Bearing data acquisition equipment based on multi-sensor fusion technology

Abstract

The utility model provides a bearing data acquisition device based on a multi-sensor fusion technology, which relates to the technical field of bearing fault diagnosis and specifically comprises a bearing test board, an operation site switch, a gateway, a server cluster, a VPN gateway, a PC (Personal Computer) and a display, wherein the bearing testboard is a cuboid with square upper and lower surfaces, a cylindrical rotatable bearing placing table is arranged in the center, and a laser Doppler vibration meter and a visual sensor are arranged on the bearing testboard; the plurality of operation site switches are connected with the bearing test bench. The gateway is connected with a plurality of operation site switches; the server cluster is connected with the gateway; the VPN gateway is connected with the server cluster; three-dimensional modeling software is built in the PC, and the PC is connected with the VPN gateway; vibration signals obtained by the laser Doppler vibration meter and the visual sensor and bearing specification data are transmitted to a PC through an Ethernet protocol, 3D modeling software of the PC is used for 3D modeling, and a displayer is connected for bearing modeling.

Description

TECHNICAL FIELD

[0001] The utility model relates to bearing fault diagnosis technical field especially relates to a bearing data acquisition equipment based on multi sensor fusion technique. BACKGROUND

[0002] Bearing fault diagnosis is crucial to ensure the safety, stability and efficient operation of mechanical equipment. As an indispensable part of mechanical equipment, the normal work of bearing directly affects the performance and life of the whole system. By diagnosing bearing failure in time and accurately, potential problems can be found in advance, unplanned downtime and maintenance caused by bearing damage can be avoided, economic losses can be reduced, and production efficiency can be improved.

[0003] When the bearing fails, abnormal signals such as vibration, sound wave and temperature will occur, so the common fault analysis methods include oil analysis method, temperature monitoring method, acoustic emission analysis method and vibration signal analysis method. The vibration signal analysis method analyzes the fault state of the bearing by installing vibration sensors to collect the vibration signals of the bearing. Compared with the other three methods, the vibration signal often contains more information, is suitable for detecting bearings of multiple types and variable working conditions, and is therefore widely used for detecting and diagnosing bearing failure.

[0004] Laser Doppler Vibrometer (LDV) is a non-contact measurement tool specially used for accurate measurement of object surface vibration. It is based on the principle of Doppler effect, that is, when there is relative motion between the light source and the observer, the frequency of the light wave received by the observer will change. In the laser Doppler vibrometer, this effect is used to measure the vibration speed or displacement of the object. Nitrile rubber (NBR), also known as nitrile rubber, is a synthetic rubber copolymerized from butadiene and acrylonitrile. It is particularly suitable for environments with oil and solvent contact, has good friction performance and aging resistance, and is widely used in automobile oil seals, rubber pads, etc.

[0005] The traditional bearing fault data acquisition equipment has the following problems:

[0006] (1) The sensors used today are generally acceleration sensors, speed sensors and displacement sensors. Data acquisition usually needs to be in contact with the measured object, and long-term use will cause wear between the sensor and the surface of the measured object.

[0007] (2) The sensitivity of the vibration sensor is not enough when collecting minor faults, and the dynamic range of the sensor is relatively small, which may miss some fault signals in certain frequency range.

[0008] (3) The test bench cannot adapt to bearings of multiple scales, has weak generalization, and has few applicable scenarios;

[0009] (4) bearing fault performance is not clear enough, the user can not intuitively handle and analyze.

[0010] Patent CN221883050U proposes a bearing fault diagnosis test bench convenient to disassemble, through the cooperation of the positioning turntable, positioning mechanism and rotation control mechanism, the bearing is fixed in the positioning mechanism, then the positioning turntable is used for rotation, and is moved to the test under the rotation control mechanism one by one, so that the detection speed and bearing test efficiency are improved; The bearing fault diagnosis test bench proposed in patent CN221764887U tests the bearing body to test the fault condition of the bearing body under different rotating speeds, has good applicability, and is convenient for clamping bearing bodies of different sizes for test; Patent CN221350530U proposes a device for detecting rolling bearing fault, the friction force between the plug and the positioning block drives the positioning block to rotate, the surface of the positioning block abuts against the surface of the detection line, the length of the detection line can be positioned, and the detection probe can be placed in the placement groove, so that the stability and practicability are improved.

