Embodiment:
Referring to Fig. 1, Fig. 2, in the present embodiment, the integral body of testing table is " T " font, anterior for satisfying the rigid platfor 4 that acoustic reflection requires, two groups of lifting tables 2 that are used to adjust back axle test attitude and drive about being equipped with on the rigid platfor 4 by lifting motor 5, tested back axle 3 is supported on the lifting table 2 of the left and right sides, to a series of back axle 3, after attitude is adjusted, do not need to adjust again.
The rear portion of testing table is the power slide 1 that is driven by slide unit motor 7, is arranged on the power slide 1 with turning to tested back axle 3 provides the main motor 5 of driving force by setting speed, and the output shaft of main motor 5 is connected with the driving shaft of tested back axle 3; Main motor 5 is respectively with 500r/min, and the rotating speed driving rear axle 3 of 1100r/min and 2200r/min under this three retainings rotating speed, is carried out the analysis of data acquisition harmony Power arithmetic to system respectively, and obtained the noise quality grade of institute's survey back axle.If the detection that next back axle is then proceeded in the requirement of quality standard is satisfied in walkaway; Then need be if defective in the continuous abnormal sound fault diagnosis that continues to finish back axle in the moderating process that rises of 100~2200r/min.
Data Collection ﹠ Processing System is the key component of whole rear-axle whine on-line detecting system, and it not only will have enough measuring accuracy and stability, and its measuring speed also must be caught up with productive temp.
Fig. 1, shown in Figure 2, in the present embodiment, the noise signal measurement has adopted seven pairs of vector sound intensity probes 8 of 14 high precision microphones compositions to be used to measure noise signal.According to the requirement that sound intensity technique is measured noise, these seven pairs of vector sound intensity probes 8 are centered around arranging of tested back axle 3 on every side, constitute a rectangle enveloping surface.Simultaneously, in order to prevent acoustical leakage and absorption, smooth rectangle plane base is installed below back axle 3, is constituted the rigidity plane of reflection, promptly rigid platfor 4.Because be arranged in the loading and unloading formation obstruction of two pairs of vector sound intensity probes 8 of back axle 3 tops for back axle 3, thereby these two pairs of vector sound intensity probes adopt portable structures, when the loading and unloading back axle it are removed, shift action is realized by electrical control.
Referring to Fig. 3, put amplification from the noise signal of vector sound intensity probe in order through signal conditioner, be sent to industrial control computer by signal picker.In concrete the enforcement, signal conditioner adopts the multi-channel high-accuracy conditioner, guarantees that signal is undistorted; Signal picker adopts the multi-channel parallel collector, guarantees signal collection in real time continuously, satisfies the industry spot online detection requirements.In industrial control computer, the acoustical signal that records is carried out integral operation to whole rectangle enveloping surface, because outside noise is zero to the integration of enveloping surface, then operation result can be eliminated the influence of outside noise, integrated value is the sound power value of tested vehicle bridge self-noise, thereby finally obtains the noise quality grade of institute's survey back axle.For the back axle that noise quality exceeds standard, system changes fault diagnostic program automatically over to.At this moment, data Collection ﹠ Processing System is gathered vibration signal simultaneously except the acquisition noise signal.A high precision vibration transducer respectively is installed on the lifting table of the left and right sides, and the vibration signal of collection is sent to industrial control computer through above-mentioned signal conditioner and signal picker, together with noise signal computing and analysis, thereby determines fault type and position.
Shown in Figure 3, control system is to be host computer with the industrial control computer, and the slave computer that constitutes " master-slave mode " structure with host computer is Programmable Logic Controller (PLC), between host computer and slave computer by serial RS232 port communications; Finish the grading of the collection of noise signal and computing, noise quality, fault diagnosis, test macro parameter calibration, measurement data management, detect report generation and printing by host computer, and communicate and handle, show the functions such as picture configuration of running status and parameter with slave computer; Slave computer is to be input signal with the steering order of host computer and measuring instrument and hand switch signal, the output logic control signal; The topworks of back axle positioning and clamping and sound intensity probe location is that the logic control signal with slave computer output serves as to carry out input signal; Slave computer provides rotating speed and steering controling signal by frequency converter for main motor, slide unit motor and lifting motor.
In the system shown in Figure 3, hand switch provides switching signal to PLC, and prompting PLC carries out actions such as clamping, test, self check; Monitoring instrument is used for monitoring the rotation situation of motor and the ruuning situation of system; Show and the part of reporting to the police is used for the display system running status, and sound and light alarm is provided when makeing mistakes.
