Ship maintenance system

Abstract

The invention relates to the technical field of ship repair and maintenance, and discloses a ship repair and maintenance system which comprises an analysis unit, a calculation unit, a processing unit, an adaptation unit, a maintenance unit and an execution unit and is used for determining a maintenance instruction according to a comprehensive maintenance value and generating a tooth surface alteration potential value through cooperation of all the units. The calculation unit obtains alteration conductivity by combining temperature and vibration, the processing unit analyzes an oil liquid image to obtain a lubricating energy attenuation coefficient, the adaptation unit generates a maintenance imbalance index in a matching mode, the maintenance unit calculates a comprehensive maintenance value by combining using duration, and the execution unit sends an instruction according to the maintenance value to accurately recognize hidden damage, match gear and oil liquid states and avoid abrasion accumulation. And the maintenance effect is ensured, and the long-term stable maintenance requirement of the wharf boat is met.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of ship maintenance, in particular to a ship maintenance system. BACKGROUND

[0002] As a non-self-propelled ship that is long-term moored in fixed waters, the pontoon is mainly used for cargo loading and unloading, personnel boarding and alighting, water operation platform or life auxiliary, and its maintenance requirements are significantly different from self-propelled ships such as cargo ships and cruise ships. The pontoon focuses more on the long-term stability maintenance of static equipment, hull structure, mooring equipment and auxiliary facilities.

[0003] At present, when the winch in the pontoon mooring equipment is maintained, the gear condition is usually checked during oil change to achieve the purpose of maintenance. However, the above maintenance method still has the following defects, specifically: the oil change time mainly depends on the state of the gear oil appearance, oil temperature and other conditions to judge whether it needs to be replaced. Although the wear of the gear is checked at the same time, more focus is on the explicit wear (such as obvious scratches and tooth surface peeling) that has occurred, and the early implicit damage (such as slight tooth surface gluing and scratches) caused by the frequent zero-speed-peak torque switching of the pontoon winch is often ignored. In this case, the protective effect of the newly replaced gear oil does not match the actual damage progress of the gear under the continuous dynamic impact, ultimately leading to the continuous accumulation of implicit wear and poor actual maintenance effect. SUMMARY

[0004] In view of the deficiencies of the prior art, the present application provides a ship maintenance system, which solves the above problems.

[0005] The above technical purpose of the present application is realized by the following technical scheme:

[0006] A ship maintenance system, comprising:

[0007] An analysis unit is configured to acquire a torque signal, a rotational speed signal, a tooth surface temperature and a vibration frequency of a target object in a target process in real time, analyze the preprocessed torque signal and rotational speed signal, and obtain a tooth surface alteration potential value. The target object is a gear disc of a pontoon winch, and the target process is a zero-speed-peak torque switching process of the winch gear disc.

[0008] A calculation unit is configured to calculate the tooth surface alteration potential value according to the tooth surface temperature and the vibration frequency, and obtain an alteration conductivity.

[0009] A processing unit is configured to acquire image data of the gear oil in the target object in real time, analyze the preprocessed image data, and generate a lubrication energy attenuation coefficient.

[0010] An adaptation unit is configured to match the alteration conductivity and the lubrication energy attenuation coefficient, and obtain a maintenance imbalance index.

[0011] The maintenance unit is used to obtain the use time of the target object's internal gear and gear oil in real time, calculate the maintenance imbalance index according to the use time of the gear and the gear oil, and obtain a comprehensive maintenance value;

[0012] The execution unit is used to determine a maintenance instruction according to the comprehensive maintenance value.

[0013] Further, the pretreated torque signal and the rotational speed signal are analyzed to obtain a gear surface alteration potential value, including:

[0014] The time sequence characteristics of the torque signal and the rotational speed signal in the target process are obtained, the target process is divided into three stages of starting, climbing and peak value maintaining based on the time sequence characteristics, and stage time length proportions are generated;

[0015] Based on the stage time length proportions, the pretreated torque signal and the rotational speed signal are subjected to stage-by-stage feature enhancement to generate stage-by-stage torque and rotational speed feature quantities;

[0016] According to the stage-by-stage torque and rotational speed feature quantities, the correlation of torque and rotational speed in the target process is analyzed to generate a torque-rotational speed linkage coefficient;

[0017] The structural properties of the target object are obtained, and the torque-rotational speed linkage coefficient and the structural properties are combined and calculated to obtain a gear surface stress fluctuation value;

[0018] The pretreated torque signal and the rotational speed signal are calculated to obtain the change rate of torque and rotational speed;

[0019] The gear surface stress fluctuation value and the change rate are fused to obtain the gear surface alteration potential value.

[0020] Further, the torque-rotational speed linkage coefficient and the structural properties are combined and calculated to obtain a gear surface stress fluctuation value, including:

[0021] The structural properties are analyzed, and a structural dynamic feature value is generated by assigning weights according to the stress sensitivity of the target object in the target process;

[0022] The change law of the structural dynamic feature value and the torque-rotational speed linkage coefficient in each stage is analyzed to obtain a structure-linkage dynamic coupling coefficient;

[0023] Based on the structural properties, the deformation amount of the gear at different meshing positions during contact is calculated to obtain a gear contact deformation amount;

[0024] The structure-linkage dynamic coupling coefficient is calibrated according to the gear contact deformation amount to generate a gear surface stress fluctuation value.

[0025] Further, the gear surface alteration potential value is calculated according to the gear surface temperature and the vibration frequency to obtain an alteration conductivity, including:

[0026] Based on the tooth surface temperature, the occurrence frequency and duration of temperature sudden rise points in the target process are analyzed to generate thermal shock characteristic values;

[0027] Based on the vibration frequency, the jump amplitude and duration period of abnormal vibration in the target process are extracted to obtain vibration frequency abnormality characteristic values;

[0028] Obtain the micro-texture structure parameters of the gear tooth surface, calculate the thermal shock characteristic values and vibration frequency abnormality characteristic values according to the micro-texture structure parameters, and obtain the thermal shock index and vibration frequency abnormality index;

[0029] Analyze the synchronization of the thermal shock index and the vibration frequency abnormality index on the time axis to generate a thermal-vibration coordination factor.

[0030] Further, the alteration potential value of the tooth surface is calculated according to the tooth surface temperature and the vibration frequency to obtain the alteration conductivity, which further includes:

[0031] Analyze the mapping relationship between the thermal-vibration coordination factor and the tooth surface alteration potential value to obtain a coordination-alteration correlation degree;

[0032] Calculate the influence value of different tooth surface temperatures and vibration frequencies on the gear, and correct the coordination-alteration correlation degree according to the influence value to obtain the alteration conductivity.

[0033] Further, the pre-processed image data is analyzed to generate a lubrication energy attenuation coefficient, including:

[0034] Analyze the image data to capture the discrete trajectory and aggregation frequency of the internal microstructure of the oil, and generate an oil phase dispersion indication;

[0035] Calculate the light and shadow gradient change of the oil film in the image data when the gear is engaged to obtain an oil film boundary stability value;

[0036] Analyze the correlation between the oil phase dispersion indication and the oil film boundary stability value within the gear operation period to generate an efficiency attenuation coupling value;

[0037] Analyze the morphological change amplitude and speed of the oil in the image data with changes in torque and speed to generate a working condition adaptation variation rate;

[0038] Fuse the efficiency attenuation coupling value and the working condition adaptation variation rate to obtain a lubrication energy attenuation coefficient.

[0039] Further, the alteration conductivity and the lubrication energy attenuation coefficient are matched to obtain a maintenance imbalance index, including:

[0040] The alteration conductivity and the lubrication energy attenuation coefficient are respectively expanded in feature dimension to generate an alteration feature vector and a lubrication energy feature vector;

[0041] The image data is analyzed to obtain the gear oil viscosity, and the gear oil viscosity is combined with the micro-texture structure parameters to obtain a viscosity-roughness fitting value;

[0042] The spatial matching degree of the alteration feature vector and the energy-lubrication feature vector is calculated to obtain an alteration-energy-lubrication matching deviation value;

[0043] According to the alteration conductivity, the decay rate of the lubrication effect with the alteration degree of the gear tooth surface is calculated to generate a lubrication decay rate value;

[0044] The viscosity-roughness fitting value and the lubrication decay rate value are used as weight parameters to weight and adjust the alteration-energy-lubrication matching deviation value to generate a dynamic fitting imbalance degree;

[0045] Based on the dynamic fitting imbalance degree, the peak value interval of the torque signal and the speed signal is mapped to generate a maintenance imbalance index.

