Fault diagnosis method for electromechanical coupling system based on current-vibration data fusion

Abstract

The present invention discloses a fault diagnosis method for an electromechanical coupling system based on current-vibration data fusion, comprising the following steps: dividing an operating state set of electromechanical equipment, specifying motor output conditions and load startup conditions of the electromechanical equipment under different operating states; establishing a vibration effective value baseline and a current effective value baseline when the electromechanical equipment operates normally under different operating states; monitoring the operating conditions of the electromechanical equipment in real time and dynamically matching the current operating state of the equipment according to the real-time operating data; further acquiring a real-time vibration acceleration signal and a current signal of the electromechanical equipment, calculating a relative deviation between the vibration acceleration data and the current data based on the matched operating states, and judging whether the real-time vibration acceleration data and the current data exceed a limit based on the vibration effective value baseline and the current effective value baseline under the operating state; and inferring the fault type based on whether the real-time vibration acceleration data and the current data of the electromechanical equipment exceed a limit and issuing an early warning according to the severity.

Description

Technical Field

[0001] The present invention relates to the technical field of fault diagnosis, and in particular to a method for diagnosing faults in an electromechanical coupling system based on current-vibration data fusion. Background Art

[0002] Existing electromechanical equipment fault diagnosis technology has the following defects:

[0003] Limitations of single-parameter monitoring: Relying solely on vibration signals can easily overlook electrical faults, while monitoring only current cannot identify mechanical damage;

[0004] Working condition interference: The traditional fixed threshold method has a high false alarm rate under changing speed and load conditions;

[0005] Insufficient diagnostic granularity: Failure to establish correlation and discrimination rules between mechanical and electrical faults results in poor maintenance targeting.

[0006] In view of this, the present invention provides a fault diagnosis method for an electromechanical coupling system based on current-vibration data fusion, so as to provide a method for solving the problem of false alarm caused by operating state changes and fault type identification. Summary of the Invention

[0007] In order to solve the above technical problems, the purpose of the present invention is to provide a mechatronic coupling system fault diagnosis method based on current-vibration data fusion, specifically a mechatronic system fault diagnosis method based on dual-parameter coupling analysis of vibration signals and current signals, which is suitable for fault warning of various mechatronic equipment.

[0008] In order to achieve the above-mentioned object, the present invention provides a method for diagnosing a fault in an electromechanical coupling system. In the technical solution of the present invention, the method for diagnosing a fault in an electromechanical coupling system specifically comprises the following steps:

[0009] Step S1, operating state division: dividing the operating state set of the electromechanical equipment, and specifying the motor output and load starting conditions of the electromechanical equipment in different operating states;

[0010] Step S2, establishing a health baseline: establishing a vibration RMS baseline and a current RMS baseline when the electromechanical equipment is operating normally under different operating conditions;

[0011] Step S3, real-time monitoring and status identification: real-time monitoring of the operating data of the electromechanical equipment, and dynamic matching of the current operating status of the equipment according to the real-time operating data of the electromechanical equipment;

[0012] Step S4, Deviation Calculation and Over-Limit Determination: Further obtaining the real-time vibration acceleration signal and current signal of the electromechanical equipment, calculating the relative deviation of the vibration acceleration data and the current data based on the matching operating state, and determining whether the real-time vibration acceleration data and the current data exceed the limit based on the vibration effective value baseline and the current effective value baseline under the operating state;

[0013] Step S5, fault diagnosis and graded warning: Based on whether the real-time vibration acceleration data and current data of the electromechanical equipment exceed the limit, the fault type is inferred and a warning is issued according to the severity.

[0014] Furthermore, in the technical solution of the present invention, in step S1,

[0015] The operating state set of the electromechanical equipment is divided into: ,in, Represented as the operating status set of electromechanical equipment, Indicated as shared operating states;

[0016] The motor output and load starting conditions of electromechanical equipment in different operating states are specified, including: the operating state of each electromechanical equipment includes the speed range of the motor in this operating state and load startup ,in, and Indicates that the electromechanical equipment is in operation The minimum and maximum motor speeds under Indicates that the electromechanical equipment is in operation The load collection started next.

