A gear fault detection method, system, device and storage medium

Abstract

This invention discloses a gear fault detection method, system, device, and storage medium. It acquires vibration and impact signals from the gear, determines the spectral characteristics of the meshing frequency and various sideband frequencies, as well as the spectral characteristics of the shaft rotation frequency. Based on the spectral characteristics of any one sideband frequency, it determines whether the gear exhibits traveling wave resonance. Based on the spectral characteristics of the shaft rotation frequency and the meshing frequency, it determines whether the gear has a fault. If the spectral characteristics of the sideband frequency match preset traveling wave resonance characteristics, it can be determined that the gear meshing state is abnormal, and it can be further determined that the traveling wave resonance mode of the gear is excited, i.e., the gear exhibits traveling wave resonance. When the spectral characteristics of both the shaft rotation frequency and the meshing frequency match preset fault characteristics, it is determined that the gear has a fault. By determining the presence of traveling wave resonance and / or a fault, it is convenient to adjust the gear's operating state in a timely manner, avoiding operation at speeds that could induce undesirable resonance, and enabling timely maintenance.

Description

Technical Field

[0001] This invention relates to the field of gear fault detection, and in particular to a gear fault detection method, system, device, and storage medium. Background Technology

[0002] Gears are crucial power transmission devices, especially in fields like aero-engines, where they are key components in accessory drives and helicopter transmission systems. With the continuous improvement of aero-engine performance, weight reduction and optimized design of components are also important considerations. Therefore, aero-engine gears typically employ thin-walled structures. However, this reduces gear stiffness, leading to a lower natural frequency. If the natural frequency equals the excitation frequency, traveling wave resonance will occur, causing vibration fatigue. If the gear breaks due to vibration fatigue, it can lead to aero-engine malfunction.

[0003] Because aero-engine transmission systems contain numerous bearings and gears, gear vibration fatigue caused by gear structure design is currently the main cause of gear fracture. This abnormality typically occurs very suddenly and can lead to catastrophic consequences. Furthermore, aero-engine failures caused by gear resonance fractures are increasingly common. Therefore, how to detect traveling wave resonance or early faults in gears in advance and prevent sudden gear failures from causing major accidents is a problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0004] The purpose of this invention is to provide a gear fault detection method, system, device, and storage medium. If the spectral characteristics of the sideband frequency match the preset traveling wave resonance characteristics, it can be determined that there is an abnormality in the gear meshing state, and it can be further determined that the traveling wave resonance mode of the gear is excited, that is, the gear has traveling wave resonance. When the spectral characteristics of both the shaft rotation frequency and the meshing frequency match the preset fault characteristics, it is determined that the gear has a fault. By determining that the gear has traveling wave resonance and / or has a fault, it is convenient to adjust the gear operating state in a timely manner, avoid operating under speed conditions that can cause undesirable resonance, and perform timely maintenance.

[0005] To solve the above-mentioned technical problems, the present invention provides a gear fault detection method, comprising:

[0006] The vibration and impact signals of the gear during operation are acquired, and the vibration and impact signals are subjected to spectral analysis respectively.

[0007] Identify the gear meshing frequency and multiple sideband frequencies of the meshing frequency from the spectrum of the vibration signal;

[0008] Determine the spectral characteristics of the meshing frequency and each of the sideband frequencies;

[0009] Identify the shaft rotation frequency of the gear from the spectrum of the impact signal, and determine the spectral characteristics of the shaft rotation frequency;

[0010] When the spectral characteristics of any of the sideband frequencies meet the preset traveling wave resonance characteristics, it is determined that the gear has traveling wave resonance, and / or when the spectral characteristics of the shaft rotation frequency and the spectral characteristics of the meshing frequency both meet the preset fault characteristics, it is determined that the gear has a fault.

[0011] Preferably, the meshing frequency has multiple sideband frequencies, and the spectral characteristics of the sideband frequencies include the vibration acceleration amplitude of each sideband frequency;

[0012] When the spectral characteristics of any of the sideband frequencies conform to the preset traveling wave resonance characteristics, it is determined that the gear exhibits traveling wave resonance, including:

[0013] When the vibration acceleration amplitude at any of the sideband frequencies is greater than the background noise amplitude, it is determined that the gear exhibits traveling wave resonance.

[0014] Preferably, before determining that the gear exhibits traveling wave resonance when the vibration acceleration amplitude at any of the sideband frequencies is greater than the background noise amplitude, the method further includes:

[0015] Determine the vibration acceleration amplitude of each sideband frequency in the spectrum of the vibration signal;

[0016] Determine the background noise amplitude of each sideband frequency in the spectrum of the vibration signal;

[0017] If the vibration acceleration amplitude of any of the sideband frequencies is greater than a preset multiple of its corresponding background noise amplitude, then the vibration acceleration amplitude of the sideband frequency is determined to be greater than the background noise amplitude.

[0018] Preferably, the meshing frequency has multiple sideband frequencies, and the spectral characteristics of the sideband frequencies include the vibration acceleration amplitude of each sideband frequency;

[0019] When the spectral characteristics of any of the sideband frequencies conform to the preset traveling wave resonance characteristics, it is determined that the gear exhibits traveling wave resonance, including:

[0020] The target multiple is determined based on the preset traveling wave resonance characteristics;

[0021] Several target frequencies are identified from a preset frequency band in the spectrum of the vibration signal, and the target multiple of the vibration acceleration amplitude of each target frequency is greater than its corresponding background noise amplitude.