[0046] Further, based on the dynamic fitting imbalance degree, the peak value interval of the torque signal and the speed signal is mapped to generate a maintenance imbalance index, including:

[0047] The transient mutation feature in the peak value interval of the torque signal and the speed signal is analyzed to generate a transient peak variation feature value;

[0048] The interaction of the transient peak variation feature value and the dynamic fitting imbalance degree in each stage of the target process is analyzed to obtain a space-time coupling imbalance coefficient;

[0049] Based on the image data, the oil film rupture critical value when the gear is engaged is calculated;

[0050] According to the oil film rupture critical value, the space-time coupling imbalance coefficient is dynamically calibrated to generate a calibrated space-time imbalance value;

[0051] The space-time imbalance value is converted to generate a maintenance imbalance index.

[0052] Further, according to the use length of the gear and the gear oil, the maintenance imbalance index is calculated to obtain a comprehensive maintenance value, including:

[0053] The performance decay of the gear and the gear oil in different use length intervals is analyzed to generate a gear aging nonlinear decay coefficient and an oil aging nonlinear decay coefficient;

[0054] The dynamic change rate of the gear aging nonlinear decay coefficient and the oil aging nonlinear decay coefficient is calculated to obtain a length-decay coordination coefficient;

[0055] According to the length-decay coordination coefficient, the maintenance imbalance index is adaptively adjusted in stages to generate a dynamic maintenance prediction value;

[0056] The stress fluctuation value of the tooth surface, the thermal shock characteristic value, the vibration frequency abnormality index and the oil film rupture critical value are fused to generate a multi-dimensional attenuation factor;

[0057] The dynamic maintenance estimation value is corrected according to the multi-dimensional attenuation factor to obtain a comprehensive maintenance value.

[0058] Further, the maintenance instruction is determined according to the comprehensive maintenance value, including:

[0059] The maintenance interval and the maintenance instruction are determined based on the comprehensive maintenance value.

[0060] To sum up, the present application mainly has the following beneficial effects:

[0061] By dividing the zero-speed-peak torque switching process into three stages of starting, climbing and peak maintenance, combining the 10ms sliding window to capture the timing characteristics of torque and speed, and through phased feature enhancement and linkage analysis, the tooth surface alteration potential value is generated; at the same time, the tooth surface stress fluctuation value is calculated by integrating the structural properties such as gear tooth number and module, which accurately maps the cumulative process of subtle damage such as slight adhesion and scratches, breaking through the limitation of traditional maintenance that can only detect explicit wear, and can capture subtle damage signs under frequent working condition switching of the ferry winch, avoiding the problem that implicit wear becomes more and more serious due to long-term neglect.

[0062] Through the cooperative evaluation of the gear and the gear oil state, and the calculation unit generates the alteration conductivity by combining the tooth surface temperature and vibration frequency, reflecting the gear damage progress, the processing unit generates the energy attenuation coefficient by analyzing the oil image, understanding the protection ability of the gear oil, the adaptation unit matches the maintenance imbalance index, and then the maintenance unit calculates the comprehensive maintenance value by combining the use time, realizing the dynamic correlation of damage state and lubrication efficiency, compared with the traditional way of relying on appearance to judge oil change time, the matching degree of gear oil protection and actual damage can be understood, avoiding the problem that new oil change does not match the progress of implicit damage, and making maintenance more in line with actual needs.

[0063] Through the execution unit, four intervals are divided according to the comprehensive maintenance value, corresponding to the instructions of separate oil change, gear replacement, simultaneous replacement or no replacement, replacing the traditional experience-based decision-making method, preventing resource waste caused by excessive maintenance, and avoiding equipment failure caused by insufficient maintenance, especially suitable for the maintenance needs of static equipment for long-term stability of the ferry, effectively prolonging the service life of the winch gear and the gear oil, and reducing the maintenance cost caused by the accumulation of implicit wear. BRIEF DESCRIPTION OF DRAWINGS

[0064] Figure 1 is a schematic diagram of a ship maintenance and repair system. DETAILED DESCRIPTION

[0065] With reference to the drawings of the embodiments of the present application, the technical solutions in the embodiments of the present application will be clearly and completely described. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments of the present application, all the other embodiments obtained by a person of ordinary skill in the art without creative work fall within the protection scope of the present application.

[0066] With reference to the drawings of the embodiments of the present application, the technical solutions in the embodiments of the present application will be clearly and completely described. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments of the present application, all the other embodiments obtained by a person of ordinary skill in the art without creative work fall within the protection scope of the present application. Figure 1 A ship maintenance system comprises:

[0067] An analysis unit is configured to acquire torque signals, rotation speed signals, gear face temperatures and vibration frequencies of a target object in a target process in real time, analyze the preprocessed torque signals and rotation speed signals, and obtain a gear face alteration potential value, the target object being a gear disc of a barge winch, and the target process being a zero-speed-peak torque switching process of the winch gear disc.

[0068] A calculation unit is configured to calculate the gear face alteration potential value according to the gear face temperatures and the vibration frequencies, and obtain an alteration conductivity.

[0069] A processing unit is configured to acquire image data of gear oil in the target object in real time, analyze the preprocessed image data, and generate an energy-lubricating attenuation coefficient.

[0070] An adaptation unit is configured to match the alteration conductivity and the energy-lubricating attenuation coefficient, and obtain a maintenance imbalance index.

[0071] A maintenance unit is configured to acquire a use duration of the gear and the gear oil in the target object in real time, calculate the maintenance imbalance index according to the use duration of the gear and the gear oil, and obtain a comprehensive maintenance value.

[0072] An execution unit is configured to determine a maintenance instruction according to the comprehensive maintenance value.

[0073] The analysis unit can capture torque, rotation speed and other signals in the zero-speed-peak torque switching process in real time, accurately identify hidden damages such as slight gear face gluing, and the calculation unit can generate the alteration conductivity in combination with the gear face temperatures and the vibration frequencies. The energy-lubricating attenuation coefficient obtained by the processing unit based on the gear oil image data, and the maintenance imbalance index formed after matching by the adaptation unit can realize dynamic correlation analysis of gear damage and lubricating oil protection capability. The comprehensive maintenance value calculated by the maintenance unit in combination with the use duration can make the maintenance instruction issued by the execution unit more suitable for actual needs, avoid the problem that new gear oil does not match the progress of hidden gear damage, and significantly improve the maintenance effect of the barge winch and prolong the service life of the equipment.

[0074] In one case of the embodiment, the analysis of the preprocessed torque signals and rotation speed signals to obtain the gear face alteration potential value comprises:

[0075] Obtain the timing characteristics of the torque signal and the rotation speed signal in the target process, the timing characteristics including the characteristics in the time dimension such as the sequence, the duration, the change rhythm, etc., divide the target process into three stages of starting, climbing and peak maintaining based on the timing characteristics, and generate the stage time length proportion, specifically including: obtaining the historical maximum torque of the target object in the target process, capturing the signal change with a 10ms sliding window step, marking the starting stage when the torque starts to rise from the initial value (zero speed torque) and the rotation speed increases from 0 to 20% of the rated rotation speed (the rotor rotation speed of the barge winch motor under the rated voltage, rated frequency and rated load condition is the rated rotation speed), and lasting until the torque reaches 30% of the peak value (the historical maximum torque); the period when the torque rises from 30% of the peak value to the peak value and the rotation speed increases from 20% of the rated rotation speed to the rated rotation speed is the climbing stage, and ends when the torque first reaches the peak value; the period when the torque is stable in the peak value ± 5% interval and the rotation speed is stable in the rated rotation speed ± 3% range is the peak stage (peak maintaining); then divide the time length of each stage by the total time length of the target process, and the stage time length proportion of each stage of starting, climbing and peak can be obtained;

