JP2006226731A - Abnormality detection device of bearing - Google Patents
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- JP2006226731A JP2006226731A JP2005038279A JP2005038279A JP2006226731A JP 2006226731 A JP2006226731 A JP 2006226731A JP 2005038279 A JP2005038279 A JP 2005038279A JP 2005038279 A JP2005038279 A JP 2005038279A JP 2006226731 A JP2006226731 A JP 2006226731A
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Abstract
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本発明は、アコースティクエミッション(AE)を利用して、軸受の潤滑切れ、摩耗、はく離等の異常を検出する軸受の異常検出装置、特に、鉄鋼業の連続鋳造設備のピンチロールに使用される軸受のように、0.1〜10rpm程度の低速回転で使用される軸受に好適な軸受の異常検出装置に関するものである。 INDUSTRIAL APPLICABILITY The present invention uses an acoustic emission (AE) to detect an abnormality such as a bearing out of lubrication, wear, or peeling, and is used for a pinch roll of a continuous casting facility in the steel industry in particular. The present invention relates to a bearing abnormality detection device suitable for a bearing used at a low speed of about 0.1 to 10 rpm, such as a bearing.
従来、AEを利用した軸受の異常検出装置では、軸受からのAEをAEセンサにより検出し、このAEセンサが出力したAE信号から、軸受の異常とは関係がないノイズをバンドパスフィルタにより除去する。次いで、ノイズを除去したAE信号を包絡線検波回路で包絡線検波し、包絡線検波したAE信号を比較器で一定の基準値と比較し、AE信号が基準値を超えたときに、軸受の異常として検出している。また、AE信号が基準値を超えた回数をカウントし、カウントした値が所定数を超えたときに、軸受の異常として検出するものがある。 Conventionally, a bearing abnormality detection apparatus using AE detects AE from a bearing by an AE sensor, and removes noise not related to the abnormality of the bearing from a AE signal output from the AE sensor by a bandpass filter. . Next, the noise-removed AE signal is envelope-detected by an envelope detection circuit, the envelope-detected AE signal is compared with a certain reference value by a comparator, and when the AE signal exceeds the reference value, Detected as abnormal. In addition, there is one that counts the number of times the AE signal exceeds a reference value and detects a bearing abnormality when the counted value exceeds a predetermined number.
上述した従来の軸受の異常検出装置では、包絡線検波する前のAE信号から、バンドパスフィルタでノイズを除去しているものの、さまざまな周波数成分を持つノイズ成分を、AE信号から十分に取り除くことはできない。その為、そのまま、ある基準値を設定して比較すると、ノイズ成分に起因するAE信号をも軸受の異常を示すものとして検出してしまい、軸受の異常検出が不正確になるという問題がある。
例えば、圧延設備では、メタルイン時等に大きなAE信号が発生するが、軸受の異常に起因するAE信号とは、バンドパスフィルタでは区別することができず、軸受の異常を誤判定することがある。
In the conventional bearing abnormality detection apparatus described above, noise is removed from the AE signal sufficiently, although noise is removed from the AE signal by the band pass filter from the AE signal before envelope detection. I can't. Therefore, if a certain reference value is set and compared as it is, the AE signal caused by the noise component is also detected as indicating the abnormality of the bearing, and there is a problem that the abnormality detection of the bearing becomes inaccurate.
For example, in a rolling facility, a large AE signal is generated at the time of metal-in or the like, but it cannot be distinguished from an AE signal caused by a bearing abnormality by a bandpass filter, and a bearing abnormality may be erroneously determined. is there.
これに対し、特許文献1には、閾値を超えるAE信号の発生周期を算出し、算出した発生周期毎の発生数を集計し、集計した発生数が所定数を超えたときに、軸受の異常と判別する軸受の異常検出装置が記載されている。
特許文献1に記載された軸受の異常検出装置では、圧延設備のような高速回転で用いられる軸受のはく離及びピッチングの異常を検出する場合には有効であるものの、連続鋳造設備のピンチロールのような0.1〜10rpm程度の低速回転で用いられる軸受の潤滑切れから起こる摩耗の異常を検出するには有効な装置とは言えなかった。
本発明は、このような低速回転で用いられる軸受で生じる潤滑切れ起因の摩耗の異常検出についても検出可能な軸受の異常検出装置を提供することを目的とする。
The bearing abnormality detection device described in Patent Document 1 is effective when detecting an abnormality in peeling and pitching of a bearing used in high-speed rotation such as a rolling facility, but like a pinch roll of a continuous casting facility. Therefore, it cannot be said that the apparatus is effective for detecting abnormalities of wear caused by running out of lubrication of a bearing used at a low speed of about 0.1 to 10 rpm.