[0022] If any of the sideband frequencies are included among the target frequencies, then the gear is determined to have traveling wave resonance.

[0023] Preferably, before identifying the gear meshing frequency and multiple sideband frequencies of the meshing frequency from the spectrum of the vibration signal, the method further includes:

[0024] Obtain the rotational speed signal of the gear;

[0025] The meshing frequency is determined based on the gear parameters of the gear and the rotational speed signal;

[0026] The shaft rotation frequency of the gear is determined based on the rotation speed signal;

[0027] Based on the sum of the meshing frequency and integer multiples of the shaft rotation frequency, a plurality of right-hand frequencies of the meshing frequency are determined;

[0028] Based on the difference between the meshing frequency and an integer multiple of the shaft rotation frequency, a plurality of left-hand frequencies of the meshing frequency are determined;

[0029] Each of the left-side frequencies and each of the right-side frequencies are the sideband frequencies.

[0030] Preferably, after determining that the gear exhibits traveling wave resonance, the method further includes:

[0031] Conduct early warning of traveling wave resonance;

[0032] After determining that the gear is faulty, the process also includes:

[0033] Issue a gear fault alarm.

[0034] Preferably, the spectral characteristics of the shaft rotation frequency include the impact energy amplitude of the shaft rotation frequency and its nth harmonic in the spectrum of the impact signal, and the spectral characteristics of the meshing frequency include the vibration acceleration amplitude of the meshing frequency in the spectrum of the vibration signal.

[0035] When both the spectral characteristics of the shaft rotation frequency and the spectral characteristics of the meshing frequency meet preset fault characteristics, it is determined that the gear has a fault, including:

[0036] When the impact energy amplitude of the shaft rotation frequency or any n-fold harmonic of the shaft rotation frequency is greater than its background noise amplitude, and the vibration acceleration amplitude of the meshing frequency is greater than its background noise amplitude, it is determined that the gear has a fault.

[0037] To solve the above-mentioned technical problems, the present invention provides a gear fault detection system, comprising:

[0038] The acquisition unit is used to acquire vibration signals and impact signals of the gear during operation, and to perform spectrum analysis on the vibration signals and the impact signals respectively;

[0039] The first identification unit is used to identify the gear meshing frequency and multiple sideband frequencies of the meshing frequency from the spectrum of the vibration signal.

[0040] The first determining unit is used to determine the meshing frequency and the spectral characteristics of each of the sideband frequencies;

[0041] The second identification unit is used to identify the shaft rotation frequency of the gear from the spectrum of the impact signal and determine the spectral characteristics of the shaft rotation frequency;

[0042] The second determining unit is used to determine that the gear has traveling wave resonance when the spectral characteristics of any of the sideband frequencies meet the preset traveling wave resonance characteristics, and / or to determine that the gear has a fault when the spectral characteristics of the shaft rotation frequency and the spectral characteristics of the meshing frequency both meet the preset fault characteristics.

[0043] To solve the above-mentioned technical problems, the present invention provides a gear fault detection device, comprising:

[0044] Memory, used to store computer programs;

[0045] A processor is used to implement the steps of the gear fault detection method as described above when executing a computer program.

[0046] To address the aforementioned technical problems, the present invention provides a computer-readable storage medium storing a computer program, which, when executed by a processor, implements the steps of the gear fault detection method described above.

[0047] This application provides a gear fault detection method, system, device, and storage medium. First, it acquires vibration and impact signals from the gear and determines the spectral characteristics of the meshing frequency, each sideband frequency, and the shaft rotation frequency. Based on the spectral characteristics of any sideband frequency, it determines whether the gear exhibits traveling wave resonance. Based on the spectral characteristics of the shaft rotation frequency and the meshing frequency, it determines whether the gear has a fault. If the spectral characteristics of the sideband frequency match preset traveling wave resonance characteristics, it can be determined that the gear meshing state is abnormal, and it can be further determined that the traveling wave resonance mode of the gear is excited, i.e., the gear exhibits traveling wave resonance. When the spectral characteristics of both the shaft rotation frequency and the meshing frequency match preset fault characteristics, it is determined that the gear has a fault. By determining the presence of traveling wave resonance and / or a fault, it is convenient to adjust the gear's operating state in a timely manner, avoiding operation at speeds that could induce undesirable resonance, and enabling timely maintenance.

