Acoustic detection system and method for in-warehouse non-disassembly railway wheel set bearing

Abstract

The invention discloses an acoustic detection system for non-disassembly of a railway wheel set bearing in a warehouse. The invention further discloses an acoustic detection method for the non-disassembly of the railway wheel set bearing in the warehouse. According to the invention, the wheel set operation sound is picked up; and a detection result is analyzed and output for a worker to judge whether the wheel set has defects or not (the wheel set is accelerated by means of a wheel set running-in machine, a proper distance is kept for the wheel set to be detected through a high-precision microphone sensor to collect sound signals, a wheel set bearing acoustic comparison oscillogram is generated, and the detector can judge whether bearing defects exist or not through the oscillogram). According to the invention, automation and intellectualization of the railway wheel set bearing maintenance process are realized, the operation safety is improved, the upgrading transformation process is accelerated, and the problems of misjudgment and missed judgment caused by strong subjectivity of existing manual detection are solved.

Description

Technical Field

[0001] The invention belongs to the field of online bearing acoustic diagnosis of railway vehicles, and in particular relates to an acoustic detection system and method for railway wheel set bearings without disassembly in a depot. Background Art

[0002] Railway transportation plays an important role in the national economy and is the main means of transportation for the circulation of goods and the commuting of passengers. Wheel bearings are the main components of railway vehicles and are also the most prone to failures.

[0003] The condition of wheelset bearings directly affects the operation status of rail transit. Therefore, it is necessary to inspect railway wheelset bearings to ensure the safety of rail transit operation.

[0004] The existing railway wheel bearing maintenance work in the depot is to use a bearing running-in machine to quickly rotate the wheelset for bearing running-in maintenance, and judge whether there is a problem with the bearing by judging the temperature rise or listening to abnormal sounds manually. However, there are many problems with the above existing solutions: the manual inspection process is long, subjective, the judgment standards are not unified, there will be misjudgments and missed judgments, and it is not convenient to implement the bearing maintenance management system.

[0005] In view of the current maintenance status, railway vehicle depots are in urgent need of an automated and intelligent bearing fault detection method to diagnose bearing faults without disassembly and reduce the occurrence of misjudgment and missed judgment. Summary of the invention

[0006] In view of the current maintenance status, the purpose of the present invention is to provide an acoustic detection system and method for railway wheelset bearings that are not disassembled in the depot. By adopting acoustic diagnosis technology and computer network technology, the working status of the rolling bearing can be identified by collecting and analyzing the sound signals of the bearing running-in operation. It can provide effective early fault diagnosis results inside the rolling bearing and realize the fault detection of the bearing without removal in the depot.

[0007] The technical solution adopted by the present invention to solve its technical problems is: The invention discloses an acoustic detection system for railway wheelset bearings that is not disassembled in a warehouse. The acoustic detection system for railway wheelset bearings that is not disassembled in a warehouse comprises a running-in machine, a sound collection device, and a control cabinet. The control cabinet is respectively communicatively connected with the running-in machine and the sound collection device. The running-in machine is connected to the railway wheelset for accelerated operation, and the sound collection device collects the sound signal of the railway wheelset rotation in a non-contact manner.

[0008] Furthermore, the straight-line distance between the sound collecting device and the bearing center point of the railway wheelset is 0.4-0.8 m, and the sound collecting device forms an angle of 20-40° with the vertical line where the bearing center point of the railway wheelset is located.

[0009] Furthermore, the sound collecting device is placed on the left and right sides of the railway wheelset, and the height of the sound collecting device is consistent with the height of the central axis of the bearing of the railway wheelset.

[0010] Furthermore, the sound collection device includes a collection box, a microphone and a tripod. The microphone is placed in the collection box, and the tripod is placed under the collection box.

[0011] An acoustic detection method for railway wheel set bearings in a depot without disassembly, the method comprising: Step 1): After the railway wheelset to be tested is connected to the running machine, the wheelset identification number is identified and input; Step 2): Install and confirm the location of the sound collection device; Step 3): Run the running machine until the railway wheelset to be tested reaches a rotation state of 180-210 rpm, and the sound collection device starts to collect sound signals; Step 4): The collected sound signal waveform is compared with the standard sound source sound signal waveform, and the two signals are integrated and plotted into a waveform comparison diagram that only highlights the differences between the two, so that the operator can judge the health status of the railway wheelset to be tested in a concise and clear manner. If the waveform is abnormal, an automatic alarm will be issued.