[0011] From the above analysis, it can be seen that the existing scheme mostly provides a solution to a single problem, and cannot meet the needs of bearing fault diagnosis data acquisition. Practical new type content

[0012] In view of the deficiencies of the prior art, the utility model provides a bearing data acquisition equipment based on multi sensor fusion technology;

[0013] The technical scheme adopted by the utility model is:

[0014] A bearing data acquisition equipment based on multi sensor fusion technology, comprising: a bearing test bench, an operation site switch, a gateway, a server cluster, a VPN gateway, a PC, and a display;

[0015] A laser Doppler vibrometer and a visual sensor are arranged on the bearing test bench.

[0016] The bearing test bench is a cuboid with square upper and lower surfaces, a cylindrical rotatable bearing placement table is arranged at the center, a motor is arranged at the bottom of the bearing test bench, the motor is connected to the bearing placement table, a sliding groove is arranged on the upper surface of the bearing placement table along the diameter, an inner diameter support is arranged in the sliding groove, the inner diameter support comprises two clamps, and the clamps are equidistantly arranged relative to the center of the bearing placement table; The surface of the clamp away from the center is covered with rubber nitrile rubber NBR, and the inner diameter support can be slidably adjusted in the sliding groove to adjust the position of the clamp.

[0017] Further, two slidable mechanical clamps are arranged along the diagonal of the upper surface of the bearing test bench, the mechanical clamp is composed of a clamping piece perpendicular to the surface of the bearing test bench and a fixing screw, and the clamping piece and the fixing screw are connected through threads; the bottom of the mechanical clamp is provided with a slidable device;

[0018] The job site switches are connected with the bearing test bench;

[0019] The gateway is connected with the job site switches;

[0020] The server cluster is connected with the gateway, and the VPN gateway is connected with the server cluster;

[0021] The PC machine is built-in three-dimensional modeling software and is connected with the VPN gateway;

[0022] The display is a high-resolution 4K display and is connected with the PC machine;

[0023] The number of the job site switches is equal to the sum of the number of the visual sensors and the number of the laser Doppler vibration meters;

[0024] Further, two laser Doppler vibration meters are used to collect vibration signals in bearing fault detection; the horizontal height of the laser Doppler vibration meter is adjustable;

[0025] Further, two visual sensors are used to scan the bearing specifications; specifically, the centers of the visual sensors are respectively directed to the center of the bearing placing table at a 30° pitch angle and a 30° elevation angle;

[0026] Further, an inner diameter support is installed on the bearing placing table; the inner diameter support and the mechanical clamp are both provided with a sliding groove;

[0027] The vibration signals obtained by the laser Doppler vibration meter and the visual sensor and the bearing specification data are transmitted to the PC machine through an EtherCAT Ethernet protocol, the bearing specifications measured by the visual sensor are used for 3D modeling by using the three-dimensional modeling software of the PC machine, and the display is connected for bearing modeling.

[0028] The technical scheme has the beneficial effects that:

[0029] The bearing data acquisition equipment based on the multi-sensor fusion technology has the following beneficial effects:

[0030] (1) Non-contact measurement: Two laser Doppler vibrometers are used instead of traditional vibration sensors, achieving non-contact vibration measurement. This measurement method not only avoids the wear and tear problem caused by long-term contact between the sensor and the surface of the measured object, prolonging the service life of the equipment, but also reduces the potential damage to the bearing itself during the installation and removal process of the sensor, improving the safety and reliability of the measurement.

[0031] (2) High sensitivity and wide dynamic range: Laser Doppler vibrometers have extremely high sensitivity and wide dynamic range, capable of capturing weaker and more complex fault signals. Compared with traditional vibration sensors, laser Doppler vibrometers have higher measurement accuracy and can detect vibration signals in a wider frequency range, reducing the likelihood of missed detection and improving the accuracy and reliability of fault detection.

[0032] (3) Adapt to various bearing specifications: The bearing placement table is equipped with a sliding groove, and the inner diameter support and mechanical clamp can be freely adjusted in the sliding groove. This design allows the device to adapt to bearings of different sizes and specifications, greatly enhancing the device's versatility and applicability, eliminating the need to frequently replace different test tables, saving time and cost.

[0033] (4) Stable bearing fixation: The two parts of the inner diameter support away from the center of the table are covered with high-friction coefficient nitrile rubber material, ensuring that the bearing does not slide during rotation. This material has excellent friction performance and anti-aging ability, maintaining stable performance under different working conditions, thereby improving the stability and accuracy of the measurement and reducing data errors caused by bearing sliding.