[0017] Furthermore, in the technical solution of the present invention, in step S2, establishing a vibration effective value baseline and a current effective value baseline when the electromechanical equipment operates normally in different operating states specifically includes the following steps:

[0018] Step M1: using an accelerometer and a current sensor to collect operating data of the electromechanical equipment under different operating conditions, including multiple sets of vibration acceleration signals, current signals, and the speed of the equipment motor under different operating conditions;

[0019] Step M2: Filter the collected signals through high-pass filtering to obtain effective vibration acceleration data of multiple sets of electromechanical equipment under normal operation in different operating states. and effective current data ,in, Represented as the obtained vibration acceleration set, is represented as the current set obtained, and Indicates that it is in running state There are a total of Group data;

[0020] Step M3: Calculate the mean and sample standard deviation of the vibration effective value and the current effective value;

[0021] , ;

[0022] , ;

[0023] in, Indicates that it is in running state The mean effective value of vibration under Indicates that it is in running state The mean effective value of the current under Indicates that it is in running state The sample standard deviation of the effective value of vibration under Indicates that it is in running state The sample standard deviation of the effective current value under

[0024] Step M4: setting the vibration RMS baseline and the current RMS baseline during normal operation under different operating conditions;

[0025] Vibration RMS baseline: ;

[0026] Current RMS baseline: ;

[0027] in, Indicates that it is in running state The sample standard deviation of the effective value of vibration under Indicates that it is in running state The sample standard deviation of the effective vibration value under .

[0028] Furthermore, in the technical solution of the present invention, in step S3, dynamically matching the current operating state of the device according to the real-time operating data of the electromechanical device specifically includes:

[0029] Collect the real-time speed of the motor of electromechanical equipment , obtain the real-time load startup status of electromechanical equipment ,in, Expressed as the real-time speed of the motor of the electromechanical equipment, It represents the set of loads started in real time by electromechanical equipment;

[0030] satisfy: and ,in, , determine whether the electromechanical equipment enters the corresponding operating state .

[0031] Furthermore, in the technical solution of the present invention, in step S4,

[0032] Calculating the relative deviation between vibration acceleration data and current data specifically includes: obtaining the real-time vibration acceleration signal of the electromechanical equipment and current signal , calculate the relative deviation:

[0033] , ,in, Indicates that it is in running state Real-time vibration acceleration signal The relative deviation of Indicates that it is in running state Real-time current signal The relative deviation of Indicates that it is in running state The mean effective value of vibration under Indicates that it is in running state The mean effective value of the current under

[0034] Determining whether the real-time vibration acceleration data and current data exceed the limit specifically includes:

[0035] , vibration acceleration exceeds the limit;

[0036] , current exceeds limit.

[0037] Furthermore, in the technical solution of the present invention, in step S5, inferring the fault type and issuing an early warning according to the severity specifically includes:

[0038] If the vibration acceleration and current do not exceed the limit, it is inferred that there is no fault and no warning is given;

[0039] If the vibration acceleration exceeds the limit but the current does not, it is inferred to be a mechanical failure and an early warning is issued;

[0040] If the vibration acceleration does not exceed the limit but the current exceeds the limit, it is inferred to be an electrical fault and an early warning is issued;

[0041] The vibration acceleration and current are out of limit, which is inferred to be a serious coupling fault and an early warning is issued.

[0042] Furthermore, in the technical solution of the present invention, in the case of early warning,

[0043] and If the rate does not exceed 30%, a warning will be issued;

[0044] and If any one of the above exceeds 30% and none exceeds 50%, a serious warning will be issued;

[0045] and If any of the above items exceeds 50%, a danger warning will be issued.

[0046] Effective gain: In summary, the present invention provides a fault diagnosis method for an electromechanical coupling system based on current-vibration data fusion. In the technical solution of the present invention, a method of using dual-parameter coupling of vibration data and current data to decide mechanical and electrical faults is more accurate and has a lower false alarm rate than traditional single-parameter monitoring. At the same time, the present invention sets different health baselines for electromechanical equipment under different operating conditions, and can select different monitoring and diagnosis standards according to the real-time status of the electromechanical equipment, thereby further improving the accuracy of diagnosis.

[0047] Other features and advantages of the present invention will be set forth in the description that follows. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] In order to more clearly illustrate the embodiments of the present invention, the following is a brief introduction to the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0049] Figure 1 Flowchart of a method for diagnosing a fault in an electromechanical coupling system according to an embodiment of the present invention;

[0050] Figure 2 The flowchart is a method for establishing a vibration effective value baseline and a current effective value baseline according to an embodiment of the present invention. DETAILED DESCRIPTION

[0051] In order to make the purpose, features, and advantages of the present invention more obvious and easy to understand, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the embodiments described below are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0052] The core of the embodiment of the present invention is to provide a mechatronic coupling system fault diagnosis method based on current-vibration data fusion, so as to provide a method for solving the problems of false alarms under variable operating conditions and fault type identification. Specifically, it is a mechatronic system fault diagnosis method based on dual-parameter coupling analysis of vibration signals and current signals, which is suitable for fault warning of various mechatronic equipment.

