Motor fault simulation test bench and test method for active hybrid multi-fault simulation

Abstract

The invention discloses an active hybrid multi-fault simulation motor fault simulation test bench and a test method. Comprising a base, an active fault changing structural component, a long shaft, an upper computer and a wireless controller. The active fault changing structural component is installed on the base and comprises a middle support, a motor support, a gear connecting rod assembly and a ball screw assembly. The gear connecting rod assembly is arranged between the middle support and the motor support, a lead screw is sleeved with the center of a sliding block of the ball screw assembly, a long shaft penetrates through the middle support through a connecting knuckle bearing and penetrates through the center of the gear connecting rod assembly, one end of the long shaft is connected with the sliding block, and the other end of the long shaft is connected with an output shaft of the motor. The control module is used for controlling the screw motor to rotate; and the upper computer is wirelessly connected with the wireless controller. According to the application, a unique active variable fault structure and a wireless remote control method are utilized to rapidly and actively change a single or mixed fault state, and the effectiveness and rapidity of a comparison experiment algorithm are stably and controllably detected in real time.

Description

Technical Field

[0001] The present invention relates to the technical field of motor fault simulation, and in particular to a motor fault simulation test bench and test method for active hybrid multi-fault simulation. Background Art

[0002] In the field of research on motor fault detection and diagnosis, using a fault simulation test bench for experiments and algorithm research is the most common method. Currently, the main method is to simulate different fault states by artificially setting fault points. For example, different-sized and -type fault points are set at different positions such as the inner ring, outer ring, or rolling elements of the motor bearing, and different motor bearings are replaced to simulate different fault states. When simulating faults such as motor imbalance and misalignment, a device that can control the length of the extension rod to change the center of gravity of the device is used to simulate different fault states. The above methods have large experimental deviations during the experiment, cannot restore the balanced state, the control process is not stable enough, and it is easier to damage the fault state, so the effectiveness of the algorithm cannot be accurately verified. Summary of the Invention

[0003] Therefore, the purpose of the present invention is to provide a motor fault simulation test bench for active hybrid multi-fault simulation, introducing the design concept of actively controllable variable faults into the field of motor bearing fault diagnosis experiments, realizing rapid and active change of the fault state, and detecting and comparing the effectiveness and rapidity of the experimental algorithm in a real-time, stable, and controllable manner.

[0004] To achieve the above purpose, a motor fault simulation test bench for active hybrid multi-fault simulation provided by the present invention includes a base, an active variable fault structural component, a long shaft, a host computer, and a wireless controller; the active variable fault structural component is installed on the base, and the active variable fault structural component includes an intermediate support, a motor support, a gear link assembly, and a ball screw assembly; the gear link assembly is arranged between the intermediate support and the motor support, and the ball screw assembly includes a screw motor, a screw, and a slider; the center of the slider is sleeved on the screw, one end of the slider is embedded in one end of the long shaft, the long shaft passes through the intermediate support through a connecting spherical bearing and passes through the center of the gear link assembly, the other end of the long shaft is connected to the output shaft of the motor through a connecting coupling, the wireless controller is arranged on the screw motor and is used to control the rotation of the screw motor; the host computer is wirelessly connected to the wireless controller; the host computer communicates with the wireless controller to control the rotation of the screw, and drives the slider to move up and down when the screw rotates, so that the long shaft forms different bending degrees, resulting in the gear link assembly changing the center of gravity to simulate motor faults.

[0005] Further preferably, one end of the base is connected to a support, and a screw support frame is installed on the support.

[0006] Further preferably, the gear-linkage assembly includes a gear device and a linkage device; the gear device includes two pinions with equal module meshing with a large gear, and an automatic control module and a counterweight are respectively arranged at the rear ends of the two pinions;

[0007] Further preferably, the central axis of the pinion is connected to the power shaft of the steering gear, the steering gear is connected to the automatic control module, the steering gear is fixed at one end of the connecting bracket, and the other end of the connecting bracket is fixed to the inner ring bracket at the rear of the large gear through a third fixing bolt.

[0008] Further preferably, the middle part of the large gear is fixed to the shaft shoulder through a first fixing bolt, and the shaft shoulder is fixed to the long shaft through a set screw.