[0034] (5) Multi-angle vibration signal acquisition: Two laser Doppler vibrometers can adjust the height and probe position to achieve multi-point and multi-directional vibration signal acquisition. This multi-angle measurement method can more comprehensively reflect the vibration state of the bearing, avoiding important data that may be missed when measuring a single angle, making fault diagnosis more accurate and comprehensive.

[0035] (6) Intuitive 3D modeling: The bearing specification data collected by two visual sensors is used to realize 3D modeling using Agisoft Metashape software in the PC, and is displayed in all directions through a high-resolution 4K display. This 3D modeling technology makes the bearing fault performance more explicit and clear, allowing users to intuitively analyze and handle faults.

[0036] (7) Efficient data transmission: EtherCAT Ethernet protocol is used to connect each component, data is sent to the server cluster through the MQTT protocol, and reaches the PC through the firewall and VPN gateway. This efficient data transmission scheme not only guarantees the real-time and security of data transmission, but also supports multiple devices to be connected and data sharing at the same time, improving the overall performance and reliability of the system. BRIEF DESCRIPTION OF DRAWINGS

[0037] Figure 1 A practical situation diagram of the bearing data acquisition equipment based on multi-sensor fusion technology is provided.

[0038] Figure 2 A structure diagram of the bearing test bench designed by the utility model is provided.

[0039] In the figure: 1-bearing test bench; 2-bearing placement table; 3-motor; 4-sliding groove; 5-inner diameter support; 6-mechanical clamp; 7-clamp; 8-fixing screw; 9-first laser Doppler vibration meter; 10-second laser Doppler vibration meter; 11-first visual sensor; 12-second visual sensor; 13-PC; 14-display. DETAILED DESCRIPTION

[0040] The specific embodiments of the utility model will be further described in detail below in combination with the drawings and examples. The following examples are used to illustrate the utility model, but not to limit the scope of the utility model.

[0041] A bearing data acquisition equipment based on multi-sensor fusion technology, as shown in Figure 1 , comprising: bearing test bench 1, job site switch, gateway, server cluster, VPN gateway, PC 13, display 14;

[0042] The bearing test bench 1 adopts multi-sensor technology, and is provided with laser Doppler vibration meter and visual sensor;

[0043] As Figure 2As shown, the bearing test bench 1 is a cuboid with square upper and lower surfaces, and a cylindrical rotatable bearing placement table 2 is arranged at the center to ensure that the friction between the placement table 2 and the bearing test bench 1 is small, so that the placement table 2 is less hindered by friction when rotating. A motor 3 is arranged at the bottom of the bearing test bench 1, and the motor is connected to the bearing placement table 2, so that the placement table and the bearing can be uniformly rotated under the set conditions. A sliding groove 4 is arranged on the upper surface of the bearing placement table 2 along the diameter, and an inner diameter support 5 is arranged in the sliding groove 4. The inner diameter support 5 includes two clamps, which are equidistantly arranged relative to the center of the bearing placement table 2. The shape of the clamp in this embodiment is similar to the inner measuring claw of a vernier caliper. The surface of the clamp away from the center is covered with high-friction coefficient rubber material nitrile rubber NBR, which is precisely cut into the same size and shape as the part and firmly attached to the surface of the part away from the center. This operation can significantly increase the friction between the inner diameter support 5 and the bearing inner ring, and allow the mechanical part to completely resist the bearing inner ring during measurement, so as to ensure that the bearing placement table 2 does not rotate relative to the bearing when rotating the bearing. The inner diameter support 5 can be slidably adjusted in the sliding groove 4 to adapt to bearings of different specifications.

[0044] Further, two slidable mechanical clamps 6 are arranged along the diagonal of the upper surface of the bearing test bench 1. The mechanical clamp 6 is composed of a clamping piece 7 perpendicular to the surface of the bearing test bench 1 and a fixed screw 8, and the clamping piece 7 and the fixed screw 8 are connected by threads. The bottom of the mechanical clamp 6 is provided with a slidable device for adjusting the position of the mechanical clamp 6 to tightly fix the outer ring of the bearing.

[0045] The job site switch has several, which are connected with the bearing test bench;

[0046] The gateway is connected with several job site switches;

[0047] The server cluster is connected with the gateway, and the VPN gateway is connected with the server cluster;

[0048] The PC machine 13 is built-in with three-dimensional modeling software and is connected with the VPN gateway;

[0049] The display 14 is a high-resolution 4K display connected with the PC machine, realizing bearing 3D modeling;

[0050] The number of job site switches is equal to the sum of the number of visual sensors and the number of laser Doppler vibration meters;

[0051] Further, two laser Doppler vibration meters are used to collect vibration signals in bearing fault detection instead of traditional vibration sensors; the horizontal height of the laser Doppler vibration meter is adjustable;

[0052] Further, two visual sensors are used to scan the bearing specifications; specifically, the centers of the visual sensors are respectively directed at the center of the bearing placement table 2 at a 30° pitch angle and a 30° elevation angle.

