齿轮传动磨损状态静电综合监测技术研究

发布时间：2018-06-12 20:19

本文选题：齿轮传动 + 摩擦磨损　；参考：《南京航空航天大学》2016年博士论文

【摘要】：齿轮传动系统作为机械设备的关键部件,其性能退化或失效会影响整机性能甚至导致设备非计划停机,造成经济损失甚至人员伤亡。由于工业生产的需要,齿轮传动系统作为机械设备中重要的传递动力部分常常需要在高速重载的条件下连续工作,因此其故障率一直居高不下,由于摩擦磨损而产生的故障和失效是引起系统严重事故的主要诱因之一。现有振动、温度等常规监测技术能够监测到表面裂纹、剥落和齿轮折断等较严重故障,但发现故障征兆到最后失效间隔时间短,难以有充分的时间制定维修策略,且恶劣的工况环境会大大降低这些手段的故障检测能力。本文针对以上问题,从系统状态监测角度出发,以新型静电监测技术为核心,开展了有关静电传感器建模、仿真、标定、信号特征提取、多参数融合等方面的研究,并结合齿轮传动系统特点,设计和搭建了配套的软硬件设备,进而开展实际的工程实验研究。研究成果对于提高机械设备关键部件的状态监测能力具有重要参考价值和指导意义。论文主要研究内容如下:(1)系统总结和归纳了机械设备摩擦磨损时的静电产生机理,摩擦荷电、摩擦发射、摩擦起电、表面荷电和磨粒荷电是静电信息的五种主要来源。详细介绍了静电监测时所依据的静电感应原理以及依据该原理设计的两类最基本的静电传感器,磨损区域静电传感器和润滑油路静电传感器。并对静电监测技术目前主要的研究方向、应用领域和优势特点进行了细致的梳理和分析。(2)由于静电感应原理特殊,难以有效的描述和衡量静电传感器特性。通过采用理论建模方法,分别建立润滑油路静电传感器和磨损区域静电传感器的数学模型,依据所建模型和传感器特点提炼出相应的性能参数指标。在此基础上进行仿真,得出相应的参数变化规律和影响因素,为静电传感器性能的准确描述和实验验证提供了基础。(3)针对实物静电传感器缺少必要的标定平台和有效的验证方法,设计并加工了可用于静电传感器标定的实验平台。以所提性能参数为基础,分别针对两类静电传感器进行了一系列的标定实验。各项参数指标的实验结果与理论仿真分析结果相一致,证明了所建模型和仿真结果的正确性。初步完成了对已完成加工制造的实物静电传感器的标定工作,并为静电传感器的进一步设计与优化提供了重要的参考依据。(4)为解决静电多传感器综合监测的问题,提高系统监测的精度和可靠性,在采用时域方法和复杂度度量方法进行静电信号多特征参数提取的基础上,提出适用于静电多传感器信息融合的移动窗局部离群因子多工况时变算法。分别通过改进的滚动轴承静电综合监测平台和销盘磨损静电综合监测平台进行实验,对比验证了所提方法在静电综合监测中的适用性和有效性。(5)为实现工程实际中机械设备摩擦磨损的静电综合监测,以齿轮传动系统为研究对象,静电监测技术为核心,围绕硬件设备的架构和软件系统的开发,设计和搭建了一套完整的面向齿轮传动磨损的静电综合监测系统,并对系统中涉及的具体硬件设备组成和软件功能模块进行了详细的介绍和分析。该系统真正实现了齿轮传动系统、静电监测技术和数据分析处理三者间的有效融合,为齿轮传动系统的静电综合监测提供必要的支持。(6)以前述一系列研究为基础,开展齿轮传动健康状态监测的工程应用实验。将静电综合监测技术分别搭载实际的轨道交通车辆齿轮传动系统和风电齿轮传动系统平台,按照相应的实验流程和步骤,分别通过负荷疲劳实验、寿命加速实验和破坏实验,验证了工程中齿轮传动健康状态静电综合监测的可行性和准确性。
[Abstract]:As the key component of the mechanical equipment, the gear transmission system is the key component of the mechanical equipment. Its performance degradation or failure will affect the performance of the whole machine and even cause the equipment not to stop, causing economic loss and even casualties. Because of the need of industrial production, the gear transmission system, as an important transmission power part of the mechanical equipment, often needs the condition of high speed heavy load. As a result of continuous work, the failure rate is always high and the failure and failure caused by friction and wear are one of the main causes of serious system accidents. The existing conventional monitoring techniques, such as vibration and temperature, can monitor the severe faults such as surface cracks, peeling and gear breaking, but the fault signs are found to the final failure interval. The time is short, it is difficult to have sufficient time to make the maintenance strategy, and the bad working condition environment will greatly reduce the fault detection ability of these means. This paper, aiming at the above problems, starts with the system state monitoring point of view, taking the new electrostatic monitoring technology as the core, and develops the modeling, simulation, calibration, signal feature extraction and multi reference of the electrostatic sensor. The study of number fusion, combined with the characteristics of gear transmission system, designed and built supporting software and hardware equipment, and then carried out practical engineering experiment research. The research results have important reference value and guiding significance for improving the state monitoring ability of the key parts of mechanical equipment. The main contents of this paper are as follows: (1) system general The mechanism of static electricity generation, friction charge, friction emission, friction and electricity, surface charge and abrasive charge are the five main sources of electrostatic information. The principle of electrostatic induction and the two basic Electrostatic Sensors Based on the original design are introduced in detail. The main research directions, application fields and advantages of static electricity monitoring technology are carefully combed