An Embedded Condition Monitoring and Fault Diagnosis System for Rotary Machines

An intelligent machine is the earnest aspiration of people. From the point of view to construct an intelligent machine with self-monitoring and self-diagnosis abilities, the technology for realizing an internet oriented embedded intelligent condition monitoring and fault diagnosis system for the rotating machine with remote monitoring, diagnosis, maintenance and upgrading functions is introduced systematically. Based on the DSP （ Digital Signal Processor） and embedded microcomputer, the system can measure and store the machine work status in real time, such as the rotating speed and vibration, etc. In the system, the DSP chip is used to do the fault signal processing and feature extraction, and the embedded microcomputer with a customized Linux operation system is used to realize the internet oriented remote software upgrading and system maintenance. Embedded fault diagnosis software based on mobile agent technology is also designed in the system, which can interconnect with the remote fault diagnosis center to realize the collaborative diagnosis. The embedded condition monitoring and fault diagnosis technology proposed in this paper will effectively improve the intelligence degree of the fault diagnosis system.     

A Study on a Remote Monitoring and Diagnosis System and Its Application

Remote monitoring and diagnosis （RMD） is a new kind of monitoring and diagnosis technology that combines computer science, communication technology and fault diagnosis technology. Via the Internet a remote monitoring and diagnosis system can be established. In this paper, the model of an Internet based remote monitoring and diagnosis system is presented; the function of every part of the RMD system is discussed. Then, we introduce a practical example of a remote monitoring and diagnosis system that we established in a factory; its traits and functions are described.     

基于粗糙集理论的机械状态监测与故障诊断

以机械状态监测和故障诊断为背景,利用粗糙集的属性约简功能,研究了基于粗糙集理论的参数优选在柴油机状态监测中的应用.结果表明:利用粗糙集约简后,信息没有丢失,但减少了需测量的参数,而且为后续的融合诊断减少了计算量.研究了基于粗糙集的灰色关联分析在齿轮状态监测中的应用,并将其与一般的灰色关联方法进行了比较,结果表明诊断的精度得到了提高.     

Research on Key Techniques of Condition Monitoring and Fault Diagnosing Systems of Machine Groups

This paper describes the development of the condition monitoring and fault diagnosing system of a group of rotating machinery. The data management is performed by means of double redundant data bases stored simultaneously in both the analyzing server and monitoring client. In this way, high reliability of the storage of data is guaranteed. Condensation of trend data releases much space resource of the hard disk. Diagnosing strategies orientated to different typical faults of rotating machinery are developed and incorporated into the system. Experimental verification shows that the system is suitable and effective for condition monitoring and fault diagnosing for a rotating machine group.     

汽轮发电机组的多微机振动监测与故障诊断系统

大型汽轮发电机组振动监测与故障诊断的多微机系统是在线运行机组的实时监测、数据管理、图谱分析、报表打印、自检报警、事故追忆和故障诊断的多功能系统。它是一种以一主计算机指挥多从属计算机的主从工作方式。应用该系统可大大提高电站设备运行的可靠性、安全性与自动化程度,预防重大事故发生,并可推广应用到风机、水轮机等旋转机械方面。     

基于动态贝叶斯网络与DS证据理论的轧机颤振监测方法

提出了基于动态贝叶斯网络和DS(Dempster/Shafer)证据理论的轧机颤振实时监测方法,该方法预选多个时域和频域的特征参数表征轧机不同工况下振动信号的不同特征,利用稳定判别率方法筛选敏感度高的特征参数;使用动态贝叶斯网络与DS证据理论实时监测模型建立轧机颤振状态实时监测系统,构建连续的速度载荷时间片,将3个连续的速度载荷时间片作为DS证据理论的证据体,给出了优化基本概率分配的信任度方法,解决了DS证据理论的证据体间冲突问题;最后在轧机实验平台进行实验,诊断结果表明：该方法对轧机颤振不同状态的识别率达到99.05%。     

径-轴向辗环机轴向轧制机构结构分析

采用三维造型软件SolidWorks建立了某型号径-轴向辗环机轴向轧制机构的实体模型。以有限元软件ANSYS为分析平台,通过合理处理接触、约束和载荷等边界条件,建立了有限元分析模型,对轴向轧制机构进行了三维弹性接触分析,得到了轴向轧制机构及主要部件的等效应力、位移变形、等效应变。对变形角进行了定义,提出了求解变形角的方法。计算结果表明,变形角为0.041°时,各部件的最大等效应力均小于屈服极限,轴向轧制机构刚度符合设计要求,各部件满足强度要求。     

振动信号时变特征的提取,压缩及机械状态监测

往复式机械和许多周期运转机械的振动激励都具有脉冲性质,振动响应的时间相关局部细节包含丰富的故障信息.本文提出了振动信号的时变模型,用以提取机械运转特征,并提出使用正交变换描述特征母体的一阶矩和二阶矩的方法,在时变特征提取、压缩的基础上,引入模式识别中的距离准则,判断任一信号与母体的相似性,以作为一种监测的度量手段.一个关于柱塞泵振动信号监测的例子说明了本方法的使用过程.     