[0076] Based on the stage time length proportion, the preprocessed torque signal and the rotation speed signal are enhanced in stages to generate the stage torque and rotation speed characteristic quantity, specifically including: in the starting stage, the torque rising rate (the average value of the torque sampling point difference in the adjacent sliding window is calculated, which is the torque rising rate) and the rotation speed growth rate (the average value of the rotation speed sampling point difference in the adjacent sliding window is calculated, which is the rotation speed growth rate) are calculated, the torque rising rate and the rotation speed growth rate are multiplied by the stage time length proportion of the starting stage respectively to obtain the torque feature weight and the rotation speed feature weight of the starting stage; in the climbing stage, the torque difference between the first sampling point and the last sampling point in the stage is divided by the total time length of the stage to obtain the torque average change rate; the rotation speed difference between the first and last sampling points is divided by the total time length of the stage to obtain the rotation speed average change rate, the torque average change rate is multiplied by the stage time length proportion of the climbing stage to obtain the torque trend weight of the climbing stage; the rotation speed average change rate is multiplied by the stage time length proportion of the climbing stage to obtain the rotation speed trend weight of the climbing stage; the difference between the torque value of each sliding window in the peak stage and the peak torque is calculated, the arithmetic average value of the squares of all the differences is taken, and then the square root is taken to obtain the torque fluctuation value; the difference between the rotation speed value of each window and the rated rotation speed is calculated, the arithmetic average value of the squares of all the differences is taken, and then the square root is taken to obtain the rotation speed fluctuation value; the torque fluctuation value is multiplied by the stage time length proportion of the peak stage to obtain the torque stability weight of the peak stage; the rotation speed fluctuation value is multiplied by the stage time length proportion of the peak stage to obtain the rotation speed stability weight of the peak stage; the starting stage torque feature weight, the starting stage rotation speed feature weight, the climbing stage torque trend weight, the climbing stage rotation speed trend weight, the peak stage torque stability weight and the peak stage rotation speed stability weight are added to obtain the stage torque and rotation speed characteristic quantity.

[0077] According to the phased torque speed characteristic quantity, the correlation of torque and speed in the target process is analyzed, and a torque speed linkage coefficient is generated, specifically including: for the starting stage, multiplying the starting torque characteristic weight by the starting speed characteristic weight and then multiplying the stage time length proportion of the starting stage to obtain the starting linkage value; multiplying the product of the torque trend weight and the speed trend weight of the climbing stage by the stage time length proportion of the climbing stage to obtain the climbing linkage value; multiplying the product of the torque stability weight and the speed stability weight of the peak value stage by the stage time length proportion of the peak value stage to obtain the peak value linkage value; adding the starting linkage value, the climbing linkage value and the peak value linkage value to obtain the torque speed linkage coefficient;

[0078] The structural properties of the target object are obtained, and the torque speed linkage coefficient and the structural properties are combined and calculated to obtain a gear face stress fluctuation value, wherein the structural properties include: the number of teeth, tooth shape, modulus, tooth width, material hardness, etc. of the gear;

[0079] The pre-processed torque signal and speed signal are calculated to obtain the change rate of torque and speed, specifically including: dividing the torque difference value of the current window and the previous window by the window time interval (10ms) to obtain the torque instantaneous change rate; dividing the speed difference value of the current window and the previous window by the window time interval (10ms) to obtain the speed instantaneous change rate; calculating the mean value of the torque and speed instantaneous rate of all windows in each stage, i.e. the torque and speed change rate of the corresponding stage can be obtained;

[0080] The gear face stress fluctuation value and the change rate are fused to obtain a gear face alteration potential value, specifically including: multiplying the stress fluctuation value by the torque change rate, then multiplying by the speed change rate, and then multiplying by the stage time length proportion of the starting stage to obtain the starting stage alteration contribution value; multiplying the stress fluctuation value by the torque change rate, then multiplying by the speed change rate, and then multiplying by the stage time length proportion of the climbing stage to obtain the climbing stage alteration contribution value; multiplying the stress fluctuation value by the torque change rate, then multiplying by the speed change rate, and then multiplying by the stage time length proportion of the peak value stage to obtain the peak value stage alteration contribution value; adding the starting stage alteration contribution value, the climbing stage alteration contribution value and the peak value stage alteration contribution value to obtain the gear face alteration potential value.

[0081] Through signal analysis, the recognition accuracy of early hidden damage of the ferry winch gear is improved, the zero-speed-peak torque switching process is divided into three stages of starting, climbing and peak maintaining, the timing characteristics are captured by combining a 10ms sliding window, the torque and speed characteristic quantities are calculated by stage length proportion weighted calculation, the dynamic impact strength of different stages can be accurately quantified, especially the gear structure attribute and the torque and speed linkage coefficient are combined to generate the gear surface stress fluctuation value, and the torque and speed change rate are fused to obtain the alteration potential value, which can capture the early signs of slight gear surface gluing, scratches and other hidden damage.

[0082] Through the alteration contribution value calculated by stages, the influence weight of different working conditions on gear damage can be dynamically reflected, the gear surface alteration potential value is more suitable for the actual working condition of frequent start and stop of the ferry winch, the gear oil replacement is dynamically matched with the progress of gear hidden damage, the problem of mismatch between new oil protection and actual damage is effectively solved, and the cumulative hidden wear is reduced.

[0083] In one case of the embodiment, the torque and speed linkage coefficient and the structure attribute are combined to calculate the gear surface stress fluctuation value, which includes:

[0084] The structure attribute is analyzed, the weight is distributed according to the stress sensitivity of the target object in the target process, and the structure dynamic characteristic value is generated, which specifically includes: setting the weight according to the stress sensitivity: the modulus weight is 0.3, the tooth width weight is 0.25, the material hardness weight is 0.2, the tooth shape weight is 0.15, and the tooth number weight is 0.1, the total weight is 1, the actual value of each attribute is divided by the maximum value (the maximum value allowed in the industry design standard, such as the maximum modulus of the same specification winch gear), then multiplied by the corresponding weight, and then the products are added, to obtain the structure dynamic characteristic value;

[0085] The change law of the structure dynamic characteristic value and the torque and speed linkage coefficient in each stage is analyzed to obtain the structure-linkage dynamic coupling coefficient, which specifically includes: multiplying the structure dynamic characteristic value and the torque and speed linkage coefficient, then multiplying the time length proportion of the starting, climbing and peak stages, to obtain the coupling components of the three stages, and then adding the coupling components of the three stages to obtain the structure-linkage dynamic coupling coefficient;

[0086] Based on the structural properties, the deformation amount of the gear at different meshing positions during contact is calculated to obtain the gear contact deformation amount, specifically including: dividing the actual hardness of the gear by the standard hardness, then multiplying the gear modulus, and then dividing by the tooth width to obtain the addendum deformation amount; based on the number of teeth and the modulus, the tooth thickness is calculated (number of teeth x modulus x 0.8), the tooth thickness is multiplied by the material hardness ratio (actual hardness of the gear divided by the standard hardness), and then divided by the tooth width to obtain the root deformation amount; the product of the modulus and the tooth width is divided by the material hardness ratio to obtain the middle tooth surface deformation amount; the addendum deformation amount, the root deformation amount and the middle tooth surface deformation amount are added to obtain the gear contact deformation amount;

[0087] According to the gear contact deformation amount, the structure-linkage dynamic coupling coefficient is calibrated to generate the tooth surface stress fluctuation value, specifically including: multiplying the structure-linkage dynamic coupling coefficient by the gear contact deformation amount to obtain a preliminary stress value, and multiplying the material hardness ratio by the preliminary stress value to obtain the tooth surface stress fluctuation value.

[0088] By fusing the torque-speed linkage coefficient with the gear structural properties, and assigning weights to the structural properties such as modulus and tooth width according to the force sensitivity, and generating structural dynamic characteristic values, the structure-linkage dynamic coupling coefficient is obtained in combination with the proportion of each stage time length, and then calibrated by the gear contact deformation amount and introduced into the material hardness ratio, so that the tooth surface stress fluctuation value can accurately map the force deformation difference of different meshing positions, and further understand the subtle stress changes of the pontoon winch under frequent switching of working conditions, so that the maintenance decision is more in line with the actual damage state of the gear.

