Diagnosis of Gearbox Typical Fault in Rolling Mills Based on the Wavelet Packets Technology

The early impulse fault diagnosis of the gearbox in rolling mills is often difficult and labour intensive because the gearbox of that high speed machine is multi-shafting transmission system, in which many gearsets and rolling bears work together at the same time and there are much complex frequency structure and various disturb. A new time-frequency method based on the wavelet packets technique was developed and used to extract the impact feature from signals collected from faulty data of one rolling mills gearbox. The method improves the signal to noise ration so that results obtained using this method represents features with fine resolution in both low-frequency and the high frequency bands. The results of analysis indicate the validity and the practicability of the method proposed here.     

Gearbox fault diagnosis of rolling mills using multiwavelet sliding window neighboring coefficient denoising and optimal blind deconvolution

Fault diagnosis of rolling mills, especially the main drive gearbox, is of great importance to the high quality products and long-term safe operation. However, the useful fault information is usually submerged in heavy background noise under the severe condition. Thereby, a novel method based on multiwavelet sliding window neighboring coefficient denoising and optimal blind deconvolution is proposed for gearbox fault diagnosis in rolling mills. The emerging multiwavelets can seize the important signal proce...     

动车组齿轮箱滚动轴承变转速故障诊断方法

动车组齿轮箱滚动轴承在运行过程中处于高温重载的变转速工况,容易产生裂纹、点蚀等故障,且不易被检测出来。为及时诊断出动车组齿轮箱滚动轴承的故障,保证动车组的安全行驶,提出了一种变转速工况下的滚动轴承故障诊断方法。首先,结合短时傅里叶变换(STFT)无干扰项与魏格纳-威尔分布(WVD)高时频分辨率的特点,提出了一种融合时频分析算法,该算法能够提高变转速信号分析时的时频矩阵精度;然后,针对动态路径规划方法无法处理归一化时频矩阵的局限性,对其进行了改进,并提取出融合时频矩阵中的转速曲线;此外,进一步提出了一种插值重采样的阶次分析方法,根据转速对采集到的原始信号进行插值重采样,在角域对信号进行重构,并得到对应的阶次谱,实现滚动轴承的故障诊断;最后,通过试验台对提出的变转速动车组故障滚动轴承诊断方法进行了验证。结果表明：本文所提出的方法在动车组转速变化的情况下,能够有效提取出滚动轴承的变转速曲线,并且准确识别出齿轮箱中滚动轴承发生的故障类型。     

基于CBR和RBR混合推理的齿轮箱智能诊断技术

针对传统齿轮箱智能诊断系统获取知识的困难,提出了基于案例(case-based reasoning,CBR)和规则(rule-based reasoning,RBR)混合推理方式的智能诊断技术.在研究此2种推理技术优缺点的基础上,取长补短,合理地将其应用到轧机齿轮箱故障诊断工作中,提高了故障诊断的准确率和效率.针对传统案例检索中相似度算法的不足之处,提出了一种新的案例检索算法,有效地解决了传统的相似度算法检索案例不准确的问题.     

风电齿轮箱齿轮传动系统非线性因素影响分析

针对风力发电机齿轮箱在实际风场中工况复杂的问题,采用集中质量参数法建立了风电齿轮箱传动系统高速级齿轮滚动轴承耦合动力学模型,考虑了传动系统的综合啮合刚度、误差激励、齿面侧隙和轴承径向刚度等非线性影响因素,对1.5 MW风力机齿轮箱传动系统的非线性动力学模型进行了仿真计算分析.采用Runge-Kutta法对模型进行求解得到传动系统的时域波形和幅频响应.结果表明:较小齿面侧隙会使系统出现较大振动响应,随着齿面侧隙增大,系统振动位移减小,会导致系统从周期走向混沌响应;轴承游隙的存在使系统产生混沌响应,呈现出非周期的特征.     