[0048] The technical solution described in this patent application can not only identify resonance during gear operation and prevent gear resonance fatigue, but also identify faults such as cracks or broken teeth in gears, thus improving the safety of equipment operation. Compared with the traditional method of using dynamic stress testing to monitor gear resonance and setting a threshold value for vibration values ​​(effective value, kurtosis, etc.) to diagnose faults such as broken teeth or cracks, the method in this application is not affected by the differences in the transmission system itself and the operating conditions of the system, and has a higher diagnostic accuracy. Attached Figure Description

[0049] To more clearly illustrate the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0050] Figure 1 A schematic flowchart of a gear fault detection method provided in this application;

[0051] Figure 2 A schematic diagram of the vibration signal of a gear when it exhibits traveling wave resonance, provided in this application;

[0052] Figure 3 A schematic diagram of the vibration signal of a gear when there is no traveling wave resonance, provided in this application;

[0053] Figure 4 A schematic diagram of an impact signal when a gear malfunctions, provided for the purposes of this application;

[0054] Figure 5 A schematic diagram of a vibration signal when a gear malfunctions, provided in this application;

[0055] Figure 6 A schematic diagram of an impact signal when a gear is not faulty, as provided in this application;

[0056] Figure 7 A schematic diagram of the vibration signal of a gear when there is no fault, as provided in this application;

[0057] Figure 8 This is a schematic diagram of the structure of a gear fault detection system provided in this application;

[0058] Figure 9 This is a schematic diagram of the structure of a gear fault detection device provided in this application;

[0059] Figure 10 This is a schematic diagram of the structure of a computer-readable storage medium provided by the present invention. Detailed Implementation

[0060] The core of this invention is to provide a gear fault detection method, system, device, and storage medium. If the spectral characteristics of the sideband frequency match the preset traveling wave resonance characteristics, it can be determined that there is an abnormality in the gear meshing state, and it can be further determined that the traveling wave resonance mode of the gear is excited, that is, the gear has traveling wave resonance. When the spectral characteristics of both the shaft rotation frequency and the meshing frequency match the preset fault characteristics, it is determined that the gear has a fault. By determining that the gear has traveling wave resonance and / or has a fault, it is convenient to adjust the gear operating state in a timely manner, avoid operating under speed conditions that can cause undesirable resonance, and perform timely maintenance.

[0061] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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, 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.

[0062] Please refer to Figure 1 , Figure 1 This application provides a flowchart illustrating a gear fault detection method, which includes:

[0063] S11: Acquire the vibration and impact signals of the gear during operation, and perform spectrum analysis on the vibration and impact signals respectively;

[0064] Due to the lightweight and thin design of gear structures, the overall stiffness of the gears is correspondingly reduced. The natural frequency of the gears also decreases with the reduction in overall stiffness, making them more sensitive to dynamic excitation and resulting in greater vibration. When the natural frequencies of the preceding and following traveling waves of gear vibration are equal to the excitation frequency, the gear or rotating disk will generate traveling wave resonance. Depending on the direction of vibration, gear vibration modes can be classified as circumferential torsional vibration, radial torsional vibration, and axial bending vibration. Regardless of the direction of vibration, if the gear generates traveling wave resonance, it may lead to resonant fatigue, which can then cause gear cracks and other faults. If this fault is not identified in time, it will affect the safe operation of the entire system.

[0065] In this embodiment, the vibration signal of the gear during operation is acquired. The vibration signal can be, but is not limited to, circumferential torsional vibration, radial torsional vibration, and axial bending vibration. The vibration signal is then subjected to spectrum analysis to determine the correspondence between the frequency of the vibration signal and the amplitude of the vibration acceleration, so as to facilitate subsequent frequency analysis.

[0066] The vibration signal can be detected by a vibration sensor installed on the surface of the gearbox or other housing, although this application does not limit this. Compared to the prior art of using strain gauges attached to gears for dynamic stress measurement to diagnose gear traveling wave resonance problems, the vibration sensor method for acquiring vibration signals is simpler to install and does not require the gear to stop running. Furthermore, the test data from attaching strain gauges needs to be output via slip ring actuators, but in practical applications, due to space limitations within aero-engines and transmission systems, slip ring actuators cannot be used to output test data. Therefore, the method in this application occupies less space and is suitable for fields such as aero-engines.

[0067] It should be noted that when acquiring vibration signals, the frequency range of the acquired vibration signals should cover all sideband frequencies of the meshing frequency to facilitate fault analysis. Of course, this application does not limit this, and a minimum frequency range of the vibration signal can be set in actual working conditions.

[0068] In addition, when acquiring the impact signal, the vibration signal can be subjected to generalized resonance demodulation processing to obtain the impact signal. The impact signal is the correspondence between the impact energy SV of the frequency and the frequency. Based on this, the impact energy amplitude at different frequencies can be determined, thereby determining whether the gear has a fault. Of course, the impact signal also needs to be subjected to spectrum analysis to determine the spectrum of the impact signal.

[0069] S12: Identify the gear meshing frequency and multiple sideband frequencies of the meshing frequency from the spectrum of the vibration signal;

[0070] S13: Determine the meshing frequency and the spectral characteristics of each sideband frequency;

[0071] The meshing frequency of gears is one of the core characteristic frequencies in a gear transmission system, directly reflecting the meshing characteristics of the gears. Specifically, it refers to the frequency at which the teeth of a pair of gears (driving gear and driven gear) come into contact (mesh) with each other when they rotate. Simply put: for every revolution of the driving gear, all its teeth mesh with the teeth of the driven gear once in sequence. Therefore, the meshing frequency = the rotational frequency of the driving gear × the number of teeth of the driving gear, or the meshing frequency = the rotational frequency of the driven gear × the number of teeth of the driven gear. Because gear meshing generates periodic impact forces, exciting gearbox vibration and noise, the meshing frequency is the most prominent fundamental frequency component in the vibration signal spectrum.