[0009] Further preferably, the linkage device includes five groups of three-link mechanisms, and the five groups of three-link mechanisms are installed at the front of the large gear.

[0010] Further preferably, vibration sensors are respectively arranged above the middle bracket and the motor bracket, and the vibration sensors are connected to the upper computer.

[0011] Further preferably, the middle bracket and the motor bracket are fixed to the base through a fourth fixing bolt. The upper computer and the wireless controller perform wireless communication through a 433 MHz antenna.

[0012] The present invention also provides a motor fault simulation test method for active hybrid multi-fault simulation, which is applied to the above-mentioned motor fault simulation test bench for active hybrid multi-fault simulation, and includes the following steps:

[0013] Send a fault instruction to be simulated, control the ball screw controlled by the wireless controller to move the slider, and change the bending state of the long shaft;

[0014] Drive the linkage mechanism to rotate through the rotation of the gear mechanism, change the center of gravity of the device, the motor speed, and simulate different fault types;

[0015] Obtain the vibration data collected by the vibration sensor, utilize the constructed multiple fault diagnosis models to judge whether the detected fault type is consistent with the fault instruction issued by the upper computer; if it is consistent, prepare to issue the next fault type instruction until all fault types are simulated; if it is inconsistent, improve the selected fault diagnosis model. In this application, the ball screw controlled by the wireless controller moves the slider up and down, thereby changing the bending state of the long shaft, so that various associated fault types such as shaft bending, cage loosening, and bearing seat deformation in different degrees under various working conditions can be simulated; drive the linkage mechanism to rotate through the rotation of the gear mechanism, and then change the position of the center of gravity of the device, so that various rotor imbalances, shaft bending, load center of gravity offset, bearing partial load wear, etc. in different degrees under various working conditions can be simulated.

[0016] An active hybrid multi-fault simulation motor fault simulation test bench and a fault diagnosis experimental method disclosed in this application introduce the idea of actively controllable variable faults into the field of motor bearing fault diagnosis experiments, and propose a new method for verifying real-time algorithms in motor fault simulation experiments. By using a unique active variable fault structure and a wireless remote control method, it is possible to quickly and actively change the fault state, and detect the effectiveness and rapidity of the comparative experimental algorithm in real time, stably and controllably. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 is a schematic structural diagram of the active hybrid multi-fault simulation motor fault simulation test bench provided by the present invention.

[0018] Figure 2 is a rear view of the active hybrid multi-fault simulation motor fault simulation test bench provided by the present invention.

[0019] Reference numerals: 1-ball screw, 2-long shaft, 3-joint bearing, 4-middle bracket, 5-vibration sensor, 6-shaft shoulder, 7-gear device, 8-five groups of three-link mechanisms, 9-coupling, 10-motor bracket, 11-motor, 12-first fixing bolt, 13-upper computer, 14-signal transceiver antenna, 15-base, 16-second fixing bolt, 17-support, 18-screw motor, 19-wireless controller, 20-slider, 21-bearing, 22-screw, 23-automatic control module, 24-servo, 25-connecting bracket, 26-third fixing bolt, 27-fixing screw, 28-set screw, 29-inner ring bracket, 30-counterweight, 31-fourth fixing bolt. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0020] The present invention will be further described in detail below with reference to the drawings and specific embodiments.

[0021] As Figure 1-2As shown in the figure, a motor fault simulation test bench for active hybrid multi-fault simulation provided by an embodiment of the present invention on the one hand includes a base 15, an active variable fault structure component, a long shaft 2, a host computer 13, and a wireless controller 19; the active variable fault structure component is installed on the base 15, and the active variable fault structure component includes an intermediate bracket 4, a motor bracket 10, a gear link assembly, and a ball screw assembly 1; the gear link assembly is arranged between the intermediate bracket 4 and the motor bracket 10, and the ball screw assembly 1 includes a screw motor 18, a screw 22, and a slider 20; the center of the slider 20 is sleeved on the screw, one end of the slider 20 is embedded in one end of the long shaft 2, and the slider is connected to the long shaft through a bearing 21. The long shaft 2 passes through the intermediate bracket 4 through a connecting spherical plain bearing 3 and passes through the center of the gear link assembly. The other end of the long shaft 2 is connected to the output shaft of the motor 11 through a connecting coupling 9. The wireless controller 19 is arranged on the screw motor 18 and is used to control the rotation of the screw motor 18; the host computer 13 is wirelessly connected to the wireless controller 19; the host computer 13 communicates with the wireless controller 19 to control the rotation of the screw, and drives the slider 20 to move up and down when the screw rotates, so that the long shaft 2 forms different bending degrees, thereby simulating various associated fault types such as shaft bending, cage loosening, and bearing seat deformation for fault simulation.