矿岩料层辊压粉碎机理的分析

本文对高压辊作用下料层的破损过程,颗粒的受力状态和破损形态进行了探讨,并对辊压粉碎的比功耗进行了测定,提出了高压辊磨机工作的四个子过程,探讨了高压辊磨机粉碎的机理。     

轧机主传动齿轮箱振动原因分析与判断

某型钢万能轧机齿轮箱是生产线的关键设备,在一次设备正常巡检时发现该轧机主传动齿轮箱振动异常.为查找齿轮箱振动的原因,利用现代振动测试手段对齿轮箱的轴承座的振动进行测量.在测试的基础上,利用故障排除法诊断出齿轮箱故障是由于齿轮箱之外其他故障引起.本齿轮箱振动故障诊断拓展了齿轮箱故障诊断方法,对其他齿轮箱振动故障诊断有所启发.     

Preset model of bending force for 6-high reversing cold rolling mill based on genetic algorithm

The hydraulic roll-bending device was studied, which was widely used in modern cold rolling mills to regulate the strip flatness. The loaded roll gap crown mathematic model and the strip crown mathematic model of the reversing cold rolling process were established, and the deformation model of roll stack system of the 6-high 1 250 mm high crown (HC) reversing cold rolling mill was built by slit beam method. The simulation results show that, the quadratic component of strip crown decreases nearly linearly with the increase of the work roll bending force, when the shifting value of intermediate roll is determined by the rolling process. From the first pass to the fifth pass of reversing rolling process, the crown controllability of bending force is gradually weakened. Base on analyzing the relationship among the main factors associated with roll-bending force in reversing multi-pass rolling, such as strip width and rolling force, a preset mathematic model of bending force is developed by genetic algorithm. The simulation data demonstrate that the relative deviation of flatness criterions in each rolling pass is improved significantly and the mean relative deviation of all five passes is decreased from 25.1% to 1.7%. The model can keep good shape in multi-pass reversing cold rolling process with the high prediction accuracy and can be used to guide the production process.     

ПW万能轧机的结构特点及其应用前景

在中小型横列式轧制机组中,在某一合适的位置上用一架万能轧机替换其中一架三辊轧机,可以在不改变原来整体工艺系统的条件下形成一种新的轧制作业线。这一作业线对于拓宽产品品种、提高产品质量均具有实际意义,并可为传统的三辊横列式轧制机组的改造提供一条可供选择的途径。用本文所论述的万能轧机在国内首次实现了矿用周期П形钢的成批生产。     

高速线材轧机辊环的应力分析

本文介绍了一种新的碳化钨辊环安装方法，并且分析了它的应力。新的安装方法使孔型寿命比老的方法提高了２倍。     

齿轮箱故障诊断中的正交匹配追踪算法

为通过齿轮箱的振动信号进行故障诊断,应用正交匹配追踪算法对振动信号进行处理.齿轮箱的振动信号包含了齿轮箱运行状态特征,但同时也掺杂了大量噪声信号,总体呈现出非平稳性.齿轮箱故障诊断的关键是从齿轮箱的振动信号中剔除冗余信息,用少量特征信息准确的表达信号,完成对信号中故障特征的提取.传统的频域分析法,只能从频域图上定性的判断故障,无法做到定量判断.正交匹配追踪算法是一种定量提取特征的方法,在傅里叶正交基下对振动信号进行时域向频域的映射,在频域上定量的得到主要特征,再根据主成分分析思想,提取出3组主要特征点,将已知故障分类的信号特征与待检测信号的特征进行对比,通过频域的位置和幅值的两次比较,判断故障状态,实验证明该方法可以准确的判断出齿轮箱从正常状态到100%磨损的5个不同形态的特征,完成对齿轮箱的故障诊断和分类.     

大型重载十字轴式万向联轴器等强度设计研究

与全国同类轧机相比，津西钢铁公司轧钢厂850轧机具有特殊工作状况，对万向联轴器要求高，用传统的设计方法很难达到使用要求。本文采用等强度设计原则，采用机械优化设计方法，完成了该万向联轴器的设计，给出了合理的设计参数。改进后的万向联轴器性能完全满足了使用要求，产生了较好的经济效益。     

基于小波包络谱分析法的齿轮箱故障振动信号诊断

利用正交小波基将齿轮箱故障振动信号变换到时间一尺度域.对高频段尺度域的小波系数进行包络细化谱分析,不仅能检测到齿轮箱内部故障的存在,而且能有效地识别故障模式,说明了正交小波分析是信号检测淹没于非平稳信号中瞬时信号的有力工具.结合实例.从小波故障特征提取来说明小波变换的有效性.     