[0053] In one aspect, an embodiment of the present invention provides a method for diagnosing a fault in an electromechanical coupling system. Figure 1 FIG. 1 is a flow chart of a method for diagnosing a fault in an electromechanical coupling system according to this embodiment. Figure 1 As shown, a method for diagnosing a fault in an electromechanical coupling system according to this embodiment includes the following steps:

[0054] Step S1, operating state division: dividing the operating state set of the electromechanical equipment, and specifying the motor output and load starting conditions of the electromechanical equipment in different operating states;

[0055] Step S2, establishing a health baseline: establishing a vibration RMS baseline and a current RMS baseline when the electromechanical equipment is operating normally under different operating conditions;

[0056] Step S3, real-time monitoring and status identification: real-time monitoring of the operating data of the electromechanical equipment, and dynamic matching of the current operating status of the equipment according to the real-time operating data of the electromechanical equipment;

[0057] Step S4, Deviation Calculation and Over-Limit Determination: Further obtaining the real-time vibration acceleration signal and current signal of the electromechanical equipment, calculating the relative deviation of the vibration acceleration data and the current data based on the matching operating state, and determining whether the real-time vibration acceleration data and the current data exceed the limit based on the vibration effective value baseline and the current effective value baseline under the operating state;

[0058] Step S5, fault diagnosis and graded warning: Based on whether the real-time vibration acceleration data and current data of the electromechanical equipment exceed the limit, the fault type is inferred and a warning is issued according to the severity.

[0059] Specifically, in this embodiment, in step S1,

[0060] The operating state set of the electromechanical equipment is divided into: ,in, Represented as the operating status set of electromechanical equipment, Indicated as shared The vibration and current characteristics of electromechanical equipment in different operating states (motor output conditions, load conditions) vary significantly. It is necessary to first classify different operating states to avoid misjudgment in different states.

[0061] The motor output and load starting conditions of electromechanical equipment in different operating states are specified, including: the operating state of each electromechanical equipment includes the speed range of the motor in this operating state and load startup ,in, and Indicates that the electromechanical equipment is in operation The minimum and maximum motor speeds under It limits the output of the motor in this operating state. Indicates that the electromechanical equipment is in operation The load collection started under Including the types and quantities of different loads started by the electromechanical equipment in this operating state, that is, It is also expressed as the load size of the electromechanical equipment in this operating state (total of all loads).

[0062] Specifically, in this embodiment, Figure 2 FIG. 1 is a flow chart of a method for establishing a vibration effective value baseline and a current effective value baseline according to an embodiment of the present invention. Figure 2 As shown, in step S2, establishing a vibration effective value baseline and a current effective value baseline when the electromechanical equipment operates normally in different operating states specifically includes the following steps:

[0063] Step M1: using an accelerometer and a current sensor to collect operating data of the electromechanical equipment during normal operation in different operating states, including multiple sets of vibration acceleration signals, current signals, and the speed of the equipment motor when the electromechanical equipment is operating normally in different operating states. It should be noted that the speed of the motor is usually collected by obtaining a pulse signal using an incremental encoder or a Hall sensor installed on the motor shaft, calculating the number of pulses per unit time, and obtaining the motor speed of the electromechanical equipment during normal operation in different operating states to obtain the speed range of the motor of the electromechanical equipment in that operating state;

[0064] Step M2: Filter the collected signals through high-pass filtering to obtain effective vibration acceleration data of multiple sets of electromechanical equipment under normal operation in different operating states. and effective current data ,in, Represented as the obtained vibration acceleration set, is represented as the current set obtained, and Indicates that it is in running state There are a total of Group data;

[0065] Step M3: Calculate the mean and sample standard deviation of the vibration effective value and the current effective value;

[0066] , ;

[0067] , ;

[0068] in, Indicates that it is in running state The mean effective value of vibration under Indicates that it is in running state The mean effective value of the current under Indicates that it is in running state The sample standard deviation of the effective value of vibration under Indicates that it is in running state The sample standard deviation of the effective current value under the condition of the vibration is calculated, and the mean value and sample standard deviation of the effective vibration value of the electromechanical equipment under different operating conditions and the mean value and sample standard deviation of the effective current value are calculated to reflect the overall vibration energy and load current of the electromechanical equipment under different operating conditions;