[0012] Furthermore, the sound collecting device is placed on the left and right sides of the railway wheelset, and the height of the sound collecting device is consistent with the height of the central axis of the bearing of the railway wheelset; the straight-line distance between the sound collecting device and the bearing center point of the railway wheelset is 0.4~0.8m, and the sound collecting device and the vertical line where the bearing center point of the railway wheelset is located are at an angle of 20~40°.

[0013] Furthermore, when the rotation speed of the railway wheelset to be tested reaches 200 revolutions per minute, the sound signal is started to be collected.

[0014] Furthermore, the acoustic data of the railway wheelset to be tested is automatically collected and stored according to the pre-set test duration, and the waveform diagram displays the fluctuation status in real time.

[0015] Furthermore, in terms of noise reduction and high-speed signal acquisition: the present invention effectively improves the system signal-to-noise ratio by adopting sensors with excellent directional characteristics and low noise levels, as well as high-fidelity, multi-stage filtering and high-speed signal acquisition technologies. At the same time, by adopting digital filters, the system's anti-interference ability is greatly improved.

[0016] The principle of the present invention is as follows: The vibrations produced by the defective wheelset when rotating at high speed are slightly different from those produced by the normal wheelset. The sound produced by the normal wheelset when running on the running-in machine is continuous and stable, while when the bearing of the wheelset running on the running-in machine has defects, the sound will be intermittent, sharp and other abnormal sounds. The detection system of the present invention picks up the running sound of the wheelset, analyzes and outputs the detection results for the staff to judge whether the wheelset has defects (specifically: the wheelset is accelerated by the wheelset running-in machine, and the sound signal is collected by keeping a proper distance from the wheelset to be tested through a high-precision microphone sensor, and a wheelset bearing acoustic comparison waveform is generated. The detection personnel can judge whether there is a bearing defect through this waveform).

[0017] The advantages of the present invention are as follows: (1) The present invention realizes the automation and intelligence of the railway wheelset bearing maintenance process, improves operation safety, and accelerates the upgrading and transformation process.

[0018] (2) The present invention realizes the automated and intelligent detection of the railway wheelset bearing maintenance process, overcoming the problem of strong subjectivity and misjudgment and missed judgment in the existing manual detection.

[0019] (3) The present invention does not require the wheelset bearing to be disassembled and inspected during the entire detection process. The bearing can be detected only by sound, thus realizing the function of detecting faults without disassembling the wheelset bearing.

[0020] (4) The whole detection process of the present invention is integrated into the working process of the bearing running-in machine, thereby improving the inspection and repair level of bearing faults, greatly improving the utilization rate of bearings, effectively reducing procurement costs, reducing labor costs and other consumption, and effectively improving inspection and repair efficiency.

[0021] (5) The present invention plays a positive role in ensuring railway transportation safety, improving railway informatization construction, and building a harmonious railway. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a top view of the acoustic detection system for railway wheel set bearings in a warehouse without disassembly of the present invention; Figure 2 It is a schematic diagram of the arrangement of the sound collection device in the detection system; Figure 3 This is an enlarged view of the arrangement of the sound collection device; Figure 4 This is the appearance diagram of the sound collection device; Figure 5 This is an exploded diagram of the sound collection device structure; Figure 6 This is a schematic diagram of the control cabinet; Figure 7This is a comparison diagram of the original waveform of a normal wheelset bearing and the original waveform of a faulty wheelset bearing (the upper part is the original waveform of a normal wheelset bearing, and the lower part is the original waveform of a faulty wheelset bearing); Figure 8 This is a comparison chart of the normal wheelset bearing waveform and the faulty wheelset bearing waveform (the left side is the faulty wheelset bearing waveform, and the right side is the normal wheelset bearing waveform); Fig. 9 It is a flow chart of the acoustic detection method of railway wheel set bearings in the warehouse without disassembly of the present invention; Among them, 1-wheel set to be tested, 2-running machine, 3-sound collection device, 4-control cabinet; 1-1 vertical line where the center point of the bearing is located, 1-2 center point of the bearing, 1-3 installation area; 3-1 Collection box, 3-2 Microphone, 3-3 Tripod; 4-1 cabinet, 4-2 KVM converter, 4-3 Gigabit switch, 4-4 industrial computer, 4-5 amplifier chassis. DETAILED DESCRIPTION

[0023] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0024] Embodiment 1: like Figure 1 As shown, the acoustic detection system for railway wheelset bearings without disassembly in the warehouse of the present invention includes a running-in machine 2, a sound collection device 3, and a control cabinet 4. The control cabinet 4 is respectively connected to the running-in machine 2 and the sound collection device 3 for communication and signal transmission.

