基于Wigner分布的齿轮箱振动信号相位估计

时域同步平均是齿轮箱诊断技术的基础,目前这种方法依赖于转速传感器提供相位同步信号。探讨了在没有转速传感器的前提下,由振动信号本身得到相位过零信号的方法。建立了齿轮箱振动信号的一种简化理论模型,通过理论分析得到了一种基于Wigner分布的相位估计方法。将这种方法应用于实际的齿轮箱振动数据,证明这种方法是有效的。     

齿轮箱故障时域和频域综合诊断技术

本文陈述了典型齿轮箱故障振动信号的特点,采用振动噪声诊断法,在传统的各种信号处理方法的基础上采用时域和频域综合分析法,准确地诊断出SG135-2型汽车变速器齿轮箱断齿故障发生部位.     

GEARBOX FAULT DIAGNOSIS BASED ON EMPIRICAL MODE DECOMPOSITION

Time synchronous averaging of vibration data is a fundament technique for gearbox diagnosis. Currently, this technique relies on hardware tachometer to give phase synchronous information. Empirical mode decomposition (HMD) is introduced to replace time synchronous averaging of gearbox vibration signal. With it, any complicated dataset can be decomposed into a finite and often small number of intrinsic mode functions (IMF). The key problem is how to assure that vibration signals deduced by gear defects could be sifted out by HMD. The characteristic vibration signals of gear defects are proved IMFs, which makes it possible to utilize EMD for the diagnosis of gearbox faults. The method is validated by data from recordings of the vibration of a single-stage spiral bevel gearbox with fatigue pitting. The results show EMD is powerful to extract characteristic information from noisy vibration signals.     

Vibration condition monitoring of planetary gearbox under varying external load

The paper shows that for condition monitoring of planetary gearboxes it is important to identify the external varying load condition. In the paper, systematic consideration has been taken of the influence of many factors on the vibration signals generated by a system in which a planetary gearbox is included. These considerations give the basis for vibration signal interpretation, development of the means of condition monitoring, and for the scenario of the degradation of the planetary gearbox. Real measured vibration signals obtained in the industrial environment are processed. The signals are recorded during normal operation of the diagnosed objects, namely planetary gearboxes, which are a part of the driving system used in a bucket wheel excavator, used in lignite mines. It is found that a planetary gearbox in bad condition is more susceptible to load than a gearbox in good condition. The estimated load time traces obtained by a demodulation process of the vibration acceleration signal for a planetary gearbox in good and bad conditions are given. It has been found that the most important factor of the proper planetary gearbox condition is connected with perturbation of arm rotation, where an arm rotation gives rise to a specific vibration signal whose properties are depicted by a short-time Fourier transform (STFT) and Wigner-Ville distribution presented as a time–frequency map. The paper gives evidence that there are two dominant low-frequency causes that influence vibration signal modulation, i.e. the varying load, which comes from the nature of the bucket wheel digging process, and the arm/carrier rotation. These two causes determine the condition of the planetary gearboxes considered. Typical local faults such as cracking or breakage of a gear tooth, or local faults in rolling element bearings, have not been found in the cases considered. In real practice, local faults of planetary gearboxes have not occurred, but heavy destruction of planetary gearboxes have been noticed, which are caused by a prolonged run of a planetary gearbox at the condition of the arm run perturbation. It may be stated that the paper gives a new approach to the condition monitoring of planetary gearboxes. It has been shown that only a root cause analysis based on factors having an influence on the vibration solves the problem of planetary gearbox condition monitoring.     

MISEP盲分离算法在振动信号分析中的应用

利用MISEP算法对直升机齿轮箱振动信号的非线性混叠进行了盲源分离,分离出了轴承故障振动信号,并将该方法应用于实际的飞机发动机的振动信号分析,分离结果表明MISEP盲源分离算法是机械故障诊断领域的一个有效的信号处理方法。     

Transient modeling and parameter identification based on wavelet and correlation filtering for rotating machine fault diagnosis

At constant rotating speed, localized faults in rotating machine tend to result in periodic shocks and thus arouse periodic transients in the vibration signal. The transient feature analysis has always been a crucial problem for localized fault detection, and the key aim for transient feature analysis is to identify the model and its parameters (frequency, damping ratio and time index) of the transient, and the time interval, i.e. period, between transients. Based on wavelet and correlation filtering, a technique incorporating transient modeling and parameter identification is proposed for rotating machine fault feature detection. With the proposed method, both parameters of a single transient and the period between transients can be identified from the vibration signal, and localized faults can be detected based on the parameters, especially the period. First, a simulation signal is used to test the performance of the proposed method. Then the method is applied to the vibration signals of different types of bearings with localized faults in the outer race, the inner race and the rolling element, respectively, and all the results show that the period between transients, representing the localized fault characteristic, is successfully detected. The method is also utilized in gearbox fault diagnosis and the effectiveness is verified through identifying the parameters of the transient model and the period. Moreover, it can be drawn that for bearing fault detection, the single-side wavelet model is more suitable than double-side one, while the double-side model for gearbox fault detection. This research proposed an effective method of localized fault detection for rotating machine fault diagnosis through transient modeling and parameter detection.     

