A signal processing system and method for automatic adjustment of guide shaft bearing clearance

Abstract

This invention relates to the field of guide bearing control, specifically to a signal processing system and method for automatic adjustment of guide bearing clearance. The system includes: a clearance measurement module, a model boundary module, a fault learning module, a clearance adjustment module, and an oil film lubrication module. The clearance measurement module monitors the oil film thickness; the model boundary module establishes a dynamic pressure lubrication model for the guide bearing and solves for the guide bearing clearance; the fault learning module determines the clearance adjustment amount; the clearance adjustment module adjusts the clearance distribution; and the oil film lubrication module regulates lubricant injection. This invention enables real-time prediction of guide bearing clearance and performs fault identification and automatic fault-tolerant adjustment, thereby reducing bearing mechanical vibration, ensuring equipment operational stability, preventing abnormal bearing clearance, improving bearing mechanical efficiency, reducing ineffective power loss, extending equipment service life, improving the thickness and pressure distribution of the lubricating oil film, and enhancing the performance of bearing turbine equipment.

Description

Technical Field

[0001] This invention relates to the field of guide bearing control, specifically to a signal processing system and method for automatic adjustment of guide bearing gap. Background Technology

[0002] A guide bearing is a sliding bearing component used to support the smooth rotation of rotating shafts such as crankshafts and camshafts in a fixed position and to bear the load transmitted from the shaft. It is widely used in equipment requiring support for rotating shafts, such as hydroelectric turbines, steam turbines, water pumps, and machine tools. The working surface of the guide bearing is designed with oil grooves and oil holes, which can form a lubricating oil film between the shaft and the bearing, guiding the rotating shaft, reducing bearing friction resistance, and preventing excessive radial runout of the rotating shaft.

[0003] During bearing operation, due to mechanical loosening, installation mismatch, and other issues, the clearance between the rotating shaft and the guide bushing will gradually increase, affecting key indicators such as bearing vibration, oscillation, and bushing temperature. Therefore, real-time adjustment of the bushing clearance is necessary. Direct measurement and plastic clearance gauge methods are commonly used to measure bushing clearance, but these methods have a certain time lag and require machine shutdown for measurement, making them unsuitable for automatic clearance adjustment during bearing operation.

[0004] In addition, many external factors can affect the expansion of the guide shaft bearing clearance, making it difficult to pre-adjust the clearance. In multi-bearing motors, inconsistent guide shaft bearing clearance can also cause eccentricity and oscillation of the rotating shaft, increasing downtime maintenance costs. Although the impact of clearance can be mitigated by adjusting bearing lubrication, problems such as excessive oil pressure and oil leakage are still likely to occur. Summary of the Invention

[0005] The purpose of this invention is to provide a signal processing system and method for automatic adjustment of guide shaft bearing clearance, so as to solve the problems mentioned in the background art.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a signal processing system for automatic adjustment of guide shaft bearing clearance, comprising: a clearance measurement module, a model boundary module, a fault learning module, a clearance adjustment module, and an oil film lubrication module;

[0007] The gap metering module is used to use a liquid level sensor embedded in the oil circuit inside the bearing bush to monitor the change in oil film thickness under static and dynamic conditions. It determines the total amount and distribution of oil by measuring the pressure at different heights in the oil tank, obtains the bearing speed and load from the unit's DCS or PLC system, detects bearing seizure by using acoustic emission sensors and vibration sensors, measures the bearing back pressure by strain gauges, transmits the bearing temperature back by temperature sensors, and stores all the collected data in the database.

[0008] The model boundary module is used to adopt the Reynolds equation as the core mathematical model for hydrodynamic lubrication modeling. Based on the oil film pressure distribution, oil film thickness distribution, lubricating oil dynamic viscosity, journal surface linear velocity and rotational speed, a mathematical model for hydrodynamic lubrication of the guide bearing is established, and pressure boundary conditions are set. The bearing clearance is represented by oil film thickness and injection volume. The bearing clearance is used as an unknown parameter in the model, and the guide bearing clearance is solved in real time using the recursive least squares method or the extended Kalman filter algorithm.

[0009] The fault learning module uses the time series of bearing clearance as training data, employs a multi-scale permutation entropy algorithm to calculate the complexity features of the sequence at different scales, constructs a high-dimensional feature vector, uses a pre-trained classifier to train and classify the extracted high-dimensional feature vector, obtains a separable high-dimensional feature set, uses multi-scale high-dimensional mapping entropy to quantitatively analyze the high-dimensional feature set and perform pattern recognition, outputs the fault type and determines the clearance adjustment amount of the guide bearing under different operating modes.

