A vibration analysis device and method based on time-domain signals

Abstract

This invention discloses a vibration analysis device and method based on time-domain signals. The vibration analysis method mainly includes three steps: sinusoidal signal period measurement, rotation center coordinate traversal, and rotating machinery vibration calculation. By designing a method to find the minimum value by changing the search radius, the number of calculations in the traversal process is reduced, improving the efficiency of rotation center coordinate traversal. The vibration analysis device is based on a time-series signal analysis method, and its hardware design uses a ZYNQ chip and a high-speed AD acquisition chip. The ZYNQ chip has a maximum main frequency of 667MHz, and the high-speed AD acquisition chip has a maximum acquisition speed of 100MHz, ensuring that the maximum error of the acquired time-domain signal does not exceed 10 microseconds, thereby guaranteeing accurate measurement and rapid processing of the sensor's periodic signal.

Description

Technical Field

[0001] This invention relates to the field of rotating machinery testing technology, and in particular to a vibration analysis device and vibration analysis method based on time-domain signals. Background Technology

[0002] Based on past experience, monitoring the vibration of the drum during the operation of rotating machinery can predict its service life to a certain extent. Furthermore, by analyzing a large amount of data, certain failure modes can be obtained, laying the foundation for predicting various failures of rotating machinery.

[0003] Currently, frequency analysis is commonly used to analyze the vibration of rotating machinery. This involves employing vibration algorithms to determine the trend of amplitude movement, thereby qualitatively assessing the machinery's operating condition. This invention addresses the problem that current frequency domain algorithms used in rotating machinery vibration analysis only provide qualitative results that characterize amplitude trends, failing to yield the magnitude of the amplitude. Summary of the Invention

[0004] The purpose of this invention is to address the technical deficiency of frequency analysis methods in obtaining amplitude values ​​by providing a vibration analysis device based on time-domain signals. This vibration analysis device can improve the signal acquisition accuracy of Hall sensors and calculate the amplitude value of the rotating drum.

[0005] Another objective of this invention is to provide a vibration analysis method based on time-domain signals, which uses a time-domain algorithm to perform vibration analysis and obtain the amplitude data of the rotating drum.

[0006] The technical solution adopted to achieve the purpose of this invention is:

[0007] A vibration analysis device based on time-domain signals includes a ZYNQ main control system and a high-speed AD acquisition module with communication connection;

[0008] The high-speed AD acquisition module is communicatively connected to a Hall sensor installed on rotating machinery to acquire the analog signal output by the Hall sensor; the ZYNQ main control system receives the analog signal acquired by the high-speed AD acquisition module and performs data processing and calculation.

[0009] The high-speed AD acquisition module consists of a high-speed AD chip and an attenuation circuit; the analog signal emitted by the Hall sensor is converted by the attenuation circuit and then acquired by the high-speed AD chip.

[0010] The ZYNQ main control system includes an XC7Z020CLG400-2 main chip module; the XC7Z020CLG400-2 main chip module is communicatively connected to the high-speed AD chip to receive analog signals acquired by the high-speed AD chip.

[0011] In the above technical solution, the high-speed AD chip is the AD9287 chip.

[0012] In the above technical solution, the ZYNQ main control system also includes a communication module.

[0013] In the above technical solution, the communication module includes two communication methods: CAN communication and Ethernet communication.

[0014] In the above technical solution, the CAN communication uses the TJA1050 chip as the CAN driver; the Ethernet communication uses the W5500 chip.

[0015] In the above technical solution, the ZYNQ main control system also includes a storage module.

[0016] In the above technical solution, the storage module includes EEPROM storage and SPI FLASH storage.

[0017] In the above technical solution, the EEPROM storage uses an AT24C16 chip, via I... 2 The C-bus interacts with the XC7Z020CLG400-2 main chip module for data exchange.

[0018] The SPI FLASH storage uses the W25Q128 chip, which interacts with the XC7Z020CLG400-2 main chip module via the SPI bus.

[0019] In the above technical solution, the ZYNQ main control system also includes module power supply; the module power supply provides power to the XC7Z020CLG400-2 main chip module, the communication module, and the storage module.

[0020] In the above technical solution, the module power supply includes 5V and 3.3V power supply.

[0021] The above technical solution also includes system power supply; the system power supply is for the ZYNQ main control system, the high-speed AD acquisition module and the Hall sensor.

[0022] In another aspect of the present invention, a vibration analysis method based on time-domain signals is performed by the aforementioned vibration analysis device.