基于SVMD与SLLE的机械设备齿轮箱故障诊断方法

针对机械设备齿轮箱故障识别难度较大,且采集的信号通常受到强背景噪声干扰等问题,提出一种将连续变分模式分解(SVMD)和监督局部线性嵌入(SLLE)相结合的算法,用于机械设备齿轮箱的故障诊断。首先通过SVMD对采集到的振动信号进行分解,得到特定的期望模式分量;然后再获取这些分量的类标签信息,并利用这些类标签信息来缩放不同类别分量间的欧几里德距离;最后通过SLLE对这些处理后的样本数据进行降维处理,从而准确识别机械设备齿轮箱的故障类型。通过对模拟仿真信号和从齿轮箱故障模拟实验平台采集到的振动信号进行分析,聚类识别的正确率可以达到95.27%,验证了所提出方法的可行性。     

瞬时频率估计的齿轮箱升降速信号阶次跟踪

提出了基于瞬时频率估计的齿轮箱升降速信号阶次跟踪的新方法。首先对振动信号进行经验模态分解得到信号的固有模态函数，再求各个固有模态函数的Hilbert变换，得到信号的瞬时频率，从而直接从振动信号得到参考轴的转速信号，然后根据参考轴的转速信号对时域振动信号进行等角度重采样，最后对重采样信号进行阶次分析。通过仿真信号和对齿轮磨损故障实验信号的分析，表明该方法能有效地诊断齿轮的故障。     

小波分析在车辆故障诊断中的应用

车辆变速箱振动信号可用小波分析法预处理后，再用小波包能量尺度图分析法识别故障，按此法对BJ212变速箱准确地进行了故障识别，结果表明利用小波分析进行变速箱故障诊断的方法行之有效。     

基于形态分量分析与能量算子解调的齿轮箱复合故障诊断方法

针对齿轮箱复合故障的故障特征分离,提出了一种基于形态分量分析与能量算子解调的齿轮箱复合故障诊断方法。该方法先根据振动信号中各组成成分形态的差异,采用形态分量分析方法构建不同形态的稀疏表示字典进行故障成分分离,将齿轮箱复合故障信号分解为包含齿轮故障信息的谐振分量、包含轴承故障信息的冲击分量和噪声分量,然后分别对谐振分量和冲击分量进行能量算子解调分析,最后根据各解调谱诊断齿轮和轴承故障。算法仿真和应用实例表明该方法能有效地分离齿轮箱复合故障振动信号中齿轮与轴承的故障特征。     

Sparse signal decomposition method based on multi-scale chirplet and its application to the fault diagnosis of gearboxes

Based on the chirplet path pursuit and the sparse signal decomposition method, a new sparse signal decomposition method based on multi-scale chirplet is proposed and applied to the decomposition of vibration signals from gearboxes in fault diagnosis. An over-complete dictionary with multi-scale chirplets as its atoms is constructed using the method. Because of the multi-scale character, this method is superior to the traditional sparse signal decomposition method wherein only a single scale is adopted, and is more applicable to the decomposition of non-stationary signals with multi-components whose frequencies are time-varying. When there are faults in a gearbox, the vibration signals collected are usually AM-FM signals with multiple components whose frequencies vary with the rotational speed of the shaft. The meshing frequency and modulating frequency, which vary with time, can be derived by the proposed method and can be used in gearbox fault diagnosis under time-varying shaft-rotation speed conditions, where the traditional signal processing methods are always blocked. Both simulations and experiments validate the effectiveness of the proposed method.     

