在线铁谱数据分析方法的研究

在线铁谱仪已成功地用于机械设备的磨损状态监测,如何根据铁谱数据来分析机器磨损状态和磨损规律一直被人们所重视。本文利用自组织特征映射神经网络对齿轮整个磨损过程的铁谱数据进行分类,提出了齿轮不同磨损状态下磨粒的分布规律,根据这种规律可以识别齿轮的不同磨损状态。这对监测机械设备运行状态具有十分重要的意义。     

齿轮磨损状态的在线铁谱监测试验研究

对ＯＬＦ１在线铁谱仪用于齿轮磨损状态的监测进行了研究。试验数据分析表明，ＯＬＦ－１在线铁谱仪对大磨粒有很强的敏感性，其采样值的大小和变化反映了齿面状态的变化。在正常磨损情况下，采样值曲线比较平稳；而一旦采样值出现无规律波动，则意味着不正常磨损的开始。与分析铁谱仪数据对比，也显示出非常近似的变化趋势。因而，ＯＬＦ－１在线铁谱仪用于齿轮磨损状态的实时和连续监测具有良好的性能。本文同时指出，ＯＬＦ－１在线铁谱与其它油液分析技术相结合，可以更准确地进行齿轮磨损状态的监测和诊断     

利用铁谱技术分析某柴油机的摩擦聚合物

发动机所处的磨损状态是判断其是否正常工作的一个重要的标准,其中各摩擦副的工作环境恶劣、磨损过程复杂,很难精确描述.在发动机磨损异常状态监测尤其要引起注意.文章利用铁谱技术对其润滑油变质产物--摩擦聚合物进行监测,通过磨粒分析来判断发动机的磨损状态.     

基于在线铁谱图像的磨损机理智能辨识

基于状态的维护(Condition based maintenance,CBM)理念为机器健康状态维护提出了实时监测的新挑战。现有研究由于缺乏在线信息获取手段,磨损状态监测逐渐成为CBM的技术瓶颈。基于特征磨粒的磨损机理判断方法已经被广泛应用在离线磨损分析中,但是在线磨损机理的表征依然是一个很大的问题。针对基于在线铁谱图像的磨损机理开展研究。为了在一副在线铁谱图像中获得分离的磨粒图像,研究磨粒在在线铁谱传感器中的沉积机理。研究结果表明,磨粒链是图像中的主要形态,这是由于先前沉积的磨粒产生的局部磁场所致。设计一种依靠自适应调节沉积时间的在线磨粒沉积方法。运用该方法可以在在线铁谱图像中获得分离的磨粒,为特征磨粒的特征辨识提供了便利。参考分析铁谱知识,提取特征磨粒的4种形态学特征(当量尺寸、长径比、形状因子和分形维数)以综合表征4种典型磨损机理,包括正常、切削、疲劳、严重滑动磨损。采用反馈式人工神经网络构建自动磨损机理辨识模型。采用离线铁谱图像样本验证所建模型,结果表明该模型可以识别在线磨粒图像中的特征磨粒。对在线磨损机理表征方法进行了有意义的探索,所得研究成果将为在线磨损状态表征提供可行方法。     

铁谱技术在判断发动机磨损状态中的应用研究

发动机中各摩擦副的工作环境恶劣,磨拟状态复杂,很难精确描述。而发动机所处的磨损状态是判断其是否正常工作的重要标准,因此建立发动机磨损状态监测具有重大的经济和社会效益。笔者利用铁谱技术作为一种监测手段,通过磨粒分析来判断发动机的磨损状态。     

铁谱技术及其应用(一)

本文概述了铁谱技术的基本原理与特点,特别评价了其在机器状态监测方面的发展。简要介绍了铁谱仪的原理、结构以及磨损颗粒识别等方面的知识。并根据国内外有关资料及作者近年来的实践,结合典型实例分析,分别阐述了铁谱技术在摩擦学基础研究和摩擦学系统状态监测中的应用。主要内容包括:一、前言;二、铁谱技术的基本原理与特点;三、铁谱仪原理与结构;四、磨损颗粒识别与定量参数的选择;五、铁谱技术在摩擦学基础研究中的应用;六、铁谱技术在摩擦学系统状态监测中的应用;七、铁谱技术的发展趋势。     

