多传感器融合和 MHA-LSTM 的电机轴承剩余寿命预测

轴承作为电机的核心部件, 主要起到支撑引导轴、 减小设备摩擦、 连接不同设备等作用, 其剩余寿命预测对系统健康 管理起着十分重要的作用。 针对单一传感器信号通常难以全面描述系统的潜在退化机制, 论文提出一种基于多头注意力机制 和长短时记忆神经网络的电机轴承剩余寿命预测模型。 首先, 基于马氏距离确定轴承性能退化起始点, 将滚动轴承全寿命周 期分为正常阶段与退化阶段; 其次, 使用自编码器自动提取振动信号特征, 并将其与电机电流、 轴承温度融合, 构成多源信息 特征矩阵; 然后基于多头注意力机制和长短时记忆网络模型动态选择相关度较高的特征, 提高寿命预测的准确性。 最后, 采 用实验数据进行验证, 结果表明所提出的模型具有更高的准确性。     

Failure mechanisms of ball bearings under lightly loaded,non-accelerated usage conditions

This paper identifies the failure mechanisms of ball bearings in low-power motors for electronics cooling. This study contrasts with previous studies on bearing life in its precipitation of failures under lightly loaded, non-accelerated usage conditions that are more representative of electronics cooling applications. Life tests were conducted on bearings composed of steel balls, steel inner and outer races, and a glass-fiber reinforced polyamide cage. Failure analysis of the ball bearings indicated that lubricant loss, transfer film formation, and wear particle generation were the failure mechanisms. Severe wear was found in the glass-fiber reinforced polyamide cages after failure. Several features extracted from the acoustic emission signals were identified as indicators of bearing degradation.     

水基纳米液压液抗磨减摩特性的分子动力学模拟*

为探究纳米颗粒对于水基纳米液压液抗磨减摩特性的影响机制,以水基Cu纳米液压液为例,构建纳米流体在平板间做剪切流动的动力学模型,采用Lennard-Jones势函数、嵌入原子势(EAM)、MCY建立原子间势能模型,研究不同压力、不同纳米颗粒含量、不同剪切速度下水基纳米液压液的抗磨减摩特性和承载能力。结果表明:水基纳米液压液的承载能力随着纳米颗粒数量的增加而增大;在一定范围内,摩擦力会随着纳米颗粒含量的增大而减小,但过大的纳米颗粒含量将导致摩擦加剧。借助分子动力学模拟的方法,探索在剪切作用下纳米颗粒的运动状态,结果发现纳米颗粒绕不同坐标轴的角速度分量存在较大的差异,表明纳米颗粒在模拟区域的上下金属壁面之间起到类似滚珠轴承中"滚珠"的作用。     

中介轴承故障动力学建模与振动特征分析

中介轴承是航空发动机转子的关键支承部件之一,工作转速高,润滑条件差,易发生故障。基于动力学模型的故障机理研究可以为中介轴承故障诊断提供依据。以Gupta圆柱滚子轴承复杂动力学建模方法为基础,考虑外圈的运动建立了中介轴承动力学模型,通过试验对模型进行验证。在此基础上,分别考虑滚道表面形貌和轴承间隙的变化,建立中介轴承磨损故障动力学模型;针对中介轴承滚道表面剥落等局部损伤故障,考虑滚动体通过损伤区域时趋近量和接触载荷方向的改变,建立中介轴承局部损伤故障动力学模型。利用所建故障动力学模型对不同磨损状态下中介轴承外圈径向振动响应进行研究。研究表明,出现磨损后,振动响应频率中出现若干随机成分;对于局部损伤和磨损的复合故障,随着磨损加剧,振动幅值随之增大,随机成分所占比重增加,损伤的故障特征不明显。     

Deep Spatiotemporal Convolutional-Neural-Network-Based Remaining Useful Life Estimation of Bearings

The remaining useful life(RUL) estimation of bearings is critical for ensuring the reliability of mechanical systems. Owing to the rapid development of deep learning methods, a multitude of data-driven RUL estimation approaches have been proposed recently. However, the following problems remain in existing methods: 1) Most network models use raw data or statistical features as input, which renders it di cult to extract complex fault-related information hidden in signals; 2) for current observations, the dependence between current states is emphasized, but their complex dependence on previous states is often disregarded; 3) the output of neural networks is directly used as the estimated RUL in most studies, resulting in extremely volatile prediction results that lack robustness. Hence, a novel prognostics approach is proposed based on a time–frequency representation(TFR) subsequence, three-dimensional convolutional neural network(3 DCNN), and Gaussian process regression(GPR). The approach primarily comprises two aspects: construction of a health indicator(HI) using the TFR-subsequence–3 DCNN model, and RUL estimation based on the GPR model. The raw signals of the bearings are converted into TFR-subsequences by continuous wavelet transform and a dislocated overlapping strategy. Subsequently, the 3 DCNN is applied to extract the hidden spatiotemporal features from the TFR-subsequences and construct HIs. Finally, the RUL of the bearings is estimated using the GPR model, which can also define the probability distribution of the potential function and prediction confidence. Experiments on the PRONOSTIA platform demonstrate the superiority of the proposed TFR-subsequence–3 DCNN–GPR approach. The use of degradation-related spatiotemporal features in signals is proposed herein to achieve a highly accurate bearing RUL prediction with uncertainty quantification.     

