Rapid identification and efficient traceability method for early failure of dynamic test shafting
By installing a vibration sensor in the power test and setting vibration limits using the external characteristic segmented curve correction method, combined with the ECU power outage counter-drag and process inspection and comparison method, the problem of difficult to identify the failure of rotating components and locking failure sources in the existing technology is solved, and the rapid identification and efficient traceability of early failure of the power test shaft system is achieved, reducing equipment damage and safety risks.
Patent Information
- Application Number
- CN202510380512.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-03-28
- Publication Date
- 2025-06-27
AI Technical Summary
In the prior art, it is difficult to accurately identify rotating component failure and fast locking failure sources in power tests, resulting in equipment damage and safety risks.
By installing a vibration sensor at the front axle position of the dynamometer, and using the external characteristic segmented curve correction method to set the vibration limits of different speed torque segments, combined with the ECU power-off counter-drag and process inspection and comparison method, the vibration abnormality source is quickly identified and locked.
It realizes rapid identification and efficient traceability of early failure of the power test shaft system, reducing equipment damage and safety risks.
Smart Images
Figure CN120213458A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of power system troubleshooting, and particularly to a method for quickly identifying and efficiently tracing the early failure of a dynamic test shafting. Background Art
[0002] During the test process of the power system, failures of rotating components (such as engine crankshafts, motor spindles, transmission shafts, etc.) may occur. Severe failures of the shafting can cause significant impact damage to the dynamometer, the protective cover of the shafting, torque flanges, etc. Severe failures may pose safety risks to the test operation. Detecting abnormalities in advance can not only reduce the damage to the test shafting and equipment, but also reduce the safety risks during the test process. The present invention mainly installs two vibration sensors at the front shaft position of the dynamometer, and sets vibration limits for different rotational speed and torque segments through the external characteristic segmented curve correction method. When an abnormal vibration over-limit alarm occurs, the source of the abnormal vibration, whether it is the test piece, the dynamometer, the transmission shaft, bolt loosening, etc., is early locked through the process inspection and comparison method, avoiding greater losses to the test piece or the dynamometer, and also being beneficial to reducing safety risks.
[0003] In the prior art, 1. When installing vibration sensors, there is no precise setting of the vibration limit curve boundary, only the maximum vibration value is set, resulting in difficult detection when vibration abnormalities occur, and only being discovered when serious failures occur; 2. The reasons for the abnormal vibration of the shafting are not elaborated, and the analysis method fails to quickly lock the failure source. Summary of the Invention
[0004] Based on this, the purpose of the present invention is to provide a method for quickly identifying and efficiently tracing the early failure of a dynamic test shafting to solve the deficiencies in the above-mentioned prior art.
[0005] The present invention provides a method for quickly identifying and efficiently tracing the early failure of a dynamic test shafting, the method comprising:
[0006] Obtaining vibration curve A and vibration curve B of the dynamometer under no-load at each rotational speed segment, and recording vibration curve C and vibration curve D from idle speed to maximum speed according to the ECU power-off reverse drag of the dynamometer;
[0007] Collecting the external characteristic data of the test piece, and obtaining vibration curve E and vibration curve F according to the external characteristic data, and obtaining vibration curve G and vibration curve H through a conversion algorithm based on vibration curve E and vibration curve F;
[0008] Segmentally inputting vibration curve G and vibration curve H into the bench alarm column, and if an over-limit alarm occurs, determining whether it is an occasional alarm:
[0009] If it is not an occasional alarm, checking whether the dynamometer, transient shaft and test piece are abnormal;
[0010] If there are no abnormalities in the dynamometer, the transient shaft, and the test piece, then perform ECU power-off reverse dragging and compare it with the vibration curve C and the vibration curve D to obtain the measured vibration curve.
[0011] Judge whether the measured vibration curve is abnormal. If the measured vibration curve is normal, then compare the measured vibration data of the dynamometer running without load with the vibration curve A and the vibration curve B to obtain comparison data.
[0012] Judge whether the comparison data is normal. If the comparison data is normal, then it is concluded that the test piece is abnormal.