[0072] The gear meshing frequency exhibits a series of key characteristics in the spectrum of vibration signals. These characteristics are the core basis for diagnosing the health status of gears. Among them, the sideband frequencies of the meshing frequency are symmetrical sideband clusters that appear on both sides of the meshing frequency and its harmonics. When gears have problems such as gear eccentricity, shaft bending, and uneven tooth backlash, these can be manifested through the sideband frequencies. Therefore, the meshing frequency and multiple sideband frequencies of the meshing frequency can be identified from the spectrum of vibration signals, and the spectral characteristics of the meshing frequency and multiple sideband frequencies can be determined from the spectrum of vibration signals.

[0073] S14: Identify the shaft rotation frequency of the gear from the spectrum of the impact signal and determine the spectral characteristics of the shaft rotation frequency;

[0074] S15: When the spectral characteristics of any sideband frequency meet the preset traveling wave resonance characteristics, it is determined that the gear has traveling wave resonance, and / or, when the spectral characteristics of the shaft rotation frequency and the spectral characteristics of the meshing frequency both meet the preset fault characteristics, it is determined that the gear has a fault.

[0075] If the spectral characteristics of any sideband frequency match the preset traveling wave resonance characteristics, it can be determined that the gear has traveling wave resonance. When the gear has traveling wave resonance, the gear stiffness decreases and the stress at some locations changes, which can lead to gear breakage in severe cases. Therefore, after determining that the gear has traveling wave resonance, it can be determined in time that the gear may already have an abnormality or is about to fail. Based on this, the staff can maintain the gear as soon as possible to avoid a major accident.

[0076] It should also be noted that when traveling wave resonance is determined to exist in the gear, it can be determined that there is an abnormality in the gear meshing state, and it can be further determined that the traveling wave resonance mode of the gear is excited. Specifically, it can include the traveling wave resonance mode of pitch diameter type vibration being excited, or the traveling wave resonance mode of pitch circle type vibration being excited, or the traveling wave resonance mode of pitch diameter-pitch circle coupled vibration being excited.

[0077] In addition, the spectral characteristics of shaft rotation frequency are determined from the impact signal. Shaft rotation frequency refers to the number of revolutions per second of the gear shaft (driving shaft or driven shaft). It is the basic rhythm of gear rotation and determines the frequency of periodic events such as gear meshing, bearing rolling, and unbalanced forces. If there are problems such as imbalance, misalignment, or bending of the shaft, vibration will be excited at the shaft rotation frequency and its harmonics. Therefore, in order to further ensure the accuracy of fault diagnosis, when the spectral characteristics of shaft rotation frequency and meshing frequency both meet the preset fault characteristics, it can be determined that the gear has a fault.

[0078] It should be noted that when it is determined that a gear has traveling wave resonance, the gear may only be in an abnormal working state and has not yet failed. Conversely, when a gear fails, it may not necessarily have traveling wave resonance. Based on this, it is possible to determine whether a gear has traveling wave resonance and whether the gear has failed at the same time, or it is possible to determine only whether a gear has traveling wave resonance or only whether the gear has failed. This application does not limit this, as long as it can identify whether the gear is working normally.

[0079] In summary, the spectral characteristics of the gear meshing frequency in this application can determine the gear meshing state. If the spectral characteristics of the meshing frequency match the preset traveling wave resonance characteristics, it can be determined that there is an abnormality in the gear meshing state, and it can be further determined that the pitch diameter vibration mode of the gear is excited, that is, the gear has traveling wave resonance. In order to avoid the abnormal breakage of the gear due to traveling wave resonance, a fault alarm is issued when traveling wave resonance is detected, avoiding operation under speed conditions that can cause adverse resonance, and facilitating timely maintenance of the gear.

[0080] Based on the above embodiments:

[0081] In a preferred embodiment, the meshing frequency has multiple sideband frequencies, and the spectral characteristics of the sideband frequencies include the vibration acceleration amplitude of each sideband frequency;

[0082] When the spectral characteristics of any sideband frequency conform to the preset traveling wave resonance characteristics, it is determined that the gear exhibits traveling wave resonance, including:

[0083] When the vibration acceleration amplitude at any sideband frequency is greater than the background noise amplitude, it is determined that the gear exhibits traveling wave resonance.

[0084] In this embodiment, the meshing frequency has multiple different sideband frequencies, and the spectral characteristics of the meshing frequency include the vibration acceleration amplitude of each sideband frequency. The preset traveling wave resonance characteristic is that the vibration acceleration amplitude of the sideband frequency is greater than the background noise amplitude. When the vibration acceleration amplitude of any sideband frequency is greater than the background noise amplitude, it can be determined that the pitch vibration mode of the gear is excited, that is, the natural frequency of the gear and the excitation frequency are consistent, and the gear has traveling wave resonance.