An object of the present invention is to provide a bearing abnormality detection device that can detect the abnormality detection of wear caused by the lack of lubrication generated in a bearing used at such low speed rotation.
低速回転で用いられる軸受の潤滑切れ起因の摩耗により発生し、AEセンサが検出し出力したAE信号は、図2の波形図に示すように、持続時間が長く、また、立上り時間が長い。よって、本発明は、AE信号の持続時間及び立上り時間を算出し評価することにより、軸受の異常に起因するAE信号とノイズであるAE信号とを弁別することができるという考察に基づいてなされた。 The AE signal, which is generated by wear due to lack of lubrication of the bearing used at low speed rotation and detected and output by the AE sensor, has a long duration and a long rise time as shown in the waveform diagram of FIG. Therefore, the present invention has been made based on the consideration that by calculating and evaluating the duration and rise time of the AE signal, it is possible to discriminate between the AE signal caused by the bearing abnormality and the AE signal which is noise. .
連続鋳造設備のピンチロールをモデル化し、図3に示す構成により、潤滑状態を変えて実験した。用いた軸受22,24は、内輪径55mm、外輪径250mmのBRG(22211CDK)である。2個の軸受22,24により両側を支持され、カップリング21によりモータ20に連結されたロール23を0.8rpmで回転させながら、油圧にてロール中央部に1.8tonの荷重をかけ、軸受24に取付けたAEセンサ1でAE信号を検出した。
実験の結果、AEセンサが検出し出力したAE信号は、図4の波形図に示すようになった。ここで、(a)は、軸受の潤滑が正常な場合、(b)は、軸受のグリースの一部を除去して、接触面の油膜を薄くした場合、(c)は、軸受のグリースを完全に除去した場合を示し、潤滑切れに起因してAE信号が変化することが分かる。
A pinch roll of a continuous casting facility was modeled, and an experiment was performed by changing the lubrication state according to the configuration shown in FIG. The bearings 22 and 24 used are BRG (22211CDK) having an inner ring diameter of 55 mm and an outer ring diameter of 250 mm. While the roll 23 supported on both sides by the two bearings 22 and 24 and connected to the motor 20 by the coupling 21 is rotated at 0.8 rpm, a load of 1.8 ton is applied to the central portion of the roll by hydraulic pressure. The AE signal was detected by the AE sensor 1 attached to 24.
As a result of the experiment, the AE signal detected and output by the AE sensor is as shown in the waveform diagram of FIG. Here, (a) is when the bearing lubrication is normal, (b) is when part of the bearing grease is removed and the oil film on the contact surface is thinned, and (c) is when the bearing grease is removed. It shows the case of complete removal, and it can be seen that the AE signal changes due to the lack of lubrication.
第1発明に係る軸受の異常検出装置は、軸受から受けたアコースティクエミッション(AE)を検出してAE信号を出力するAEセンサを備え、該AEセンサが出力したAE信号に基づき、前記軸受の異常を検出する軸受の異常検出装置において、前記AE信号の所定範囲の周波数成分を弁別する周波数弁別手段と、該周波数弁別手段が弁別した信号を検波する検波手段と、該検波手段が検波した信号のレベル及び閾値を比較する比較手段と、該比較手段の比較結果が、前記信号のレベルの方が大となってから、前記信号のレベルの方が小となる迄の該信号の持続時間を算出する持続時間算出手段と、前記比較結果が、前記信号のレベルの方が大となってから、該信号のレベルが極大値になる迄の立上り時間を算出する立上り時間算出手段とを備え、前記持続時間算出手段が算出した持続時間、及び前記立上り時間算出手段が算出した立上り時間に基づき、前記軸受の異常を検出するように構成してあることを特徴とする。 A bearing abnormality detection device according to a first aspect of the present invention includes an AE sensor that detects an acoustic emission (AE) received from a bearing and outputs an AE signal, and based on the AE signal output by the AE sensor, In a bearing abnormality detecting device for detecting an abnormality, a frequency discriminating means for discriminating frequency components within a predetermined range of the AE signal, a detecting means for detecting a signal discriminated by the frequency discriminating means, and a signal detected by the detecting means The comparison means for comparing the level and threshold value of the signal and the comparison result of the comparison means indicate the duration of the signal from when the level of the signal becomes larger until the level of the signal becomes smaller. A duration calculation means for calculating, and a rise time calculation means for calculating a rise time from when the level of the signal becomes larger until the level of the signal reaches a maximum value, as a result of the comparison. Provided, duration of the duration calculation means has calculated, and based on the rise time of the rise time calculation means has calculated, characterized in that is arranged to detect an abnormality of the bearing.