[0013] Compared with the prior art, the beneficial effects of the present invention are as follows: The vibration curves G and H obtained through the conversion algorithm are input into the bench alarm column in segments. If an overlimit alarm appears, the occasional alarm can be excluded, so as to achieve the purpose of efficient troubleshooting. And by performing ECU power-off reverse dragging and comparing it with the vibration curve C and the vibration curve D, the source of abnormal failure can be quickly locked. By comparing the measured vibration data of the dynamometer running without load with the vibration curve A and the vibration curve B, the troubleshooting of the failure source can be further carried out, the failure cause can be quickly locked, and greater losses of the engine and the testing machine can be avoided.
[0014] Further, the step of obtaining the vibration curves G and H by converting the vibration curves E and F through the conversion algorithm and based on the vibration curves E and F includes:
[0015] Obtain the magnification factor through the test experience data and according to the average value of the vibration data in each rotation speed section.
[0016] Magnify the vibration curves E and F according to the magnification factor to obtain the vibration curves G and H.
[0017] Further, after the step of judging whether it is an occasional alarm, the method further includes:
[0018] If it is an occasional alarm, then ignore the overlimit alarm this time.
[0019] Further, after the step of checking whether the dynamometer, the transient shaft, and the test piece are abnormal, the method further includes:
[0020] If the dynamometer, the transient shaft, and the test piece are abnormal, then check the shaft system bolts of the test piece, the rubber body of the transient shaft, and the shock-absorbing pulley of the test piece in sequence.
[0021] Further, after the step of judging whether the measured vibration curve is abnormal, the method further includes:
[0022] If the measured vibration curve is abnormal, replace the transient shaft and perform the ECU power-off reverse drag again, and compare it with the vibration curve C and the vibration curve D to obtain a new measured vibration curve;
[0023] Judge whether the new measured vibration curve is abnormal. If the new measured vibration curve is normal, it is determined that the transient shaft fails.
[0024] Further, after the step of judging whether the new measured vibration curve is abnormal, the method further includes:
[0025] If the new measured vibration curve is abnormal, perform the comparison of the measured vibration data of the dynamometer under no-load operation with the vibration curve A and the vibration curve B.
[0026] Further, after the step of judging whether the comparison data is normal, the method further includes:
[0027] If the comparison data is abnormal, it is determined that the dynamometer is abnormal.
[0028] Further, the abnormality of the test piece includes engine misfire or abnormal operation of cylinder misfiring and failure of the shafting of the test piece itself.
[0029] Further, the vibration curve A and the vibration curve B are respectively the vibration curves of the dynamometer under no-load operation in the X-axis direction and the Z-axis direction at each rotational speed section;
[0030] The vibration curve C and the vibration curve D are respectively the vibration curves in the X-axis direction and the Z-axis direction recorded by the ECU power-off reverse drag of the dynamometer from idling speed to the maximum speed. Description of the Drawings
[0031] Figure 1 It is a flowchart of a method for quickly identifying and efficiently tracing the early failure of the power test shafting in an embodiment of the present invention;
[0032] Figure 2 It is a schematic installation diagram of sensors on a dynamometer in an embodiment of the present invention.
[0033] The following specific embodiments will further illustrate the present invention in conjunction with the above-mentioned drawings. Specific Embodiments
[0034] To facilitate the understanding of the present invention, the present invention will be described more comprehensively below with reference to the relevant drawings. Several embodiments of the present invention are given in the drawings. However, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, these embodiments are provided to make the disclosure of the present invention more thorough and comprehensive.
[0035] It should be noted that when an element is referred to as being "fixed to" another element, it can be directly on the other element or there can also be an intermediate element. When an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intermediate element at the same time. The terms "vertical", "horizontal", "left", "right" and similar expressions used herein are for illustrative purposes only.
[0036] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the technical field to which this invention belongs. The terms used herein in the specification of this invention are only for the purpose of describing specific embodiments and are not intended to limit this invention. The term "and / or" used herein includes any and all combinations of one or more of the related listed items.
