, then carrying out principal component analysis calculation on the characteristics, and calculating the health index until the continuous 3 health index values exceed the threshold value T.
The method for constructing the health index provided by the method of the invention is adopted, and the method for determining the early fault provided by the invention is adopted to judge the early fault of the bearing, and the monitoring result is shown in fig. 3 and fig. 4. As can be seen from the figure, the health indicator of the bearing varies greatly in the early stage and then gradually increases after returning to a certain value. Since 150 values (namely 1500 seconds) of the initial vibration signal of the rolling bearing are used as the basis for the subsequent data processing, the first 1500 seconds are removed when the fault time of the bearing is monitored in real time, and the fault time of the bearing is monitored only after the 151 th value is added. Even if extreme health indicator values suddenly change in the middle of a slow increase, we can judge that this is an impulse signal caused by environmental noise, rather than a true fault signal. Until the bearing 1 to 14040 seconds and the bearing 2 to 24110 seconds, the continuous 3 values in the health index of the rolling bearing exceed the respective threshold values, that is, the rolling bearing has an early failure.
Two specific cases are used in the application to show the principle and the detection effect of the invention, and the cases can help to understand the idea and the using method of the invention. These should not be construed as limitations of the invention, but all modifications made based on the idea of the invention should be within the scope of protection of the invention.
Claims (8)
1. A method for diagnosing early failure of a rolling bearing is characterized by comprising the following steps:
step 1, acquiring initial vibration data S of a whole life cycle of a rolling bearing, and selecting initial p data to perform feature extraction;
step 2, carrying out Gaussian weighted moving average filtering processing and evolution accumulation addition technology conversion processing on the features;
step 3, selecting characteristics by utilizing a Pearson correlation coefficient;
and 4, constructing a new health index by utilizing a principal component analysis technology, calculating a threshold value, and monitoring early faults of the rolling bearing in real time by utilizing a continuous alarm frequency triggering mechanism.
2. The early failure diagnosis method for a rolling bearing according to claim 1, characterized in that: in the step 1, initial vibration data S of the whole life cycle of the rolling bearing is obtained, p pieces of initially collected historical data are selected, A pieces of characteristics are extracted, and an original characteristic index set F is formed (F) 1 ,f 2 ,...,f i ) 1,2, a, wherein f i ＝(f i1 ,f i2 ,...,f ip )。
3. The early failure diagnosis method of a rolling bearing according to claim 2, characterized in that: step 2 specifically operates to perform gaussian denoising algorithm smoothing processing on each feature in the original feature set F to obtain F ═ F' 1 ,f 2 ',...,f i ') to a host; then, each feature in the feature set F' is subjected to evolution accumulation summation technology conversion processing to obtain CF (CF) 1 ,cf 2 ,...,cf i )。
4. The early failure diagnosis method of a rolling bearing according to claim 3, characterized in that: step 3 specifically comprises the steps of calculating Pearson correlation coefficients of A-1 features of the evolution cumulative sum root mean square in the feature set and other evolution cumulative sum transformation, and setting a preset threshold q which is larger than the threshold qThe B features of the set are retained to obtain a new feature index set CF ═ CF 1 ,cf 2 ,...,cf B )。
5. The early failure diagnosis method of a rolling bearing according to claim 4, characterized in that: step 4, specifically, performing principal component analysis calculation on the new characteristic index set CF', and selecting a differential array of the first principal component array as a health index HI; calculating to obtain the average value of the health index by utilizing p-1 initial historical data of the health index
And standard deviation sigma, calculating initial threshold
Calculating A characteristics of the new vibration signal acquired in real time, adding the characteristics into F', using the characteristic sets selected in the steps 1-3, wherein each characteristic has p +1 values; then, performing principal component analysis and calculation on the characteristics, taking the first principal component, and calculating the difference number of the first principal component as a new health index HI';
if there are consecutive 3 values of HI' m 、HI' m+1 And HI' m+2 Exceeding the threshold T indicates a time T m Early failure of the rolling bearing occurs; and if no continuous 3 values exceed the threshold value T, reading the next vibration signal, calculating A characteristics of the new vibration signal, adding the A characteristics to the last F', reusing the characteristic sets selected in the steps 1-3, then carrying out principal component analysis calculation on the characteristics, and calculating the health index until the continuous 3 health index values exceed the threshold value T.
6. The early failure diagnosis method of a rolling bearing according to claim 2, characterized in that: the characteristics in the step 1 comprise 14 time domain characteristics and 4 frequency domain characteristics; the 14 time domain features include 10 dimensional time domain features, which are respectively root mean square, maximum value, minimum value, average value, peak-to-peak value, absolute average value, variance, standard deviation, kurtosis and skewness, and the specific expression is as follows:
root mean square value
Maximum value F 2 ＝max(x(i))；
Minimum value F 3 Min (x (i)); mean value
Peak to peak value F 5 Max (x (i)) -min (x (i)); absolute mean value
Variance (variance)
Standard deviation of
Kurtosis
Deflection degree
The 4 dimensionless time domain characteristics are a waveform factor, a peak factor, a pulse factor and a margin factor respectively, and the specific expression is as follows:
form factor
Crest factor
Pulse factor
Margin factor
The 4 frequency domain characteristics comprise average frequency, barycentric frequency, root mean square frequency and frequency standard deviation, in order to obtain the frequency domain characteristics of the vibration signal, the time domain signal can be subjected to Fourier transform FFT to obtain a frequency domain signal, and the specific expression is as follows:
mean frequency
Frequency of center of gravity
Root mean square frequency
Standard deviation of frequency
Wherein f is k The frequency value corresponding to the k-th spectral line is s (k), and the corresponding frequency amplitude value is s (k);
k＝1,2,...,N fft ，N fft is the length of the spectral signal;
frequency characteristic F 15 Reflecting the magnitude of the frequency vibration energy, F 16 ～F 17 Reflecting the change of the position of the main frequency band, F 18 Reflecting the degree of spectral dispersion.
7. The early failure diagnosis method of a rolling bearing according to claim 3, characterized in that: in step 2, smoothing is performed by using a gaussian denoising algorithm, namely, a gaussian weighted moving average filter, and the formula is as follows:
when the length of the sliding window is n, and n is even or odd:
where G is a weight vector satisfying a Gaussian distribution, f i ' is the feature of the ith feature after the smoothing of the gaussian weighted moving average filter, and the expression of the gaussian weight vector G is:
where A is the normalized coefficient, a is the width of the Gaussian denoising window,
and the formula of the evolution cumulative sum algorithm is as follows:
wherein
The ith characteristic of the bearing during initial operation is averaged.
8. The early failure diagnosis method for a rolling bearing according to claim 1, characterized in that: the formula of the pearson correlation coefficient in step 3 is as follows:
where k is the length of the feature x (i),
and
are the mean values of x (i) and y (i), respectively; the Pearson correlation coefficient has a value range of [ -1,1 [)](ii) a The closer the absolute value of the correlation coefficient is to 1, the higher the correlation degree of x and y is; the closer the absolute value of the correlation coefficient is to 0, the lower the correlation of x with y.
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