この軸受の異常検出装置では、AEセンサが、軸受から受けたアコースティクエミッション(AE)を検出してAE信号を出力し、AEセンサが出力したAE信号に基づき、軸受の異常を検出する。周波数弁別手段が、AE信号の所定範囲の周波数成分を弁別し、検波手段が、周波数弁別手段が弁別した信号を検波する。比較手段が、検波手段が検波した信号のレベル及び閾値を比較し、持続時間算出手段が、比較手段の比較結果が、信号のレベルの方が大となってから、信号のレベルの方が小となる迄の信号の持続時間を算出する。立上り時間算出手段が、比較手段の比較結果が、信号のレベルの方が大となってから、信号のレベルが極大値になる迄の立上り時間を算出する。持続時間算出手段が算出した持続時間、及び立上り時間算出手段が算出した立上り時間に基づき、軸受の異常を検出する。 In this bearing abnormality detection device, the AE sensor detects acoustic emission (AE) received from the bearing and outputs an AE signal, and detects an abnormality of the bearing based on the AE signal output by the AE sensor. The frequency discriminating means discriminates frequency components in a predetermined range of the AE signal, and the detecting means detects the signal discriminated by the frequency discriminating means. The comparison means compares the level and threshold value of the signal detected by the detection means, and the duration calculation means determines that the comparison result of the comparison means is greater than the signal level and then the signal level is smaller. Calculate the duration of the signal until. The rise time calculation means calculates the rise time from the comparison result of the comparison means until the signal level reaches the maximum value after the signal level becomes larger. A bearing abnormality is detected based on the duration calculated by the duration calculation means and the rise time calculated by the rise time calculation means.
第2発明に係る軸受の異常検出装置は、前記持続時間算出手段が算出した持続時間が第1時間より長いか否かを判定する第1判定手段と、前記立上り時間算出手段が算出した立上り時間が、前記第1時間より短い第2時間より長いか否かを判定する第2判定手段とを更に備え、前記第1判定手段及び第2判定手段が共に長いと判定した回数に基づき、前記軸受の異常を検出するように構成してあることを特徴とする。 According to a second aspect of the present invention, there is provided a bearing abnormality detection device, comprising: a first determination unit that determines whether the duration calculated by the duration calculation unit is longer than a first time; and the rise time calculated by the rise time calculation unit. And a second determination means for determining whether or not the second time is shorter than the second time, and the bearing is based on the number of times that the first determination means and the second determination means are both determined to be longer. The present invention is characterized in that it is configured to detect any abnormality.
この軸受の異常検出装置では、第1判定手段が、持続時間算出手段が算出した持続時間が第1時間より長いか否かを判定し、第2判定手段が、立上り時間算出手段が算出した立上り時間が、第1時間より短い第2時間より長いか否かを判定し、第1判定手段及び第2判定手段が共に長いと判定した回数に基づき、軸受の異常を検出する。 In this bearing abnormality detection device, the first determination means determines whether the duration calculated by the duration calculation means is longer than the first time, and the second determination means determines the rise calculated by the rise time calculation means. It is determined whether or not the time is longer than the second time shorter than the first time, and the abnormality of the bearing is detected based on the number of times that the first determination means and the second determination means are both determined to be long.
本発明に係る軸受の異常検出装置によれば、軸受の異常に起因するAE信号とノイズ成分とを弁別し、軸受の異常を正確に検出できる軸受の異常検出装置を実現することができる。特に、連続鋳造設備のピンチロールに使用される軸受のように、0.1〜10rpm程度の低速回転で使用される軸受の異常検出に有効である。 According to the bearing abnormality detection device of the present invention, it is possible to realize a bearing abnormality detection device that can discriminate between AE signals and noise components caused by bearing abnormality and accurately detect the bearing abnormality. In particular, it is effective for detecting an abnormality of a bearing used at a low speed of about 0.1 to 10 rpm, such as a bearing used for a pinch roll of a continuous casting facility.