内燃机车机油光谱数据特征分析与故障诊断

机油光谱分析技术已广泛用于内燃机车柴油机的磨损状态监测 ,但是 ,受现场补换油不确定性的影响 ,光谱数据所反映的系统磨损信息受到严重干扰。本文以 DF4内燃机车机油光谱分析为对象 ,在研究补换油影响、样本总体分布、柴油机磨损机理的基础上 ,提出了分析柴油机主要摩擦付磨损状况的特征量 ,并将这些特征量用于实例分析     

机械设备磨损状态的远程监测诊断系统研究

本文结合铁谱技术和网络技术，建立机械设备磨损状态远程监测诊断中心，提出了基于油液分析的机械设备磨损状态远程监测诊断系统的体系结构及其运行模式。分析探讨了系统中使用的关键技术，机械设备磨损状态远程监测诊断系统降低了企业实施油液分析的技术要求，充分利用了专家的专业知识，实现了异地数据共享、协同诊断，提高了磨损状态监测诊断的准确性。     

采煤机截割部内漏水的危害性及治理

基于油液分析与铁谱技术,在线监测诊断采煤机截割部的润滑磨损故障。介绍采用铁谱技术定性定量测定润滑油中水分含量的方法;揭示截割部传动系统润滑条件恶化造成严重磨损及故障状态下磨损磨粒的宏微观特征;阐述润滑失效机制。分析内漏水对采煤机润滑系统危害的严重性,找出采煤机截割部内漏水源结点,采取治理措施,实际应用取得明显效果。     

基于铁谱分析技术的齿轮磨损研究

齿轮的运行状态直接影响整个机械系统的工作状况。文中利用铁谱技术分析齿轮副各个磨损期的形成机理及形成的磨粒特征,从而实现在实际工况中应该如何合理使用齿轮副,使其具有实用性。     

Advances in research on a multi-channel on-line ferrograph

This paper introduces the basic principle, functions and test results of a multi-channel on-line ferrograph. The instrument catches wear debris with an electromagnet, detects wear debris with a photoelectric sensor, and controls sampling and data processing with an 8098 single-chip microprocessor which can communicate with a master computer. The instrument has four sampling channels, which can monitor not only one machine but also four machines one by one. The software of the instrument includes five modules which are a main program, a keyboard control program, a floating point operation program, a serial communication program and a self-checking program. The results of experiments on a gear box show that increasing average values detected by the instrument correspond to increasing load, so the instrument can meet the need for on-line monitoring of the wear condition of machines.     

Intelligent identification of wear mechanism via on-line ferrograph images

Condition based maintenance（CBM） issues a new challenge of real-time monitoring for machine health maintenance. Wear state monitoring becomes the bottle-neck of CBM due to the lack of on-line information acquiring means. The wear mechanism judgment with characteristic wear debris has been widely adopted in off-line wear analysis; however, on-line wear mechanism characterization remains a big problem. In this paper, the wear mechanism identification via on-line ferrograph images is studied. To obtain isolated wear debris in an on-line ferrograph image, the deposition mechanism of wear debris in on-line ferrograph sensor is studied. The study result shows wear debris chain is the main morphology due to local magnetic field around the deposited wear debris. Accordingly, an improved sampling route for on-line wear debris deposition is designed with focus on the self-adjustment deposition time. As a result, isolated wear debris can be obtained in an on-line image, which facilitates the feature extraction of characteristic wear debris. By referring to the knowledge of analytical ferrograph, four dimensionless morphological features, including equivalent dimension, length-width ratio, shape factor, and contour fractal dimension of characteristic wear debris are extracted for distinguishing four typical wear mechanisms including normal, cutting, fatigue, and severe sliding wear. Furthermore, a feed-forward neural network is adopted to construct an automatic wear mechanism identification model. By training with the samples from analytical ferrograph, the model might identify some typical characteristic wear debris in an on-line ferrograph image. This paper performs a meaningful exploratory for on-line wear mechanism analysis, and the obtained results will provide a feasible way for on-line wear state monitoring.     