[0010] The gap adjustment module is used to convert the gap adjustment amount into the rotation parameters of the motor, compile commands and control the servo motor or stepper motor to drive the locking nut, adjust the height of the wedge plate or the pre-tightening width of the feeler gauge, synchronously adjust all guide bearings in the same part, determine the gap distribution of different rotating shafts, so that the bearings of the guide bearings in the same part are evenly distributed on the same circumference, and each guide bearing is concentrically arranged and its center position is consistent with the rotation center.

[0011] The oil film lubrication module is used to simulate the oil film pressure distribution and load-bearing capacity changes based on the level gauge parameters and oil parameters. It calculates the injection flow rate and oil temperature when the pressure distribution and load-bearing capacity changes are uniform based on the current unit load and oil film thickness, and adjusts the variable frequency oil pump to automatically inject and regulate the lubricating oil.

[0012] Furthermore, the gap measurement module includes: a level gauge unit and a bearing detection unit;

[0013] The level gauge unit is used to acquire changes in oil film thickness using a magnetostrictive level gauge or radar level gauge with dense frequency response, and to perform temperature and pressure compensation.

[0014] The bearing bearing seizure detection unit is used to detect bearing seizure, monitor macroscopic abnormal vibration and microscopic crack conditions, and adjust the bearing back preload.

[0015] Furthermore, the model boundary module includes: a hydrodynamic lubrication unit, an environmental boundary unit, and a fast solution unit;

[0016] The hydrodynamic lubrication unit is used to describe the hydrodynamic lubrication state of the sliding bearing using a mathematical model based on the two-dimensional Reynolds equation.

[0017] The environmental boundary element is used to take the pressure at the beginning and end of the oil film as the environmental pressure, and calculates the thrust bearing deformation through thermo-mechanical coupling simulation as a correction parameter.

[0018] The rapid solution unit is used to discretize the Reynolds equation using the finite difference method or the finite element method, and substitute the bearing pressure, temperature and speed as known quantities into the equation to solve for the bearing clearance.

[0019] Furthermore, the fault learning module includes: a high-dimensional quantitative unit, a feature extraction unit, and a pattern recognition unit;

[0020] The high-dimensional unit is used to analyze bearing clearance time series data and construct a high-dimensional fault feature set based on the high-dimensional mapping entropy quantization sequence.

[0021] The feature extraction unit is used to extract the mean, variance, skewness, kurtosis, and elliptic parameters of the axisymmetric trajectory of the gaps in the high-dimensional fault feature set.

[0022] The pattern recognition unit is used to train a classifier model based on historical operating data and cloud data, classify operating modes, and output the gap adjustment amount.

[0023] Furthermore, the gap adjustment module includes: an actuator unit and a coordinated adjustment unit;

[0024] The actuator unit is used to receive the gap adjustment amount and convert it into motor steps, and uses a servo motor or stepper motor to drive the locking nut to adjust the gap.

[0025] The coordinated adjustment unit is used to measure the radial runout of the spindle at each guide bearing by an eddy current displacement sensor, and to measure the concentricity of each bearing housing by a laser alignment instrument, thereby adjusting the clearance of multiple bearings.

[0026] Furthermore, the oil film lubrication module includes: a pressure modeling unit and a lubrication injection unit;

[0027] The pressure modeling unit is used to obtain bearing clearance, oil cavity pressure, lubricating oil injection flow rate and oil temperature, and to model the oil film distribution.

[0028] The lubrication injection unit is used to adjust the oil supply pressure and flow rate of the bearing bush in real time, thereby changing the oil film thickness distribution within the bearing clearance.

[0029] A signal processing method for automatic adjustment of guide shaft bearing clearance includes the following steps:

[0030] Step S1. Embed the closed liquid level metering device into the internal oil circuit of the bearing bush, obtain the total oil volume and oil film thickness change by measuring the pressure at different liquid levels in the oil tank, obtain the bearing speed and load from the industrial control system, and perform bearing seizure detection.

[0031] Step S2. Based on the oil film pressure distribution, oil film thickness distribution, lubricating oil dynamic viscosity, journal surface linear velocity and rotational speed, a mathematical model based on the Reynolds equation is used to model the dynamic pressure lubrication, and the dynamic pressure lubrication model of the guide bearing is obtained. The model parameters are adjusted according to the ambient pressure and temperature.

[0032] Step S3. Represent the bearing clearance with oil film thickness and injection volume, treat the bearing clearance as an unknown parameter in the model, solve for the guide bearing clearance, quantify the time series of the clearance based on high-dimensional mapping entropy, and construct a high-dimensional fault feature set.