[0023] The above technical solution includes the following steps:

[0024] Step 1: Measurement of the period of the sinusoidal signal

[0025] Take the four consecutive voltage values V1, V2, V3, V4 closest to 0V in each monotonic interval of the sine signal. The values should satisfy monotonicity, i.e., V1 < V2 < 0 < V3 < V4 or V1 > V2 > 0 > V3 > V4. At this time, the zero point of the voltage signal is between V2 and V3, and the voltage acquisition time interval is 10 μs;

[0026] Record the acquisition time of V2 as t1 and the acquisition time of V3 as t2. Let the zero-crossing time be t0, then

[0027]

[0028] Repeat the above method to obtain the time of each zero-crossing in turn; then calculate the sine periods Tmv1, Tmv2…Tmvn based on the time intervals between adjacent zero-crossings;

[0029] Step 2: Traverse the coordinates of the rotation center

[0030] Let the coordinates of the rotation center o’ be (x, y), the distance between the rotation center and the geometric center o be r μm, the maximum vibration amplitude be a μm, and the calculation step size be p μm;

[0031] r gradually increases from 0 to a in steps of p. Each time r increases by p, the x value changes from 0 to r in steps of p for r / p + 1 times, and the y value is calculated once according to formula (2);

[0032]

[0033] After calculating the y value, use the symmetry of the circle to obtain the symmetric coordinates of the point (x, y) with respect to the y-axis, x-axis, and the center of the circle, which are (-x1, y1), (x2, -y2), and (-x3, -y3) respectively. Substitute these coordinates into the Δi calculation formula, i.e., formula (3), to find four And compare them one by one to retain the minimum value and its corresponding coordinates;

[0034]

[0035] After the traversal, compare all the values to obtain the coordinates (xn, yn) corresponding to the minimum value. This coordinate is the actual rotation center obtained by measurement;

[0036] Step 3: Calculate the vibration of the rotating machinery

[0037] Calculate the actual rotation radius based on the obtained actual rotation center coordinates. The difference between it and the ideal rotation radius is the vibration amount of the rotating machinery.

[0038] Compared with the prior art, the beneficial effects of the present invention are:

[0039] 1. The vibration analysis method provided by this invention reduces the number of calculations during the traversal process and improves the efficiency of traversing the rotation center coordinates by designing a method to find the minimum value by changing the search radius. Combined with the high computing speed of the ZYNQ chip, the processing speed of vibration analysis can meet practical requirements.

[0040] 2. The vibration analysis device based on time-domain signals provided by this invention uses a ZYNQ chip and a high-speed AD acquisition chip to design a vibration analysis method based on time-series signal analysis. The ZYNQ chip has a maximum main frequency of 667MHz, and the high-speed AD acquisition chip has a maximum acquisition speed of 100MHz, which can ensure that the maximum error of the acquired time-domain signal does not exceed 10 microseconds, thereby ensuring accurate measurement and rapid processing of the sensor's periodic signal. Attached Figure Description

[0041] Figure 1 The diagram shows a flowchart of a vibration analysis method based on time-domain signals.

[0042] Figure 2 The diagram shows the position of the rotating drum during the operation of the rotating machinery.

[0043] Figure 3 The diagram shows a vibration analysis system based on time-domain signals.

[0044] Figure 4 The diagram shown is a schematic of the ZYNQ main control system structure.

[0045] Figure 5 The diagram shows the structure of a high-speed AD module.

[0046] In the diagram: 1-ZYNQ main control system, 2-high-speed AD acquisition module, 3-Hall sensor, 4-system power supply, 5-XC7Z020CLG400-2 main chip module, 6-communication module, 7-storage module, 8-module power supply, 9-high-speed AD chip, 10-attenuation circuit. Detailed Implementation

[0047] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0048] Example 1

[0049] A vibration analysis method based on time-domain signals, such as Figure 1 As shown, it includes the following steps:

[0050] Step 1: Measurement of the period of the sinusoidal signal

[0051] Take the four consecutive voltage values V1, V2, V3, and V4 closest to 0V in each monotonic interval of the sine signal. The values should satisfy monotonicity, i.e., V1 < V2 < 0 < V3 < V4 or V1 > V2 > 0 > V3 > V4. At this time, the zero point of the voltage signal is between V2 and V3, and the voltage acquisition time interval is 10 μs for all;

[0052] Record the acquisition time of V2 as t1 and the acquisition time of V3 as t2. Let the zero-crossing time be t0, then

[0053]

[0054] Repeat the above method to obtain the time of each zero-crossing in turn; then calculate the sine periods Tmv1, Tmv2…Tmvn based on the time intervals between adjacent zero-crossings.

