Sound-vibration integrated intelligent coupling and online monitoring method thereof

Abstract

The invention provides a sound and vibration integrated intelligent coupling and an online monitoring method thereof, and relates to the technical field of rotating machinery fault diagnosis and health monitoring. The device comprises a coupling body, a sound measurement module, a strain measurement module and a signal acquisition and processing system. The coupler has the advantages of being compact in structure, convenient to install, high in real-time online monitoring capacity and the like, the coupler can complete the torque transmission function and the signal measurement function at the same time, and the coupler is particularly suitable for rapid positioning and early warning of hard friction and abrasion faults of rotating machinery and shaft system torsional vibration abnormity.

Description

Technical Field

[0001] This invention relates to the technical field of fault diagnosis and health monitoring of rotating machinery, and more particularly to an integrated acoustic and vibration intelligent coupling and its online monitoring method. Background Technology

[0002] Under complex field environments and high-intensity loads, the axle systems of tracked vehicles experience complex stresses on the couplings, making them prone to wear, fatigue, and abnormal torsional vibration, which seriously affect vehicle reliability and safety. Real-time online monitoring of the axle system is crucial for ensuring its operation and enabling predictive maintenance. However, existing monitoring technologies face challenges in tracked vehicle axle system applications: directly deploying sensors on rotating axles is difficult and wiring is complex; single signals are insufficient to comprehensively capture early faults; and traditional wired transmission limits real-time and remote monitoring capabilities. Therefore, there is an urgent need for a compact, easy-to-install intelligent monitoring device capable of simultaneously acquiring multi-source signals such as acoustics and strain, and possessing wireless transmission capabilities, to improve the early warning and health assessment capabilities of tracked vehicle axle system faults. Summary of the Invention

[0003] In response to the technical problems mentioned in the background section, this invention provides an integrated acoustic and vibration intelligent coupling and its online monitoring method. This invention provides a compact, easy-to-install, integrated acoustic and vibration intelligent coupling and its online monitoring method that can collect and analyze acoustic and strain information in real time, thereby improving the intelligent monitoring capabilities of rotating machinery, especially the drive shaft systems of tracked vehicles, and enabling real-time fault warning and health assessment during operation.

[0004] The technical means employed in this invention are as follows: An integrated acoustic and vibration measurement intelligent coupling based on STM32 includes: The coupling body is used to connect the driving shaft and the driven shaft and also serves as a dynamic isolation device; The sound measurement module is used to collect acoustic signals during the operation of the shaft system and convert the acoustic signals into digital signals for output through the built-in RS-485 driver chip; The strain measurement module is used to acquire the torsional strain signal of the shaft system. The strain signal is converted into a voltage signal through a Wheatstone bridge, and then amplified and filtered by the signal conditioning circuit before being output. Additionally, a signal acquisition and processing system is used to simultaneously acquire three audio signals and three strain signals, and to analyze and process the signals.

[0005] Furthermore, the coupling body includes: a driving end flange, a driven end flange, and a central isolating plate; The driving end flange is connected to the drive shaft via a rotating shaft connecting sleeve; the driven end flange is fastened to the driving end flange by nuts and bolts, and a central isolation spring is provided between the driven end flange and the driving end flange. The central isolation spring is used to reduce the transmission of micro vibrations of the shaft system and protect the coupling structure.

[0006] Furthermore, the active end flange is also provided with a sound sensor mounting hole and a strain gauge connection wire fixing hole; both the active end flange and the driven end flange are provided with wiring grooves and PCB mounting holes for wiring and fixing the PCB main control board.

[0007] Furthermore, the sound measurement module includes an industrial-grade sound sensor; the industrial-grade sound sensor is disposed in the sensor mounting hole of the coupling's driving end flange.

[0008] Furthermore, the strain measurement module includes: strain gauges, a Wheatstone bridge, and an operational amplifier conditioning circuit; the strain gauges are disposed on the coupling flange surface and the shaft surface.

[0009] Furthermore, the operational amplifier conditioning circuit includes a Wheatstone bridge circuit, an operational amplifier circuit, and an RC filter circuit; the operational amplifier conditioning circuit is used to condition the voltage signal.

[0010] Furthermore, the sound sensor of the sound measurement module uses an industrial-grade microphone, and the signal transmission uses RS-485 digital communication.

