Portable detection instrument for rolling bearing and fault detection method

Abstract

The invention provides a portable detection instrument for a rolling bearing and a fault detection method. The portable detection instrument for the rolling bearing comprises an operation host, a vibration impact sensor, a vibration speed sensor, a photoelectric rotating speed sensor and an infrared temperature sensor, the vibration impact sensor is electrically connected to the operation host and is used for measuring an impact pulse value of the rolling bearing; the vibration speed sensor is electrically connected to the operation host and is used for measuring the vibration intensity value of the rolling bearing; the photoelectric rotating speed sensor is electrically connected to the operation host and is used for measuring the rotating speed value of the rolling bearing; the infrared temperature sensor is electrically connected to the operation host and is used for measuring the temperature value of the rolling bearing.

Description

Technical Field

[0001] The present invention relates to the technical field of bearing detection instruments, and more particularly to a portable detection instrument for rolling bearings and a fault detection method. Background Art

[0002] Rolling bearings, often called the joints of machinery, are widely used as supporting components and foundational components in the machinery industry. They are also the most vulnerable component in mechanical equipment, posing a significant risk to operational safety. According to statistics, approximately 30% of rotating machinery failures are caused by rolling bearings. Furthermore, compared to other mechanical components, rolling bearing lifespans vary significantly. Bearings with identical dimensions, materials, and processing methods, operating under the same operating conditions, can have significantly different lifespans. Therefore, monitoring and diagnosing rolling bearing faults can not only prevent the loss of precision in mechanical equipment and reduce or eliminate accidents, but also maximize the bearing's operating potential and save costs.

[0003] Rolling bearing fault monitoring and diagnosis has always been one of the research focuses of mechanical fault diagnosis technology development at home and abroad. However, the detection functions that current detection instruments can achieve are relatively simple and the fault diagnosis capabilities are relatively weak. Summary of the Invention

[0004] (1) Technical issues to be resolved The technical problem to be solved by the present invention is that the existing detection instruments have relatively simple detection functions and relatively weak fault diagnosis capabilities.

[0005] (2) Technical solution To achieve the above object, the technical solution adopted by the present invention is: In the first aspect, the present invention provides a portable detection instrument for rolling bearings, including an operating host, a vibration impact sensor, a vibration velocity sensor, a photoelectric speed sensor and an infrared temperature sensor; the vibration impact sensor is electrically connected to the operating host, and is used to measure the impact pulse value of the rolling bearing; the vibration velocity sensor is electrically connected to the operating host, and is used to measure the vibration intensity value of the rolling bearing; the photoelectric speed sensor is electrically connected to the operating host, and is used to measure the rotation speed value of the rolling bearing; the infrared temperature sensor is electrically connected to the operating host, and is used to measure the temperature value of the rolling bearing.

[0006] Preferably, the operating host includes an impact pulse data processing module, a vibration intensity data processing module, a rotation speed data processing module and a temperature value data processing module; the impact pulse data processing module is electrically connected to the vibration impact sensor, the vibration intensity data processing module is electrically connected to the vibration speed sensor, the rotation speed data processing module is electrically connected to the photoelectric rotation speed sensor, and the temperature value data processing module is electrically connected to the infrared temperature sensor.

[0007] Preferably, the operating host further includes a display screen, which is used to display the vibration spectrum, vibration severity value, rotation speed value and temperature value.

[0008] Preferably, the operating host includes an ADC conversion module and an ARM microprocessor, the ARM microprocessor is electrically connected to the ADC conversion module, and the ADC conversion module is electrically connected to the vibration impact sensor and the vibration velocity sensor.

[0009] Preferably, the operating host further includes a power supply, and the power supply is electrically connected to the ARM microprocessor.

[0010] Preferably, the vibration impact sensor has a magnetic base, and / or the vibration velocity sensor has a magnetic base.