[0033] Step S4. Train a classifier based on historical operating data and cloud data, use the classifier to perform multi-scale pattern analysis on the fault feature set, identify the current operating mode of the bearing, and output the clearance adjustment amount of the guide bearing according to the operating mode.

[0034] Step S5. Drive the motor to adjust the bearing clearance according to the clearance adjustment amount, distribute the clearance among all guide bearings in the same bearing area, so that the guide bearings are concentrically arranged and evenly distributed. At the same time, according to the level gauge parameters and oil parameters, simulate the oil film pressure distribution and load-bearing capacity changes, and adjust the oil supply pressure and flow rate of the bearings in real time.

[0035] Furthermore, step S1 includes:

[0036] Step S11. Use a magnetostrictive level gauge or radar level gauge with dense frequency response to embed in the oil circuit inside the bearing bush to monitor the change in oil film thickness under static and dynamic conditions. Obtain the total amount and distribution of oil by measuring the pressure at different heights in the oil tank, and obtain the bearing speed and load from the unit's DCS or PLC system.

[0037] Step S12. Temperature sensors are installed at the oil inlet edge, middle, oil outlet edge and inside the bearing body of the guide bearing to transmit bearing temperature. Bearing seizure is detected by acoustic emission sensor and vibration sensor. Strain gauge is used to measure bearing back pressure, monitor macroscopic abnormal vibration and microscopic crack status, adjust bearing back preload, and store the collected data in the database.

[0038] Furthermore, step S2 includes:

[0039] Step S21. Use a mathematical model based on the two-dimensional Reynolds equation to describe the hydrodynamic lubrication state of the sliding bearing:

[0040]

[0041] Where p is the oil film pressure distribution function, h is the oil film thickness distribution function, μ is the dynamic viscosity of the lubricating oil, U is the journal surface linear velocity, x and z are spatial position parameters, and V is the extrusion speed term;

[0042] Step S22. Using the pressure at the beginning and end of the oil film as the ambient pressure, the thrust bearing deformation is calculated through thermo-mechanical coupling simulation and used as correction parameters to adjust the distribution functions of oil film pressure and oil film thickness.

[0043] Furthermore, step S3 includes:

[0044] Step S31. Discretize the Reynolds equation using the finite difference method or the finite element method, substitute the bearing pressure, temperature and speed as known quantities into the equation, and solve for the bearing clearance using the recursive least squares method or the extended Kalman filter algorithm.

[0045] Step S32. Using the time series of bearing clearance as training data, the multi-scale permutation entropy algorithm is used to calculate the complexity features of the sequence at different scales, construct a high-dimensional feature vector, and extract the mean, variance, skewness, kurtosis and elliptic parameters of the shaft center trajectory of the clearance in the high-dimensional fault feature set.

[0046] Furthermore, step S4 includes:

[0047] Step S41. Train a classifier based on historical running data and cloud data, train and classify the extracted high-dimensional feature vectors to obtain a separable high-dimensional feature set;

[0048] Step S42. Quantitatively analyze the high-dimensional feature set using multi-scale high-dimensional mapping entropy and perform pattern recognition to output the fault type and determine the clearance adjustment amount of the guide bearing under different operating modes.

[0049] Furthermore, step S5 includes:

[0050] Step S51. Receive the gap adjustment amount and convert it into motor steps. Use a servo motor or stepper motor to drive the locking nut and adjust the height of the wedge plate or the preload width of the feeler gauge.

[0051] Step S52. Measure the radial runout of the spindle at each guide bearing by using an eddy current displacement sensor, measure the concentricity of each bearing housing by using a laser alignment instrument, adjust the clearance of multiple bearings, determine the clearance distribution of different rotating shafts, and ensure that the bearing bushes of the same part of the guide bearing are evenly distributed on the same circumference, and that each guide bearing bush is concentrically arranged and its center position is consistent with the rotation center.

[0052] Step S53. Based on the level gauge parameters and oil parameters, obtain the bearing clearance, oil chamber pressure, lubricating oil injection flow rate and oil temperature, model the oil film distribution, simulate the oil film pressure distribution and load-bearing capacity changes, calculate the injection flow rate and oil temperature when the pressure distribution and load-bearing capacity changes are uniform based on the current unit load and oil film thickness, and change the oil film thickness distribution in the bearing clearance.

[0053] Compared with the prior art, the beneficial effects achieved by the present invention are:

[0054] This invention establishes a mathematical model for the hydrodynamic lubrication of the guide bearing by setting a closed liquid level metering device in the gap of the guide bearing, calculating the distribution of oil film pressure, temperature, thickness and thrust bearing deformation, and solving the thrust bearing gap in real time. This enables real-time prediction of the guide bearing gap, fault identification and automatic fault-tolerant adjustment, thereby reducing bearing mechanical vibration and ensuring equipment operation stability.