[0089] In one case of the embodiment, the tooth surface alteration potential value is calculated according to the tooth surface temperature and vibration frequency to obtain the alteration conductivity, including:

[0090] Based on the tooth surface temperature, the occurrence frequency and duration of temperature sudden rise points in the target process are analyzed to generate a thermal shock characteristic value, specifically including: setting the temperature sudden rise threshold to 10℃ / 10ms, counting the number of times (frequency) exceeding the threshold in the target process, multiplying the window number of each sudden rise by 10 to obtain the total duration; multiplying the frequency by 0.6 (weight) + total duration by 0.4 (weight) to obtain the thermal shock characteristic value; wherein, in the zero-speed-peak-torque switching process of the pontoon winch gear disc, the winch gear bears instantaneous impact load during the switching process, and the immediate lubrication failure risk (such as sudden rupture of the oil film) of the gear oil has a more direct impact on the tooth surface damage, the frequency reflects the frequency of immediate failure, the higher the frequency, the more severe the fluctuation of lubricating capacity, the greater the immediate damage risk, therefore a higher weight (0.6) is given; while the total duration reflects the cumulative effect of lubrication failure, although it also aggravates the tooth surface wear, but compared with the immediate high-frequency failure, its impact on the instantaneous damage of the tooth surface during the current torque switching process is smaller, therefore the weight is lower (0.4);

[0091] Based on the vibration frequency, the jump amplitude and the duration cycle of the abnormal vibration in the target process are extracted to obtain the vibration frequency anomaly characteristic value, which specifically includes: setting the abnormal vibration threshold as ±15% of the rated frequency (the rated working frequency of the gear disc), counting the jump amplitude (the difference between the current window frequency and the previous window frequency) that exceeds the threshold, adding the jump amplitudes of all windows to obtain the total jump amplitude; counting the abnormal duration cycle (abnormal duration window number x 10) that exceeds the threshold each time, adding all the abnormal duration cycles to obtain the total cycle; multiplying the total jump amplitude by 0.7 + the total cycle by 0.3 to obtain the vibration frequency anomaly characteristic value;

[0092] The micro-texture structure parameters of the gear tooth surface are obtained, and the thermal shock characteristic value and the vibration frequency anomaly characteristic value are calculated according to the micro-texture structure parameters to obtain the thermal shock index and the vibration frequency anomaly index. The micro-texture structure parameters include tooth surface roughness, texture direction angle, texture depth, etc., and specifically include: multiplying the tooth surface roughness by the thermal shock characteristic value + multiplying the texture depth by the thermal shock characteristic value and then multiplying by 0.5 to obtain the thermal shock index; multiplying the product of the texture direction angle and the vibration frequency anomaly characteristic value by the product of the tooth surface roughness and the vibration frequency anomaly characteristic value, and then multiplying by 0.5 to obtain the vibration frequency anomaly index.

[0093] The synchronism of the thermal shock index and the vibration frequency anomaly index on the time axis is analyzed to generate a thermal vibration coordination factor, which specifically includes: taking 10ms as a fixed window, traversing the time axis of the entire target process, each window corresponds to a group of thermal shock index and vibration frequency anomaly index, when the thermal shock index in a certain window >0.6 and the vibration frequency anomaly index >0.5, mark it as a synchronous window, divide the number of all synchronous windows by the total number of windows to obtain the synchronization rate; for each synchronous window, calculate the product of the thermal shock index and the vibration frequency anomaly index in the window, then add the product results of all synchronous windows and divide by the number of synchronous windows to obtain the product mean; multiply the product mean by the synchronization rate to obtain the thermal vibration coordination factor.

[0094] By analyzing the gear surface temperature and the vibration frequency, the temperature sudden rise frequency and the duration are counted for the frequently switched working conditions of the ferry winch with a threshold of 10℃ / 10ms, the thermal shock characteristic value is calculated combined with the weight, and then the risk of instantaneous lubrication failure of the gear oil is understood. At the same time, the jump amplitude and the cycle are extracted by the abnormal vibration threshold to generate the vibration frequency anomaly characteristic value, which can sensitively capture the abnormal meshing of the gear, and is helpful to intervene in the lubrication failure and meshing abnormal problems in advance.

[0095] By combining the micro-texture structure parameters of the gear with the collaborative analysis of the thermal vibration characteristics, the thermal shock and vibration frequency abnormal characteristics are calibrated through parameters such as gear surface roughness and texture depth, the thermal shock index and vibration frequency abnormal index are generated, and the synchronization of the two on the time axis is calculated to obtain the thermal vibration synergy factor, which can accurately map the formation process of hidden damage such as slight gluing and scratches, make the calculation of the alteration conductivity more in line with the actual damage of the gear, avoid the neglect of hidden damage in traditional maintenance, and make the maintenance mode more targeted.

[0096] In one case of the embodiment, the tooth surface alteration potential value is calculated according to the tooth surface temperature and the vibration frequency, and the alteration conductivity is obtained, further comprising:

[0097] The mapping relationship between the thermal vibration synergy factor and the tooth surface alteration potential value is analyzed to obtain the synergy-alteration correlation degree, specifically including: calculating the absolute value of the difference between the thermal vibration synergy factor and the tooth surface alteration potential value in each 10ms window, adding the absolute values of the differences of all windows to obtain the total deviation; calculating the product of the total number of target processes and the product of the thermal vibration synergy factor and the tooth surface alteration potential value to obtain the reference value; subtracting the total deviation from the reference value, i.e. the synergy-alteration correlation degree is obtained;

[0098] The influence value of different tooth surface temperatures and vibration frequencies on the gear is calculated, and the synergy-alteration correlation degree is corrected according to the influence value to obtain the alteration conductivity, specifically including: (real-time tooth surface temperature minus standard tooth surface temperature divided by standard tooth surface temperature) x 0.005 to obtain the fatigue strength attenuation rate under different temperatures; (actual vibration frequency divided by standard vibration frequency and subtracted by 1) x 0.003 to obtain the vibration frequency influence coefficient; adding the fatigue strength attenuation rate and the vibration frequency influence coefficient after being multiplied by 0.5 respectively to obtain the total influence value; multiplying the synergy-alteration correlation degree by (1+total influence value) to obtain the alteration conductivity.

[0099] By constructing the mapping relationship between the thermal vibration synergy factor and the tooth surface alteration potential value, and combining the actual influence correction of temperature and vibration, the accuracy of the alteration conductivity is greatly improved. The synergy-alteration correlation degree obtained by calculating the total deviation and the reference value in 10ms windows can accurately reflect the internal relationship between the thermal vibration synergy and the tooth surface alteration. Then, the total influence value is calculated by the fatigue strength attenuation rate and the vibration frequency influence coefficient to correct the correlation degree, so that the alteration conductivity can dynamically adapt to the actual damage state of the gear, and the damage state of the ferry winch under frequent switching of working conditions can be understood, which is convenient for later maintenance and maintenance.

[0100] In one case of the embodiment, the pre-processed image data is analyzed to generate a lubricant attenuation coefficient, including:

[0101] The image data is analyzed to capture the discrete trajectories and aggregation frequency of the internal microstructure of the oil, and an oil phase dispersity index is generated, specifically including: taking the pre-processed image data as a window of 10 ms, setting a gray threshold (higher than 200 as a highlight area, lower than 50 as a dark area), scanning the pixel gray value of the oil image in the 10 ms window, identifying the continuous edge profile of the gray mutation, when the profile is closed and the area is in the interval of 5-500 pixels, it is determined to be a microstructure; wherein, the closed profile in the dark area is marked as a contaminant particle, the irregular edge in the highlight area is marked as an oil film fragment, and the pixels of each microstructure are marked; the moving distance of the same microstructure in adjacent windows is calculated (the pixel difference in the horizontal direction and the pixel difference in the vertical direction are squared respectively, then added, and then the square root of the added result is taken to obtain the straight line distance in pixels; finally, multiply by the actual length corresponding to a single pixel (0.01 mm), which is the actual straight line distance between two points, that is, the moving distance), the average of the moving distances of all microstructures is taken as the average trajectory length in the window; the number of times that the distance between two microstructures in the window is less than 5 pixels is counted, and the number of times is taken as the aggregation frequency; the average trajectory length is multiplied by 0.6+ the aggregation frequency is multiplied by 0.4, and the dispersity of the window is obtained, and the average of the dispersities of all windows is calculated, which is the oil phase dispersity index;