Design of Accelerated Life Test for Sleeve Bearing of Construction Equipment Based on Wear Prediction

Joint bearings of attachments play a key role in the reliability of construction equipment. These joint bearings operate in very harsh environments with strongly varying dynamic impact loads and oscillating under low sliding speeds. The bearings therefore operate in boundary lubrication, which means that direct metal-to-metal contact inevitably renders the sleeve bearing highly prone to wear. The assessment of durability for sleeve bearings is carried out using a test bench with oscillatory motion. However, estimating a quantitative accelerated factor considering the actual operating conditions is limited. The aim of this work is to determine the experimental conditions of the accelerated life test and to analyze the quantitative accelerated factor considering the wear limits of bearings. The wear limits are determined by the analysis of dimensional management that simulates the dispersion of a bucket end position by using 3DCS dedicated software. The accelerated factor is obtained by the comparing the times required to reach the wear limits. This test duration is calculated by the prediction methodology of wear depth based on the correlation between wear rate and film parameter. After the wear tests are performed using a test bench with actual bearings, the wear depth is measured to verify the estimated bearings. The proposed methodology is useful to design an accelerated life test under periodically changed lubrication condition caused by oscillatory motion.     

基于小波域对数正态模型的滚动轴承故障诊断

针对小波分析无法全面准确描述滚动轴承振动信号的非高斯问题,提出一种结合小波变换与对数正态分布模型的故障特征提取方法,以提取能准确反映滚动轴承运行状态的特征信息。首先,通过小波变换对滚动轴承运行时产生的非平稳、非高斯振动信号进行分解重构,得到不同尺度下的重构信号;然后对重构信号建立对数正态分布模型,提取模型的对数均值和对数标准差作为表征滚动轴承运行状态的统计特征;最后采用支持向量机分类器对提取的特征进行故障分类与识别。实验结果表明,该方法可以有效、准确地识别滚动轴承的运行状态。     

纯电动汽车无刷电机控制系统的建模与仿真

针对无刷直流电机传统PI控制的局限性,从无刷直流电机的基本原理出发,通过模糊PD控制器与积分相结合,将永磁无刷直流电机应用于纯电动汽车驱动系统。采用Matlab／Simulink平台,同时结合S-函数,构建了基于模糊控制的无刷直流电机转速一电流双闭环控制系统模型,利用该模型分析无刷直流电机的动静态性能,得到了无刷直流电机运行时的反电势、相电流、转矩和速度的曲线。结果表明,采用转速一电流双闭环模糊控制调速策略具有超调小、响应速度快、鲁棒性好、自适应能力强等优点,使系统获得了较好的控制性能,为实际纯电动汽车驱动控制系统的分析与设计提供了新的思路。     

Wear Prediction of Earth-Moving Machinery Joint Bearing via Correlation between Wear Coefficient and Film Parameter: Experimental Study

ABSTRACT

A wear life prediction of a grease-lubricated bearing in earth moving machinery has to be made based on actual wear data for its accuracy, but much effort should be devoted to obtain the wear data from the actual bearing. Currently, manufacturers provide a very conservative maintenance guide to schedule the replacement of the bearings to prevent the mechanical failure due to wear, causing economic losses, and the market requires finding optimal maintenance cycles to reduce maintenance costs. In this study, an economical wear prediction methodology for the grease-lubricated bearing based on typical pin-on-disk (POD) tests is proposed. POD tests were performed under boundary and mixed lubrication regimes considering the actual operating conditions of the bearings. It was found that there is a linear relation between the lubrication film parameter and the wear coefficient in log-log scale. The amount of wear of actual bearings was estimated by the wear coefficient from the linear regression analysis based on the POD test. The wear tests were further performed with the actual bearing under two loading cases and then the lubrication film parameter and wear coefficient were calculated, respectively. The estimated amount of wear shows good agreement with the measurement of wear depth. This leads us to conclude that it is possible to economically predict the wear amount in an actual bearing from POD wear test results by analysis of the correlation between the wear coefficient and the lubrication film parameter.     