[0055] This invention can extract features for real-time bearing clearance based on a high-dimensional mapping entropy algorithm, construct a well-separable clearance fault feature set, and use multi-scale high-dimensional mapping entropy to quantitatively analyze the fault feature set and perform pattern recognition to complete automatic clearance adjustment. This avoids problems such as spindle bending and poor gear meshing caused by abnormal bearing clearance, improves bearing mechanical efficiency, reduces ineffective power loss, and extends equipment service life.

[0056] This invention enables the concentric arrangement of each guide bearing with its center position aligned with the rotation center, evaluates the influence of different oil chamber parameters on the gap oil film pressure, models the instantaneous pressure field of the oil film, adjusts the lubricating oil injection amount, forms a stable oil film in the gap, reduces direct metal-to-metal contact friction, improves the thickness and pressure distribution of the lubricating oil film, ensures maximum lubrication effect, and improves the performance of bearing turbine equipment. Attached Figure Description

[0057] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:

[0058] Figure 1 This is a schematic diagram of the signal processing system for automatic adjustment of guide shaft bearing gap according to the present invention;

[0059] Figure 2 This is a schematic diagram of the signal processing method for automatic adjustment of guide shaft bearing gap according to the present invention. Detailed Implementation

[0060] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0061] like Figure 1 As shown in the structure, the present invention provides a technical solution: a signal processing system for automatic adjustment of guide shaft bearing clearance, specifically including: a clearance measurement module, a model boundary module, a fault learning module, a clearance adjustment module, and an oil film lubrication module;

[0062] The gap metering module is used to use a liquid level sensor embedded in the oil circuit inside the bearing bush to monitor the change in oil film thickness under static and dynamic conditions. It determines the total amount and distribution of oil by measuring the pressure at different heights in the oil tank, obtains the bearing speed and load from the unit's DCS or PLC system, detects bearing seizure by using acoustic emission sensors and vibration sensors, measures the bearing back pressure by strain gauges, transmits the bearing temperature back by temperature sensors, and stores all the collected data in the database.

[0063] The gap measurement module includes: a level gauge unit and a bearing detection unit;

[0064] The level gauge unit is used to acquire changes in oil film thickness using a magnetostrictive level gauge or radar level gauge with dense frequency response, and to perform temperature and pressure compensation.

[0065] The bearing bearing seizure detection unit is used to detect bearing seizure, monitor macroscopic abnormal vibration and microscopic crack conditions, and adjust the bearing back preload.

[0066] The model boundary module is used to adopt the Reynolds equation as the core mathematical model for hydrodynamic lubrication modeling. Based on the oil film pressure distribution, oil film thickness distribution, lubricating oil dynamic viscosity, journal surface linear velocity and rotational speed, a mathematical model for hydrodynamic lubrication of the guide bearing is established, and pressure boundary conditions are set. The bearing clearance is represented by oil film thickness and injection volume. The bearing clearance is used as an unknown parameter in the model, and the guide bearing clearance is solved in real time using the recursive least squares method or the extended Kalman filter algorithm.

[0067] The model boundary module includes: a hydrodynamic lubrication unit, an environmental boundary unit, and a fast solution unit;

[0068] The hydrodynamic lubrication unit is used to describe the hydrodynamic lubrication state of the sliding bearing using a mathematical model based on the two-dimensional Reynolds equation.

[0069] The environmental boundary element is used to take the pressure at the beginning and end of the oil film as the environmental pressure, and calculates the thrust bearing deformation through thermo-mechanical coupling simulation as a correction parameter.

[0070] The rapid solution unit is used to discretize the Reynolds equation using the finite difference method or the finite element method, and substitute the bearing pressure, temperature and speed as known quantities into the equation to solve for the bearing clearance.

[0071] The fault learning module uses the time series of bearing clearance as training data, employs a multi-scale permutation entropy algorithm to calculate the complexity features of the sequence at different scales, constructs a high-dimensional feature vector, uses a pre-trained classifier to train and classify the extracted high-dimensional feature vector, obtains a separable high-dimensional feature set, uses multi-scale high-dimensional mapping entropy to quantitatively analyze the high-dimensional feature set and perform pattern recognition, outputs the fault type and determines the clearance adjustment amount of the guide bearing under different operating modes.

[0072] The fault learning module includes: a high-dimensional quantitative unit, a feature extraction unit, and a pattern recognition unit;

[0073] The high-dimensional unit is used to analyze bearing clearance time series data and construct a high-dimensional fault feature set based on the high-dimensional mapping entropy quantization sequence.