[0022] Further, the gear link assembly includes a gear device 7 and a link device; the gear device includes two pinions with equal module meshing with a large gear. An automatic control module 23 and a counterweight 30 are respectively arranged at the rear ends of the two pinions; equal module means the same size in both large and small dimensions. The two pinions are arranged on opposite sides of the large gear, and the pinions mesh with the large gear.

[0023] The central axis of the pinion is connected to the power shaft of the servo 24. The servo 24 is connected to the automatic control module 23. The servo 24 is fixed at one end of the connecting bracket 25, and the other end of the connecting bracket 25 is fixed to the inner ring bracket 29 at the rear of the large gear through a third fixing bolt 26.

[0024] Further preferably, the middle of the large gear is fixed to the shaft shoulder 6 through a first fixing bolt 12, and the shaft shoulder 6 is fixed to the long shaft 2 through a set screw 28.

[0025] Further preferably, the link device includes five groups of three-link mechanisms 8, and the five groups of three-link mechanisms 8 are installed at the front of the large gear. The five groups of three-link mechanisms 8 are connected to the inner ring bracket 29 through fixing screws 27.

[0026] Further preferably, vibration sensors 5 are respectively arranged above the intermediate bracket 4 and the motor bracket 10, and the vibration sensors 5 are connected to the host computer 13.

[0027] Further preferably, the middle bracket 4 and the motor bracket 10 are fixed to the base 15 by the fourth fixing bolts 31 below. One end of the base 15 is connected to the support 17, and a lead screw support frame is installed on the support 17. The bottom of the middle bracket 4 is fixedly connected to the base 15 by the second fixing bolts 16, ensuring the stability during motor fault simulation.

[0028] Further preferably, a signal transceiver antenna is inserted on the upper computer 13, and wireless communication is performed with the wireless controller 19 through a 433 MHz antenna.

[0029] The present invention also provides a motor fault simulation test method for active hybrid multi-fault simulation, which is applied to the above-mentioned motor fault simulation test bench for active hybrid multi-fault simulation, and includes the following steps:

[0030] Send the fault instruction to be simulated, and control the ball screw driven by the wireless controller to move the slider to change the bending state of the long shaft;

[0031] Drive the link mechanism to rotate through the rotation of the gear mechanism, change the center of gravity of the device and the motor speed, and simulate different fault types;

[0032] Obtain the vibration data collected by the vibration sensor, use the constructed multiple fault diagnosis models to judge whether the detected fault type is consistent with the fault instruction issued by the upper computer; if it is consistent, prepare to issue the next fault type instruction until all fault types are simulated; if it is inconsistent, improve the selected fault diagnosis model.

[0033] It should be noted that the vibration data collected by the vibration sensor is used for offline learning to train the constructed multiple fault diagnosis models. When judging whether the detected fault type is consistent with the fault instruction issued by the upper computer, the fault model can be adaptively selected according to input parameters, etc. or manually selected.

[0034] The user of this application issues a fault instruction to be simulated by the host computer. The ball screw controlled by the wireless controller moves the slider up and down, thereby changing the bending state of the long shaft, and thus various associated fault types such as shaft bending, cage loosening, and bearing seat deformation at different degrees under various working conditions can be simulated; the rotation of the gear mechanism drives the rotation of the link mechanism, thereby changing the position of the center of gravity of the device, and thus various different associated fault types such as rotor imbalance, shaft bending, load center of gravity offset, and bearing eccentric wear at different degrees under various working conditions can be simulated. The vibration sensor collects data and transmits it to the host computer; after receiving it, the host computer is prepared to send the next fault type instruction until all fault types are simulated; the vibration data collected by the vibration sensor is used for offline learning, and in the future, it can also include constructing a fault diagnosis model using different algorithms; real-time online diagnosis experiments are carried out on each fault diagnosis model; the fault diagnosis model is selected and improved, etc. The present invention uses a unique active variable fault structure and a wireless remote control method to achieve rapid and stable active change of a single or multiple mixed fault states.