[0102] The light and shadow gradient change of the oil film when the gears mesh is calculated in the image data to obtain an oil film boundary stability value, specifically including: for the image data, setting a gray gradient threshold of 30-150, screening the pixel area with a gradient value greater than the gradient threshold, connecting the continuous closed profile to form a continuous area which is the oil film candidate area; setting the addendum feature as a convex circular arc with a curvature radius of 5-8 pixels; the dedendum feature is a concave circular arc with a curvature radius of 3-5 pixels; traverse the oil film candidate area, match the complete gear profile line containing the addendum and dedendum features, mark the top end point of each tooth (addendum) and the bottom end point between two teeth (dedendum), connect the addendum points of adjacent gears to form an addendum connecting line, and connect the dedendum points on the same side to form a dedendum connecting line; the area enclosed by the intersection of the addendum connecting line and the dedendum connecting line is the meshing area; the intersection area of the oil film candidate area and the meshing area is taken as the meshing area oil film image in the 10 ms window; the gradient value of the light and shadow of each pixel in the meshing area oil film image is calculated (the square value of the horizontal direction gradient and the square value of the vertical direction gradient are obtained respectively, the two square values are added, and then the square root of the added result is taken, the obtained value is the gradient value), the number of pixels with a gradient value less than 20 is divided by the total number of pixels in the oil film image to obtain the stability value of the window, and the arithmetic mean of the stability values of all windows is calculated, which is the oil film boundary stability value;

[0103] The correlation between the oil phase dispersion index and the oil film boundary stability value in the gear running period is analyzed, and the performance degradation coupling value is generated, specifically including: taking the gear running period as a unit (such as 30 10ms windows), for each window, multiplying the oil phase dispersion index by 0.4 plus the oil film boundary stability value by 0.6, and the coupling value of each window is obtained; the average value of all window coupling values is calculated to obtain the performance degradation coupling value; wherein, for the gears of the landing winch, the oil phase dispersion index can reflect the dispersion state of the microstructure (contaminants, oil film fragments) in the gear oil, mainly reflecting the uniformity of the oil, which is the basic condition of lubrication performance, but it is an indirect influence, so the weight is low, which is 0.4; and the oil film boundary stability value directly reflects the stability of the oil film in the gear meshing area (such as whether it is broken or whether it continuously covers the tooth surface), and the landing winch gear bears instantaneous impact when switching from zero speed to peak torque, and the stability of the oil film is the core guarantee to prevent tooth surface wear and corrosion, and directly determines the effectiveness of lubrication, because the weight is high, which is 0.6, and it is more in line with the core needs of lubrication protection under instantaneous impact.

[0104] The shape change amplitude and speed of the oil in the image data with the change of torque and speed are analyzed, and the working condition adaptation variation rate is generated, specifically including: taking 10ms as a window, traversing each pixel of the oil film candidate area, setting the actual area corresponding to each pixel (1 pixel = 0.01mm²), multiplying the total number of pixels of the oil film candidate area by the area of a single pixel, which is the area of the oil film enclosed by the contour (oil film contour); the difference between the oil film area of the current window and the previous window is divided by the initial window oil film area (when the torque is zero), and the shape change amplitude is obtained; the shape change amplitude is divided by the window interval to obtain the shape change speed; the shape change amplitude is multiplied by 0.6 plus the shape change speed multiplied by 0.4 to obtain the variation component of each window; the arithmetic mean of all window variation components is calculated, and the working condition adaptation variation rate is obtained.

[0105] The performance degradation coupling value and the working condition adaptation variation rate are fused to obtain the lubrication energy attenuation coefficient, specifically including: for each 10ms window, multiplying the performance degradation coupling value by the working condition adaptation variation rate and then multiplying by 0.5 to obtain the synergistic parameter; the absolute value of the difference between the performance degradation coupling value and the working condition adaptation variation rate is multiplied by 0.5 to obtain the antagonistic parameter; the synergistic parameter and the antagonistic parameter are added to obtain the fusion value, and the average value of all window fusion values is calculated, which is the lubrication energy attenuation coefficient.

[0106] Through multi-dimensional analysis of the gear oil image data, the discrete trajectory and aggregated frequency of the oil microstructure are captured in a 10 ms window, the contaminants and oil film fragments are identified in combination with the gray scale threshold, the oil phase dispersion index generated can reflect the uniformity of the oil, the oil film boundary stability value is calculated through the light and shadow gradient change, and the stability of the oil film is directly embodied, the early failure signs of the gear oil under frequent impact are captured, and it is convenient to judge whether the gear oil needs to be replaced or not in the later period, and the energy attenuation coefficient is generated by fusing the energy attenuation coupling value and the working condition adaptation variation rate, and the dynamic matching of the gear oil performance and the working condition is realized. Considering the instantaneous impact characteristics of the barge winch, a higher weight is given to the oil film stability value, and the energy attenuation coefficient can accurately map the real-time changes of the gear oil protection capability by combining the change amplitude and speed of the oil shape with the torque speed, solving the problem of mismatching between the new gear oil and the progress of the hidden damage of the gear, making the maintenance measures more in line with the actual needs, reducing the cumulative hidden wear and tear, and significantly improving the maintenance effect of the barge winch.

[0107] In one case of the embodiment, the alteration conductivity and the energy attenuation coefficient are matched to obtain a maintenance imbalance index, including:

[0108] The feature dimension of the alteration conductivity and the energy attenuation coefficient is respectively expanded to generate an alteration feature vector and an energy feature vector, specifically including: calculating the average value of the alteration conductivity in each stage of starting, climbing and peak value; finding the maximum value and the minimum value of the alteration conductivity by traversing all windows of the whole target process; arranging the five features of the average value, the maximum value and the minimum value of the alteration conductivity in each stage of starting, climbing and peak value in order to form an alteration feature vector; calculating the average value of the energy attenuation coefficient of each gear operation period to obtain a period average value; calculating the difference value between the current period average value and the previous period average value to obtain a period fluctuation value; finding the maximum value and the minimum value of the energy attenuation coefficient by traversing all windows of the whole process; arranging the four features of the period average value, the period fluctuation value, the maximum value and the minimum value in order to form an energy feature vector;

[0109] The image data is analyzed to obtain the gear oil viscosity, and the gear oil viscosity is combined with the micro-texture structure parameters to obtain a viscosity-roughness matching value, which specifically includes: taking 10 ms as a window, marking the center coordinates of the oil film profile, calculating the straight line distance between the center coordinates of the current window and the previous window, and then dividing the straight line distance by 10 to obtain the average flow speed of the oil film; the viscosity corresponding to the speed is set as: the viscosity corresponding to the speed 0.2 mm / ms is 150 cSt, the viscosity corresponding to the speed 0.3 mm / ms is 120 cSt (the viscosity decreases by 30 cSt for every interval of 0.1 mm / ms), and then the viscosity corresponding to the average flow speed of the oil film can be obtained; the viscosity is multiplied by 0.6+the roughness of the tooth surface is multiplied by 0.4, and the sum is the viscosity-roughness matching value; wherein, for the gears of the barge winch, the gear oil viscosity directly determines the oil film carrying capacity, and under the instantaneous impact of the zero speed-peak torque switching, the gear oil viscosity needs to match the impact load to maintain the integrity of the oil film, which plays a leading role in lubrication effectiveness, so the weight is higher, which is 0.6; and the roughness of the tooth surface reflects the micro concave-convex degree of the tooth surface, which affects the stability of the oil film adhesion, but plays a more auxiliary role, so the weight is lower, which is 0.4;