[0085] As a preferred embodiment, before determining that the gear exhibits traveling wave resonance when the vibration acceleration amplitude at any sideband frequency is greater than the background noise amplitude, the method further includes:

[0086] Determine the vibration acceleration amplitude at each sideband frequency in the spectrum of the vibration signal;

[0087] Determine the background noise amplitude at each sideband frequency in the spectrum of the vibration signal;

[0088] If the vibration acceleration amplitude of any sideband frequency is greater than a preset multiple of its corresponding background noise amplitude, then the vibration acceleration amplitude of the sideband frequency is determined to be greater than the background noise amplitude.

[0089] To avoid misjudging the presence of traveling wave resonance due to interference, in this embodiment, when determining that the vibration acceleration amplitude of the sideband frequency is greater than the background noise amplitude, specifically when the vibration acceleration amplitude of the sideband frequency is greater than a preset multiple of its corresponding background noise amplitude, the determination of traveling wave resonance of the gear is triggered. In the spectrum image of the vibration signal, this is manifested as the sideband frequency having a significantly prominent phenomenon relative to the background noise amplitude, that is, the vibration acceleration amplitude of the sideband frequency is significantly greater than the surrounding background noise amplitude. Therefore, the preset multiple is not less than 3 times, which can be set to make it significantly prominent with the background noise amplitude. Of course, this application does not limit this, and the specific determination shall be based on the actual working conditions.

[0090] In a preferred embodiment, the meshing frequency has multiple sideband frequencies, and the spectral characteristics of the sideband frequencies include the vibration acceleration amplitude of each sideband frequency;

[0091] When the spectral characteristics of any sideband frequency conform to the preset traveling wave resonance characteristics, it is determined that the gear exhibits traveling wave resonance, including:

[0092] The target multiple is determined based on the preset traveling wave resonance characteristics;

[0093] Several target frequencies are identified from a preset frequency band in the spectrum of the vibration signal, and the target multiple of the vibration acceleration amplitude of each target frequency is greater than its corresponding background noise amplitude.

[0094] If any of the target frequencies includes any sideband frequency, then the gear is confirmed to have traveling wave resonance.

[0095] In another embodiment, the target multiple can be determined first based on the preset traveling wave resonance, and then several target frequencies within the preset frequency band can be selected from the spectrum of the vibration signal. If the target frequency includes any sideband frequency of the meshing frequency, the spectral characteristics of the sideband frequency are determined to conform to the preset traveling wave resonance characteristics. Of course, this application does not limit this.

[0096] It should be noted that the preset frequency band can be, but is not limited to, a frequency band lower than the meshing frequency.

[0097] As a preferred embodiment, before identifying the gear meshing frequency and multiple sideband frequencies of the meshing frequency from the spectrum of the vibration signal, the method further includes:

[0098] Obtain the gear rotation speed signal;

[0099] The meshing frequency is determined based on the gear parameters and rotational speed signal.

[0100] The shaft rotation frequency of the gear is determined based on the rotation speed signal;

[0101] Multiple right-hand frequencies of the meshing frequency are determined based on the sum of integer multiples of the meshing frequency and the shaft rotation frequency.

[0102] Based on the difference between the meshing frequency and an integer multiple of the shaft rotation frequency, multiple left-hand frequencies of the meshing frequency are determined;

[0103] The left and right frequencies are the sideband frequencies.

[0104] When determining the sideband frequencies of the gear meshing frequency, first determine the gear shaft rotation frequency, multiply the shaft rotation frequency by different integers, and then add them to the meshing frequency respectively. This gives the right sideband frequency of the meshing frequency. Subtracting the meshing frequency from the result of multiplying the shaft rotation frequency by different integers gives the right sideband frequency of the meshing frequency. Both the left and right sideband frequencies are sideband frequencies.

[0105] Wherein, the integer multiple is the order of resonance generated by the gear pitch diameter, such as 2, 3 and 4, depending on the actual working conditions. This application does not limit this.

[0106] Specifically, the meshing frequency is fc, the shaft rotation frequency is fn, the sideband frequency is f, and m is an integer multiple, which can be 2, 3, or 4. Therefore, the expression for the sideband frequency is:

[0107] f = fc ± m × fn.

[0108] Please refer to Figure 2 ,and Figure 3 , Figure 2 This is a schematic diagram of the vibration signal of a gear when it exhibits traveling wave resonance, as provided in this application. Figure 3 This is a schematic diagram of the vibration signal of a gear when there is no traveling wave resonance, as provided in this application.

[0109] from Figure 2 As can be seen from the data, when the meshing frequency fc = 14081 Hz, and the third-order right-hand frequency of the meshing frequency, that is, when there is a third-order right-hand frequency of the shaft rotation frequency fn next to the meshing frequency fc, the vibration acceleration amplitude of f = fc + 3fn = 15405 Hz is significantly prominent, which is significantly higher than the preset multiple of the background noise amplitude. Therefore, it can be determined that the gear has traveling wave resonance and a fault alarm should be triggered.

[0110] and Figure 3 As can be seen from the data, when there are no left and right frequencies of the shaft rotation frequency m next to the meshing frequency fc, the vibration acceleration amplitude of each sideband frequency does not have a significant prominence. That is, the vibration acceleration amplitude of each sideband frequency is consistent with the background noise amplitude. Therefore, it can be determined that the gear has traveling wave resonance.

[0111] As a preferred embodiment, after determining that the gear exhibits traveling wave resonance, the method further includes:

[0112] Conduct early warning of traveling wave resonance;

[0113] After confirming that the gears are faulty, the following steps are also included:

[0114] Issue a gear fault alarm.