[0025] The structure of the sound collecting device 3 is as follows: Figure 4 and Figure 5 As shown, it includes a collection box 3-1, a microphone 3-2 and a tripod 3-3. The microphone 3-2 uses B&K4938 (sensor) of B&K Company and is placed in the collection box 3-1. The tripod 3-3 is placed under the collection box 3-1, and the sound collection device 3 can be moved and fixed in the non-working stage. The data line of the microphone 3-2 is led out from the bottom of the collection box 3-1 under the protection of the corrugated tube and connected to the control cabinet 4.

[0026] The specific structure of the sound collection device 3 can also refer to the Chinese patent "An acoustic collection device for non-removal bearings in railway vehicle depot" (application number: 2022205067239), which will not be repeated here.

[0027] The installation position of the sound collection device 3 determines the accuracy of the collected data. The specific arrangement is as follows: Figures 1 to 3As shown. The installation position of the sound collection device 3 is: from the forward direction of the wheelset, the two sound collection devices 3 are placed on the left and right sides of the wheelset 1 to be tested. Each sound collection device 3 forms an angle of 20 to 40 degrees with the vertical line 1-1 where the bearing center point of the wheelset 1 to be tested is located, and the straight-line distance between the sound collection device 3 and the bearing center point 1-2 of the wheelset 1 to be tested is 0.4 to 0.8 meters. The height of the microphone 3-2 is consistent with the height of the bearing center axis of the wheelset 1 to be tested.

[0028] Among them, Figure 1 As shown, the running-in machine 2 is located on the left and right sides of the wheelset 1 to be tested, and the running-in machine 2 can accelerate the wheelset 1 to be tested.

[0029] Among them, the structure of the control cabinet 4 is as follows Figure 6 As shown, it includes a cabinet 4-1, a KVM converter 4-2, a gigabit switch 4-3, an industrial computer 4-4, and an amplifier chassis 4-5.

[0030] In this embodiment, the KVM converter 4-2 uses the DT1708-C model produced by Jiangsu Datang Guardian Technology Co., Ltd.; the Gigabit switch 4-3 uses the CM633 model produced by Shenzhen Green Link Technology Co., Ltd.; the industrial computer 4-4 uses the 4320 4U cabinet-type industrial computer produced by Advantech Technology; the amplifier chassis 4-5 uses the B&K2670 (preamplifier) ​​and B&K2690 (multi-channel intelligent signal amplification processing unit) of B&K Company, which are installed in a standard aluminum chassis together with the power supply; the above equipment is integrated and installed in the cabinet 4-1, and the external 220v power supply is connected. The KVM converter 4-2, the industrial computer 4-4 and the amplifier chassis 4-5 are combined and connected to each other, receiving the signal of the sound collection device 3, converting the collected signal into data for recording, analysis, storage, and displaying through the display; the Gigabit switch 4-3 provides the function of remote data transmission.

[0031] In summary, the functions of the control cabinet 4 are: through external power supply, the picked-up sound signal is analyzed for energy and power, and fuzzy diagnosis and wavelet analysis theory are used to draw a concise and clear waveform diagram (pick up sample conversion, and compare it with the standard sample, and output the compared waveform diagram) to help the inspection personnel determine whether the wheelset to be tested has a fault.

[0032] Acoustic signal acquisition principle: The sensor uses B&K4938 (sensor) from B&K Company, and the amplifier uses B&K2670 (preamplifier) ​​and B&K2690 (multi-channel intelligent signal amplification processing unit); Figure 1As shown, the sensor is located in the sound collection device 3; B&K2670 (preamplifier) ​​and B&K2690 (multi-channel intelligent signal amplification processing unit) are located in the amplifier chassis 4-5 of the control cabinet 4. B&K2690 is a multifunctional intelligent sound signal processing unit, and the user and software can set the sensitivity of its output, filtering mode and parameters, and provide the working voltage of the sensor, etc., especially in conjunction with B&K4938 and B&K2670 to achieve self-calibration function.