[0011] Furthermore, the signal acquisition and processing system transmits the measurement data to the host computer via the ESP32 wireless module.

[0012] This invention also includes an online monitoring method for an integrated acoustic and vibration measurement coupling based on STM32, comprising the following steps: Acoustic signals during shaft operation are acquired in real time and converted into digital signals; Real-time acquisition of shaft torsional strain and conversion of it into analog voltage signal; The acquired acoustic and strain signals are acquired, processed, and analyzed simultaneously. The processed measurement data is transmitted to the host computer via a wireless module for online monitoring and fault early warning.

[0013] Compared with the prior art, the present invention has the following advantages: 1. This invention highly integrates acoustic and strain measurement modules into the coupling body, achieving a perfect fusion of torque transmission and signal measurement functions, and simplifying the sensor layout, installation and maintenance of tracked vehicle axle systems.

[0014] 2. This invention adopts a multi-channel acoustic and strain signal synchronous acquisition scheme. Through the efficient processing of the STM32 microcontroller, it can provide more comprehensive and accurate shaft system operating status information, which helps to detect and accurately locate complex faults such as hard friction, wear and torsional vibration abnormalities at an early stage.

[0015] 3. This invention utilizes the ESP32 wireless module for data transmission, effectively solving the problems of complex wiring and susceptibility to rotation in traditional wired monitoring solutions. It enables real-time wireless transmission of measurement data and remote online monitoring, significantly improving the convenience and applicability of monitoring, especially performing exceptionally well under harsh working conditions.

[0016] 4. This invention uses an industrial-grade microphone and an RS-485 driver chip to ensure the stability and anti-interference capability of acoustic signal acquisition; at the same time, the strain conditioning circuit combining a Wheatstone bridge and an operational amplifier ensures the accuracy of torsional strain measurement and improves the reliability of monitoring data. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is an exploded structural diagram of the integrated acoustic and vibration intelligent coupling of the present invention; Figure 2 This is a schematic diagram of the flange structure of the integrated acoustic and vibration intelligent coupling of the present invention; Figure 3 This is a system block diagram illustrating the working principle of the integrated acoustic and vibration intelligent coupling of the present invention; Figure 4 This is a signal flow diagram of the strain measurement module of the integrated acoustic and vibration intelligent coupling of the present invention; Figure 5 This is a schematic diagram of the strain signal conditioning circuit of the integrated acoustic and vibration intelligent coupling of the present invention; Wherein; 1 is the active end flange; 2 is the rotating shaft connecting sleeve; 3 is the nut; 4 is the central isolation spring; 5 is the bolt; 6 is the driven end flange; 7 is the PCB main control board; 8 is the sound sensor; 9 is the sound sensor mounting hole; 10 is the strain gauge fixing hole; 11 is the wiring groove; 12 is the PCB mounting hole. Detailed Implementation

[0019] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. 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 should fall within the scope of protection of the present invention.

[0020] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0021] like Figure 1-3 As shown, this invention provides an integrated acoustic and vibration measurement intelligent coupling based on STM32, comprising: The coupling body is used to connect the driving shaft and the driven shaft and also serves as a dynamic isolation device; The sound measurement module is used to collect acoustic signals during the operation of the shaft system and convert the acoustic signals into digital signals for output through the built-in RS-485 driver chip; The strain measurement module is used to acquire the torsional strain signal of the shaft system. The strain signal is converted into a voltage signal through a Wheatstone bridge, and then amplified and filtered by the signal conditioning circuit before being output. Additionally, a signal acquisition and processing system is used to simultaneously acquire three audio signals and three strain signals, and to analyze and process the signals.

[0022] In a preferred embodiment, the coupling body in this application includes: a driving end flange, a driven end flange, and a central isolating plate; The driving end flange is connected to the drive shaft via a rotating shaft connecting sleeve; the driven end flange is fastened to the driving end flange by nuts and bolts, and a central isolation spring is provided between the driven end flange and the driving end flange. The central isolation spring is used to reduce the transmission of micro vibrations of the shaft system and protect the coupling structure.

[0023] In a preferred embodiment, the active end flange is also provided with a sound sensor mounting hole and a strain gauge connection wire fixing hole; both the active end flange and the driven end flange are provided with wiring grooves and PCB mounting holes for wiring and fixing the PCB main control board.