[0069] Step M4: setting the vibration RMS baseline and the current RMS baseline during normal operation under different operating conditions;

[0070] Vibration RMS baseline: ;

[0071] Current RMS baseline: ;

[0072] Among them, based on the fact that the vibration effective value and current effective value of the electromechanical equipment in different operating states conform to the normal distribution, three times the sample standard deviation on both sides is used as the baseline boundary to ensure that more than 99.73% of the normal data are within the interval range, thereby reducing statistical errors. At the same time, in this embodiment, different vibration effective value baselines and current effective value baselines are set for the electromechanical equipment in different operating states, that is, different baseline diagnostic standards can be selected according to the different operating states of the electromechanical equipment, which can further improve the accuracy of diagnosis.

[0073] Specifically, in this embodiment, in step S3, dynamically matching the current operating state of the device according to the real-time operating data of the electromechanical device specifically includes:

[0074] Collect the real-time speed of the motor of electromechanical equipment , obtain the real-time load startup status of electromechanical equipment ,in, Expressed as the real-time speed of the motor of the electromechanical equipment, Represents a load collection of electromechanical equipment that is started in real time. Including the types and quantities of different loads started by the electromechanical equipment in this real-time operating state, that is, Expressed as the load size of the electromechanical equipment in real-time operation state (accumulated all loads);

[0075] satisfy: and ,in, , determine whether the electromechanical equipment enters the corresponding operating state .

[0076] In step S4,

[0077] Calculating the relative deviation between vibration acceleration data and current data specifically includes: obtaining the real-time vibration acceleration signal of the electromechanical equipment and current signal , calculate the relative deviation:

[0078] , ,in, Indicates that it is in running state Real-time vibration acceleration signal The relative deviation of Indicates that it is in running state Real-time current signal The relative deviation of Indicates that it is in running state The mean effective value of vibration under Indicates that it is in running state The average current RMS value and acceleration signal The relative deviation and current signal The relative deviation The size of is used to reflect the severity of the fault, that is, after the fault is diagnosed, the larger the relative deviation is, the more serious the fault is;

[0079] Specifically, in this embodiment, determining whether the real-time vibration acceleration data and current data exceed the limit specifically includes:

[0080] , vibration acceleration exceeds the limit;

[0081] , current exceeds limit;

[0082] in, Indicates that it is in running state The sample standard deviation of the effective value of vibration under Indicates that it is in running state The sample standard deviation of the vibration effective value under the condition of the load is obtained; that is, by judging whether the real-time vibration acceleration data and current data are within the vibration effective value baseline and the current effective value baseline, when the real-time vibration acceleration data and current data exceed the vibration effective value baseline and the current effective value baseline, it is diagnosed as a fault, and then the type and severity of the fault are further diagnosed according to the specific circumstances and degrees of the exceeding of the limit.

[0083] Specifically, in this embodiment, in step S5, inferring the fault type and issuing an early warning according to the severity specifically includes:

[0084] If the vibration acceleration and current do not exceed the limit, it is inferred that there is no fault and no warning is given;

[0085] If the vibration acceleration exceeds the limit but the current does not, it is inferred to be a mechanical failure and an early warning is issued;

[0086] If the vibration acceleration does not exceed the limit but the current exceeds the limit, it is inferred to be an electrical fault and an early warning is issued;

[0087] If the vibration acceleration and current exceed the limit, it is inferred that there is a serious coupling fault and an early warning is issued;

[0088] This embodiment uses dual parameters of vibration data and current data to diagnose and determine mechanical and electrical faults. Compared with traditional single-parameter monitoring, the method is more accurate and has a lower false alarm rate.

[0089] Among them, in the case of early warning,

[0090] and If the rate does not exceed 30%, a warning will be issued;

[0091] and If any one of the above exceeds 30% and none exceeds 50%, a serious warning will be issued;

[0092] and If any of the above items exceeds 50%, a danger warning will be issued.