[0074] The feature extraction unit is used to extract the mean, variance, skewness, kurtosis, and elliptic parameters of the axisymmetric trajectory of the gaps in the high-dimensional fault feature set.

[0075] The pattern recognition unit is used to train a classifier model based on historical operating data and cloud data, classify operating modes, and output the gap adjustment amount.

[0076] The gap adjustment module is used to convert the gap adjustment amount into the rotation parameters of the motor, compile commands and control the servo motor or stepper motor to drive the locking nut, adjust the height of the wedge plate or the pre-tightening width of the feeler gauge, synchronously adjust all guide bearings in the same part, determine the gap distribution of different rotating shafts, so that the bearings of the guide bearings in the same part are evenly distributed on the same circumference, and each guide bearing is concentrically arranged and its center position is consistent with the rotation center.

[0077] The gap adjustment module includes: an actuator unit and a coordinated adjustment unit;

[0078] The actuator unit is used to receive the gap adjustment amount and convert it into motor steps, and uses a servo motor or stepper motor to drive the locking nut to adjust the gap.

[0079] The coordinated adjustment unit is used to measure the radial runout of the spindle at each guide bearing by an eddy current displacement sensor, and to measure the concentricity of each bearing housing by a laser alignment instrument, thereby adjusting the clearance of multiple bearings.

[0080] The oil film lubrication module is used to simulate the oil film pressure distribution and load-bearing capacity changes based on the level gauge parameters and oil parameters. It calculates the injection flow rate and oil temperature when the pressure distribution and load-bearing capacity changes are uniform based on the current unit load and oil film thickness, and adjusts the variable frequency oil pump to automatically inject and regulate the lubricating oil.

[0081] The oil film lubrication module includes: a pressure modeling unit and a lubrication injection unit;

[0082] The pressure modeling unit is used to obtain bearing clearance, oil cavity pressure, lubricating oil injection flow rate and oil temperature, and to model the oil film distribution.

[0083] The lubrication injection unit is used to adjust the oil supply pressure and flow rate of the bearing bush in real time, thereby changing the oil film thickness distribution within the bearing clearance.

[0084] like Figure 2 As shown, a signal processing method for automatic adjustment of guide shaft bearing clearance includes the following steps:

[0085] Step S1. Embed the closed liquid level metering device into the internal oil circuit of the bearing bush, obtain the total oil volume and oil film thickness change by measuring the pressure at different liquid levels in the oil tank, obtain the bearing speed and load from the industrial control system, and perform bearing seizure detection.

[0086] Step S1 includes:

[0087] Step S11. Use a magnetostrictive level gauge or radar level gauge with dense frequency response to embed in the oil circuit inside the bearing bush to monitor the change in oil film thickness under static and dynamic conditions. Obtain the total amount and distribution of oil by measuring the pressure at different heights in the oil tank, and obtain the bearing speed and load from the unit's DCS or PLC system.

[0088] Step S12. Temperature sensors are installed at the oil inlet edge, middle, oil outlet edge and inside the bearing body of the guide bearing to transmit bearing temperature. Bearing seizure is detected by acoustic emission sensor and vibration sensor. Strain gauge is used to measure bearing back pressure, monitor macroscopic abnormal vibration and microscopic crack status, adjust bearing back preload, and store the collected data in the database.

[0089] Step S2. Based on the oil film pressure distribution, oil film thickness distribution, lubricating oil dynamic viscosity, journal surface linear velocity and rotational speed, a mathematical model based on the Reynolds equation is used to model the dynamic pressure lubrication, and the dynamic pressure lubrication model of the guide bearing is obtained. The model parameters are adjusted according to the ambient pressure and temperature.

[0090] Step S2 includes:

[0091] Step S21. Use a mathematical model based on the two-dimensional Reynolds equation to describe the hydrodynamic lubrication state of the sliding bearing:

[0092]

[0093] Where p is the oil film pressure distribution function, h is the oil film thickness distribution function, μ is the dynamic viscosity of the lubricating oil, U is the journal surface linear velocity, x and z are spatial position parameters, and V is the extrusion speed term;

[0094] Step S22. Using the pressure at the beginning and end of the oil film as the ambient pressure, the thrust bearing deformation is calculated through thermo-mechanical coupling simulation and used as correction parameters to adjust the distribution functions of oil film pressure and oil film thickness.

[0095] Step S3. Represent the bearing clearance with oil film thickness and injection volume, treat the bearing clearance as an unknown parameter in the model, solve for the guide bearing clearance, quantify the time series of the clearance based on high-dimensional mapping entropy, and construct a high-dimensional fault feature set.