Also comprise in concrete the enforcement:
About testing table clamping part:
The action of testing table clamping part mainly comprise lifting table lifting, move forward and backward, move left and right and angular setting, and the moving forward and backward of dynamic slide unit, the clamping of back axle with unclamp.Wherein, the moving forward and backward of the lifting of lifting table, power slide, the clamping of back axle with unclamp by electrical control, other actions are manually carried out by mechanical hook-up.
Control about main rotating speed of motor:
According to the requirement of walkaway, during walkaway, power master motor provides 500r/min, 1100r/min and 2200r/min totally three kinds of rotating speeds, and keeps 10~20s; During fault diagnosis, power master motor provides the continuous raising speed of 100~2200r/min and 2200~100r/min to slow down continuously.
About the frequency converter Configuration Design:
Referring to Fig. 4, in same testing table, need to use four motors that model power has nothing in common with each other, comprise on main motor 5.5KW, the power slide slide unit motor 250W and about two lifting motor 250W, running during owing to difference when measuring, therefore the interlock circuit that adopts Mitsubishi's frequency converter and be made of contactor 1KM, 2KM, 3KM and 4KM drags, interlock circuit comprises: contactor 1KM and 2KM, 3KM, 4KM realize interlocking, 3KM is synchronoused working with 4KM, 2KM and 3KM and 4KM interlocking.Shown in Figure 4, when relay K 24 adhesives, the electromagnetic actuation of contactor 1KM, the major loop conducting, main machine operation, this moment, the normally closed contact of contactor 1KM disconnected, and the contactor control loop that other three motors are connected is in off-state, when guaranteeing main machine operation, other three motors are shut down; When relay K 25 adhesives, the electromagnetic actuation of contactor 2KM, major loop conducting, the slide unit machine operation, this moment, the normally closed contact of contactor 2KM disconnected, and the contactor control loop that other three motors are connected is in off-state, when guaranteeing the slide unit machine operation, other three motors are shut down; When relay K 1 (or K2) adhesive, the electromagnetic actuation of contactor 3KM (or 4KM), the major loop conducting, lifting motor work, the normally closed contact of contactor 3KM this moment (or 4KM) disconnects, the contactor control loop that main motor is connected with the slide unit motor is in off-state, and when guaranteeing lifting motor work, main motor and slide unit motor are shut down; During relay K 1 adhesive, left lifting motor work, during relay K 2 adhesives, right lifting motor work, during relay K 1 and K2 adhesive simultaneously, left and right lifting motor is worked simultaneously.
In frequency converter, at first arrange terminal AU to be used for the input of REX multistage speed signal, determine the different travelling speed of main motor, slide unit motor and lifting motor then by setup parameter; When each machine operation, by its travelling speed of combination selection of contact signal (RH, RM, RL, REX).
In concrete the enforcement, PLC program basic module comprises:
1, reports to the police;
2, system's automatic/hand conversion;
3, the self-diagnostic function of system.
4, slide unit rotating speed of motor control, slide unit motor require to realize to advance at a high speed advances with low speed and retreats 3 kinds of controls at a high speed.
5, the rotating speed of lifting motor control.
6, back axle master rotating speed of motor control requires to realize rotating, continuous lifting speed, and 500/1100/2200r/min3 keeps off speed.
7, the control that puts in place of pressing system and detecting sensor.
Its control method flow process as shown in Figure 5
Consider the friendly of real-time requirement, data processing calculated amount and the user interface of detection system, system software selects Windows as development platform, employing Visual C++6.0 directly operates bottom hardware as developing instrument, thereby has improved the efficient of application program.
The software configuration of on-line detecting system:
Testing process is the voice signal of gathering according to sound intensity probe; calculate the sound intensity of every pair of vector sound intensity probe; then according to the area of the position of sound intensity probe and each envelope and consider the factors such as absorption of sound intensity probe safeguard protection shell to sound; calculate the acoustical power of back axle under different rotating speeds, and show its waveform.If noise objective is qualified, then according to quality grading criteria grade; If exceed standard, then remeasure.If the acoustical power difference of twice measurement then changes the Fault Identification subroutine over to less than 1dB.
When the noise of back axle exceeded standard, system prompt carried out Fault Identification.At this moment, drive motor at the uniform velocity rose to 2200r/min from 100r/min in 8 seconds, kept then 10 seconds, at the uniform velocity decelerated to 100r/min from 2200r/min again in 8 seconds.During this period, measuring system is carried out continuous sampling, by calculating, obtains corresponding power sound spectrum and main dominant frequency.Comprehensive advantage frequency and noise spectrum battle array, fault is made principium identification, adopt cepstral analysis and kurtosis analysis then, and in conjunction with the structure vibration signals of sensitive spot, obtain fault signature, determine possible fault type and position according to the fault model in fault knowledge storehouse at last.