[0093] The above shows and describes the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The above embodiments and descriptions are merely preferred examples of the present invention and are not intended to limit the present invention. Various changes and improvements may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and improvements fall within the scope of the present invention. The scope of protection claimed in the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for diagnosing faults in an electromechanical coupling system, characterized in that: The steps include: Step S1, operating state division: dividing the operating state set of the electromechanical equipment, and specifying the motor output and load starting conditions of the electromechanical equipment in different operating states; Step S2: Establishing a health baseline: Establishing a vibration RMS baseline and a current RMS baseline when the electromechanical equipment is operating normally under different operating conditions, specifically including the following steps: Step M1: using an accelerometer and a current sensor to collect operating data of the electromechanical equipment under different operating conditions, including multiple sets of vibration acceleration signals, current signals, and the speed of the equipment motor under different operating conditions; Step M2: Filter the collected signals through high-pass filtering to obtain effective vibration acceleration data of multiple sets of electromechanical equipment under normal operation in different operating states. and effective current data ,in, Represented as the obtained vibration acceleration set, is represented as the current set obtained, and Indicates that it is in running state There are a total of Group data; Step M3: Calculate the mean and sample standard deviation of the vibration effective value and the current effective value; ， ； ， ； in, Indicates that it is in running state The mean effective value of vibration under Indicates that it is in running state The mean effective value of the current under Indicates that it is in running state The sample standard deviation of the effective value of vibration under Indicates that it is in running state The sample standard deviation of the effective current value under Step M4: setting the vibration RMS baseline and the current RMS baseline during normal operation under different operating conditions; Vibration RMS baseline: ; Current RMS baseline: ; Step S3, real-time monitoring and status identification: real-time monitoring of the operating data of the electromechanical equipment, and dynamic matching of the current operating status of the equipment according to the real-time operating data of the electromechanical equipment; Step S4, Deviation Calculation and Over-Limit Determination: Further obtaining the real-time vibration acceleration signal and current signal of the electromechanical equipment, calculating the relative deviation of the vibration acceleration data and the current data based on the matching operating state, and determining whether the real-time vibration acceleration data and the current data exceed the limit based on the vibration effective value baseline and the current effective value baseline under the operating state; Calculating the relative deviation between vibration acceleration data and current data specifically includes: obtaining the real-time vibration acceleration signal of the electromechanical equipment and current signal , calculate the relative deviation: , ,in, Indicates that it is in running state Real-time vibration acceleration signal The relative deviation of Indicates that it is in running state Real-time current signal Relative deviation, operating status Indicates the matching running state; Determining whether the real-time vibration acceleration data and current data exceed the limit specifically includes: , vibration acceleration exceeds the limit; , current exceeds limit; Step S5, fault diagnosis and graded warning: Based on whether the real-time vibration acceleration data and current data of the electromechanical equipment exceed the limit, the fault type is inferred and a warning is issued according to the severity.

2. A method for diagnosing faults in an electromechanical coupling system according to claim 1, characterized in that: In the step S1, The operating state set of the electromechanical equipment is divided into: ,in, Represented as the operating status set of electromechanical equipment, Indicated as shared operating states; The motor output and load starting conditions of electromechanical equipment in different operating states are specified, including: the operating state of each electromechanical equipment includes the speed range of the motor in this operating state and load startup ,in, and Indicates that the electromechanical equipment is in operation The minimum and maximum motor speeds under Indicates that the electromechanical equipment is in operation The load collection started next.

3. The electromechanical coupling system fault diagnosis method according to claim 2, characterized in that: In step S3, dynamically matching the current operating state of the device according to the real-time operating data of the electromechanical device specifically includes: Collect the real-time speed of the motor of electromechanical equipment , obtain the real-time load startup status of electromechanical equipment ,in, Expressed as the real-time speed of the motor of the electromechanical equipment, It represents the set of loads started in real time by electromechanical equipment; satisfy: and ,in, , determine whether the electromechanical equipment enters the corresponding operating state .

4. A method for diagnosing faults in an electromechanical coupling system according to claim 3, characterized in that: In step S5, inferring the fault type and issuing an early warning according to the severity specifically includes: If the vibration acceleration and current do not exceed the limit, it is inferred that there is no fault and no warning is given; If the vibration acceleration exceeds the limit but the current does not, it is inferred to be a mechanical failure and an early warning is issued; If the vibration acceleration does not exceed the limit but the current exceeds the limit, it is inferred to be an electrical fault and an early warning is issued; The vibration acceleration and current are out of limit, which is inferred to be a serious coupling fault and an early warning is issued.

5. The electromechanical coupling system fault diagnosis method according to claim 4, characterized in that: In the event of an early warning, and If the rate does not exceed 30%, a warning will be issued; and If any one of the above exceeds 30% and none exceeds 50%, a serious warning will be issued; and If any of the above items exceeds 50%, a danger warning will be issued.

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