[0053] Further, an inner diameter support is installed on the bearing placement table 2 to stably support the inner ring of the bearing; the inner diameter support and the mechanical clamp 6 are both provided with sliding grooves to adapt to bearings of different sizes.

[0054] The vibration signals obtained by the laser Doppler vibration meter and the visual sensor and the bearing specification data are transmitted to the PC 13 through the EtherCAT Ethernet protocol, the bearing specifications detected by the visual sensor are modeled in three dimensions using the three-dimensional modeling software Agisoft Metashape of the PC 13, and the display 14 is connected to model the bearing.

[0055] The bearing test bench 1 designed in this embodiment uses a first laser Doppler vibration meter 9 and a second laser Doppler vibration meter 10 instead of the conventional vibration sensor commonly used to measure vibration signals, in addition, a first visual sensor 11 and a second visual sensor 12 are used to scan the bearing specifications, and data is collected by multi-sensor fusion.

[0056] Further, in this embodiment, the first laser Doppler vibration meter 9 and the second laser Doppler vibration meter 10 are placed in the center of two opposite sides of the test bench 1, the center height of the first laser Doppler vibration meter 9 and the second laser Doppler vibration meter 10 is adjustable, the initial position is consistent with the center height of the bearing placement table 2, and after placing the bearing, the first laser Doppler vibration meter 9 and the second laser Doppler vibration meter 10 are adjusted to align their centers with the outer ring of the bearing, and the vibration signals of the outer ring are measured. In addition, the height and probe position of the two vibration meters can be adjusted, and the vibration signals of multiple points and multiple position angles on the bearing can also be measured.

[0057] The first visual sensor 11 and the second visual sensor 12 are placed in the center of the other two opposite sides, the centers of the first visual sensor 11 and the second visual sensor 12 are respectively directed at the center of the bearing placement table 2 at a 30° pitch angle and a 30° elevation angle, and they scan the bearing specifications during the rotation of the bearing. The placement method and angle ensure that they can completely cover the bearing, and there is an overlapping part in the scanning area to align the photos during modeling. Specifically, the horizontal distance between the first laser Doppler vibration meter 9, the second laser Doppler vibration meter 10, the first visual sensor 11, and the second visual sensor 12 and the center of the test bench 1 is the same, and they are all connected to the corresponding EtherCAT I / O module.

[0058] The bearing test bench 1 is connected to a job site switch through an EtherCAT Ethernet protocol, multiple job site switches are connected to a gateway through an EtherCAT field bus, data is sent through information queue telemetry transmission (MQTT), reaches a server cluster through a firewall, and reaches a PC 13 through a VPN gateway.

[0059] Further, data returned by the first visual sensor 11 and the second visual sensor 12 is used to realize 3D modeling by using Agisoft Metashape software in the PC 13, and the specific steps are importing images, aligning photos, generating dense point clouds, generating polygon meshes, generating textures, and then exporting, and the PC 13 is connected to a high-resolution 4K display 14.

[0060] The specific measurement steps of the utility model are as follows: first, place the bearing on the bearing placement table 2, slide the inner diameter support 5 to make it tightly fit the inner ring of the bearing and cannot rotate relatively, slide the mechanical clamp 6 to make it tightly fit the outer ring of the bearing, rotate the fixing screw 8 to fix the outer ring of the bearing. Start the power supply of the test bench 2, set the parameters of the motor 3, and make the motor 3 drive the inner ring of the bearing to rotate.

[0061] Turn on the first laser Doppler vibration meter 9 and the second laser Doppler vibration meter 10, adjust the height of the vibration meter, use the adjustment knob on the laser head to ensure that the laser beam accurately irradiates the surface of the measured object. Use the calibration function of the first laser Doppler vibration meter 9 and the second laser Doppler vibration meter 10 to ensure that the spot size and position of the laser beam are correct. Turn on the first visual sensor 11 and the second visual sensor 12 to collect the specification data of the bearing.

[0062] Turn on the power supply of the motor 3 to drive the inner ring of the bearing to start rotating, the first laser Doppler vibration meter 9 and the second laser Doppler vibration meter 10 emit a laser beam, which irradiates the surface of the measured object. The laser beam is divided into two beams by a beam splitter, one beam as reference light and the other beam as measurement light. The measurement light irradiates the surface of the measured object and reflects back, and the reflected measurement light and the reference light interfere on the detector to form an interference signal. Adjust the direction of the laser beam to measure the vibration of multiple points and multiple directions.