[0024] In this application, the sound measurement module includes: an industrial-grade sound sensor; the industrial-grade sound sensor is disposed in the sensor mounting hole of the coupling's driving end flange.

[0025] In this application, the strain measurement module includes: a strain gauge, a Wheatstone bridge, and an operational amplifier conditioning circuit; the strain gauge is disposed on the coupling flange surface and the shaft surface.

[0026] In this application, the operational amplifier conditioning circuit includes a Wheatstone bridge circuit, an operational amplifier circuit, and an RC filter circuit; the operational amplifier conditioning circuit is used to condition the voltage signal.

[0027] In this application, the sound sensor of the sound measurement module is an industrial-grade microphone, and the signal transmission uses RS-485 digital communication.

[0028] Preferably, the signal acquisition and processing system transmits the measurement data to the host computer via an ESP32 wireless module.

[0029] This invention also includes an online monitoring method for an integrated acoustic and vibration measurement coupling based on STM32, comprising the following steps: Acoustic signals during shaft operation are acquired in real time and converted into digital signals; Real-time acquisition of shaft torsional strain and conversion of it into analog voltage signal; The acquired acoustic and strain signals are acquired, processed, and analyzed simultaneously. The processed measurement data is transmitted to the host computer via a wireless module for online monitoring and fault early warning.

[0030] Example 1 like Figure 1 As shown, an integrated acoustic and vibration intelligent coupling of this embodiment includes: an active end flange 1, a driven end flange 6, a central isolation spring 4, a nut 3, a bolt 5, and a shaft connecting sleeve 2.

[0031] The active end flange 1 is connected to the drive shaft via the rotating shaft connecting sleeve 2; the driven end flange 6 is fastened to the active end flange 1 by nuts 3 and bolts 5, and a central isolation spring 4 is provided in the middle to reduce the transmission of micro vibrations of the shaft system and protect the coupling structure.

[0032] like Figure 2As shown, the active end flange 1 is provided with a sound sensor mounting hole 9 and a strain gauge connection wire fixing hole 10 for sensor installation and maintenance; the flange structure is designed with a wiring groove 11 and a PCB mounting hole 12 for wiring and fixing the PCB main control board 7.

[0033] like Figure 3 As shown in the diagram, the system block diagram of this invention includes a sound sensor, a strain measurement module, an STM32F407 microcontroller, an ESP32 wireless module, and a PC-based host computer. The acoustic signal collected by the sound sensor is transmitted to the STM32F407 via an RS-485 interface. The strain signal collected by the strain measurement module is conditioned and converted into an analog voltage signal, which is then acquired by the STM32F407's ADC module. After processing the acquired signal, the STM32 microcontroller connects to the ESP32 module via a serial port, and the ESP32 transmits the data to the PC in real time via WiFi for monitoring and analysis.

[0034] like Figure 4 As shown, the signal flow of the strain measurement module includes strain gauge acquiring strain signals, converting them into small voltage signals via a bridge circuit, and then conditioning them into stable analog voltage signals through signal amplification and filtering circuits before inputting them into the STM32 microcontroller ADC.

[0035] like Figure 5 As shown, the strain signal conditioning circuit includes a Wheatstone bridge and two operational amplifiers. The first operational amplifier amplifies the weak signal output from the bridge, and the second operational amplifier further filters and stabilizes the output to ensure the stability of the ADC signal input to the STM32 microcontroller.

[0036] In practice, the sound sensor 8 uses an industrial-grade high-sensitivity microphone to ensure that it can effectively capture the acoustic characteristics generated by the shaft operation in complex working environments. It has a built-in RS-485 communication interface to ensure stable and reliable acoustic signal transmission.

[0037] In practice, 350Ω resistance strain gauges are selected and can be installed in the strain gauge installation areas of the active end flange 10 and the driven end flange 12 according to actual measurement needs, so as to effectively sense the torsional strain of the shaft system.

[0038] In practice, the STM32F407 microcontroller and the ESP32 module are connected via serial communication to ensure the real-time performance and stability of data transmission.

[0039] Example 2 The specific application process of the integrated acoustic and vibration intelligent coupling described in this invention is as follows: First, the coupling body, which integrates the sound measurement module, strain measurement module, and signal acquisition and processing system, is reliably connected to the transmission shaft of the rotating machinery to be monitored, following the standard coupling installation method. During this process, it is essential to ensure that the strain gauge placement area is aligned with the shaft's torsional direction and that the microphone faces the sound source.