1420冷连轧机的动态特性及颤振分析

冷连轧的颤振现象是世界各国普遍关心的课题。针对我国某钢厂1420冷连轧出现的颤振现象,从实测人手分析了它的振源和颤振频率,又用有限元分析方法验证了机座发生颤振的实验结论。作为颤振振因的深化研究,对颤振出现前的“拍振”现象进行了分析,推证了轧制过程中有一个自激频率,存在,而且当它与轧机系统的某个固有频率无限接近时会立即引起轧机工作的不稳定。最后,通过建立该系统的非线性扭振微分方程和它的摄动解,进一步证明这种不稳定现象出现是由于轧制速度提高到一定值时系统内产生了负阻尼,其结论是负阻尼是引起轧机颤振的振因。     

A Fault Diagnosis Expert System for a Heavy Motor Used in a Rolling Mill

A fault diagnosis expert system for a heavy motor used in a rolling mill is established in this paper.The fault diagnosis knowledge base was built,and its knowledge was represented by production rules.The knowledge base includes daily inspection system,brief diagnosis system and precise diagno-sis system.A pull-down menu was adopted for the management of the knowledge base.The system can run under the help of expert system development tools.Practical examples show that the expert system can diagnose faults rapidly and precisely.     

Signal Processing for Remote Condition Monitoring of Railway Points

Abstract:  The dependability of railway points (turnouts or switches) is a key part of any railway system; the Potters Bar crash (10 May 2002) in the UK, which led to seven fatalities is a key example of a failure of this subsystem. Present maintenance of points involves overly frequent inspection by maintenance staff. A remote condition monitoring approach would lead to more efficient inspection routines and directed anticipatory maintenance trips. To assist the creation of a suitable fault-detection algorithm, the authors analysed existing force and current data for the 'as commissioned' case of a turnout and for situations with different fault conditions. Signal processing of this data revealed several different methods that can be used to distinguish between fully functioning points, and different fault conditions of the points. Specifically, clustering of statistical parameters and their application to wavelet levels and coefficients, provided clear discrimination of most critical faults. This demonstrates a good first step towards a condition monitoring-based maintenance regime for points that is both safer for passengers and maintenance personnel and that has the potential to be more effective and economical.     

Influence of Lubrication Performance on the Service Life of Rolling Mill Bearings

In order to confirm the early failure cause of a four-row cylindrical roller bearing at the backup roll position of a six-high cold sheet mill, its lubrication behavior under harsh operating conditions is investigated. Through establishing and solving the Elastohydrodynamic Lubrication （EHL） model of the roller-inner raceway contact region, the minimum oil film thickness and the real lubrication performance are achieved. The results show the bearing failures come from the poor oil film thickness in the case of high temperature and low rotational speed, which leads to contact wear. So various approaches to improve bearing life via improving lubrication are compared. It has been proved decreasing surface roughness of both contact bodies is an effective way.     

轧机主传动系统扭振减振器参数设计及特性分析

针对咬钢时突加负载时轧机主传动系统轴系的扭振现象,引入扭振减振器控制装置,建立电动机与扭振减振器的扭振抑制模型;通过对扭振减振器特性参数的设计,得出扭振减振器的惯量比、定调比、阻尼比;同时运用定点理论,得到最佳定调比和阻尼比;通过对比加入扭振减振器前后的时域特性曲线,得出扭振减振器能降低振动幅值;通过调节惯量比、扭转刚度、阻尼系数的大小,得出不同参数变化对轧机主传动系统幅频特性曲线的影响规律,适当的增大惯量比μ可以减小振动幅值,增大扭转刚度K_d可以缩小系统的不稳定区域,增大阻尼系数C_d可以有效降低系统扭转振动幅值,因此选取恰当的参数数值能有效提高轧机系统的稳定性。     

On-line Condition Monitoring and Diagnostic Network System for Rotating Machine Set