以下に、本発明をその実施の形態を示す図面に基づき説明する。
図1は、本発明に係る軸受の異常検出装置の実施の形態の構成を示すブロック図である。この軸受の異常検出装置は、図示しない軸受から発生するAE(アコースティクエミッション)を検出するAEセンサ1と、AEセンサ1が出力したAE信号を増幅するプリアンプ2と、増幅されたAE信号の内、80kHz〜500kHzの周波数成分を周波数弁別するバンドパスフィルタ3(周波数弁別手段)とを備えている。
Hereinafter, the present invention will be described with reference to the drawings illustrating embodiments thereof.
FIG. 1 is a block diagram showing a configuration of an embodiment of a bearing abnormality detection device according to the present invention. This bearing abnormality detection device includes an AE sensor 1 that detects AE (acoustic emission) generated from a bearing (not shown), a
この軸受の異常検出装置は、また、バンドパスフィルタ3が周波数弁別した80kHz〜500kHzの周波数成分のAE信号を包絡線検波する検波回路4(検波手段)と、検波回路4が包絡線検波したAE信号のレベルと閾値とを比較するレベル比較回路5(比較手段)と、レベル比較回路5の比較結果に基づき、AE信号の持続時間を算出する持続時間算出回路7(持続時間算出手段)と、持続時間算出回路7が算出したAE信号の持続時間と所定時間(第1時間)とを比較する持続時間比較回路8(第1判定手段)とを備えている。
This bearing abnormality detection device also includes a detection circuit 4 (detection means) that detects an AE signal having a frequency component of 80 kHz to 500 kHz, which is frequency-discriminated by the
この軸受の異常検出装置は、また、検波回路4が包絡線検波したAE信号をディジタル信号に変換するA/Dコンバータ6と、レベル比較回路5の比較結果及びA/Dコンバータ6からのディジタル信号に基づき、AE信号の立上り時間を算出する立上り時間算出回路9(立上り時間算出手段)と、立上り時間算出回路9が算出したAE信号の立上り時間と所定時間(第2時間)とを比較する立上り時間比較回路10(第2判定手段)とを備えている。
This bearing abnormality detection device also includes an A /
この軸受の異常検出装置は、また、持続時間比較回路8及び立上り時間比較回路10の各比較結果の論理積を演算するAND回路11と、AND回路11の演算結果をカウントするカウンタ12と、カウンタ12のカウント値と所定値とを比較するカウント値比較回路13と、カウント値比較回路13の比較結果が軸受の異常を示すときに、軸受異常を点灯等により表示する表示回路14とを備えている。
The bearing abnormality detection device also includes an
以下に、このような構成の軸受の異常検出装置の動作を説明する。
AEセンサ1が、軸受から発生するAEを検出し出力したAE信号は、プリアンプ2により増幅され、バンドパスフィルタ3に与えられる。バンドパスフィルタ3は、与えられたAE信号の内、80kHz〜500kHzの周波数成分を周波数弁別し、検波回路4に与える。
尚、軸受鋼又はその他の鋼からなる軸受の、潤滑切れ、摩耗、はく離等の異常時に発生するAEの周波数は、80kHz〜500kHz(軸受鋼の場合は200kHz前後)の範囲に収まることが、実験により確認されている。
Below, operation | movement of the abnormality detection apparatus of the bearing of such a structure is demonstrated.
The AE signal output by the AE sensor 1 detecting and outputting the AE generated from the bearing is amplified by the
It should be noted that the frequency of the AE generated when the bearing made of bearing steel or other steel is abnormal, such as running out of lubrication, wear, or peeling, is within the range of 80 kHz to 500 kHz (around 200 kHz in the case of bearing steel). Has been confirmed.