[0115] In this embodiment, a traveling wave resonance warning is issued when the gear exhibits traveling wave resonance, and a fault alarm is issued when the gear has a fault. Based on the traveling wave resonance warning, the staff can determine that the gear is about to experience an abnormality, or based on the fault alarm, they can determine that the gear has already experienced an abnormality. In other words, the staff can determine that the gear has an abnormality, and thus they can inspect and maintain the gear, saving the staff from the complexity of the work.

[0116] In certain operating conditions, staff need to determine the condition of the gears before performing maintenance to improve maintenance efficiency. Based on this, when traveling wave resonance is detected in the gears, a traveling wave resonance warning is issued so that staff know that maintenance is needed for the gears that have traveling wave resonance. When a gear is detected to have a fault, a gear fault alarm is issued so that staff know that the gears have a fault. This allows staff to determine whether the gears need to be replaced before performing gear maintenance.

[0117] Whether different fault alarms are needed depending on the specific scenario depends on the actual working conditions, and this application does not impose any restrictions on this.

[0118] In summary, this application not only detects the presence of traveling wave resonance in the gears during operation and provides early warning of traveling wave resonance to operators when it is present, but also detects whether a gear has malfunctioned during operation and issues a fault alarm when a malfunction is confirmed. Therefore, this application combines traveling wave resonance early warning and fault alarm technologies to monitor gear operation from multiple perspectives, ensuring the safe and stable operation of the entire system.

[0119] As a preferred embodiment, the spectral characteristics of the shaft rotation frequency include the impact energy amplitude of the shaft rotation frequency and its nth harmonic in the spectrum of the impact signal, and the spectral characteristics of the meshing frequency include the vibration acceleration amplitude of the meshing frequency in the spectrum of the vibration signal.

[0120] When the spectral characteristics of the shaft rotation frequency and the meshing frequency match preset fault characteristics, a gear fault is determined to exist, including:

[0121] If the impact energy amplitude of any one of the shaft rotation frequency and its nth harmonic is greater than its background noise amplitude, and the vibration acceleration amplitude of the meshing frequency is greater than its background noise amplitude, then the gear is determined to have a fault.

[0122] In the spectrum of the impact signal, the shaft rotation frequency and its nth harmonic can be identified, and the impact energy amplitude of the shaft rotation frequency and its nth harmonic can be determined. In the spectrum of the vibration signal, the meshing frequency can be identified, and the vibration acceleration amplitude of the meshing frequency can be determined. The preset fault characteristics are that the impact energy amplitude of any one of the shaft rotation frequency and its nth harmonic is greater than its background noise amplitude, and the vibration acceleration amplitude of the meshing frequency is greater than its background noise amplitude.

[0123] Among them, since the impact signal is a high-frequency resonant signal energy extracted from the vibration signal through envelope demodulation technology, it reflects the transient impact intensity. The impact energy amplitude of shaft rotation frequencies of different orders can reflect the impact received by the gear per revolution. However, in order to avoid the impact energy amplitude of any of the n harmonics of the gear shaft rotation frequency being greater than its background noise amplitude due to interference, the judgment of the vibration acceleration amplitude of the meshing frequency is also added. The vibration acceleration amplitude of the meshing frequency reflects the dynamic force intensity during gear meshing, which is directly affected by load, tooth surface condition, and assembly accuracy. Based on this, the shaft system faults of the gear can be detected early according to the impact energy amplitude of the shaft rotation frequency and any of the n harmonics of the shaft rotation frequency. The vibration acceleration amplitude of the meshing frequency directly quantifies the gear meshing state, thereby accurately determining whether there is a fault in the gear.

[0124] Please refer to Figure 4 and Figure 5 , Figure 4 This is a schematic diagram illustrating the impact signal when a gear malfunctions, as provided in this application. Figure 5 This is a schematic diagram of the vibration signal when a gear has a fault, as provided in this application.

[0125] in, Figure 4 The three frequencies in the middle circle, from left to right, are the shaft rotation frequency, the second harmonic of the shaft rotation frequency, and the second harmonic of the shaft rotation frequency. It is clear that the impact amplitude of the shaft rotation frequency, the second harmonic of the shaft rotation frequency, and the second harmonic of the shaft rotation frequency are significantly more prominent than the background noise amplitude. Figure 5 The frequencies within the middle circle are the meshing frequencies. It can be seen that the vibration acceleration amplitude at the meshing frequency is significantly higher than the background noise amplitude. Therefore, combining... Figure 4 and Figure 5 This confirms that there is a fault in the gear.

[0126] Please refer to Figure 6 and Figure 7 , Figure 6This is a schematic diagram illustrating the impact signal when a gear is free of faults, as provided in this application. Figure 7 This is a schematic diagram of the vibration signal of a gear when there is no fault, as provided in this application.