基于小波分析多尺度分解的轴承故障检测

归纳和总结了小波分析多尺度分解的滚动轴承故障检测方法的实施步骤,阐述了故障轴承振动与信号的关系以及离散小波算法的原理和实现过程,并以滚动轴承故障诊断为例,运用MATLAB小波分析工具箱将滚动轴承振动信号进行小波离散多尺度分解,然后在分解的结果中寻找滚动轴承的故障特征频率。结果表明,如果在故障检测过程中合理选择小波函数和各种参数,则小波分析多尺度分解具有很强的故障识别能力。     

Stability Analysis of Floating Ball Bearing

Conventional disk drive motors supported on ball bearings (BBs) cause nonrepeatable runout (NRRO) due to the surface imperfections on balls and raceways. NRRO is a source of track misregistration between head and disk that inhibits high track density in a hard disk drive. Fluid dynamic bearings with herringbone grooves either on the rotating or stationary surfaces are a suitable replacement for conventional ball bearings. Herringbone grooved bearings have considerably lower noise level than ball bearings and have better stability compared to plain journal bearings at concentric operating position. However, herringbone-grooved patterns are difficult to manufacture because groove depth is of the order of bearing clearance. The major limitation of the BBs is the direct contact between the rotating and stationary parts and also lack of damping effects. This present work attempts to overcome these drawbacks in BBs by eliminating the metal-to-metal contact using a layer of fluid film, and a theoretical analysis of stability characteristics of a floating BB is presented. Results indicate that there is an improvement in the stability of floating BB rotor systems with increase in outer to inner film clearance ratio (β) from 0.7 to 1.3, and with decrease in ratio of outer race radius to inner race radius (δ) from 3.0 to 1.2.     

Abrasive jet machining for the microprofile control patterning of herringbone grooves

Fluid bearings have features of high speed and high rotation accuracy, and therefore, they are used in spindle motors of hard disk drives, cooling fans of central processing units, and other devices. Further, these bearings have microherringbone grooves on the shaft or sleeve inner surface that help generate dynamic pressure in the lubricant fluid around the shaft. Although the depth of the groove is constant, dynamic pressure can be increased by decreasing the depth from both ends to the central corner of each groove on a micron scale. This study aims to verify the effect of sloped herringbone grooves using computational fluid dynamics (CFD) analysis and to develop a new microfabrication method for manufacturing microsloped herringbone grooves on the shaft surface using abrasive jet machining. The generated dynamic pressure is analyzed using CFD; the results indicated that the sloped herringbone grooves result in an increase in the dynamic pressure at the groove tips and cause a decrease in the fluctuations in dynamic pressure in the circumferential direction.     

Application of computational fluid dynamics and fluid structure interaction techniques for calculating the 3D transient flow of journal bearings coupled with rotor systems

Journal bearings are important parts to keep the high dynamic performance of rotor machinery. Some methods have already been proposed to analysis the flow field of journal bearings, and in most of these methods simplified physical model and classic Reynolds equation are always applied. While the application of the general computational fluid dynamics (CFD)-fluid structure interaction (FSI) techniques is more beneficial for analysis of the fluid field in a journal bearing when more detailed solutions are needed. This paper deals with the quasi-coupling calculation of transient fluid dynamics of oil film in journal bearings and rotor dynamics with CFD-FSI techniques. The fluid dynamics of oil film is calculated by applying the so-called ’’dynamic mesh’’ technique. A new mesh movement approach is presented while the dynamic mesh models provided by FLUENT are not suitable for the transient oil flow in journal bearings. The proposed mesh movement approach is based on the structured mesh. When the journal moves, the movement distance of every grid in the flow field of bearing can be calculated, and then the update of the volume mesh can be handled automatically by user defined function (UDF). The journal displacement at each time step is obtained by solving the moving equations of the rotor-bearing system under the known oil film force condition. A case study is carried out to calculate the locus of the journal center and pressure distribution of the journal in order to prove the feasibility of this method. The calculating results indicate that the proposed method can predict the transient flow field of a journal bearing in a rotor-bearing system where more realistic models are involved. The presented calculation method provides a basis for studying the nonlinear dynamic behavior of a general rotor-bearing system.     