and analyzed. (2) because of the special principle of electrostatic induction, it is difficult to effectively describe and measure the specificity of electrostatic sensors. The mathematical model of the electrostatic sensor of the lubricating oil road and the electrostatic sensor of the wear area is extracted according to the characteristics of the model and the sensor. On this basis, the simulation is carried out, and the corresponding parameter variation and the influencing factors are obtained, which provides the basis for the accurate description of the performance of the electrostatic sensor and the experimental verification. (3) The physical static sensor lacks the necessary calibration platform and effective verification method, and designs and processes the experimental platform which can be used to calibrate the electrostatic sensor. Based on the performance parameters, a series of calibration experiments for two kinds of electrostatic sensors are carried out respectively. The experimental results of the parameters refer to the results of the theoretical simulation analysis. The correctness of the model and simulation results is proved. The calibration of the physical static sensor has been completed preliminarily, and it provides an important reference for the further design and optimization of the electrostatic sensor. (4) to solve the problem of the multi-sensor integrated monitoring of the electrostatic sensor and improve the accuracy and the accuracy of the system monitoring. On the basis of using the time domain method and the complexity measurement method to extract the multi characteristic parameters of the electrostatic signal, the time-varying algorithm for the multi operating conditions of the mobile window local outliers suitable for the static multi-sensor information fusion is proposed. The improved electrostatic comprehensive monitoring platform for rolling bearings and the integrated monitoring platform for the wear and wear of the pin and disk are carried out respectively. Experiments are carried out to verify the applicability and effectiveness of the proposed method in the comprehensive electrostatic monitoring. (5) in order to realize the comprehensive electrostatic monitoring of the friction and wear of the machinery and equipment in the engineering practice, the research object of the gear transmission system, the static monitoring technology as the core, the development of the architecture and software system around the hardware, and the design and construction of the system. A complete set of integrated electrostatic monitoring system for gear transmission wear is made, and detailed introduction and analysis are made of the specific hardware equipment and software function modules involved in the system. The system has truly realized the effective fusion of the gear transmission system, the electrostatic monitoring technology and the data analysis place between the three parties, and for the gear transmission system. The comprehensive electrostatic monitoring provides the necessary support. (6) on the basis of a series of previous studies, the engineering application experiment of the health monitoring of gear transmission is carried out. The integrated electrostatic monitoring technology is carried out on the actual rail vehicle gear transmission system and the wind power gear transmission system platform respectively, according to the corresponding experimental process and steps, respectively. Through load fatigue test, life accelerated test and destruction test, the feasibility and accuracy of comprehensive monitoring of gear transmission health condition in engineering are verified.
【学位授予单位】：南京航空航天大学
【学位级别】：博士
【学位授予年份】：2016
【分类号】：TH132.41;TH117.1

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