[0127] in, Figure 6 The three frequencies in the middle circle, from left to right, are the shaft rotation frequency, the second harmonic of the shaft rotation frequency, and the second harmonic of the shaft rotation frequency. It is quite clear that the impact amplitudes of the shaft rotation frequency, the second harmonic of the shaft rotation frequency, and the second harmonic of the shaft rotation frequency are relatively close to the amplitude of the background noise. Figure 7 The frequency within the middle circle is the meshing frequency. It can be seen that the amplitude of the vibration acceleration at the meshing frequency is relatively close to the amplitude of the background noise. Therefore, combining... Figure 6 and Figure 7 This confirms that the gears are not faulty.

[0128] It should be noted that the preset fault characteristics in this application are that the impact energy amplitude of any one of the shaft rotation frequency and its nth harmonic is greater than its background noise amplitude, and the vibration acceleration amplitude of the meshing frequency is greater than its background noise amplitude. Specifically, it can be that the impact energy amplitude of any one of the shaft rotation frequency and its nth harmonic is greater than its background noise amplitude by a preset multiple, and the vibration acceleration amplitude of the meshing frequency is greater than its background noise amplitude by a preset multiple. The preset multiple can be a number greater than 3, which can be set to be significantly different from the background noise amplitude.

[0129] Please refer to Figure 8 , Figure 8 This application provides a schematic diagram of a gear fault detection system, which includes:

[0130] The acquisition unit 81 is used to acquire the vibration signal and impact signal of the gear during operation, and to perform spectrum analysis on the vibration signal and impact signal respectively;

[0131] The first identification unit 82 is used to identify the gear meshing frequency and multiple sideband frequencies of the meshing frequency from the spectrum of the vibration signal.

[0132] The first determining unit 83 is used to determine the meshing frequency and the spectral characteristics of each sideband frequency;

[0133] The second identification unit 84 is used to identify the shaft rotation frequency of the gear from the spectrum of the impact signal and determine the spectral characteristics of the shaft rotation frequency;

[0134] The second determining unit 85 is used to determine that the gear has traveling wave resonance when the spectral characteristics of any sideband frequency meet the preset traveling wave resonance characteristics, and / or to determine that the gear has a fault when the spectral characteristics of the shaft rotation frequency and the spectral characteristics of the meshing frequency both meet the preset fault characteristics.

[0135] For a description of the gear fault detection system provided by this invention, please refer to the above-described gear fault detection method embodiments; the invention will not be repeated here.

[0136] Please refer to Figure 9 , Figure 9 This application provides a schematic diagram of the structure of a gear fault detection device, which includes:

[0137] Memory 91 is used to store computer programs;

[0138] The processor 92 is used to implement the steps of the gear fault detection method described above when executing a computer program.

[0139] For a description of the gear fault detection device provided by the present invention, please refer to the above-described gear fault detection method embodiment; the present invention will not be described again here.

[0140] Please refer to Figure 10 , Figure 10 This is a schematic diagram of a computer-readable storage medium provided by the present invention. The computer-readable storage medium 101 stores a computer program 102. When the computer program 102 is executed by the processor 92, it implements the steps of the gear fault detection method described above.

[0141] For a description of the computer-readable storage medium provided by the present invention, please refer to the above method embodiments; the present invention will not be described again here.

[0142] It should also be noted that, in this specification, 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 a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0143] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for detecting gear faults, characterized in that, include: The vibration and impact signals of the gear during operation are acquired, and the vibration and impact signals are subjected to spectral analysis respectively. Identify the gear meshing frequency and multiple sideband frequencies of the meshing frequency from the spectrum of the vibration signal; Determine the spectral characteristics of the meshing frequency and each of the sideband frequencies; Identify the shaft rotation frequency of the gear from the spectrum of the impact signal, and determine the spectral characteristics of the shaft rotation frequency; When the spectral characteristics of any of the sideband frequencies meet the preset traveling wave resonance characteristics, it is determined that the gear has traveling wave resonance, and / or when the spectral characteristics of the shaft rotation frequency and the spectral characteristics of the meshing frequency both meet the preset fault characteristics, it is determined that the gear has a fault. The meshing frequency has multiple sideband frequencies, and the spectral characteristics of the sideband frequencies include the vibration acceleration amplitude of each sideband frequency. When the spectral characteristics of any of the sideband frequencies conform to the preset traveling wave resonance characteristics, it is determined that the gear exhibits traveling wave resonance, including: When the vibration acceleration amplitude at any of the sideband frequencies is greater than the background noise amplitude, it is determined that the gear exhibits traveling wave resonance. Before identifying the gear meshing frequency and multiple sideband frequencies of the meshing frequency from the spectrum of the vibration signal, the method further includes: Obtain the rotational speed signal of the gear; The meshing frequency is determined based on the gear parameters of the gear and the rotational speed signal; The shaft rotation frequency of the gear is determined based on the rotation speed signal; Based on the sum of the meshing frequency and integer multiples of the shaft rotation frequency, a plurality of right-hand frequencies of the meshing frequency are determined; Based on the difference between the meshing frequency and an integer multiple of the shaft rotation frequency, a plurality of left-hand frequencies of the meshing frequency are determined; Each of the left-side frequencies and each of the right-side frequencies are the sideband frequencies; The spectral characteristics of the shaft rotation frequency include the shaft rotation frequency in the spectrum of the impact signal and the impact energy amplitude of the nth harmonic of the shaft rotation frequency; the spectral characteristics of the meshing frequency include the vibration acceleration amplitude of the meshing frequency in the spectrum of the vibration signal. When both the spectral characteristics of the shaft rotation frequency and the spectral characteristics of the meshing frequency meet preset fault characteristics, it is determined that the gear has a fault, including: When the impact energy amplitude of the shaft rotation frequency or any n-fold harmonic of the shaft rotation frequency is greater than its background noise amplitude, and the vibration acceleration amplitude of the meshing frequency is greater than its background noise amplitude, it is determined that the gear has a fault.