[0096] Step S3 includes:

[0097] Step S31. Discretize the Reynolds equation using the finite difference method or the finite element method, substitute the bearing pressure, temperature and speed as known quantities into the equation, and solve for the bearing clearance using the recursive least squares method or the extended Kalman filter algorithm.

[0098] Step S32. Using the time series of bearing clearance as training data, the multi-scale permutation entropy algorithm is used to calculate the complexity features of the sequence at different scales, construct a high-dimensional feature vector, and extract the mean, variance, skewness, kurtosis and elliptic parameters of the shaft center trajectory of the clearance in the high-dimensional fault feature set.

[0099] Step S4. Train a classifier based on historical operating data and cloud data, use the classifier to perform multi-scale pattern analysis on the fault feature set, identify the current operating mode of the bearing, and output the clearance adjustment amount of the guide bearing according to the operating mode.

[0100] Step S4 includes:

[0101] Step S41. Train a classifier based on historical running data and cloud data, train and classify the extracted high-dimensional feature vectors to obtain a separable high-dimensional feature set;

[0102] Step S42. Quantitatively analyze the high-dimensional feature set using multi-scale high-dimensional mapping entropy and perform pattern recognition to output the fault type and determine the clearance adjustment amount of the guide bearing under different operating modes.

[0103] Step S5. Drive the motor to adjust the bearing clearance according to the clearance adjustment amount, distribute the clearance among all guide bearings in the same bearing area, so that the guide bearings are concentrically arranged and evenly distributed. At the same time, according to the level gauge parameters and oil parameters, simulate the oil film pressure distribution and load-bearing capacity changes, and adjust the oil supply pressure and flow rate of the bearings in real time.

[0104] Step S5 includes:

[0105] Step S51. Receive the gap adjustment amount and convert it into motor steps. Use a servo motor or stepper motor to drive the locking nut and adjust the height of the wedge plate or the preload width of the feeler gauge.

[0106] Step S52. Measure the radial runout of the spindle at each guide bearing by using an eddy current displacement sensor, measure the concentricity of each bearing housing by using a laser alignment instrument, adjust the clearance of multiple bearings, determine the clearance distribution of different rotating shafts, and ensure that the bearing bushes of the same part of the guide bearing are evenly distributed on the same circumference, and that each guide bearing bush is concentrically arranged and its center position is consistent with the rotation center.

[0107] Step S53. Based on the level gauge parameters and oil parameters, obtain the bearing clearance, oil chamber pressure, lubricating oil injection flow rate and oil temperature, model the oil film distribution, simulate the oil film pressure distribution and load-bearing capacity changes, calculate the injection flow rate and oil temperature when the pressure distribution and load-bearing capacity changes are uniform based on the current unit load and oil film thickness, and change the oil film thickness distribution in the bearing clearance.

[0108] Example: An ultrasonic level gauge is installed inside the bearing. The gap volume is determined based on the amount of oil injected and the liquid level. The observed value is adjusted by the temperature data from the temperature sensor. The oil film pressure and oil film thickness distribution are simulated based on the pressure at different liquid levels. The actual gap is solved by the two-dimensional Reynolds equation and the gap change sequence over time is output. After pattern recognition of the sequence, the gap space that needs to be adjusted is determined, and the drive motor automatically adjusts the gap and oil volume.

[0109] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0110] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A signal processing method for automatic adjustment of the guide bushing clearance, characterized by, The method comprises the following steps: Step S1. Embed the closed liquid level metering device into the bearing bush internal oil circuit, obtain the total amount of oil and the change of oil film thickness by measuring the pressure of different liquid levels of the oil tank, obtain the bearing rotating speed and load from the industrial control system, and detect the bearing bushing; Step S2. According to the oil film pressure distribution, the oil film thickness distribution, the dynamic viscosity of lubricating oil, the shaft neck surface linear speed and the rotating speed, a mathematical model based on the Reynolds equation is used for dynamic pressure lubrication modeling to obtain the dynamic pressure lubrication model of the guide bushing, and the model parameters are adjusted according to the environmental pressure and temperature; Step S3. The bearing gap is expressed by the oil film thickness and the injection amount, the bearing gap is taken as an unknown parameter in the model, the guide bushing gap is solved, the time series of the gap is quantified based on high-dimensional mapping entropy, and a high-dimensional fault feature set is constructed; Step S4. The classifier is trained based on historical operation data and cloud data, the fault feature set is analyzed by using the classifier, the running mode of the current bearing is identified, and the gap adjustment amount of the guide bushing is output according to the running mode; Step S5. The motor is driven according to the gap adjustment amount to adjust the bearing gap, the gap is distributed among all guide bushings at the same bearing position, the guide bushings are arranged concentrically and uniformly distributed, and the oil film pressure distribution and the change of bearing capacity are simulated according to the liquid level meter parameters and the oil parameters, so as to adjust the oil supply pressure and flow of the bearing bushing in real time; Step S2 comprises: Step S21. A mathematical model based on the two-dimensional Reynolds equation is used to describe the dynamic pressure lubrication state of the sliding bearing: where p is the oil film pressure distribution function, h is the oil film thickness distribution function, μ is the dynamic viscosity of the lubricating oil, U is the surface linear velocity of the journal, x and z are spatial position parameters, and V is the squeeze velocity term; Step S22. The starting and ending point pressures of the oil film are taken as the environmental pressure, the thrust pad deformation is calculated through thermal-mechanical coupling simulation, which is used as a correction parameter to adjust the distribution functions of the oil film pressure and the oil film thickness; Step S3 comprises: Step S31. The finite difference method or the finite element method is used to discretize the Reynolds equation, the bearing pressure, temperature and rotating speed are taken as known quantities and substituted into the equation, and the recursive least square method or the extended Kalman filtering algorithm is used to solve the bearing gap; Step S32. The time series of the bearing gap is taken as the training data, the multiscale permutation entropy algorithm is used to calculate the complexity characteristics of the sequence at different scales, a high-dimensional feature vector is constructed, and the mean, variance, skewness, kurtosis of the gap in the high-dimensional fault feature set and the elliptical parameters of the shaft center trajectory are extracted.