[0035] Obviously, the above embodiments are only examples clearly described and not limitations on the implementation manners. For those of ordinary skill in the art, other different forms of changes or variations can be made based on the above description. It is not necessary and impossible to enumerate all the implementation manners here. And the obvious changes or variations derived therefrom are still within the protection scope of the present invention.

Claims

1. An active hybrid multi-fault simulation motor fault simulation test bench, characterized in that: It includes a base, active variable fault structure components, a long shaft, a host computer and a wireless controller; The active variable fault structure component is installed on the base, and the active variable fault structure component includes an intermediate bracket, a motor bracket, a gear connecting rod assembly and a ball screw assembly; the gear connecting rod assembly is arranged between the intermediate bracket and the motor bracket, and the ball screw assembly includes a screw motor, a screw and a slider; the slider is centrally sleeved on the screw, one end of the slider is embedded in one end of the long shaft, the long shaft passes through the intermediate bracket through the connecting joint bearing, and passes through the center of the gear connecting rod assembly, the other end of the long shaft is connected to the output shaft of the motor through the connecting coupling, and the wireless controller is arranged on the screw motor for controlling the rotation of the screw motor; the host computer is wirelessly connected to the wireless controller.

2. The motor fault simulation test bench for active hybrid multi-fault simulation according to claim 1 is characterized in that: One end of the base is connected to a support, and a lead screw support frame is installed on the support.

3. The motor fault simulation test bench for active hybrid multi-fault simulation according to claim 1 is characterized in that: The gear-connecting rod assembly comprises a gear device and a connecting rod device; the gear device comprises two small gears with equal modulus meshing with a large gear, and an automatic control module and a counterweight are respectively arranged at the rear ends of the two small gears.

4. The motor fault simulation test bench for active hybrid multi-fault simulation according to claim 3 is characterized in that: The center axis of the small gear is connected to the power shaft of the steering gear, the steering gear is connected to the automatic control module, the steering gear is fixed to one end of the connecting bracket, and the other end of the connecting bracket is fixed to the inner ring bracket at the rear of the large gear through a third fixing bolt.

5. The motor fault simulation test bench for active hybrid multi-fault simulation according to claim 4 is characterized in that: The middle part of the large gear is fixed to the shaft shoulder by a first fixing bolt, and the shaft shoulder is fixed to the long shaft by a set screw.

6. The motor fault simulation test bench for active hybrid multi-fault simulation according to claim 1 is characterized in that: The connecting rod device comprises five groups of three-link mechanisms, and the five groups of three-link mechanisms are installed at the front of the large gear.

7. The motor fault simulation test bench for active hybrid multi-fault simulation according to claim 1 is characterized in that: Vibration sensors are respectively arranged above the intermediate bracket and the motor bracket, and the vibration sensors are connected to a host computer.

8. The motor fault simulation test bench for active hybrid multi-fault simulation according to claim 1 is characterized in that: The middle bracket and the motor bracket are fixed to the base through the fourth fixing bolt; the host computer and the wireless controller communicate wirelessly through the 433MHz antenna.

9. An active hybrid multi-fault simulation motor fault simulation test method, applied to the active hybrid multi-fault simulation motor fault simulation test bench as claimed in any one of claims 1 to 8, comprising the following steps: Send the fault command to be simulated, and move the slider up and down through the ball screw controlled by the wireless controller to change the bending state of the long axis, simulating different degrees of axis bending, loose cage, and bearing seat deformation under various working conditions; The rotation of the gear mechanism drives the connecting rod mechanism to rotate, thereby changing the center of gravity of the device, so as to simulate different degrees of rotor imbalance, shaft bending, load center of gravity offset, bearing eccentric wear and different fault types under various working conditions; The vibration data collected by the vibration sensor is obtained, and multiple fault diagnosis models are constructed to determine whether the detected fault type is consistent with the fault instruction issued by the host computer; if they are consistent, prepare to issue the next fault type instruction until all fault types are simulated; if they are inconsistent, improve the selected fault diagnosis model.

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