[0063] The data obtained by the first laser Doppler vibrometer 9, the second laser Doppler vibrometer 10, the first visual sensor 11 and the second visual sensor 12 are transmitted to the PC 13, and the Agisoft Metashape software in the PC 13 performs 3D modeling on the data scanned by the first visual sensor 11 and the second visual sensor 12. First, a new project is created and images are imported, a workspace is selected depending on requirements and computing resources, photos are aligned, alignment parameters (accuracy, matching, key point limit and preprocessing) are set, point cloud generation parameters (quality, depth filtering and memory limit) are set and point clouds are generated, mesh generation parameters (type and quality) are set and meshes are generated, and finally, texture generation parameters (resolution, mapping mode and color format) are set and textures are generated. The display 14 is turned on, and full-range visual modeling of the bearing is realized, so that the bearing can be analyzed and adjusted conveniently and intuitively.

[0064] The above description is merely preferred embodiments of the present disclosure and a description of the principles of the technology used. Those skilled in the art should understand that the scope of the utility model involved in the embodiments of the present disclosure is not limited to the technical solutions formed by the specific combinations of the technical features described above, and should also cover other technical solutions formed by any combination of the above technical features or equivalent features without departing from the above utility model concept. For example, the above features are replaced with the technical features disclosed in the embodiments of the present disclosure (but not limited to) having similar functions to form technical solutions.

Claims

1. A bearing data acquisition device based on multi-sensor fusion technology, characterized in that, include: Bearing test bench, on-site switch, gateway, server cluster, VPN gateway, PC, monitor; The bearing test bench is equipped with a laser Doppler vibration meter and a vision sensor. The bearing test stand is a cuboid with square upper and lower surfaces. A cylindrical rotatable bearing placement platform is set in the center. A motor is set at the bottom of the bearing test stand and connected to the bearing placement platform. A sliding groove is set along the diameter of the upper surface of the bearing placement platform. An inner diameter support is set in the sliding groove. The inner diameter support includes two grippers, which are equidistant from the center of the bearing placement platform. The surface of the grippers away from the center is covered with nitrile rubber (NBR). The inner diameter support can slide and adjust the position of the grippers within the sliding groove. There are several on-site switches, all of which are connected to the bearing test bench; The gateway is connected to several field switches; The server cluster is connected to the gateway, and the VPN gateway is connected to the server cluster. The display is a high-resolution 4K display and is connected to a PC.

2. The bearing data acquisition device based on multi-sensor fusion technology according to claim 1, characterized in that, An inner diameter support is installed on the bearing placement platform; both the inner diameter support and the mechanical clamp are provided with sliding grooves.

3. The bearing data acquisition device based on multi-sensor fusion technology according to claim 1, characterized in that, The PC has built-in 3D modeling software and is connected to a VPN gateway.

4. The bearing data acquisition device based on multi-sensor fusion technology according to claim 1, characterized in that, Two sliding mechanical clamps are installed diagonally along the upper surface of the bearing test bench. The mechanical clamps consist of clamping plates perpendicular to the surface of the bearing test bench and fixing screws. The clamping plates and fixing screws are connected by threads. The bottom of the mechanical clamps is equipped with a sliding device.

5. A bearing data acquisition device based on multi-sensor fusion technology according to claim 1, characterized in that, The number of switches at the work site is equal to the sum of the number of vision sensors and laser Doppler vibration meters.

6. A bearing data acquisition device based on multi-sensor fusion technology according to claim 1, characterized in that, Two laser Doppler vibration meters are used to collect vibration signals in bearing fault detection; the horizontal height of the laser Doppler vibration meters is adjustable.

7. A bearing data acquisition device based on multi-sensor fusion technology according to claim 1, characterized in that, Two vision sensors are used to scan the bearing specifications; specifically, the centers of the two vision sensors are pointed at the center of the bearing placement platform at 30° depression and 30° elevation angles, respectively.

8. A bearing data acquisition device based on multi-sensor fusion technology according to claim 1, characterized in that, Vibration signals and bearing specification data obtained from laser Doppler vibration meter and vision sensor are transmitted to PC via EtherCAT Ethernet protocol. The bearing specifications measured by vision sensor are used to create a 3D model on PC using 3D modeling software, and the model is then connected to a monitor.

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