1IntroductionThemachineryinfactoryisalwaysthekeyequipment,soOn-lineConditionMonitoringandDiagnosticSystemCMDS)isveryimportant.Usingthissy000000stem,engineerscanknowtherunningconditionclearlyandanalyzethepossiblefaultswhenthesemachinesetscannotrunnormally.Computerscience,numericsignalprocessing,sensorandnetworktechnologyarethekeytechnologiesofnetworkbaseddistributedon-lineCMDS,anddevelopmentofthesetechnologiesmakeCMDSplayamoreimportantroleinindustry.NetworkstructureandfunctionofCMDSare…     

远程监测与故障诊断系统中的视频子系统及实现

视频会议系统在现实中起到了很好的交流与沟通的作用。现在越来越多的企业建立了自己的视频会议系统。在远程故障监测与诊断系统中，融入视频交流系统，能够改变过去单一的诊断模式，更加实时、有效地进行沟通，从而提高诊断的效果。本文在分析开发视频系统的几种技术的基础上，提出了一个视频交流子系统的方案。实际中，按照本方案实现的视频交流系统也达到了一定的预期效果。     

基于IVMD和马田系统的滚动轴承故障检测方法

针对滚动轴承运转信号单一特征参数对早期故障的敏感性、可靠性问题,提出一种基于IVMD和马田系统的滚动轴承故障诊断方法。该方法首先根据谱相关系数确定VMD分解层数;其次,通过VMD方法对机械振动信号进行处理得到一系列有限带宽固有模态函数,并计算各模态函数的特征参数,在此基础上构建MTS系统的基准空间。引用信噪比的方法筛选有效特征变量,并重新构建MTS的基准空间。最后,计算待诊断信号到基准空间的马氏距离来检测轴承故障,建立滚动轴承早期故障的诊断控制指标。     

大中型矿渣立式磨磨盘结构的动态分析

为了探索改进立式磨动态性能的途径,以大中型矿渣立式磨为研究对象,采用有限元软件ANSYS对立式磨磨盘的结构参数调整和设置减震情况进行有限元模态分析,分析振型和固有频率的变化。结果表明,增大磨盘颈部的壁厚,减小磨盘的高度,增大磨盘落料区支撑板的厚度以及减小磨盘的直径,都可以改善立式磨磨盘的动态性能;立式磨磨盘颈部的壁厚增大100 mm,立式磨磨盘落料区支撑板的厚度增大40 mm,固有频率提高了17.77%,实现了磨盘的动态优化。     

基于EMD与AR谱的轧机主传动系统故障诊断研究

针对轧机故障信号的非线性、非平稳特征,研究了一种基于经验模态分解和AR模型功率谱相结合的分析方法。该方法首先对轧机主传动系统的故障信号进行EMD分解,然后通过选取含有故障信息的IMF分量进行AR模型的功率谱分析,从而提取出故障频率,判断引起故障的原因。通过仿真信号和实例验证了该方法的有效性。     

液压缸非线性弹簧力约束下轧机吸振器参数的优化

考虑四辊轧机液压缸非线性弹簧力约束的因素,引入吸振器控制装置,建立带有轧机吸振器的轧机辊系振动动力学模型;通过对轧机吸振器基本参数的优化,得出吸振器最优的阻尼系数和刚度系数;仿真分析不同质量、弹簧力、摩擦力对轧机辊系振动幅频特性曲线的影响规律,得到轧机吸振器的最优质量可以有效提高系统稳定性,轧机吸振器的最优弹簧力可以缩小系统的不稳定区域,轧机吸振器的最优摩擦力可以有效降低幅频特性曲线的高度,为有效抑制轧机辊系垂直振动提供理论支持。     

1220冷连轧机带钢表面振纹机理的研究

针对某1220冷轧机带钢表面振纹形成的原因进行了跟踪测试和深入研究。在对1220冷轧机振动测试的基础上,通过对机架动态特性分析及工作辊周期内各阶段振动信号的分析研究,发现在支撑辊使用中后期,轧机以600Hz左右的第7阶固有振动为主;在轧制速度为中高速稳定轧制阶段,工作辊对中间辊的相对运动形成工作辊表面振纹;该辊面振纹反作用于轧机,引起轧机强迫振动,进一步加速振纹的形成,轧机的振动为共振与强迫振动共存。在分析振纹产生机理的基础上,结合振纹间距与振源的关系,找到了引起1220轧机产生振纹的原因,提出了振纹抑制措施,并取得了很好的抑制效果。