HYBRID WAVELET PACKET-TEAGER ENERGY OPERATOR ANALYSIS AND ITS APPLICATION FOR GEARBOX FAULT DIAGNOSIS

Based on wavelet packet decomposition (WPD) algorithm and Teager energy operator (TEO), a novel gearbox fault detection and diagnosis method is proposed. Its process is expatiated after the principles of WPD and TEO modulation are introduced respectively. The preprocessed signal is interpolated with the cubic spline function, then expanded over the selected basis wavelets. Grouping its wavelet packet components of the signal based on the minimum entropy criterion, the interpolated signal can be decomposed into its dominant components with nearly distinct fault frequency contents. To extract the demodulation information of each dominant component, TEO is used. The performance of the proposed method is assessed by means of several tests on vibration signals collected from the gearbox mounted on a heavy truck. It is proved that hybrid WPD-TEO method is effective and robust for detecting and diagnosing localized gearbox faults.     

多共振分量融合CNN的行星齿轮箱故障诊断

针对行星齿轮箱中各部件所激起的振动成分混叠、早期故障特征经常被较强的各级齿轮谐波成分以及环境噪声所湮没的问题,提出一种多共振分量融合卷积神经网络（multi-resonance component fusion based convolutional neural network,简称MRCF-CNN）的行星齿轮箱故障诊断方法。首先,对振动信号进行共振稀疏分解,得到包含齿轮谐波成分的高共振分量和可能包含轴承故障冲击成分的低共振分量;其次,构建多共振分量融合卷积神经网络,将得到的高、低共振分量和原始振动信号进行自适应的特征级融合,通过有监督的方式训练模型并进行行星齿轮箱故障诊断。对行星齿轮箱实验数据的分析结果表明,该方法能够有效分类行星齿轮箱中滚动轴承和齿轮的故障,成功对行星齿轮箱故障进行诊断,同时能够进一步增强卷积神经网络对振动信号所蕴含的故障信息的辨识能力。     

基于改进经验小波变换的行星齿轮箱故障诊断

行星齿轮箱振动信号具有复杂多分量和调幅-调频的特点。幅值解调和频率解调方法能够避免传统Fourier频谱中的复杂边带分析,有效识别故障特征频率。经验小波变换通过对信号Fourier频谱的分割构造一组正交滤波器组,能提取具有紧支撑Fourier频谱的单分量成分,再对单分量成分运用Hilbert变换即可实现信号的解调分析。经验小波变换能够有效分离出调幅-调频成分,不存在模态混叠现象,具有完备的理论基础,自适应性好、算法简单、计算速度快。将改进的经验小波变换应用于行星齿轮箱振动信号的解调分析;提出了一种单分量个数的估算方法,解决了经验小波变换中的Fourier频谱划分问题;给出了对故障敏感的信号分量的选取方法,提高了分析的针对性。将改进方法应用于行星齿轮箱振动仿真信号和实验信号分析,验证了该方法的有效性。     

Detection of signal transients based on wavelet and statistics for machine fault diagnosis

This paper presents a transient detection method that combines continuous wavelet transform (CWT) and Kolmogorov–Smirnov (K–S) test for machine fault diagnosis. According to this method, the CWT represents the signal in the time-scale plane, and the proposed “step-by-step detection” based on K–S test identifies the transient coefficients. Simulation study shows that the transient feature can be effectively identified in the time-scale plane with the K–S test. Moreover, the transients can be further transformed back into the time domain through the inverse CWT. The proposed method is then utilized in the gearbox vibration transient detection for fault diagnosis, and the results show that the transient features both expressed in the time-scale plane and re-constructed in the time domain characterize the gearbox condition and fault severity development more clearly than the original time domain signal. The proposed method is also applied to the vibration signals of cone bearings with the localized fault in the inner race, outer race and the rolling elements, respectively. The detected transients indicate not only the existence of the bearing faults, but also the information about the fault severity to a certain degree.     

Adaptive filtering based system for extracting gearbox condition feature from the measured vibrations

Vibration signals measured from a gearbox are complex multi-component signals, generated by tooth meshing, gear shaft rotation, gearbox resonance vibration signatures and a substantial amount of noise. This article presents a novel scheme for extracting gearbox fault features using adaptive filtering techniques for enhancing condition features, meshing frequency sidebands. A modified least mean square (LMS) algorithm is developed and validated using only one accelerometer, instead of using two accelerometers in traditional arrangement, as the main signal and a desired signal is artificially generated from the measured shaft speed and gear meshing frequencies. The proposed scheme is applied to a signal simulated from gearbox frequencies with a numerous values of step size. Findings confirm that 10⁻⁵ step size invariably produces more accurate results and there has been a substantial improvement in signal clarity (better signal-to-noise ratio); which make meshing frequency sidebands more discernible. The developed scheme is validated via a number of experiments carried out using two-stage helical gearbox for a pair of healthy gears and one pair suffering from a tooth breakage with severity fault 1 (25% tooth removal), and fault 2 (50% tooth removal) under loads (0%, and 80% of the total load). The experimental results show remarkable improvements and enhance gear fault features. This paper illustrates that the new approach offers a more effective way to detect early faults.     