2. A signal processing method for automatic adjustment of the guide bushing clearance according to claim 1, characterized in that: Step S1 comprises: Step S11. A dense frequency response magnetostrictive liquid level meter or a radar liquid level meter is embedded into the bearing bush internal oil circuit to monitor the change of oil film thickness under static and dynamic conditions, the total amount of oil and the distribution state are obtained by measuring the pressure at different heights of the oil tank, and the bearing rotating speed and load are obtained from the unit DCS or PLC system; Step S12. Temperature sensors are arranged at the oil inlet edge, the middle part, the oil outlet edge and the pad body of the guide bushing to return the bushing temperature, bearing bushing detection is carried out through acoustic emission sensors and vibration sensors, pad back pressure is measured by strain gauges to monitor macroscopic abnormal shaking and microscopic crack state, pad back pre-tightening force is adjusted, and the collected data are stored in the database.

3. The signal processing method for automatic adjustment of the guide bushing gap according to claim 2, characterized in that: Step S4 comprises: Step S41. Train the classifier based on historical operation data and cloud data, train and classify the extracted high-dimensional feature vector, and obtain a high-dimensional feature set with separability; Step S42. Quantitatively analyze the high-dimensional feature set using multi-scale high-dimensional mapping entropy and perform pattern recognition, output the fault type, and determine the gap adjustment amount of the guide bush under different operating modes.

4. A signal processing method for automatic adjustment of the guide bushing clearance according to claim 3, characterized in that: Step S5 includes: Step S51. Receive the gap adjustment amount and convert it into motor steps, drive the locking nut using a servo motor or a stepper motor, and adjust the height of the wedge plate or the pre-tightening width of the feeler gauge; Step S52. Measure the radial runout of the main shaft at each guide bearing through the eddy current displacement sensor, measure the concentricity of each bearing seat through the laser alignment instrument, perform multi-bearing gap adjustment, determine the gap distribution of different rotating shafts, and make the bushings of the guide bearings at the same part uniformly distributed on the same circumference, and each guide bushing is concentrically arranged with the center position consistent with the rotation center; Step S53. According to the parameters of the liquid level meter and the oil parameters, obtain the bushing gap, oil cavity pressure, lubricating oil injection flow and oil temperature, model the oil film distribution, simulate the oil film pressure distribution and load capacity change, calculate the injection flow and oil temperature when the pressure distribution and load capacity change are uniform according to the current unit load and oil film thickness, and change the oil film thickness distribution in the bearing gap.