[0055] Step 2: Traverse the coordinates of the rotation center

[0056] Let the coordinates of the rotation center o’ be (x, y). The distance between the rotation center and the geometric center o is r μm, the maximum vibration amplitude is a μm, and the calculation step size is p μm;

[0057] r gradually increases from 0 to a in steps of p. Each time r increases by p, the value of x changes from 0 to r in steps of p for r / p + 1 times, and the value of y is calculated once according to formula (2);

[0058]

[0059] After calculating the value of y, use the symmetry of the circle to obtain the symmetric coordinates of the point (x, y) with respect to the y-axis, x-axis, and the center of the circle, which are (-x1, y1), (x2, -y2), and (-x3, -y3) respectively. Substitute the coordinates into the Δi calculation formula, that is, formula (3), to find four And compare them one by one to retain the minimum value and its corresponding coordinates;

[0060]

[0061] After the traversal, compare all the values to obtain the coordinates (xn, yn) corresponding to the minimum value. This coordinate is the actual rotation center obtained by measurement.

[0062] Step 3: Calculate the vibration of the rotating machinery

[0063] As Figure 2 shown, calculate the actual rotation radius based on the obtained actual rotation center coordinates. The difference between it and the ideal rotation radius is the vibration amount of the rotating machinery.

[0064] When performing time-domain analysis on Hall sensor signals, in addition to ensuring the acquisition frequency meets requirements, the traversal efficiency of the rotation center directly affects the speed of vibration analysis. The vibration analysis method in this embodiment can traverse all coordinate points within a set maximum vibration amplitude range, reducing the number of calculations during the traversal process. Combined with the high processing speed of the ZYNQ chip, the vibration analysis processing speed can meet practical needs.

[0065] Example 2

[0066] A vibration analysis device based on time-domain signals, such as Figure 3 As shown, it includes the ZYNQ main control system 1 with communication connection, the high-speed AD acquisition module 2 and the system power supply 4;

[0067] The high-speed AD acquisition module 2 is communicatively connected to the Hall sensor 3 installed on the rotating machinery to acquire the analog signal output by the Hall sensor 3.

[0068] The ZYNQ main control system 1 receives the analog signals acquired by the high-speed AD acquisition module 2 and performs data processing and calculation;

[0069] The system power supply 4 provides power to the ZYNQ main control system 1, the high-speed AD acquisition module 2, and the Hall sensor 3.

[0070] Specifically, the high-speed AD acquisition module 2 consists of a high-speed AD chip 9 and an attenuation circuit 10. The high-speed AD chip 9 is an AD9287 chip, which is a single-chip, 8-bit, 100MSPS analog-to-digital converter manufactured by Analog Devices (ADI), characterized by high performance and low power consumption. The attenuation circuit 10 converts the analog signal emitted by the Hall sensor 3 into a 0-2V voltage signal for acquisition by the AD9287 chip.

[0071] Since vibration analysis based on time-domain signals requires high acquisition frequency and data processing speed, this embodiment uses a ZYNQ chip and a high-speed AD acquisition chip to design a vibration analysis method based on time-series signal analysis. The ZYNQ chip has a maximum main frequency of 667MHz, and the high-speed AD acquisition chip has a maximum acquisition speed of 100MHz, which can ensure that the maximum error of the acquired time-domain signal does not exceed 10 microseconds, thereby ensuring accurate measurement and rapid processing of the sensor's periodic signal.

[0072] Example 3

[0073] This embodiment further introduces the ZYNQ main control system based on embodiment 2.

[0074] The ZYNQ main control system 1 consists of an XC7Z020CLG400-2 main chip module 5, a communication module 6, a storage module 7, and a module power supply 8.

[0075] The XC7Z020CLG400-2 main chip module 5 is communicatively connected to the high-speed AD chip 9 to receive analog signals acquired by the high-speed AD chip 9. The communication module 6 and the storage module 7 are communicatively connected to the XC7Z020CLG400-2 main chip module 5, respectively.

[0076] The communication module 6 includes both CAN and Ethernet communication modes, which provide data or calculation results to field devices or remote computers, respectively. CAN communication uses the TJA1050 chip as the CAN driver, and Ethernet communication is implemented using the W5500 chip, which has its own hardware protocol stack and interacts with the XC7Z020CLG400-2 main chip module 5 via SPI.

[0077] The storage module 7 includes EEPROM storage and SPI FLASH storage, used for storing basic parameters and real-time data, respectively. The EEPROM storage uses an AT24C16 chip and connects via I... 2 The C-bus communicates with the XC7Z020CLG400-2 main chip module 5 for data exchange. The SPI FLASH storage uses the W25Q128 chip, which communicates with the XC7Z020CLG400-2 main chip module 5 via the SPI bus.