[0110] The spatial matching degree of the alteration feature vector and the lubrication feature vector is calculated to obtain an alteration-lubrication matching deviation value, which specifically includes: since the alteration feature vector contains 5 elements (start mean value, climbing mean value, peak mean value, maximum value, and minimum value), and the lubrication feature vector contains 4 elements (period mean value, period fluctuation value, maximum value, and minimum value), the last element of the lubrication feature vector is supplemented with 0 to form a 5-element vector, ensuring that the dimensions of the two vectors are consistent, the difference values of the corresponding position elements of the alteration feature vector and the lubrication feature vector are calculated, each difference value is squared and summed, and the square root is taken to obtain the Euclidean distance; the lengths of the alteration feature vector and the lubrication feature vector are calculated (the length is the square root of the sum of the squares of the elements), and the two lengths are added to obtain the total length; the Euclidean distance is divided by the total length to obtain the alteration-lubrication matching deviation value;

[0111] The decay rate of the lubrication effect with the alteration degree of the gear tooth surface is calculated according to the alteration conductivity to generate a lubrication decay rate value, which specifically includes: taking 10 ms as a window, the difference between the alteration conductivities of the current window and the previous window in the start, climbing, and peak stages is calculated respectively, and the difference is divided by 10 to obtain the instantaneous decay rate; the mean value of the instantaneous rates of all windows in each stage is calculated to obtain the stage average decay rate; the three stage average rates are multiplied by the corresponding stage duration proportion and then added to obtain the lubrication decay rate value;

[0112] The viscosity-roughness adaptation value and the lubrication attenuation rate value are taken as weight parameters to weight and adjust the alteration-lubrication energy matching deviation value, to generate a dynamic adaptation imbalance degree, specifically including: multiplying the viscosity-roughness adaptation value by the lubrication attenuation rate value to obtain a coupling coefficient; multiplying the alteration-lubrication energy matching deviation value by the viscosity-roughness adaptation value and the lubrication attenuation rate value respectively, then adding the two products and dividing by (the viscosity-roughness adaptation value plus the lubrication attenuation rate value) to obtain a reference imbalance degree; multiplying the coupling coefficient by the reference imbalance degree, which is the dynamic adaptation imbalance degree;

[0113] Based on the dynamic adaptation imbalance degree, the peak value interval of the torque signal and the speed signal is mapped to generate a maintenance imbalance index.

[0114] By extending the alteration conductivity by phase mean value and extreme value into a feature vector, and extending the lubrication attenuation coefficient into a vector according to the period characteristics, the spatial matching degree is calculated after the dimension is unified by zero filling, and the alteration-lubrication energy matching deviation value obtained can directly reflect the adaptation difference between the two, and the deviation value is adjusted by weighting in combination with the adaptation value of the viscosity of the gear oil and the roughness of the tooth surface, and the attenuation rate of the lubrication effect with the alteration, so that the dynamic adaptation imbalance degree can be fitted to the actual working condition under the instantaneous impact of the barge winch, and the limitation of the separation evaluation of the gear and the oil state in the traditional maintenance is broken through.

[0115] The maintenance imbalance index is generated by mapping the torque speed peak value interval through the dynamic adaptation imbalance degree, which realizes the collaborative evaluation of damage and lubrication, and can capture hidden damage such as slight gluing, and can also reflect the attenuation of the protection ability of the gear oil, effectively solving the problem of mismatch between new oil change and actual damage, and improving the effect of long-term stability maintenance of the equipment.

[0116] In one case of the embodiment, based on the dynamic adaptation imbalance degree, the peak value interval of the torque signal and the speed signal is mapped to generate a maintenance imbalance index, including:

[0117] The transient mutation characteristics in the peak interval of the torque signal and the rotation speed signal are analyzed (the transient mutation characteristics include signal rising edge steepness, peak drop rate, and abnormal pulse density, etc.), and a transient peak mutation characteristic value is generated, specifically including: dividing continuous windows at 10 ms intervals in the torque and rotation speed peak interval (the torque is stable at the peak value ± 5%, and the rotation speed is stable at the rated rotation speed ± 3%), calculating the torque difference (rotation speed difference) between each window and the previous window, dividing the torque difference by 10 to obtain the instantaneous steepness; traversing all windows in the peak interval, selecting the maximum instantaneous steepness as the signal rising edge steepness; after the end of the peak interval, calculating the absolute value of the torque (rotation speed) difference between the first window and the peak window, dividing the absolute value by 10 to obtain the drop rate; dividing the number of windows in which the torque (rotation speed) exceeds the peak value ± 10% in the peak interval by the total number of windows in the interval to obtain the proportion; multiplying the signal rising edge steepness by 0.35, the drop rate by 0.35, and the proportion by 0.3, and then adding the three product results to obtain the transient peak mutation characteristic value;

[0118] The interaction of the transient peak mutation characteristic value and the dynamic adaptation imbalance degree in each stage of the target process is analyzed to obtain a space-time coupling imbalance coefficient, specifically including: in the start-up, climb and peak stages, the product and the absolute value of the difference of the transient peak mutation characteristic value and the dynamic adaptation imbalance degree in each stage are calculated, respectively, to obtain the synergistic term and the antagonistic term; adding the synergistic term and the antagonistic term after multiplying them by 0.5, respectively, to obtain the stage coupling value; adding the three stage coupling values after multiplying them by the corresponding stage duration proportion, respectively, to obtain the space-time coupling imbalance coefficient;

[0119] Based on the image data, the oil film rupture critical value when the gear is engaged is calculated, specifically including: taking 10 ms as a window, in the image, establishing a correspondence between the gray value and the actual oil film thickness: a gray value of 200 corresponds to a thickness of 0.5 μm, and for every 10 gray value decrease, the thickness increases by 0.1 μm; traversing the oil film image in the engagement area, marking the windows in which the oil film profile appears to be broken (the continuous edge is interrupted by more than 5 pixels) as broken windows, and finding the 3 consecutive normal windows before the broken window (i.e. if the broken window is the nth, then the nth-1, nth-2, and nth-3 windows are selected); for the 3 normal windows, the minimum thickness of the oil film in each window is calculated (there is only one minimum value in each window, if there are multiple pixels with the same minimum thickness in the same window, it is still counted as one value); if there are multiple broken windows, the minimum thickness of the 3 normal windows corresponding to each broken window is extracted; adding all the extracted minimum thickness values, and then dividing by the total number of extracted minimum thickness values (i.e. each broken window corresponds to 3 values, and the total number is the number of broken windows multiplied by 3), to obtain the oil film rupture critical value;

[0120] According to the oil film rupture critical value, the space-time coupling imbalance coefficient is dynamically calibrated to generate a calibrated space-time imbalance value, specifically including: dividing the actual thickness of the oil film in the current 10ms window by the oil film rupture critical value to obtain a critical approach degree; multiplying the space-time coupling imbalance coefficient by (1+critical approach degree) and then multiplying by 0.5 to obtain a calibration coefficient; then multiplying the space-time coupling imbalance coefficient by the calibration coefficient to obtain the calibrated space-time imbalance value;

[0121] The space-time imbalance value is converted to generate a maintenance imbalance index, specifically including: finding the maximum value of the calibrated space-time imbalance value in the target process, dividing the space-time imbalance value by the maximum value of the space-time imbalance value to obtain a normalization coefficient; multiplying the normalization coefficient by 100 and taking the integer part, which is the maintenance imbalance index (range 0-100, the higher the value, the more serious the imbalance).

[0122] The maintenance imbalance index is generated by analysis, and the imbalance degree of the damage and lubrication protection of the barge winch gear is understood. By analyzing the transient mutation characteristics of the torque and speed peak value interval, the space-time coupling imbalance coefficient is obtained by combining the dynamic adaptive imbalance degree, and then calibrated according to the oil film rupture critical value, and finally a maintenance imbalance index of 0-100 is generated. It not only captures the impact of signal mutation on the gear, but also integrates the key influence of oil film stability, can sensitively reflect the correlation between slight adhesion and lubrication failure, avoid the problem of mismatch between new oil and damage, reduce the cumulative hidden wear and tear, and improve the maintenance effect.