[0033] The signal acquisition uses the intelligent data acquisition card Idsc 1816 of Microstar Laboratories, which is inserted into the industrial computer 4-4 and the bus is PCI bus mode. The function is to collect the collected signals into the industrial computer 4-4 so that the industrial computer 4-4 can process the data information. In addition to the data acquisition function, the acquisition card also includes a dedicated data processing mechanism, including 2 DSP processors and an on-board computer structure with a dedicated 32-bit on-board operating system. It can complete the anti-aliasing filtering of sound signals, sound processing and other advanced functions according to requirements.

[0034] The method for performing acoustic detection of railway wheelset bearings in a warehouse without disassembly using the in-warehouse non-disassembly railway wheelset bearing acoustic detection system of this embodiment is as follows: Fig. 9 As shown, the details are as follows: Step (1): After the wheelset 1 to be tested is connected to the bearing running-in machine (running-in machine 2), the wheelset identification number is identified and input.

[0035] Step (2): Install and confirm the location of the sound collection device. The installation location of the sound collection device 3 determines the accuracy of the collected data.

[0036] like Figure 2 and Figure 3 As shown, based on the forward direction of the wheelset, two sound collection devices 3 are placed on the left and right sides of the wheelset, each device is at an angle of 20 to 40 degrees to the vertical line 1-1 where the bearing center point of the wheelset 1 to be measured is located, and the straight-line distance range from the bearing center point 1-2 is 0.4 to 0.8 meters. The data line of the microphone 3-2 is led out from the bottom of the collection box 3-1 under the protection of the bellows and connected to the control cabinet 4.

[0037] Step (3): Run the running-in machine 2 until the wheelset 1 to be tested reaches a rotation state of 180-210 rpm, and the sound collection device 3 starts collecting sound signals.

[0038] Preferably, when the rotation speed of the wheelset 1 to be tested reaches 200 rpm, the sound signal is started to be collected.

[0039] Step (4): Rolling bearings have several natural vibrations, represented by the bending natural vibration of the outer ring. Together with the bearing vibration frequency associated with the unevenness of the inner ring rolling surface, it constitutes the natural vibration spectrum of the rolling bearing. If the surface roughness is damaged due to poor lubrication and foreign matter, the unevenness of the surface becomes larger, and the corresponding vibration force and amplitude increase accordingly, which is significantly different from the natural sound waveform. Or due to peeling failure, that is, when local peeling or cracking occurs on the surface due to material fatigue, the defect will generate impact vibration force when the bearing rotates, and because of continuous rotation, the fault impact occurs periodically, which will also appear in the collected sound signal waveform as a periodic waveform different from the natural waveform.

[0040] Therefore, the collected sound signal waveform is compared with the system standard sound source sound signal waveform, such as Figure 7 In the figure, the upper part is the original waveform of the sound of a standard wheelset, and the lower part is the original waveform of the sound of a faulty wheelset.

[0041] The system integrates the data through a program, and then draws a waveform comparison chart that only highlights the differences between the two signals (such as Figure 8 As shown in the figure, the operator can judge the health status of the wheelset in a concise and clear manner. If the waveform is abnormal, an alarm will be automatically triggered. Specifically, open the corresponding icon on the screen of the control cabinet 4, and after confirming that the bearing model is consistent with the bearing model of the wheelset 1 to be tested, click the start test button to start the test; The system automatically collects and stores bearing acoustic data according to the preset test duration, during which the waveform interface displays the fluctuation status in real time.

[0042] When the predetermined test duration is reached, the test stops automatically and a data packet is generated and displayed in the data list on the system interface. Users can view relevant information including detection time, axle number, bearing model, left / right side fault level, threshold value, sampling times, etc. through the data list. Users can also double-click a single list data to jump to the acquisition interface to view specific waveforms.

[0043] Embodiment 2: The system for acoustic detection of railway wheelset bearings without disassembly in the depot of Example 1 is used to perform acoustic detection of railway wheelset bearings without disassembly in the depot.