5. A signal processing system for automatic adjustment of the guide bushing clearance, characterized by The system includes the following modules: a gap metering module, a model boundary module, a fault learning module, a gap adjustment module, and an oil film lubrication module; The gap metering module is used to embed a liquid level sensor in the oil channel inside the bushing to monitor the oil film thickness change under static and dynamic conditions, determine the total amount and distribution state of the oil by measuring the pressure at different heights of the oil tank, obtain the bearing speed and load from the unit DCS or PLC system, detect the bearing bushing through acoustic emission sensors and vibration sensors, measure the bushing back pressure through strain gauges, and return the bushing temperature through temperature sensors. All collected data are stored in the database; The model boundary module is used to use the Reynolds equation as the core mathematical model of dynamic pressure lubrication modeling, establish a mathematical model of guide bush dynamic pressure lubrication according to the oil film pressure distribution, oil film thickness distribution, lubricating oil dynamic viscosity, shaft neck surface linear speed and rotation speed, and set the pressure boundary condition. The bearing gap is expressed by the oil film thickness and the injection amount, the bearing gap is taken as an unknown parameter in the model, and the recursive least squares method or the extended Kalman filter algorithm is used to solve the guide bush gap in real time; The fault learning module is used to take the time series of the bearing gap as the training data, calculate the complexity characteristics of the sequence at different scales using the multi-scale permutation entropy algorithm, construct a high-dimensional feature vector, train and classify the extracted high-dimensional feature vector using a pre-trained classifier, obtain a high-dimensional feature set with separability, quantitatively analyze the high-dimensional feature set using multi-scale high-dimensional mapping entropy and perform pattern recognition, output the fault type, and determine the gap adjustment amount of the guide bush under different operating modes; The gap adjustment module is used for converting the gap adjustment amount into a rotation parameter of the motor, compiling a command, and controlling a servo motor or a step motor to drive a locking nut, so as to adjust the height of a wedge plate or the pre-tightening width of a feeler gauge, synchronize the adjustment of all guide bushings at the same position, determine the gap distribution of different rotation shafts, and make the bushings of the guide bearing at the same position uniformly distributed on the same circumference and concentrically arranged with the center position consistent with the rotation center. The oil film lubrication module is used for simulating the oil film pressure distribution and the bearing capacity variation according to the liquid level meter parameter and the oil parameter, calculating the injection flow and the oil temperature when the pressure distribution and the bearing capacity variation are uniform according to the current unit load and the oil film thickness, and adjusting the variable frequency oil pump to automatically inject and adjust the lubricating oil.

6. A signal processing system for automatic adjustment of the guide bushing clearance according to claim 5, characterized in that: The gap measurement module comprises a liquid level meter unit and a bushing detection unit. The liquid level meter unit is used for acquiring the oil film thickness variation by using a dense frequency response magnetostrictive liquid level meter or a radar liquid level meter, and performing temperature and pressure compensation. The bushing detection unit is used for bearing bushing detection, monitoring macroscopic abnormal jitter and microscopic crack state, and adjusting the bushing back pre-tightening force.

7. A signal processing system for automatic adjustment of the guide bushing clearance according to claim 6, characterized in that: The model boundary module comprises a dynamic pressure lubrication unit, an environment boundary unit and a fast solving unit. The dynamic pressure lubrication unit is used for describing the dynamic pressure lubrication state of the sliding bearing by using a mathematical model based on the two-dimensional Reynolds equation. The environment boundary unit is used for taking the oil film starting and ending point pressure as the environmental pressure, and taking the thrust pad deformation calculated by thermal-mechanical coupling simulation as a correction parameter. The fast solving unit is used for discretizing the Reynolds equation by using the finite difference method or the finite element method, taking the bearing pressure, temperature and rotation speed as known quantities, and substituting them into the equation to solve the bearing gap.

8. A signal processing system for automatic adjustment of the guide bushing clearance according to claim 7, characterized in that: The fault learning module comprises a high-dimensional measurement unit, a feature extraction unit and a pattern recognition unit. The high-dimensional measurement unit is used for taking the bearing gap time series data as an analysis object, quantizing the sequence based on high-dimensional mapping entropy, and constructing a high-dimensional fault feature set. The feature extraction unit is used for extracting the mean, variance, skewness, kurtosis of the gap in the high-dimensional fault feature set and the elliptical parameters of the shaft center trajectory. The pattern recognition unit is used for training a classifier model based on historical operation data and cloud data, classifying the operation mode, and outputting the gap adjustment.

9. A signal processing system for automatic adjustment of the guide bushing clearance according to claim 8, characterized in that: The gap adjustment module comprises an actuator unit and a cooperative adjustment unit. The actuator unit is used for receiving the gap adjustment amount and converting it into motor steps, and driving the locking nut by using a servo motor or a step motor to adjust the gap. The cooperative adjustment unit is used for measuring the radial runout of the main shaft at each guide bearing by using an eddy current displacement sensor, measuring the concentricity of each bearing seat by using a laser alignment instrument, and adjusting the gap of multiple bearings. The oil film lubrication module comprises a pressure modeling unit and a lubrication injection unit. The pressure modeling unit is used for acquiring the bushing gap, oil cavity pressure, lubricating oil injection flow and oil temperature, and modeling the oil film distribution. The lubrication injection unit is used for adjusting the oil supply pressure and flow of the bushing in real time, and changing the oil film thickness distribution in the bearing gap.

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