[0011] In a second aspect, the present invention further provides a fault detection method, which uses the portable rolling bearing detection instrument described in any one of the above technical solutions to perform fault detection on the rolling bearing, and the fault detection method comprises the following steps: A portable testing instrument performs fault detection on a rolling bearing, and the fault detection method comprises the following steps: Install and fix the vibration impact sensor, vibration velocity sensor, photoelectric speed sensor and infrared temperature sensor at the corresponding positions of the rolling bearing; The operating host is started, the vibration impact sensor measures the impact pulse value of the rolling bearing during operation, the vibration velocity sensor measures the vibration severity value of the rolling bearing during operation, the photoelectric rotation speed sensor measures the rotation speed value of the rolling bearing during operation, and the infrared temperature sensor measures the temperature value of the rolling bearing during operation; A standard shock pulse value is calculated based on the shock pulse value, and the standard shock pulse value, the vibration severity value, the rotation speed value, and the temperature value are compared with their corresponding thresholds to determine the degree of bearing failure.

[0012] Preferably, comparing the standard shock pulse value with its corresponding threshold value to determine the degree of bearing failure includes the following steps: Calculate the absolute shock pulse value and the initial shock pulse value; Calculate a standard shock pulse value dBn, where the standard shock pulse value is the difference between the absolute shock pulse value and its initial shock pulse value; When dBn≤25dB, the rolling bearing is judged to be in normal working condition; when 25dB<dBn≤35dB, the rolling bearing is judged to have signs of slight damage; when 35dB<dBn≤45dB, the rolling bearing is judged to be damaged; when 45dB<dBn≤60dB, the rolling bearing is judged to be seriously damaged; when dBn>60dB, the rolling bearing is judged to have reached the end of its service life.

[0013] Preferably, the absolute shock pulse value dBsv is calculated according to the following formula: Among them, a is the peak value of the vibration acceleration of the rolling bearing under test within a period of time, and a0 is the reference acceleration, whose value is 9.8*10 -3 m / s 2 .

[0014] Preferably, the initial shock pulse value is calculated according to the following formula: Where n is the rotational speed of the rolling bearing; d is the inner ring diameter of the rolling bearing.

[0015] (3) Beneficial effects The above technical solution of the present invention has at least the following advantages: The present invention uses a vibration impact sensor, a vibration velocity sensor, a photoelectric speed sensor, and an infrared temperature sensor to collect the impact pulse value, vibration severity value, rotational speed value, and temperature value of the tested bearing. It then uses a fast Fourier transform (FFT) algorithm to perform spectrum analysis of the bearing fault vibration signal, thereby enabling monitoring of the bearing's operating status and fault detection and diagnosis. The present invention features impact pulse measurement, vibration severity measurement, vibration spectrum analysis, rotational speed measurement, temperature measurement, graphical data preview, and rapid fault diagnosis. It can use impact pulse technology to assess rolling bearing faults, and the test result data can be graphically displayed for trend analysis. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces 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 paying any creative work.

[0017] Figure 1 It is a structural schematic diagram of a portable testing instrument for rolling bearings provided by an embodiment of the present invention.

[0018] Figure 2 This is a schematic diagram of the internal circuit of a portable testing instrument for rolling bearings provided by an embodiment of the present invention.

[0019] Figure 3 It is a schematic diagram of a graphical interface of a display screen provided by an embodiment of the present invention.

[0020] Figure 4 This is a diagram showing the usage status of the portable testing instrument for rolling bearings provided by an embodiment of the present invention.

[0021] The reference numerals in the figures are: 10. Bearing seat; 20. Tested rolling bearing; 1. Operating host; 11. Display screen; 2. Vibration impact sensor; 3. Vibration velocity sensor; 4. Photoelectric speed sensor; 5. Infrared temperature sensor; 6. Magnetic base. DETAILED DESCRIPTION

[0022] In order to make the technical problems, technical solutions and beneficial effects to be solved by the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0023] It should be noted that when an element is referred to as being “fixed to” or “disposed on” another element, it may be directly located on the other element or indirectly located on the other element. When an element is referred to as being “connected to” another element, it may be directly connected to the other element or indirectly connected to the other element.