直读铁谱在舰船机械状态监测上的应用

采用直读铁谱仪对某型船用机械在用润滑油进行了跟踪监测,选择IS(磨损烈度指数)作为定性分析的判据,利用三线值法对某型船用齿轮箱润滑油样的直读铁谱数据进行处理,并制定出了监测标准。诊断实践证明,直读铁谱监测特征参数IS的选择,是合理准确的,基于三线值法建立的润滑油直读铁谱分析诊断标准,具有良好的实效性,能够较准确地判断和预测船用发动机油润部件的磨损状态和磨损趋势。     

Engine Wear Monitoring with OLVF

In this article, an on-line visual ferrograph (OLVF) was used to monitor the wear condition of a vehicle engine during a bench test. A quantitative index of particle coverage area (IPCA) and wear debris ferro-image were obtained via OLVF to characterize wear degrees. On-line ferrograph analysis indicated some problems with the engine from about the 17th hour. A linear threshold value method to identify running condition of engines with the OLVF data was proposed. The OLVF data were in a fault zone after running for 25 h, when a base bolt broke and the engine stopped working during the test. The engine was disassembled and inspected after the test. Several wear scars were found on the cylinder walls as well as on the bearing surfaces. The oil was added at the 26th and 55th hours, which was also reflected by the variation of IPCA. Moreover, several off-line analyses were carried out in parallel. Off-line ferrograph data did not give any information about the abnormality and only showed stable wear debris content. Spectrometric oil analysis showed that there was no significant change in contents of metal elements.     

钢质渐开线直齿在不同润滑介质下滚滑磨合磨损的试验研究

将金属切削乳化液、机械油和极压齿轮油分别作为齿轮磨合介质,测试和分析了齿轮磨合振动、磨合油样铁谱、油膜电阻、油液温度以及三维表面形貌,建立了摩擦振动加速度的动力学分析模型,得到了3种润滑介质磨合特性及其测试参数特性,并初步分析了磨合磨损机制。结果表明,以金属切削乳化液为介质时,齿轮磨合时间最长;以矿物机械油和以同粘度极压齿轮油为介质时,齿轮磨合完成时间相当,但以极压齿轮油为介质时磨合磨损更为剧烈。齿轮磨合过程中,振动加速度,直读、分析铁谱参数,油膜电阻和油液温度参数都可以作为磨合是否完成的判断依据。磨合完成后,小齿轮的三维粗糙度略有减小,而大齿轮的三维粗糙度皆增大,大齿轮和小齿轮齿面粗糙度值差使两者磨损率达到相互平衡。磨合阶段的磨损机制非常复杂,同时伴有犁沟、粘着、疲劳、氧化以及润滑磨损等。     

考虑油膜压力作用的直齿圆锥齿轮应力分析

采用Solidworks建立直齿锥齿轮三维模型,通过Solidworks软件和Ansys软件数据接口将锥齿轮三维模型导入Ansys软件中,考虑润滑的影响,在Ansys软件中进行直齿圆锥齿轮的应力分析.将齿轮弹流数值计算的油膜压力作为加载项,同时将轮齿接触线扩展成接触面,将线载荷转化成面载荷,计算得到轮齿应力值.与其他计算方法相比,该方法计算结果与真实工作环境下产生的轮齿应力值之间的误差最小.对提高轮齿强度、改进和优化齿轮设计具有一定的参考价值.     

Research on an on-line wear condition monitoring system for marine diesel engine

This paper introduces a kind of on-line wear condition monitoring system for marine diesel engines. The system consists of three functions i.e. particle detecting, lubricant quality detecting and shaft torque moment and instantaneous rotation velocity detecting. The system detects wear particles in lubricant with an on-line ferrograph so as to judge wear condition of tribo-pairs of the diesel engine. A vertical detector fixed is used for environment of the marine diesel engine in this system, and the rule of distribution of particles in the vertical detector fixed and the horizontal detector fixed are alike in substance. The system detects the relative variation of lubricant quality by the grid capacitance sensors in an on-line way, which consists of an upper capacitance and a lower capacitance and can distinguish the relative variation of the dielectric constant of lubricant caused by pollutants such as water, metal particles etc. The system detects the shaft torque moment and the instantaneous rotation velocity of the diesel engine with photoelectric sensors, and corresponds the wear condition with the power condition by the change of instantaneous rotation velocity due to burning pressure change, which is helpful to judge cylinder wear.