Application of Instantaneous Rotational Speed to Detect Gearbox Faults Based on Double Encoders

Considerable studies have been carried out on fault diagnosis of gears, with most of them concentrated on conventional vibration analysis. However, besides the complexity of gear dynamics, the diagnosis results in terms of vibration signal are easily misjudged owing to the interference of sensor position or other components. In this paper, an alternative gearbox fault detection method based on the instantaneous rotational speed is proposed because of its advantages over vibration analysis. Depending on the timer/counter-based method for the pulse signal of the optical encoder, the varying rotational speed can be obtained e ectively. Owing to the coupling and meshing of gears in transmission, the excitations are the same for the instantaneous rotational speed of the input and output shafts. Thus, the di erential signal of instantaneous rotational speeds can be adopted to eliminate the e ect of the interference excitations and extract the associated feature of the localized fault e ectively. With the experiments on multistage gearbox test system, the di erential signal of instantaneous speeds is compared with other signals. It is proved that localized faults in the gearbox generate small angular speed fluctuations, which are measurable with an optical encoder. Using the di erential signal of instantaneous speeds, the fault characteristics are extracted in the spectrum where the deterministic frequency component and its harmonics corresponding to crack fault characteristics are displayed clearly.     

齿轮早期疲劳裂纹的混沌检测方法

齿轮箱振动信号中调制现象普遍存在,而且啮合频率产生的周期冲击成分占很大比重,反映齿轮箱故障的特征信号的幅值相对较低,难以检测。根据齿轮箱振动信号的特点,提出了基于混沌振子的齿轮早期疲劳裂纹检测方法,区别于目前常用的基于混沌振子的微弱信号检测方法。该方法通过辨识混沌振子加入齿轮箱振动信号后发生的由大尺度周期状态到混沌状态的反向状态改变,确定齿轮啮合频率边频带的状态,从而判断齿轮裂纹的发展情况,在齿轮裂纹的监测中取得了良好的效果。     

An experimental study on the fault diagnosis of wind turbines through a condition monitoring system

To detect wind turbine faults at an early stage, an investigation into a practical maintenance and repair approach was carried out on Jeju Island, South Korea. A condition monitoring system was installed in each wind turbine nacelle to detect the vibration signals from the gearbox and the generator. The vibration signals were measured by strain gauges on the gearbox and the generator for a period of approximately one to two years. A time domain analysis to detect the components’ faults was performed, and a frequency domain analysis was conducted to find the location of the faults that occurred. Using the criteria of acceptance level for the root mean square suggested in Verein Deutscher Ingenieure standard 3834, it was determined whether or not the gearbox and the generator were operated normally. After a fault was detected by root mean square analysis, the fast fourier transform spectrum was analyzed and then compared with that suggested by the International Organization for Standardization standard 10816–21 and 13373–1. Repair work was then conducted on the defective parts of the components. The root mean square and the acceleration value of the normal, the warning and the abnormal conditions were compared with one another. As a result, cavitation might occur in the gear oil pump attached to the gearbox due to the high acceleration values observed for frequencies ranging from 5000 Hz to 11000 Hz. Additionally, the generator bearing at the non drive end was found to be broken because the defect frequency of the bearing was 88 Hz, which was derived from envelope spectrum analysis. The root mean square and the acceleration values for the gearbox and the generator decreased to values indicating normal operating conditions after the damage repair. The annual energy production increased by 1.8 % after the generator bearing repair.     

Local fault detection in helical gears via vibration and acoustic signals using EMD based statistical parameter analysis

Gear is a vital transmission element, finding numerous applications in small, medium and large machinery. Excessive loads, speeds and improper operating conditions may cause defects on their bearing surfaces, thereby triggering abnormal vibrations in whole machine structures. This paper describes the implementation of empirical mode decomposition (EMD) method for monitoring simulated faults using vibration and acoustic signals in a two stage helical gearbox. By using EMD method, a complicated signal can be decomposed into a number of intrinsic mode functions (IMF) based on the local characteristic time scale of the signal. Vibration and acoustic signals are decomposed to extract higher order statistical parameters. Results demonstrate the effectiveness of EMD based statistical parameters to diagnose severity of local faults on helical gear tooth. Kurtosis values from EMD and that obtained from vibration and acoustic signals are compared to demonstrate the superiority of EMD based technique.