[0024] It should be understood that the terms "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention, and do not indicate that the device or element must have a specific orientation, be constructed and operate in a specific orientation. Therefore, it should not be understood as a limitation on the present invention.

[0025] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating relative importance or the number of technical features. In the description of the present invention, "plurality" means two or more, unless otherwise specifically defined. The following is a more detailed description of the specific implementation of the present invention in conjunction with specific embodiments: like Figures 1 to 4As shown, an embodiment of the present invention provides a portable detection instrument for rolling bearings, including an operating host 1, a vibration impact sensor 2, a vibration velocity sensor 3, a photoelectric speed sensor 4 and an infrared temperature sensor 5; the vibration impact sensor 2 is electrically connected to the operating host 1, and is used to measure the impact pulse value of the rolling bearing; the vibration velocity sensor 3 is electrically connected to the operating host 1, and is used to measure the vibration intensity value of the rolling bearing; the photoelectric speed sensor 4 is electrically connected to the operating host 1, and is used to measure the rotation speed value of the rolling bearing; the infrared temperature sensor 5 is electrically connected to the operating host 1, and is used to measure the temperature value of the rolling bearing.

[0026] Specifically, the portable multifunctional bearing fault detector provided in this embodiment has an operating host whose dimensions (width×height×depth) are preferably 174mm×105mm×60mm, and a weight of preferably 0.8kg, and is powered by a lithium battery.

[0027] Specifically, the vibration impact sensor 2 receives the impact pulse signal generated during the operation of the rolling bearing. After passing through a specially designed signal processing circuit, it is sent to a high-precision ADC conversion module for acquisition. After further processing and calculation, the impact pulse value measurement result is obtained, which serves as the basis for the impact pulse method for rolling bearing fault diagnosis. The vibration velocity sensor 3 receives the vibration intensity signal generated during the operation of the rolling bearing. After being converted into voltage by a current signal processing circuit, it is sent to a high-precision ADC conversion module for acquisition. After further processing and calculation, the vibration intensity value measurement result is obtained, which serves as the basis for the vibration method for rolling bearing fault diagnosis. The photoelectric rotation speed sensor 4 measures the rotation speed of the rolling bearing. Through a level buffer conversion circuit and a microprocessor high-speed counting channel, it accurately and reliably captures and counts the rotation speed TTL level signal, providing a main frequency reference for vibration spectrum analysis of rolling bearing fault characteristics. The infrared temperature sensor 5 measures the temperature of the outer ring of the rolling bearing. It uses non-contact infrared temperature measurement and collects and analyzes the temperature measurement value through a 485 communication module, which serves as a supplement and reference for the vibration analysis method for rolling bearing fault diagnosis.

[0028] In one embodiment, the operating host 1 includes a shock pulse data processing module, a vibration severity data processing module, a rotation speed data processing module, and a temperature value data processing module. The shock pulse data processing module is electrically connected to the vibration impact sensor, the vibration severity data processing module is electrically connected to the vibration speed sensor, the rotation speed data processing module is electrically connected to the photoelectric rotation speed sensor, and the temperature value data processing module is electrically connected to the infrared temperature sensor. Specifically, the operating host 1 is equipped with a core signal acquisition and processing board, which integrates the shock pulse data processing module, the vibration severity data processing module, the rotation speed data processing module, and the temperature value data processing module. The core signal acquisition and processing board is designed based on a high-performance ARM and high-precision 24-bit AD conversion chip and mainly includes sensor signal processing circuitry, AD conversion circuitry, 485 communication circuitry, USB communication circuitry, and touch screen display circuitry. By adopting a low-temperature drift, high-precision reference voltage chip, isolating the analog and digital grounds of the circuit, and implementing heat dissipation design in the PCB layout, the temperature drift effect of the signal acquisition circuit is reduced, improving the stability, resolution, and detection accuracy of the instrument signal acquisition.