[0040] After the system powers on, the sound measurement module and strain measurement module begin real-time data acquisition. Acoustic signals are processed by an RS-485 chip and then directly fed into the STM32F407, while strain signals are conditioned by a Wheatstone bridge and operational amplifier before being input to the STM32F407's ADC. The STM32F407 microcontroller synchronously processes the acquired multi-channel acoustic and vibration data and sends the processed data to the ESP32 wireless module via serial port. The ESP32 wireless module then transmits the received data to a remote PC in real-time via WiFi. The PC software further displays, stores, analyzes, and processes the received data.

[0041] The sequence numbers of the above embodiments of the present invention are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments. In the above embodiments of the present invention, the descriptions of each embodiment have their own emphasis; parts not described in detail in a certain embodiment can be referred to in the relevant descriptions of other embodiments. It should be understood that the disclosed technical content in the several embodiments provided in this application can be implemented in other ways.

[0042] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An integrated acoustic and vibration measurement intelligent coupling based on STM32, characterized in that, include: The coupling body is used to connect the driving shaft and the driven shaft and also serves as a dynamic isolation device; The sound measurement module is used to collect acoustic signals during the operation of the shaft system and convert the acoustic signals into digital signals for output through the built-in RS-485 driver chip; The strain measurement module is used to acquire the torsional strain signal of the shaft system. The strain signal is converted into a voltage signal through a Wheatstone bridge, and then amplified and filtered by the signal conditioning circuit before being output. Additionally, a signal acquisition and processing system is used to simultaneously acquire three audio signals and three strain signals, and to analyze and process the signals.

2. The integrated acoustic and vibration measurement coupling based on STM32 according to claim 1, characterized in that, The coupling body includes: a driving end flange, a driven end flange, and a central isolating plate; The driving end flange is connected to the drive shaft via a rotating shaft connecting sleeve; the driven end flange is fastened to the driving end flange by nuts and bolts, and a central isolation spring is provided between the driven end flange and the driving end flange. The central isolation spring is used to reduce the transmission of micro vibrations of the shaft system and protect the coupling structure.

3. The integrated acoustic and vibration measurement coupling based on STM32 according to claim 2, characterized in that, The active end flange is also provided with a sound sensor mounting hole and a strain gauge connection wire fixing hole; both the active end flange and the driven end flange are provided with wiring grooves and PCB mounting holes for wiring and fixing the PCB main control board.

4. The integrated acoustic and vibration measurement coupling based on STM32 according to claim 1, characterized in that, The sound measurement module includes an industrial-grade sound sensor; the industrial-grade sound sensor is installed in the sensor mounting hole of the coupling's driving end flange.

5. The integrated acoustic and vibration measurement coupling based on STM32 according to claim 1, characterized in that, The strain measurement module includes: strain gauges, a Wheatstone bridge, and an operational amplifier conditioning circuit; the strain gauges are disposed on the coupling flange surface and the shaft surface.

6. The integrated acoustic and vibration measurement coupling based on STM32 according to claim 5, characterized in that, The operational amplifier conditioning circuit includes a Wheatstone bridge circuit, an operational amplifier circuit, and an RC filter circuit; the operational amplifier conditioning circuit is used to condition the voltage signal.

7. The integrated acoustic and vibration measurement coupling based on STM32 according to claim 1, characterized in that, The sound sensor of the sound measurement module uses an industrial-grade microphone, and the signal transmission uses RS-485 digital communication.

8. The integrated acoustic and vibration measurement coupling based on STM32 according to claim 1, characterized in that, The signal acquisition and processing system transmits measurement data to the host computer via the ESP32 wireless module.

9. An online monitoring method for an integrated acoustic and vibration measurement coupling based on STM32, using the measurement coupling described in any one of claims 1-8, characterized in that, Includes the following steps: Acoustic signals during shaft operation are acquired in real time and converted into digital signals; Real-time acquisition of shaft torsional strain and conversion of it into analog voltage signal; The acquired acoustic and strain signals are acquired, processed, and analyzed simultaneously. The processed measurement data is transmitted to the host computer via a wireless module for online monitoring and fault early warning.

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