2. The gear fault detection method as described in claim 1, characterized in that, Before determining that the gear exhibits traveling wave resonance when the vibration acceleration amplitude at any of the sideband frequencies is greater than the background noise amplitude, the procedure further includes: Determine the vibration acceleration amplitude at each of the sideband frequencies in the spectrum of the vibration signal; Determine the background noise amplitude of each sideband frequency in the spectrum of the vibration signal; If the vibration acceleration amplitude of any of the sideband frequencies is greater than a preset multiple of its corresponding background noise amplitude, then the vibration acceleration amplitude of the sideband frequency is determined to be greater than the background noise amplitude.

3. The gear fault detection method as described in claim 1, characterized in that, The meshing frequency has multiple sideband frequencies, and the spectral characteristics of the sideband frequencies include the vibration acceleration amplitude of each sideband frequency. When the spectral characteristics of any of the sideband frequencies conform to the preset traveling wave resonance characteristics, it is determined that the gear exhibits traveling wave resonance, including: The target multiple is determined based on the preset traveling wave resonance characteristics; Several target frequencies are identified from a preset frequency band in the spectrum of the vibration signal, and the target multiple of the vibration acceleration amplitude of each target frequency is greater than its corresponding background noise amplitude. If any of the sideband frequencies are included among the target frequencies, then the gear is determined to have traveling wave resonance.

4. The gear fault detection method as described in claim 1, characterized in that, After determining that the gear exhibits traveling wave resonance, the process further includes: Conduct early warning of traveling wave resonance; After determining that the gear is faulty, the process also includes: Issue a gear fault alarm.

5. A gear fault detection system, characterized in that, The system, applied to the gear fault detection method as described in any one of claims 1-4, comprises: The acquisition unit is used to acquire vibration signals and impact signals of the gear during operation, and to perform spectrum analysis on the vibration signals and the impact signals respectively; The first identification unit is used to identify the gear meshing frequency and multiple sideband frequencies of the meshing frequency from the spectrum of the vibration signal. The first determining unit is used to determine the meshing frequency and the spectral characteristics of each of the sideband frequencies; The second identification unit is used to identify the shaft rotation frequency of the gear from the spectrum of the impact signal and determine the spectral characteristics of the shaft rotation frequency; The second determining unit is used to determine that the gear has traveling wave resonance when the spectral characteristics of any of the sideband frequencies meet the preset traveling wave resonance characteristics, and / or to determine that the gear has a fault when the spectral characteristics of the shaft rotation frequency and the spectral characteristics of the meshing frequency both meet the preset fault characteristics. The meshing frequency has multiple sideband frequencies, and the spectral characteristics of the sideband frequencies include the vibration acceleration amplitude of each sideband frequency. When the second determining unit performs the step of determining that the gear has traveling wave resonance when the spectral characteristics of any sideband frequency meet the preset traveling wave resonance characteristics, it is specifically used to determine that the gear has traveling wave resonance when the vibration acceleration amplitude of any sideband frequency is greater than the background noise amplitude. Before triggering the second determining unit, the gear fault detection system is also used to: Obtain the rotational speed signal of the gear; The meshing frequency is determined based on the gear parameters of the gear and the rotational speed signal; The shaft rotation frequency of the gear is determined based on the rotation speed signal; Based on the sum of the meshing frequency and integer multiples of the shaft rotation frequency, a plurality of right-hand frequencies of the meshing frequency are determined; Based on the difference between the meshing frequency and an integer multiple of the shaft rotation frequency, a plurality of left-hand frequencies of the meshing frequency are determined; Each of the left-side frequencies and each of the right-side frequencies are the sideband frequencies; The spectral characteristics of the shaft rotation frequency include the shaft rotation frequency in the spectrum of the impact signal and the impact energy amplitude of the nth harmonic of the shaft rotation frequency; the spectral characteristics of the meshing frequency include the vibration acceleration amplitude of the meshing frequency in the spectrum of the vibration signal. When the second determining unit performs the step of determining that the gear has a fault when both the spectral characteristics of the shaft rotation frequency and the spectral characteristics of the meshing frequency meet the preset fault characteristics, it is specifically used for: When the impact energy amplitude of the shaft rotation frequency or any n-fold harmonic of the shaft rotation frequency is greater than its background noise amplitude, and the vibration acceleration amplitude of the meshing frequency is greater than its background noise amplitude, it is determined that the gear has a fault.

6. A gear fault detection device, characterized in that, include: Memory, used to store computer programs; A processor, configured to, when executing a computer program, implement the steps of the gear fault detection method as described in any one of claims 1-4.

7. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores a computer program that, when executed by a processor, implements the steps of the gear fault detection method as described in any one of claims 1 to 4.

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