[0029] In one embodiment, the operating host 1 also includes a display screen 11 for displaying vibration spectra, vibration severity values, rotational speed values, and temperature values. Specifically, the operating host 1 is installed with embedded bearing fault detection and analysis software, which has functions such as shock pulse measurement, vibration severity measurement, vibration spectrum analysis, rotational speed measurement, temperature measurement, graphical data preview, and rapid fault diagnosis. The detection and analysis software is developed and designed based on the UCOS III multi-task embedded system and primarily includes software functions such as system parameter setting, signal AD conversion and acquisition processing, shock pulse processing algorithms, vibration severity processing algorithms, rotational speed processing algorithms, temperature data parsing, FFT algorithms, display and storage of detection and analysis results data, and historical data reading and display. User interaction is achieved through a designed parameter input interface, GUI drawing functions are used to display spectrum analysis waveforms and trend curves, list controls are used to preview data files, and the FatFS file system and SD card are used to store and read detection result data.

[0030] Vibration spectrum analysis utilizes a fast Fourier transform (FFT) algorithm, combined with the theoretical characteristic frequencies of rolling bearing fault defects, to determine the defect location. Shock pulse measurement utilizes a standard shock pulse value (dBn) to determine the operating condition of the rolling bearing. Furthermore, a Hanning window filter is incorporated to effectively suppress spectrum leakage, eliminate high-frequency interference from the vibration signal, reduce noise, and improve the instrument's spectrum analysis accuracy. The characteristic frequencies of the spectrum peaks are accurately analyzed and compared with the theoretical characteristic frequencies of rolling bearing fault defects to determine the defect location.

[0031] Furthermore, when using shock pulse measurement to determine the working condition of a rolling bearing, the standard shock pulse value dBn is used. This is the difference between the absolute shock pulse value of the bearing and its initial shock pulse value. This detector defines "zero decibel" as one thousandth of the Earth's gravitational acceleration. Therefore, the absolute shock pulse value dBsv is calculated as: Where a is the peak value of the vibration acceleration of the rolling bearing under test within a period of time, and the unit is m / s 2 ; a0 is the reference acceleration, its value is 9.8*10 -3 m / s 2 The initial shock pulse value is calculated based on the inner diameter and operating speed of the rolling bearing being tested according to the following empirical formula: Where: n is the rolling bearing speed, r / min; d is the rolling bearing inner ring diameter, mm. The standard shock pulse value dBn is the difference between the absolute shock pulse value of the bearing and its initial shock pulse value. The calculation formula is: Furthermore, when using vibration severity to judge the working state of rolling bearings, the vibration severity value Vel is used, which is the vibration acceleration value obtained by integration operation, and then the maximum value of the vibration velocity (single peak value) during the analysis time is divided by Obtain the vibration severity value of the rolling bearing (in mm / s). At the same time, establish a threshold for determining the bearing's operating status based on the power and type of the equipment being tested. Determine the bearing's fault status by detecting whether the current vibration severity value exceeds the fault threshold.

[0032] In one embodiment, the operating host 1 includes an ADC conversion module and an ARM microprocessor. The ARM microprocessor is electrically connected to the ADC conversion module, and the ADC conversion module is electrically connected to the vibration impact sensor and the vibration velocity sensor.

[0033] In one embodiment, the operating host 1 further includes a power supply electrically connected to the ARM microprocessor.

[0034] In one embodiment, the vibration shock sensor 2 has a magnetic base 6 , and / or the vibration velocity sensor 3 has a magnetic base 6 .

[0035] An embodiment of the present invention further provides a fault detection method, which uses any of the above embodiments to perform fault detection on a rolling bearing. The fault detection method includes the following steps: The present invention collects the impact pulse value, vibration intensity value, rotation speed value and temperature value of the tested bearing through a vibration impact sensor, a vibration velocity sensor, a photoelectric speed sensor and an infrared temperature sensor, and uses the fast Fourier transform (FFT) algorithm to perform spectrum analysis of the bearing fault vibration signal to monitor the bearing working status and detect and judge the fault.