[0037] Please refer to Figure 1 , which shows the method for rapid identification and efficient traceability of early failures of the dynamic test shafting in the embodiment of the present invention. The method includes steps S1 to S7:
[0038] S1. Obtain the vibration curves A and B of the no-load dynamometer at each speed segment, and record the vibration curves C and D from idle speed to maximum speed according to the reverse drag of the ECU power-off of the dynamometer.
[0039] In specific implementation, mainly install two vibration sensors near the end face of the output flange of the dynamometer, which are installed in the X-axis direction and the Z-axis direction respectively, as specifically shown in Figure 2 . When the engine or the test piece is put on the test bench for testing, according to the speed-torque range of the engine type (gasoline engine, diesel engine or motor), first perform initial segmented limit setting according to the vibration experience data table. The speed segments are divided into four segments (including below 1000 rpm, maximum torque speed, maximum power speed, and maximum speed).
[0040] It can be understood that at the start of the test, confirm that the dynamometer is in good condition, measure the vibration curves A and B of the dynamometer body in the X-axis direction and the Z-axis direction at each speed segment under no-load, and find the speed region with the largest vibration. Before the test, the dynamometer is dragged with the engine from idle speed to maximum speed by ECU power-off, and record the vibration curves C (X-axis) and D (Z-axis). The above vibration curves A, B, C, and D are used for comparison when vibration anomalies occur.
[0041] S2. Collect the external characteristic data of the test piece, and obtain the vibration curves E and F according to the external characteristic data. Through the conversion algorithm and based on the vibration curves E and F, convert to obtain the vibration curves G and H.
[0042] Specifically, step S2 includes steps S21 to S22:
[0043] S21, obtaining the magnification factor by testing empirical data and based on the average value of the vibration data for each rotational speed range;
[0044] S22, magnifying the vibration curve E and the vibration curve F by the magnification factor to obtain the vibration curve G and the vibration curve H;
[0045] It should be noted that before the formal start of the test, the external characteristic data is collected for 0 hours to obtain the vibration curve E (X-axis) and the vibration curve F (Z-axis). Referring to the vibration curves E and F of the external characteristics, considering that the entire system will generate alternating working conditions such as acceleration and deceleration that will affect the vibration, the vibration curves G (X-axis) and H (Z-axis) are obtained through testing empirical data according to a value about 1.5 times the average value of the vibration data for the rotational speed range (but slightly larger than the maximum vibration value in this rotational speed range).
[0046] S3, inputting the vibration curve G and the vibration curve H into the bench alarm column in segments. If an overlimit alarm occurs, it is judged whether it is a sporadic alarm:
[0047] It should be noted that the magnified vibration curves G and H are used as the final limits and input into the bench alarm column in the form of segmented rotational speeds. The maximum values of the vibration curves G and H after conversion for each rotational speed range do not exceed 7 mm / s.
[0048] Furthermore, if it is a sporadic alarm, the overlimit alarm of this time is ignored.
[0049] It should be noted that when an abnormal overlimit value alarm of vibration occurs, first preliminarily judge whether the operating condition of the test piece (engine or motor) is a transient acceleration / deceleration condition or a stable condition. First, exclude the sporadic transient alarms. When there are frequent alarms under stable conditions, efficient troubleshooting is carried out through such inspection and comparison methods.
[0050] S4, if it is not a sporadic alarm, check whether the dynamometer, the transient shaft, and the test piece are abnormal;
[0051] Specifically, step S4 includes step S41:
[0052] S41, if the dynamometer, the transient shaft, and the test piece are abnormal, sequentially check the shaft bolts of the test piece, the rubber body of the transient shaft, and the shock-absorbing pulley of the test piece;
[0053] It should be noted that if it is not an accidental alarm, first check whether it is an X-axis alarm or a Z-axis alarm. An X-axis alarm mainly indicates abnormalities in the dynamometer and the transient shaft, while a Z-axis alarm indicates abnormalities in the test piece. After an alarm occurs, first check whether the bolts of the shafting are loose, whether the rubber body of the transient shaft is normal visually, and whether the shock-absorbing pulley of the test piece is normal. If obvious abnormalities in the shafting are found, replace the abnormal parts, recheck the alignment, and then continue the test.