[0078] The module power supply 8 includes 5V and 3.3V power supplies, which power the XC7Z020CLG400-2 main chip module 5, the communication module 6, and the storage module 7, respectively.

[0079] The above description is only a preferred embodiment of the present invention. It should be noted that, for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A vibration analysis method based on time-domain signals, characterized in that, Completed by the vibration analysis device; The vibration analysis device includes a ZYNQ main control system and a high-speed AD acquisition module that are communicatively connected; The high-speed AD acquisition module is communicatively connected to a Hall sensor installed on a rotating machine to collect the analog signal output by the Hall sensor; the ZYNQ main control system receives the analog signal collected by the high-speed AD acquisition module and performs data processing and calculation; The high-speed AD acquisition module consists of a high-speed AD chip and an attenuation circuit; the analog signal emitted by the Hall sensor is converted by the attenuation circuit and then collected by the high-speed AD chip; The ZYNQ main control system includes an XC7Z020CLG400-2 main chip module; the XC7Z020CLG400-2 main chip module is communicatively connected to the high-speed AD chip to receive the analog signal collected by the high-speed AD chip; The high-speed AD chip uses an AD9287 chip; The vibration analysis method includes the following steps: Step 1: Sine signal period measurement. Take four consecutive voltage values V1, V2, V3, V4 closest to 0V in each monotonic interval of the sine signal, and the values satisfy monotonicity, that is, V1 < V2 < 0 < V3 < V4 or V1 > V2 > 0 > V3 > V4. At this time, the zero point of the voltage signal is between V2 and V3, and the voltage acquisition time interval is 10 μs; Record the acquisition time of V2 as t1 and the acquisition time of V3 as t2. Let the zero-crossing time be t0, then Repeat the above method to obtain the time of each zero-crossing in turn; then calculate the sine periods Tmv1, Tmv2... Tmvn according to the time intervals between adjacent zero-crossings; Step 2: Rotation center coordinate traversal. Assume the coordinates of the rotation center o' are (x, y), the distance between the rotation center and the geometric center o is r μm, the maximum vibration amplitude is a μm, and the calculation step size is p μm; r gradually increases from 0 to a with a step size of p. Every time r increases by p, the x value changes from 0 to r with a step size of p for r / p + 1 times, and the y value is calculated once according to formula (2); After calculating the y-value, the symmetry of the circle is used to obtain the coordinates of the point (x, y) about the y-axis, x-axis, and center of the circle, which are (-x1, y1), (x2, -y2), and (-x3, -y3), respectively. Substituting these coordinates into the formula for calculating Δi, i.e., formula (3), four values ​​are obtained. And compare and retain the minimum value and its corresponding coordinates one by one; After the traversal is complete, for all the calculated results The values ​​are compared to obtain the coordinates (xn, yn) corresponding to the minimum value, and these coordinates are the actual rotation center obtained by measurement; Step 3: Rotating machine vibration calculation. Calculate the actual rotation radius based on the obtained actual rotation center coordinates, and the difference between it and the ideal rotation radius is the vibration amount of the rotating machine.

2. The vibration analysis method as described in claim 1, characterized in that, The ZYNQ main control system further includes a communication module.

3. The vibration analysis method as described in claim 2, characterized in that, [[ID=X]]The communication module includes two methods: CAN communication and Ethernet communication.

4. The vibration analysis method as described in claim 3, characterized in that, The CAN communication uses a TJA1050 chip as the CAN driver; the Ethernet communication uses a W5500 chip.

5. The vibration analysis method as described in claim 2, characterized in that, The ZYNQ main control system further includes a storage module.

6. The vibration analysis method as described in claim 5, characterized in that, The storage module includes EEPROM storage and SPI FLASH storage.

7. The vibration analysis method as described in claim 6, characterized in that, The EEPROM storage uses an AT24C16 chip and performs data interaction with the XC7Z020CLG400-2 main chip module through the I2C bus; The SPI FLASH storage uses a W25Q128 chip and performs data interaction with the XC7Z020CLG400-2 main chip module through the SPI bus.

8. The vibration analysis method as described in claim 5, characterized in that, The ZYNQ main control system also includes module power supplies; the module power supplies supply power to the XC7Z020CLG400-2 main chip module, the communication module, and the storage module.

9. The vibration analysis method as described in claim 8, characterized in that, The module is powered by 5V and 3.3V.

10. The vibration analysis method as described in claim 1, characterized in that, It also includes system power supply; the system power supply is for the ZYNQ main control system, the high-speed AD acquisition module and the Hall sensor.

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