[0036] First, the impact pulse value is used to analyze the bearing fault. When the impact pulse value of the tested bearing is dBn≤25dB, the rolling bearing is judged to be in normal working condition; when 25dB<dBn≤35dB, the rolling bearing is judged to have signs of slight damage; when 35dB<dBn≤45dB, the rolling bearing is judged to be damaged; when 45dB<dBn≤60dB, the rolling bearing is judged to be seriously damaged; when dBn>60dB, that is, the impact energy reaches one thousand times the initial value, the rolling bearing is judged to have reached the end of its service life. Vibration severity is then used for further analysis. For example, for small equipment under 15kW, if the vibration severity of the bearing under test is Vel ≤ 2.0 mm / s, the rolling bearing is considered to be operating normally. If it is 2.0 mm / s < Vel ≤ 4.0 mm / s, the bearing is considered to be slightly damaged. If it is 4.0 mm / s < Vel ≤ 6.0 mm / s, the bearing is considered to be damaged. If it is Vel > 6.0 mm / s, the bearing is considered to be severely damaged. The outer ring temperature of the bearing under test is then measured to detect any signs of rapid temperature rise, supplementing the vibration analysis for bearing fault diagnosis. Simultaneously, vibration spectrum analysis is performed to analyze the frequency characteristics of the current rolling bearing vibration in real time. The fault location of the bearing is determined based on the theoretical characteristic frequencies of the inner ring, outer ring, and roller failures of the rolling bearing, combined with the main frequency corresponding to the current bearing speed.

[0037] The method of using the portable testing instrument for rolling bearings provided in this embodiment is as follows: 1) Before measurement, attach the vibration impact sensor 2 and vibration velocity sensor 3 to the external bearing seat 10 of the rolling bearing 20 being measured using a magnetic base 6. Attach reflective speed measurement paper to the exposed rotating parts of the mechanical equipment. Secure the photoelectric speed sensor 4 to the mechanical equipment using a magnetic base, adjusting the distance between the photoelectric speed sensor 4 and the rotating parts to 5-20 cm. Secure the infrared temperature sensor 5 to the mechanical platform using a magnetic base, adjusting the distance between the infrared temperature sensor 5 and the rolling bearing 20 being measured to an appropriate distance.

[0038] 2) The vibration impact sensor 2, the vibration velocity sensor 3, the photoelectric rotation speed sensor 4, and the infrared temperature sensor 5 are electrically connected to the operating host 1 through the corresponding BNC connectors and the Lemo aviation connector.

[0039] 3) Press the power button, the display screen 11 on the portable testing instrument for rolling bearings lights up, and the software main operation interface is entered.

[0040] 4) Click the "SPM Detection" icon on the main interface to enter the bearing fault shock pulse detection interface. Click "Parameters" to set parameters such as the bearing model, measurement point name, bearing inner diameter, and rated speed. Save and return to the shock vibration measurement interface. Click "Test" and wait for about two seconds to obtain the test results of the current shock pulse value. The shock vibration spectrum and bearing fault diagnosis status information are also displayed.

[0041] 5) Click the "Vibration Severity" icon on the main interface to enter the bearing fault vibration severity detection interface; click "Parameters" to set parameters such as the test point name, equipment type, and rated speed. Save and return to the vibration severity measurement interface. Click the "Test" button to obtain real-time vibration acceleration and velocity values ​​at the measured location. The vibration signal's time domain curve, FFT frequency domain analysis results, and bearing fault diagnosis information are also displayed.

[0042] 6) Click the "Speed" or "Temperature" icon on the main interface to enter the bearing rotation speed and temperature detection function interface; click "Start Detection" to obtain the current bearing speed and temperature detection results in real time, and display the speed and temperature curve graphs.

[0043] 7) Click the "Historical Data" button on the main interface to enter the historical data query function interface; you can query historical data such as the test results of impact vibration and vibration intensity at each measurement point, as well as the change trend curve and spectrum analysis results.

[0044] 8) After the test is completed, the data line can be connected to the host computer to directly export the test result data for data management and trend analysis.