轿车轮毂轴承微动磨损试验分析

利用自行设计的轿车轮毂轴承径向式微动磨损试验系统,对三组轮毂轴承进行试验。试验轴承滚道上出现宏观条状磨损痕迹,轴承次表面约20 ?m处出现了连续微孔,严重微动磨损的轴承次表面出现了近似平行于滚道的微裂纹。同时,模拟径向载荷下轮毂轴承的内部3D应力分布,结果表明,轮毂轴承载荷区出现条状应力/应变峰的幅值波动。在此基础上,结合轿车行驶时轮毂轴承的承载特点,提出了轮毂轴承广义复合微动磨损机理模型。该模型为减缓轮毂轴承微动磨损程度和提高轴承可靠性提供了新的途径。     

基于气穴模型的动压轴承动态油膜刚度计算方法

针对雷诺方程很难准确反映动压轴承高速转动过程中引起的周向惯性效应、动态挤压效应等的影响,进而导致油膜动态刚度计算精度难以满足高精度轴承设计的现状,提出用ADINA软件先求解瞬态油膜压力分布和瞬态油膜力,得到轴心轨迹,然后结合差分计算模型计算油膜动态刚度的方法。该计算方法基于流固耦合和气穴模型,定义油膜和轴的流固耦合时,采用任意的拉格朗日-欧拉(ALE)算法有效避免了油膜网格畸变的问题,再现轴心动态平衡过程和三维流场压力分布的动态发展过程,得到瞬态过程中的动态油膜力和动态油膜刚度。试验结果和基于流固耦合和气穴模型的计算结果对比分析发现两者基本吻合,说明该基于流固耦合和气穴模型的数值仿真计算方法是可行和有效的。     

基于小波包-AR谱的变速器轴承故障特征提取

提出了一种小波包-AR谱估计和计算散度相结合的汽车变速器轴承故障特征提取方法.将6种不同磨损状况下的变速器轴承振动信号进行小波包分解,重构各频段信号并进行自回归(auto regressive,简称AR)谱估计,最后计算各故障轴承到新轴承之间的散度值.试验结果表明,不论是轴承的轴向间隙,还是径向间隙差异及疲劳剥落,在小波包-AR谱的谱图上均有明显的反映,该方法可以有效提取出汽车变速器轴承振动信号中的故障特征.     

The role of micro-cavitation on EHL: A study using a multiscale mass conserving approach

The role of micro-cavitation in Elastohydrodynamic Lubrication is numerically investigated using a multiscale approach whereby both the small scale topographical features and the micro-cavitation of the lubricant due to the features are resolved. Micro-cavitation and the fluid׳s shear-thinning property are modelled at the small scale of topological feature. The effects of topographical features on the film thickness of the line contact bearings and friction coefficient are presented with a focus on the role of micro-cavitation. This highlights how a mass conserving small scale model can be used to model both micro-cavitation and cavitation occurring at the bearing scale, and how topological features can be designed to reduce friction while maintaining bearing load.     

Controllable high speed journal bearings, lubricated with electro-rheological fluids. An analytical and experimental approach

The problem of journal bearings control is of great importance in mechanical engineering. A very recent method for doing this is the creation of ‘smart' journal bearings using electro-rheological (ER) fluids. If such a fluid is used to lubricate a journal bearing system, it is expected that the imposition of an electric field between the rotor and the stator will cause an alteration in the dynamic properties of the journal bearing. In this paper an experiment in a high speed journal bearing (16 000 to 35 000 s⁻¹), with small radial clearance is presented. The alternation of the attitude locus (eccentricity and attitude angle) and the stiffness coefficients in a loaded journal bearing lubricated with ER fluid is investigated and presented. The Reynolds equation is solved using the finite element method in order to get the dynamic characteristics of the ER bearings vs the electric field and to simulate its dynamic behavior. The Bingham plastic model of non-Newtonian fluid flow behavior is used to described the ER lubricant. The accuracy of the algorithm is obtained by comparing the results published by previous investigators and the experimental data described in this paper. It is concluded that ER fluids can be used to create ‘smart' journal bearings. and vibration controllers can be constructed to control the dynamics and stability of the ER fluid lubricated bearings.     

反作用飞轮驱动电机的电磁设计

为解决反作用飞轮用永磁无刷直流电机的电磁设计问题,提出了一种采用有限元法与磁路法相结合方式进行电机电磁设计的目标设计法。根据飞轮电机有效电磁气隙宽、径长比大的结构特点,推导了电枢尺寸与机械特性、有效电磁气隙、径长比等参数间的关系表达式,得到新的电枢尺寸计算公式;利用磁场逆问题求解策略结合等效气隙磁通密度方法,给出磁钢尺寸的计算模型;最后描述了整个电磁设计过程。与一台最高转速为6000r/min、角动量为5Nms的反作用飞轮驱动电机的对比验证表明,该方法最大设计误差为2.89%,精度较高。该方法不受传统方法取值思想的限制,目标明确,速度快,适用于大的有效电磁气隙,大径长比结构的飞轮电机的电磁设计。     

Bearing materials for small electric motors

Operation of small electrical machines with bearings under boundary lubrication conditions does not receive much attention in the literature. Yet there are some fifty million fhp (fractional horsepower) induction motors made every year. This article outlines the bearing types used in these motors and examines a new polymer lined bearing which seems attractive for many applications using sleeve or ball bearings