[0054] S5. If there are no abnormalities in the dynamometer, the transient shaft, and the test piece, then perform ECU power-off reverse dragging and compare it with the vibration curve C and the vibration curve D to obtain the measured vibration curve.
[0055] It can be understood that if there are no abnormalities in the shafting during the preliminary inspection, then perform ECU power-off reverse dragging on the dynamometer and compare it with the vibration curve C and the vibration curve D, so as to obtain the measured vibration curve.
[0056] S6. Judge whether the measured vibration curve is abnormal. If the measured vibration curve is normal, then compare the measured vibration data of the dynamometer under no-load operation with the vibration curve A and the vibration curve B to obtain comparison data.
[0057] In addition, the step S6 further includes steps S61 to S62:
[0058] S61. If the measured vibration curve is abnormal, then replace the transient shaft and perform ECU power-off reverse dragging again and compare it with the vibration curve C and the vibration curve D to obtain a new measured vibration curve.
[0059] S62. Judge whether the new measured vibration curve is abnormal. If the new measured vibration curve is normal, then judge that the transient shaft has failed.
[0060] It can be understood that if the measured vibration curve is abnormal, it means that changes have occurred in the stiffness of the entire shafting from the dynamometer to the test piece. First, replace the transient shaft and perform reverse dragging comparison again. If the measured vibration curve becomes normal, it means that the elastomer of the transient shaft is gradually aging during the failure process. If the measured vibration curve is still abnormal, then distinguish the abnormalities between the dynamometer and the test piece body.
[0061] Furthermore, the step S62 includes step S621:
[0062] S621. If the new measured vibration curve is abnormal, then perform the comparison of the measured vibration data of the dynamometer under no-load operation with the vibration curve A and the vibration curve B.
[0063] S7. Judge whether the comparison data is normal. If the comparison data is normal, then it is determined that the test piece is abnormal.
[0064] Among them, the abnormalities of the test piece include engine misfire or abnormal operation of cylinder misfiring and the failure of the shafting of the test piece itself.
[0065] It should be noted that when the test piece is disconnected and the actually measured vibration data of the dynamometer running without load is compared with the vibration curves A and B in the initial state, if the comparison data is abnormal, it indicates that there is a problem with the dynamometer itself; if the comparison data is normal, the problem of the dynamometer is checked. This shows that the main problem of the abnormal vibration of the entire shafting is concentrated on the test piece. Then, analyze the reasons for locking the speed and torque working conditions when the vibration exceeds the limit. When the working condition is below 1000 rpm, the abnormal idle speed control is the main reason. When the working condition is near the power point or torque point, the intermittent misfire or cylinder misfiring of the test piece causes vibration imbalance. In other working conditions, the shafting of the test piece is in the process of failure.
[0066] In summary, in the early failure rapid identification and efficient traceability method of the power test piece in the above embodiments of the present invention, the abnormal vibration state is quickly identified by accurately setting the vibration curves G and H in segments, the shafting failure is detected in advance, and the source of the abnormal vibration, whether it is the engine, the dynamometer, the transmission shaft, the bolt looseness, etc., is locked in the early stage through the process inspection method and the comparison method, avoiding greater losses to the engine and the dynamometer, and also helping to reduce safety risks. In addition, it is very important to define the vibration limit curve value. If it is defined too high, it cannot play a role in predicting before the shafting fails and no alarm is generated when the shafting fails; if it is defined too low, the shafting vibration prediction is too frequent and affects the test. By using the external characteristic segmented curve correction method for limit setting, the abnormal vibration can be quickly identified.
[0067] In the description of this specification, the descriptions with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples", etc. mean that the specific features, structures, materials, or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in a suitable manner in any one or more embodiments or examples.
[0068] The above-described embodiments only represent several implementation manners of the present invention, and the descriptions are relatively specific and detailed, but should not be construed as limiting the scope of the patent of the present invention. It should be noted that for those of ordinary skill in the art, without departing from the concept of the present invention, several deformations and improvements can still be made, and these all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention should be subject to the appended claims.