[0045] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A portable testing instrument for rolling bearings, characterized in that: include: operating host; A vibration shock sensor, electrically connected to the operating host, for measuring the shock pulse value of the rolling bearing; A vibration velocity sensor, electrically connected to the operating host, for measuring the vibration severity value of the rolling bearing; A photoelectric rotation speed sensor, electrically connected to the operating host, for measuring the rotation speed value of the rolling bearing; The infrared temperature sensor is electrically connected to the operating host and is used to measure the temperature value of the rolling bearing.

2. The portable testing instrument for rolling bearings according to claim 1, characterized in that: The operating host includes an impact pulse data processing module, a vibration intensity data processing module, a rotation speed data processing module and a temperature value data processing module; the impact pulse data processing module is electrically connected to the vibration impact sensor, the vibration intensity data processing module is electrically connected to the vibration speed sensor, the rotation speed data processing module is electrically connected to the photoelectric rotation speed sensor, and the temperature value data processing module is electrically connected to the infrared temperature sensor.

3. The portable testing instrument for rolling bearings according to claim 1, characterized in that: The operating host also includes a display screen, which is used to display the vibration spectrum, vibration severity value, rotation speed value and temperature value.

4. The portable testing instrument for rolling bearings according to claim 1, characterized in that: The operating host includes an ADC conversion module and an ARM microprocessor. The ARM microprocessor is electrically connected to the ADC conversion module, and the ADC conversion module is electrically connected to the vibration impact sensor and the vibration velocity sensor.

5. The portable testing instrument for rolling bearings according to claim 4, characterized in that: The operating host further includes a power supply, which is electrically connected to the ARM microprocessor.

6. The portable testing instrument for rolling bearings according to claim 1, characterized in that: The vibration shock sensor has a magnetic base, and / or the vibration velocity sensor has a magnetic base.

7. A fault detection method, characterized in that: A rolling bearing fault detection method is performed using the portable rolling bearing detection instrument according to any one of claims 1 to 6, wherein the fault detection method comprises the following steps: Install and fix the vibration impact sensor, vibration velocity sensor, photoelectric speed sensor and infrared temperature sensor at the corresponding positions of the rolling bearing; The operating host is started, the vibration impact sensor measures the impact pulse value of the rolling bearing during operation, the vibration velocity sensor measures the vibration severity value of the rolling bearing during operation, the photoelectric rotation speed sensor measures the rotation speed value of the rolling bearing during operation, and the infrared temperature sensor measures the temperature value of the rolling bearing during operation; A standard shock pulse value is calculated based on the shock pulse value, and the standard shock pulse value, the vibration severity value, the rotation speed value, and the temperature value are compared with their corresponding thresholds to determine the degree of bearing failure.

8. The fault detection method according to claim 7, wherein: Comparing the standard shock pulse value with its corresponding threshold value to determine the degree of bearing failure includes the following steps: Calculate the absolute shock pulse value and the initial shock pulse value; Calculate a standard shock pulse value dBn, where the standard shock pulse value is the difference between the absolute shock pulse value and its initial shock pulse value; When dBn≤25dB, the rolling bearing is judged to be in normal working condition; when 25dB<dBn≤35dB, the rolling bearing is judged to have signs of slight damage; when 35dB<dBn≤45dB, the rolling bearing is judged to be damaged; when 45dB<dBn≤60dB, the rolling bearing is judged to be seriously damaged; when dBn>60dB, the rolling bearing is judged to have reached the end of its service life.

9. The fault detection method according to claim 8, wherein: The absolute shock pulse value dBsv is calculated according to the following formula: Among them, a is the peak value of the vibration acceleration of the rolling bearing under test within a period of time, and a0 is the reference acceleration, whose value is 9.8*10 -3 m / s 2 .

10. The fault detection method according to claim 8, wherein: The initial shock pulse value is calculated according to the following formula: Where n is the rotational speed of the rolling bearing; d is the inner ring diameter of the rolling bearing.

Images