[0123] In one case of the embodiment, the maintenance imbalance index is calculated according to the use length of the gear and the gear oil to obtain a comprehensive maintenance value, including:

[0124] The performance attenuation of gears and gear oil in different use time intervals is analyzed, and gear aging nonlinear attenuation coefficients and oil aging nonlinear attenuation coefficients are generated, specifically including: obtaining the service life of the gear and the gear oil, dividing the service life into three intervals of 0-30%, 30%-70% and 70%-100%, and the weights of the three intervals are 0.2, 0.5 and 0.3 respectively; taking the new gear tooth surface image as the reference (the gray value is set to 200), the current tooth surface image is analyzed in a 10ms window, and the continuous pixel area with a gray value lower than the reference by 20% (i.e. <160) is marked as the wear area; the actual area corresponding to a single pixel is 0.01mm2, and the total number of pixels in the wear area multiplied by 0.01mm2 gives the wear area; the difference between the gray value of each pixel in the wear area and the reference gray value (the reference gray value is 200) is calculated, and the depth increases by 0.01mm for every 10 differences, the difference multiplied by 10 and 0.01mm gives the wear pixel depth, and the average depth is calculated as the average of all wear pixel depths; the actual wear of the gear is obtained by multiplying the wear area by the average depth; the total limit value is set according to the hardness of the gear material (HB) = hardness value x 0.02mm (for example, the total limit value of a 300HB gear = 6mm); wherein the maximum allowable wear in the 0-30% life interval is 20% of the total limit value, the maximum allowable wear in the 30%-70% life interval is 50% of the total limit value, and the maximum allowable wear in the 70%-100% life interval is 100% of the total limit value; for each interval, the actual wear is divided by the maximum allowable wear in the interval, and the three product results are multiplied by the corresponding interval weights 0.2, 0.5 and 0.3 respectively and then summed to obtain the gear aging nonlinear attenuation coefficient; the initial viscosity of the gear oil is set as the initial viscosity at the factory; the current viscosity is obtained by converting according to the average flow speed of the oil film (0.2mm / ms corresponds to 150cSt, and the viscosity decreases by 30cSt for every 0.1mm / ms increase); the actual viscosity attenuation rate is obtained by subtracting the current viscosity from the initial viscosity and then dividing by the initial viscosity; wherein the maximum attenuation rate in the 0-30% life interval is 10% of the initial viscosity, the maximum attenuation rate in the 30%-70% life interval is 20% of the initial viscosity, and the maximum attenuation rate in the 70%-100% life interval is 30% of the initial viscosity; for each interval, the actual attenuation rate is divided by the maximum attenuation rate in the interval, and the product results of the three intervals are multiplied by the corresponding interval weights 0.2, 0.5 and 0.3 respectively and then summed to obtain the oil aging nonlinear attenuation coefficient.

[0125] The dynamic change rate of the gear time-dependent nonlinear attenuation coefficient and the oil time-dependent nonlinear attenuation coefficient is calculated to obtain the time-dependent attenuation synergy coefficient, specifically including: taking 10ms as a window, taking the gear time-dependent nonlinear attenuation coefficient of 3 windows continuously, dividing the difference between the last window and the previous window by 20, and obtaining the gear average rate; taking 10ms as a window, taking the oil time-dependent nonlinear attenuation coefficient of 3 windows continuously, dividing the difference between the last window and the previous window by 20, and obtaining the oil average rate; multiplying the gear average rates of the three windows by weights of 0.3, 0.5, and 0.2 respectively, and adding them together to obtain the gear total weighted rate; multiplying the oil average rates of the three windows by weights of 0.3, 0.5, and 0.2 respectively, and adding them together to obtain the oil total weighted rate. Weighted rate; multiply the total weighted rate of the gear by 0.4 and add the total weighted rate of the oil by 0.6 to obtain the duration-attenuation synergy coefficient. During the zero-speed to peak torque switching process of the pontoon winch, the lubrication performance of the gear oil is the core guarantee for preventing instantaneous impact damage to the tooth surface. However, the performance degradation of the oil (gear oil) (such as decreased viscosity and reduced oil film stability) will directly lead to lubrication failure. Under instantaneous high-torque impact, the rupture of the oil film may instantly exacerbate tooth surface wear and corrosion. Its dynamic changes are more sensitive to maintenance timing. Therefore, the weight of the total weighted rate of the oil is relatively high, at 0.6. Gear wear is the result of long-term accumulation, and its decay rate has a relatively delayed impact on immediate maintenance decisions. Therefore, the weight of the total weighted rate of the gear is relatively low, at 0.4.

[0126] The maintenance imbalance index is adjusted in stages based on the duration-decay synergy coefficient to generate a dynamic maintenance estimate. Specifically, the maintenance imbalance index is multiplied by the duration-decay synergy coefficient in each of the 0-30%, 30%-70%, and 70%-100% lifespan intervals to obtain a stage-adjusted value. The three stage-adjusted values ​​are multiplied by weights of 0.2, 0.5, and 0.3, respectively, and then added together to obtain a dynamic maintenance estimate.

[0127] The tooth surface stress fluctuation value, thermal shock characteristic value, vibration frequency variation index, and oil film rupture critical value are integrated to generate a multidimensional attenuation factor. Specifically, the following steps are performed: the entire target process is traversed in a 10ms window. In each window, the tooth surface stress fluctuation value is multiplied by the vibration frequency variation index to obtain the mechanical shock component; the thermal shock characteristic value is multiplied by the oil film rupture critical value to obtain the lubrication failure component; the mechanical shock component is multiplied by 0.55 and the lubrication failure component is multiplied by 0.45, and the two are added to obtain the window factor; the mean of all the window factors is calculated as the multidimensional attenuation factor.

[0128] The dynamic maintenance estimate is corrected according to the multidimensional attenuation factor to obtain the comprehensive maintenance value. Specifically, the dynamic maintenance estimate is multiplied by the multidimensional attenuation factor to obtain the basic correction value; the absolute value of the difference between the dynamic maintenance estimate and the multidimensional attenuation factor is multiplied by 0.3, and then added to the basic correction value to obtain the comprehensive maintenance value (if the comprehensive maintenance value 0, then the value is 0, if the comprehensive maintenance value 100, then the value is 100, if 0 Comprehensive maintenance value 100, retain the original value). The comprehensive maintenance value ranges from 0 to 100.

[0129] By dividing the service life into three intervals and assigning different weights, the nonlinear attenuation coefficient is calculated in combination with the actual wear amount and viscosity attenuation rate, and then the time-attenuation synergy coefficient is obtained through the dynamic change rate. This can fit the nonlinear characteristics of the performance attenuation of the pontoon winch during long-term use, so that the adjustment of the maintenance imbalance index is more in line with the actual loss law. In addition, the dynamic maintenance estimate is corrected by the multi-dimensional attenuation factor to generate a comprehensive maintenance value, and the mechanical and lubrication factors such as tooth surface stress fluctuation and thermal shock are integrated to correct the deviation of the maintenance estimate at different life stages, so that the comprehensive maintenance value can accurately reflect the dynamic matching state of the hidden damage of the gear and the protection capability of the oil, solving the problem of mismatch between the new oil change and the actual damage progress, and significantly improving the effectiveness of pontoon winch maintenance.

[0130] In one case of this embodiment, determining a maintenance instruction based on the comprehensive maintenance value includes:

[0131] Based on the comprehensive maintenance value, the maintenance interval and maintenance instructions are determined, specifically including: setting four maintenance intervals, namely:

[0132] The first dimension range is: 61-80;

[0133] The second dimension range is: 81-100;

[0134] The third dimension range is: 41-60;

[0135] The fourth dimension range is: 0-40;

[0136] When the comprehensive maintenance value is in the first maintenance range, the first maintenance instruction is triggered: replace the gear oil alone;

[0137] When the comprehensive maintenance value is in the second maintenance range, the second maintenance instruction is triggered: replace the gear alone;

[0138] When the comprehensive maintenance value is in the third maintenance range, the third maintenance instruction is triggered: replace the gear oil and gears at the same time;

[0139] When the comprehensive maintenance value is in the fourth maintenance interval, the fourth maintenance instruction is triggered: no replacement of gear oil and gear.

[0140] By dividing the comprehensive maintenance value into four intervals and corresponding different maintenance instructions, the precise adaptation of the barge winch maintenance measures is realized. When the comprehensive maintenance value is in different intervals, the instructions of separate oil replacement, separate gear replacement, simultaneous replacement or no replacement are triggered respectively. According to the actual matching state of gear hidden damage and oil protection ability, the maintenance scheme can be developed pertinently. It not only prevents resource waste caused by over-maintenance, but also avoids hidden wear accumulation caused by insufficient maintenance, thereby ensuring the effect of barge winch maintenance.