Remote Monitoring and Diagnosis System for High-speed Wire Rolling Mills

Traditional fault diagnosis systems of rolling mills mostly use single machine monitoring net,which leads the re- al-time data running only in the enterprise locally and can not monitor and manage the high-speed wire rolling mills between units, workshops and factories concentratedly.A new-type structure of remote diagnosis system for high-speed wire rolling mills is pre- sented in this paper.The signal processing,computer network and remote diagnosis etc techniques are used to predictive maintenance manage the rolling mills units in this system.The new structure reinforced the remote feedback function,made up the existing fault diagnosis systems' insufficiency in the extension and the function,promoted resource sharing and avoided the repeat develop- ment.The remote diagnosis example shows that the system can monitor and diagnose the fault information of remote machine timely and effectively.     

平整机组制造方法探寻

平整机组设备精度高,制造难度大．对我国目前最大规格的平整机组加工制造中的一些突出问题、制造方法进行了分析研究．重点介绍了卷取机,平整机牌坊、楔型块的加工．     

旋转设备在线健康监控指数研究

利用小波包分解方法对在线监控中收集到的齿轮箱振动信号进行频域划分,并在其划分后的频段上有选择地进行了信号重构。在其基础上提出齿轮在线健康监控指数,可以用来反映齿轮箱整个寿命期间的健康状态。同时,为了实现对齿轮早期故障的预警,提出了一个用来在线检测的动态阈值。通过3套不同的齿轮箱全寿命振动信号数据进行了健康指数和早期预警的验证。实验结果证明,该健康监控指数及其动态阈值可以准确地检测出齿轮早期故障发生的时刻。     

基于EMD和FFT的齿轮箱故障诊断

提出了一种基于小波包分析（WPA）,经验模态分解（EMD）和快速傅里叶变换（FFT）的齿轮箱故障诊断方法,此方法适合于非线性非稳态信号的自适应分析.首先运用WPA对采集的齿轮箱振动信号进行分解可得到不同频率的子频带;然后对各子频带信号进行EMD,从而得到一定数量的本征模态函数（IMF）;最后选取特定的IMF,对其作FFT可得到相应的功率谱,从而提取齿轮箱故障特征频率,进而对齿轮箱故障模式进行识别和诊断.分析结果表明本文所提议的方法能有效地检测出齿轮箱故障特征频率.     

轧机四列圆锥滚子轴承当量动载荷的研究

轴承的当量动载荷是轧机重载轴承疲劳寿命计算的一个重要影响因素。采用弹性力学有限元法对它进行研究得出结果表明,它的取值大小应随轴承工况条件的改变而改变,当轴承工作时的轧制宽度B和轧制力位置l发生变化时,轴承内各列滚子所受载荷不同,此时应在采用力矩载荷系数对当量动载荷进行修正。     

基于自适应滤波的滚动轴承故障诊断研究

针对固有频率未知的滚动轴承故障诊断问题，提出了一种基于经验模态分解的自适应滤波方法。讨论了经验模态分解方法及其在获取固有模态函数过程中的自适应滤波特性。通过对滚动轴承故障振动信号进行经验模态分解得到固有模态函数，运用希尔伯特变换解调固有模态函数得到包络幅频图，获取滚动轴承故障特征频率，进而确定滚动轴承的故障位置。应用该方法对仿真和实际数据进行了分析，并与冲击脉冲法作了比较。结果表明，基于经验模态分解自适应滤波的滚动轴承振动信号解调方法能够更有效地突出故障特征频率成分，避免误诊断。     

应用振型叠加法分析轧机系统动态响应

用振型叠加法求解和分析轧机系统的动态响应，并编制了通用程序对实例进行计算。结果表明，振型叠加法用来分析轧机系统的动态响应是令人满意的。