[0044] Note: In actual testing, the railway wheelset bearings need to be transported to the Xuzhou factory for inspection and disassembly to finally confirm whether there is a real fault, and it is impossible to test and check at the same time. Therefore, this embodiment first finds the wheelset with known faults, uses this system to measure, and confirms the accuracy of this system. The specific tests are shown in the following table: In the above table: The problematic wheelset bearings of No. 1-6 are first detected by manual inspection and then tested by the system of this embodiment. The results show that the results of the detection by the system of this embodiment are consistent with the results of manual inspection.

[0045] No. 7 first uses the system of this embodiment to detect and finds that there is a problem with the wheelset bearing, and then manually checks it. The results show that the detection of the system of this embodiment is more detailed and accurate.

[0046] No. 8-10 is a wheel set bearing that was found to have problems after disassembly during inspection at the Xuzhou factory. The system of this embodiment was then used for detection, and the results showed that the results of the detection using the system of this embodiment were consistent with the results of the Xuzhou factory inspection.

[0047] It is proved by Example 2 that the in-depot non-disassembly railway wheelset bearing acoustic detection system of the present invention performs in-depot non-disassembly railway wheelset bearing acoustic detection on railway wheelsets, and the result is accurate, and automatic and intelligent bearing acoustic detection can be realized.

[0048] The above description is only a preferred embodiment of the present invention and does not constitute a limitation on the protection scope of the present invention. Any modification, equivalent substitution and improvement made within the spirit and principle of the present invention shall be included in the protection scope of the claims of the present invention.

Claims

1. An acoustic detection system for railway wheel bearings without disassembly in a warehouse, characterized by: The acoustic detection system for railway wheelset bearings that are not disassembled in the warehouse includes a running-in machine, a sound collection device, and a control cabinet. The control cabinet is communicatively connected to the running-in machine and the sound collection device respectively. The running-in machine is connected to the railway wheelset for accelerated operation, and the sound collection device collects the sound signal of the railway wheelset rotation in a non-contact manner.

2. The in-depot non-disassembly railway wheelset bearing acoustic detection system as claimed in claim 1, characterized in that: The straight-line distance between the sound collecting device and the bearing center point of the railway wheelset is 0.4-0.8 m, and the sound collecting device forms an angle of 20-40° with the vertical line where the bearing center point of the railway wheelset is located.

3. The in-depot non-disassembly railway wheelset bearing acoustic detection system as claimed in claim 2, characterized in that: The sound collecting device is placed on the left and right sides of the railway wheelset, and the height of the sound collecting device is consistent with the height of the central axis of the bearing of the railway wheelset.

4. An acoustic detection system for railway wheelset bearings in a warehouse without disassembly as claimed in any one of claims 1 to 3, characterized in that: The sound collection device comprises a collection box, a microphone and a tripod. The microphone is arranged in the collection box, and the tripod is arranged under the collection box.

5. An acoustic detection method for railway wheel bearings without disassembly in a warehouse, characterized in that: The method comprises: Step 1): After the railway wheelset to be tested is connected to the running machine, the wheelset identification number is identified and input; Step 2): Install and confirm the location of the sound collection device; Step 3): Run the running machine until the railway wheelset to be tested reaches a rotation state of 180-210 rpm, and the sound collection device starts to collect sound signals; Step 4): The collected sound signal waveform is compared with the standard sound source sound signal waveform, and the two signals are integrated and plotted into a waveform comparison diagram that only highlights the differences between the two, so that the operator can judge the health status of the railway wheelset to be tested in a concise and clear manner. If the waveform is abnormal, an automatic alarm will be issued.

6. The method according to claim 5, characterized in that The sound collecting device is placed on the left and right sides of the railway wheelset, and the height of the sound collecting device is consistent with the height of the central axis of the bearing of the railway wheelset; the straight-line distance between the sound collecting device and the bearing center point of the railway wheelset is 0.4~0.8m, and the sound collecting device and the vertical line where the bearing center point of the railway wheelset is located are at an angle of 20~40°.

7. The method according to claim 5 or 6, characterized in that When the rotation speed of the railway wheelset to be tested reaches 200 revolutions per minute, the sound signal is started to be collected.

8. The method according to claim 5 or 6, characterized in that The acoustic data of the railway wheelset to be tested is automatically collected and stored according to the pre-set test duration, and the waveform graph displays the fluctuation status in real time.

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