[0141] Although the embodiments of the present application have been shown and described, it is to be understood that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present application, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A marine vessel repair and maintenance system, characterized by, The method comprises the following steps: an analysis unit is configured to acquire torque signals, rotation speed signals, gear surface temperatures and vibration frequencies of a target object in a target process in real time, analyze the preprocessed torque signals and rotation speed signals, and obtain a gear surface alteration potential value, the target object being a gear disc of a pontoon winch, and the target process being a zero-speed-peak torque switching process of the winch gear disc; a calculation unit is configured to calculate the gear surface alteration potential value according to the gear surface temperatures and the vibration frequencies, and obtain an alteration conductivity; a processing unit is configured to acquire image data of gear oil in the target object in real time, analyze the preprocessed image data, and generate an energy lubrication attenuation coefficient; an adaptation unit is configured to match the alteration conductivity and the energy lubrication attenuation coefficient, and obtain a maintenance imbalance index; a maintenance unit is configured to acquire the service life of the gear and the gear oil in the target object in real time, calculate the maintenance imbalance index according to the service life of the gear and the gear oil, and obtain a comprehensive maintenance value; an execution unit is configured to determine a maintenance instruction according to the comprehensive maintenance value.

2. A marine maintenance system according to claim 1, wherein, The analysis of the preprocessed torque signals and rotation speed signals to obtain the gear surface alteration potential value comprises the following steps: obtaining time sequence characteristics of torque signal and rotation speed signal transformation in the target process, dividing the target process into three stages of starting, climbing and peak maintaining based on the time sequence characteristics, and generating stage time length ratios; based on the stage time length ratios, performing stage-by-stage feature enhancement on the preprocessed torque signals and rotation speed signals, and generating stage-by-stage torque and rotation speed feature quantities; analyzing the correlation of torque and rotation speed in the target process according to the stage-by-stage torque and rotation speed feature quantities, and generating a torque and rotation speed linkage coefficient; obtaining the structural properties of the target object, combining the torque and rotation speed linkage coefficient with the structural properties, and obtaining a gear surface stress fluctuation value; calculating the change rate of torque and rotation speed from the preprocessed torque signals and rotation speed signals; fusing the gear surface stress fluctuation value with the change rate to obtain the gear surface alteration potential value.

3. A marine maintenance system according to claim 2, wherein, The combination of the torque and rotation speed linkage coefficient with the structural properties to obtain the gear surface stress fluctuation value comprises the following steps: analyzing the structural properties, assigning weights according to the stress sensitivity of the target object in the target process, and generating a structural dynamic feature value; analyzing the change law of the structural dynamic feature value and the torque and rotation speed linkage coefficient in each stage to obtain a structure-linkage dynamic coupling coefficient; based on the structural properties, calculating the deformation amount of the gear at different meshing positions during contact to obtain a gear contact deformation amount; calibrating the structure-linkage dynamic coupling coefficient according to the gear contact deformation amount to generate the gear surface stress fluctuation value.

4. A marine maintenance system as claimed in claim 2, wherein, The calculation of the gear surface alteration potential value according to the gear surface temperatures and the vibration frequencies to obtain the alteration conductivity comprises the following steps: based on the gear surface temperatures, analyzing the occurrence frequency and duration of temperature surges in the target process to generate a thermal shock feature value; based on the vibration frequencies, extracting the jump amplitude and duration cycle of abnormal vibration in the target process to obtain a vibration frequency abnormality feature value; obtaining micro-texture structure parameters of the gear surface, calculating the thermal shock feature value and the vibration frequency abnormality feature value according to the micro-texture structure parameters to obtain a thermal shock index and a vibration frequency abnormality index; Synchronize the thermal shock index and the vibration frequency anomaly index on the time axis to generate a thermal-vibration coordination factor.

5. A marine maintenance system as claimed in claim 4, wherein, Calculate the potential value of gear surface alteration according to the gear surface temperature and the vibration frequency to obtain an alteration conductivity, which also includes: Analyze the mapping relationship between the thermal-vibration coordination factor and the potential value of gear surface alteration to obtain a coordination-alteration correlation degree. Calculate the influence value of different gear surface temperatures and vibration frequencies on the gear, and correct the coordination-alteration correlation degree according to the influence value to obtain the alteration conductivity.

6. A marine maintenance system as claimed in claim 1, wherein, Analyze the pre-processed image data to generate a lubrication energy attenuation coefficient, which includes: Analyze the image data to capture the discrete trajectory and aggregated frequency of the internal microstructure of the oil to generate an oil phase dispersion indication. Calculate the light and shadow gradient change of the oil film in the image data when the gear is engaged to obtain an oil film boundary stability value. Analyze the correlation between the oil phase dispersion indication and the oil film boundary stability value within the gear operation cycle to generate an efficiency attenuation coupling value. Analyze the morphological change amplitude and speed of the oil in the image data with changes in torque and rotational speed to generate a working condition adaptation variation rate. Fuse the efficiency attenuation coupling value and the working condition adaptation variation rate to obtain the lubrication energy attenuation coefficient.

7. A marine maintenance system as claimed in claim 6, wherein, Match the alteration conductivity and the lubrication energy attenuation coefficient to obtain a maintenance imbalance index, which includes: Expand the feature dimensions of the alteration conductivity and the lubrication energy attenuation coefficient respectively to generate an alteration feature vector and a lubrication energy feature vector. Analyze the image data to obtain the gear oil viscosity, combine the gear oil viscosity with the micro-texture structure parameters to obtain a viscosity-roughness adaptation value. Calculate the spatial matching degree of the alteration feature vector and the lubrication energy feature vector to obtain an alteration-lubrication matching deviation value. Calculate the lubrication effect attenuation rate with the gear surface alteration degree according to the alteration conductivity to generate a lubrication attenuation rate value. Weight the viscosity-roughness adaptation value and the lubrication attenuation rate value as weight parameters to weight and adjust the alteration-lubrication matching deviation value to generate a dynamic adaptation imbalance degree. Map the peak value interval of the torque signal and the rotational speed signal based on the dynamic adaptation imbalance degree to generate the maintenance imbalance index.

8. A marine maintenance system as claimed in claim 7, characterised in that, Map the peak value interval of the torque signal and the rotational speed signal based on the dynamic adaptation imbalance degree to generate the maintenance imbalance index, which includes: Analyze the transient mutation characteristics in the peak value interval of the torque signal and the rotational speed signal to generate a transient peak variation characteristic value. Analyze the interaction of the transient peak variation characteristic value and the dynamic adaptation imbalance degree at each stage of the target process to obtain a time-space coupling imbalance coefficient. Calculate the oil film rupture critical value when the gear is engaged based on the image data. Dynamically calibrate the time-space coupling imbalance coefficient according to the oil film rupture critical value to generate a calibrated time-space imbalance value. Convert the time-space imbalance value to generate the maintenance imbalance index.

9. A marine maintenance system as claimed in claim 8, wherein, Calculate the maintenance imbalance index according to the service life of the gear and the gear oil to obtain a comprehensive maintenance value, which includes: Analyze the performance attenuation of the gear and the gear oil in different service life intervals to generate a gear aging non-linear attenuation coefficient and an oil aging non-linear attenuation coefficient. Calculate the dynamic change rate of the gear aging non-linear attenuation coefficient and the oil aging non-linear attenuation coefficient to obtain a time length-attenuation coordination coefficient. According to the time length-attenuation coordination coefficient, a maintenance imbalance index is adaptively adjusted in stages to generate a dynamic maintenance estimation value; Fusion is performed on the tooth surface stress fluctuation value, the thermal shock characteristic value, the vibration frequency abnormality index, and the oil film rupture critical value to generate a multi-dimensional attenuation factor; According to the multi-dimensional attenuation factor, a deviation correction is performed on the dynamic maintenance estimation value to obtain a comprehensive maintenance value.

10. A marine maintenance system as claimed in claim 9, wherein, According to the comprehensive maintenance value, a maintenance instruction is determined, including: Based on the comprehensive maintenance value, a maintenance interval and a maintenance instruction are determined.

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