Referring to Fig. 6, about the wiring of Programmable Logic Controller (PLC):
S14 is a scram button, when up-set condition occurring, presses this button, Programmable Logic Controller (PLC) input end X0 conducting, and all output terminals disconnect, and system quits work; After recovering normally, lift this button, system recovery.
S13 is manual switching button, get to manual, input end X2 conducting, system enters manual state, this moment main motor three the retaining rotating speeds need manual intervention to switch; Get to automatic transmission, input end X2 disconnects, and system enters auto state, and this moment, three retaining rotating speeds of main motor can automatically switch.
S12 is the slide unit button that advances at utmost speed, and presses this button, input end X2 conducting, and output terminal Y6, Y13, Y14, Y16, Y27 conducting, the slide unit motor just changes at a high speed; Press this button once more, input end X2 disconnects, and the slide unit motor stops.
S25 is a slide unit low-speed forward button, presses this button always, input end X46 conducting, and output terminal Y0, Y13, Y17, Y27 conducting, slide unit motor low speed just changes; Unclamp this button, input end X46 disconnects, and the slide unit motor stops.
S11 is the slide unit back, presses this button, input end X4 conducting, output terminal Y6, Y12, Y15, Y16, Y27 conducting, slide unit motor high speed reverse rotation; Press this button once more, input end X4 disconnects, and the slide unit motor stops.
S10 is the left and right sides lifting table button that rises simultaneously, presses this button always, input end X11 conducting, and output terminal Y6, Y7, Y10, Y13, Y20, Y30, Y31 conducting, left and right sides lifting motor just changes simultaneously; Unclamp this button, input end X11 disconnects, and left and right sides lifting motor stops simultaneously.
S9 is the left and right sides lifting table button that descends simultaneously, presses this button always, input end X12 conducting, and output terminal Y6, Y7, Y10, Y12, Y21, Y30, Y31 conducting, left and right sides lifting motor reverses simultaneously; Unclamp this button, input end X12 disconnects, and left and right sides lifting motor stops simultaneously.
S20 is left lifting table rising button, presses this button always, input end X40 conducting, and output terminal Y6, Y7, Y10, Y13, Y30, Y34 conducting, left lifting motor just changes, and pilot lamp H18 lights; Unclamp this button, input end X40 disconnects, and pilot lamp H18 extinguishes, and left lifting motor stops.
S21 is left lifting table decline button, presses this button always, input end X41 conducting, and output terminal Y6, Y7, Y10, Y12, Y30, Y35 conducting, left lifting motor counter-rotating, pilot lamp H19 lights; Unclamp this button, input end X41 disconnects, and pilot lamp H19 extinguishes, and left lifting motor stops.
S22 is right lifting table rising button, presses this button always, input end X42 conducting, and output terminal Y6, Y7, Y10, Y13, Y31, Y36 conducting, right lifting motor just changes, and pilot lamp H20 lights; Unclamp this button, input end X42 disconnects, and pilot lamp H20 extinguishes, and right lifting motor stops.
S23 is right lifting table decline button, presses this button always, input end X43 conducting, and output terminal Y6, Y7, Y10, Y12, Y31, Y37 conducting, right lifting motor counter-rotating, pilot lamp H21 lights; Unclamp this button, input end X43 disconnects, and pilot lamp H21 extinguishes, and right lifting motor stops.
S18 is that main motor is just changeing button, and S19 is main motor invert button, and S01 is main motor low-speed running button, S02 is main motor middling speed running button, S03 is the main motor button that runs up, and S04 is the continuous raising speed button of main motor, and S05 is the continuous push buttondown of main motor.Press S18 and S01, input end X26 and X30 conducting, output terminal Y6, Y13, Y26 conducting, main motor just changes with 500r/min; Press S18 and S02, input end X26 and X31 conducting, output terminal Y7, Y13, Y26 conducting, main motor just changes with 1100r/min; Press S18 and S03, input end X26 and X32 conducting, output terminal Y10, Y13, Y26 conducting, main motor just changes with 2200r/min; Press S19 and S01, input end X27 and X30 conducting, output terminal Y6, Y12, Y26 conducting, main motor reverses with 500r/min.(annotate: when S13 is in automatic catch, press S18 and S01, main motor automatically switches to 1100r/min and 2200r/min after just changeing with 500r/min at the appointed time)
Press S18 and S04, input end X26 and X33 conducting, output terminal Y4, Y13, Y26 conducting, main motor is just changeing raising speed to 2200r/min continuously from 100r/min within a certain period of time, pressing S05 this moment, input end X34 conducting, output terminal Y5, Y13, Y26 conducting, main motor is just changeing continuously from 2200r/min within a certain period of time and is decelerating to 100r/min.