検波回路4は、与えられた80kHz〜500kHzの周波数成分のAE信号を包絡線検波し、高周波数成分が除去されたAE信号を、レベル比較回路5及びA/Dコンバータ6へ与える。
レベル比較回路5は、包絡線検波されたAE信号のレベルと閾値とを比較し、その比較結果を持続時間算出回路7及び立上り時間算出回路9へ与える。
持続時間算出回路7は、レベル比較回路5の比較結果が、AE信号のレベルの方が大となってから、AE信号のレベルの方が小となる迄の時間を、AE信号の持続時間として算出し、持続時間比較回路8へ与える。
持続時間比較回路8は、与えられたAE信号の持続時間と、予め実験した結果から定められた所定時間(第1時間、例えば10msec)とを比較し、その比較結果をAND回路11へ与える。
The
The
The
The
A/Dコンバータ6によりディジタル信号に変換されたAE信号は、立上り時間算出回路9へ与えられる。立上り時間算出回路9は、レベル比較回路5の比較結果が、AE信号のレベルの方が大となってから、ディジタル信号に変換されたAE信号が極大値となる迄の時間を、AE信号の立上り時間として算出し、立上り時間比較回路10へ与える。例えば、A/Dコンバータ6からのディジタル信号の隣合う前後の値を比較して行き、後の値の方が小となった前の値をAE信号の極大値とする。
立上り時間比較回路10は、与えられたAE信号の立上り時間と、予め実験した結果から定められた所定時間(第2時間、例えば1msec)とを比較し、その比較結果をAND回路11へ与える。
The AE signal converted into a digital signal by the A /
The rise
AND回路11は、持続時間比較回路8の比較結果が、持続時間の方が長いことを示し、また、立上り時間比較回路10の比較結果が、立上り時間の方が長いことを示したときに、オン信号をカウンタ12へ与え、カウンタ12は、このオン信号をカウントし、そのカウント値をカウント値比較回路13へ与える。
カウント値比較回路13は、与えられたカウント値が、予め設定された値(1以上)に達したときに、軸受が異常であることを示す信号を表示回路14に与える。表示回路14、与えられた信号に基づき、軸受が異常であることを、表示灯の点灯等により表示する。
The AND
The count
1 AEセンサ
2 プリアンプ
3 バンドパスフィルタ(周波数弁別手段)
4 検波回路(検波手段)
5 レベル比較回路(比較手段)
6 A/Dコンバータ
7 持続時間算出回路(持続時間算出手段)
8 持続時間比較回路(第1判定手段)
9 立上り時間算出回路(立上り時間算出手段)
10立上り時間比較回路(第2判定手段)
11 AND回路
12 カウンタ
13 カウント値比較回路
14 表示回路
22,24 軸受
23 ロール
1
4 detection circuit (detection means)
5 level comparison circuit (comparison means)
6 A /
8 Duration comparison circuit (first determination means)
9 Rise time calculation circuit (rise time calculation means)
10 rise time comparison circuit (second determination means)
11 AND
Claims (2)
前記AE信号の所定範囲の周波数成分を弁別する周波数弁別手段と、該周波数弁別手段が弁別した信号を検波する検波手段と、該検波手段が検波した信号のレベル及び閾値を比較する比較手段と、該比較手段の比較結果が、前記信号のレベルの方が大となってから、前記信号のレベルの方が小となる迄の該信号の持続時間を算出する持続時間算出手段と、前記比較結果が、前記信号のレベルの方が大となってから、該信号のレベルが極大値になる迄の立上り時間を算出する立上り時間算出手段とを備え、前記持続時間算出手段が算出した持続時間、及び前記立上り時間算出手段が算出した立上り時間に基づき、前記軸受の異常を検出するように構成してあることを特徴とする軸受の異常検出装置。 In a bearing abnormality detection device that includes an AE sensor that detects acoustic emission (AE) received from a bearing and outputs an AE signal, and detects an abnormality of the bearing based on the AE signal output by the AE sensor.
A frequency discriminating means for discriminating frequency components within a predetermined range of the AE signal; a detecting means for detecting a signal discriminated by the frequency discriminating means; a comparing means for comparing the level and threshold value of the signal detected by the detecting means; The comparison result of the comparison means is a duration calculation means for calculating a duration of the signal from when the level of the signal becomes larger until the level of the signal becomes smaller; and the comparison result A rise time calculating means for calculating a rise time until the level of the signal reaches a maximum value after the level of the signal becomes larger, the duration calculated by the duration calculation means, And a bearing abnormality detection device configured to detect the bearing abnormality based on the rise time calculated by the rise time calculation means.
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EP3730228A4 (en) * | 2017-12-21 | 2021-09-22 | Hitachi Metals, Ltd. | Online crack detection device for roll for rolling, roll for rolling, and online crack detection method for roll for rolling |
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