Claims
1. A method for rapid identification and efficient tracing of early failure of a power test shaft system, characterized in that: The method comprises: Obtain vibration curve A and vibration curve B of the no-load dynamometer at each speed range, and record vibration curve C and vibration curve D from idle speed to maximum speed according to the reverse drag of the ECU of the dynamometer when the ECU is powered off; Collecting external characteristic data of the test piece, and obtaining a vibration curve E and a vibration curve F according to the external characteristic data, and converting the vibration curve G and the vibration curve H based on the vibration curve E and the vibration curve F through a conversion algorithm; Enter the vibration curve G and the vibration curve H into the test bench alarm column in sections. If an over-limit alarm occurs, first determine whether it is an occasional alarm: If the alarm is not an occasional one, check whether the dynamometer, transient axis and the test piece are abnormal; If the dynamometer, the transient shaft and the test piece do not have any abnormal appearance details, the ECU is powered off and reverse dragged to compare with the vibration curve C and the vibration curve D to obtain the measured vibration curve; Determine whether the measured vibration curve is abnormal. If the measured vibration curve is normal, compare the measured vibration data of the dynamometer under no-load operation with the vibration curve A and the vibration curve B to obtain comparison data; It is determined whether the comparison data is normal. If the comparison data is normal, it is determined that the test piece is abnormal.
2. The method for rapid identification and efficient tracing of early failure of a power test shaft system according to claim 1 is characterized in that: The step of converting the vibration curve G and the vibration curve H based on the vibration curve E and the vibration curve F by using a conversion algorithm comprises: The magnification factor is obtained by testing empirical data and according to the average value of the vibration data of each speed section; The vibration curve E and the vibration curve F are amplified according to the amplification factor to obtain the vibration curve G and the vibration curve H.
3. The method for rapid identification and efficient tracing of early failure of a power test shaft system according to claim 1 is characterized in that: After the step of determining whether it is an occasional alarm, the method further includes: If it is an occasional alarm, ignore the over-limit alarm.
4. The method for rapid identification and efficient tracing of early failure of a power test shaft system according to claim 1 is characterized in that: After the step of checking whether the dynamometer, the transient shaft and the test piece are abnormal, the method further includes: If the dynamometer, the transient shaft and the test piece are abnormal, the shaft bolts of the test piece, the rubber body of the transient shaft and the damping pulley of the test piece are checked in sequence.
5. The method for rapid identification and efficient tracing of early failure of a power test shaft system according to claim 1 is characterized in that: After the step of determining whether the measured vibration curve is abnormal, the method further includes: If the measured vibration curve is abnormal, the transient shaft is replaced and the ECU is powered off and reversely dragged again to compare with the vibration curve C and the vibration curve D to obtain a new measured vibration curve; It is determined whether the new measured vibration curve is abnormal. If the new measured vibration curve is not abnormal, it is determined that the transient shaft fails.
6. The method for rapid identification and efficient source tracing of early failure of a power test shaft system according to claim 5 is characterized in that: After the step of determining whether the new measured vibration curve is abnormal, the method further includes: If the new measured vibration curve is abnormal, the step of comparing the measured vibration data of the dynamometer under no-load operation with the vibration curve A and the vibration curve B is performed.
7. The method for rapid identification and efficient tracing of early failure of a power test shaft system according to claim 1 is characterized in that: After the step of determining whether the comparison data is normal, the method further includes: If the comparison data is abnormal, it is determined that the dynamometer is abnormal.
8. The method for rapid identification and efficient tracing of early failure of a power test shaft system according to claim 1 is characterized in that: The abnormality of the test piece includes engine misfire or cylinder missing operation abnormality and failure of the shaft system of the test piece itself.
9. The method for rapid identification and efficient tracing of early failure of a power test shaft system according to claim 1 is characterized in that: The vibration curve A and the vibration curve B are vibration curves of the no-load dynamometer in the X-axis direction and the Z-axis direction in each speed range respectively; The vibration curve C and the vibration curve D are respectively the vibration curves in the X-axis direction and the Z-axis direction recorded when the ECU of the dynamometer is powered off and reversely dragged from idle speed to maximum speed.