S07 is main motor stop button, presses this button, input end X37 conducting, and main motor is out of service.
S08 is that back axle compresses button, presses this button, input end X16 conducting, and output terminal Y23 conducting, the clamping cylinder action compresses back axle.
S15 is the back axle release button, presses this button, input end X20 conducting, and output terminal Y22 conducting, clamping cylinder discharges, and unclamps back axle.
S16 is back axle top two sound intensity probe carries button, presses this button, input end X22 conducting, and output terminal Y24 conducting, the rotary cylinder action, sound intensity probe enters test position.
S17 is two the sound intensity probe reset button in back axle top, presses this button, input end X24 conducting, and output terminal Y25 conducting, rotary cylinder discharges, and sound intensity probe is got back to the origin-location, is convenient to the back axle loading and unloading.
S06 is the ann silence button, presses this button, input end X36 conducting, and output terminal Y3 disconnects, the Y33 conducting, alarm buzzer F1 stops, and alarm lamp H4 extinguishes, and frequency converter resets.
S24 is the System self-test button, presses this button, input end X44 conducting, and system carries out self-examination, as non-fault, then output terminal Y2, Y32 conducting, pilot lamp H3 and H5 light.
Input end X35 is connected with the unusual output terminal of frequency converter, when frequency converter breaks down, and the X35 conducting, output terminal Y3 conducting, alarm buzzer F1 pipes, and alarm lamp H4 lights.
Input end X17 connects the clamping stroke switch, when back axle compresses, travel switch close and, the X17 conducting, the reporting system back axle compresses.
Input end X21 connects and to unclamp travel switch, when back axle unclamps, travel switch close and, the X21 conducting, the reporting system back axle unclamps
Input end X13 connects the lifting table rising and puts in place near switch, when lifting table rises to this position, and near switch closure, the X13 conducting, the reporting system lifting table has risen to the extreme higher position.
Input end X14 connects lifting table decline and puts in place near switch, when lifting table drops to this position, and near switch closure, the X14 conducting, the reporting system lifting table has dropped to extreme lower position.
Input end X15 connects lifting table upper limit travel switch, shields, and when rising put in place near switch failure, lifting table continued to rise to this position, the travel switch closure, and the X15 conducting, the reporting system lifting table has risen to extreme position.
Input end X45 connects lifting table lower limit travel switch, shields, and when dropping to the position near switch failure, lifting table continues to drop to this position, the travel switch closure, and the X45 conducting, the reporting system lifting table has dropped to extreme position.
Input end X5 connects power slide and moves into place near switch, when power slide with high-speed mobile so far during the position, near switch closure, the X5 conducting, the slide unit motor stops, reporting system slide unit motor must be with slow running.
Input end X6 connects power slide and advances and put in place near switch, when power slide moves so far the position with low speed, and near switch closure, the X6 conducting, the slide unit motor stops, and the reporting system slide unit has arrived the working position.
Input end X7 connects power slide front limit travel switch, shields, when slide unit advances when putting in place near switch failure; power slide continues to move position so far, travel switch closure, X7 conducting; the slide unit motor stops, and the reporting system slide unit has been advanced to extreme position.
Input end X10 connects limitation travel switch behind the power slide, shields, and when slide unit retreats position so far, the travel switch closure, the X10 conducting, the slide unit motor stops, and the reporting system slide unit retreats to extreme position.
Input end X23 connects the sound intensity probe test and puts in place near switch, and when the two pairs of sound intensity probes in vehicle bridge top arrived test position, this was near switch closure, the X23 conducting, and the two pairs of sound intensity probes in reporting system vehicle bridge top have arrived test position.
Input end X25 connects the sound intensity probe test reset near switch, and when the two pairs of sound intensity probes in vehicle bridge top returned the origin-location, this was near switch closure, the X25 conducting, and the two pairs of sound intensity probes in reporting system vehicle bridge top have returned the origin-location.
Input end X1 connects tach signal, after the PLC computing, exports tachometer gage to by output terminal Y1 and shows rotating speed.