外径30-140mm圆锥滚子轴承振动检测仪研制
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摘要
随着我国工业的迅猛发展,圆锥滚子轴承的需求量将不断加大,同时对其质量要求也不断提高,然而目前国内对轴承质量进行评定的轴承振动检测仪基本按照2001年的标准设计和制造的。由于我国现基本采用国际标准,原有的轴承振动检测仪存在着主轴承载力不足、检测项目少、升级困难等问题。
研制出了外径30-140mm圆锥滚子轴承振动检测仪。对轴承的精确检测、轴承生产质量的提高至关重要。
本文的主要内容包括：
(1)采用基于功能的设计方法,对圆锥滚子轴承振动检测仪的方案进行了设计；并利用计算机辅助设计技术(CAD)对振动检测仪的机械结构进行了设计。而且使用理论计算和经验设计方法设计了振动检测仪的主轴系统。
(2)对轴承故障诊断的理论进行了探讨和研究,利用虚拟仪器技术将虚拟仪器和数据采集结合起来作为对轴承振动信号的提取和分析的工具,并将相关理论应用于Labview软件设计中。对轴承的各项参数进行计算并自动判断轴承的优劣等级。并在控制系统中采用人机工程技术。
(3)利用研制的设备进行加载力实验,验证轴承的承载能力及进行软件检测和模拟电箱检测对比试验,验证采集和分析系统的可行性和准确性。
结合实际需求,在轴向上采用静压支承、径向上采用动压支承相结合的方式作为轴承振动检测仪的主轴支承系统,相对于国内常用的同类型轴承振动测量仪,主轴在轴向上的承载能力从250N提高到1400N,主轴端而跳动从原来的3μm提高到现在的0.5um；采用PCI数据采集卡、labview软件、PC机作为轴承振动数据的采集分析系统,检查项目可以根据需求设计和添加,升级方便,只需更改Labview程序即可达到要求。
本课题的研究成果已应用于实际生产,提高了轴承测量的精确度、降低对操作工人的要求。同时本研究成果还可以应用于其他类型轴承的振动检测设备中。
Along with the rapid development of the industry in our country, the demand for the quantity of the tapered roller bearing will increase a lot, meanwhile, the demand for its quality will increase a lot, too. However, the bearing vibrometer, which is presently used to qualify the quality of the bearing in domestics, is still basically designed and manufactured according to the standards of2001. Due to accepting the international standards in our country, now the formal bearing vibrometer exists many deficiencies, such as unsufficient bearing capacity of the main spindle, fewer testing projects, difficult upgrading problems, and so on.
Developed the bearing vibrometer for tapered roller bearing with outside diameter from30mm to140mm. It is vital to improve the accuracy of the bearing's testing and the quality of its production.
The main contents of this paper include:
(1) Designing the scheme of bearing vibrometer for tapered roller bearing based on function and the sturcture of bearing vibrometer by using the computer aid design (CAD). By using the method of theoretical calculation and experienced design, developed the spindle system of bearing vibrometer.
(2) Made a discussion and research about the theory of the diagnosis of the bearing faults, combined virtual instrument with data acquisition as the tool to extract and analyze the bearing vibration signals, and applied the related theory to the design of Labview software. Calculated the parameters of the bearing and automatically judged the quality level of the bearing. Adopted the man-machine engineering technology in the control system.
(3) Using the developed equipment to carry out the loading force experiment to demonstrate the bearing capacity of the bearing, and using the contrasted experiment between soft testing and simulation electricity box testing to verify the feasibility and accuracy of the collection and analysis system.
Combined with the actual demands, the spindle bearing system is put up as that the main spindle is supported by hydrostatic bearing in the axial direction and hydrodynamic journal bearing in the radial direction. Compared to the same type of bearing vibrometer commonly used in domestic country, the bearing capacity of the spindle in the axial direction is promoted to1400N from the original250N and the face runout of the spindle is improved to0.5μm from the original3μm. m. Using the PCI data acquisition card, virtual instrument, computer as the collection and analysis system of the bearing vibration data. The testing projects can be designed and enlarged according to the demands, upgrading will be convenient, it can be achieved just by changing the Labview program.
The research on the subject has been used in actual production, ensuring the quality of powder liner, and it increased production efficiency. Meanwhile the results of this study can also be applied to other manufacturing powder metallurgy products.
研制出了外径30-140mm圆锥滚子轴承振动检测仪。对轴承的精确检测、轴承生产质量的提高至关重要。
本文的主要内容包括：
(1)采用基于功能的设计方法,对圆锥滚子轴承振动检测仪的方案进行了设计；并利用计算机辅助设计技术(CAD)对振动检测仪的机械结构进行了设计。而且使用理论计算和经验设计方法设计了振动检测仪的主轴系统。
(2)对轴承故障诊断的理论进行了探讨和研究,利用虚拟仪器技术将虚拟仪器和数据采集结合起来作为对轴承振动信号的提取和分析的工具,并将相关理论应用于Labview软件设计中。对轴承的各项参数进行计算并自动判断轴承的优劣等级。并在控制系统中采用人机工程技术。
(3)利用研制的设备进行加载力实验,验证轴承的承载能力及进行软件检测和模拟电箱检测对比试验,验证采集和分析系统的可行性和准确性。
结合实际需求,在轴向上采用静压支承、径向上采用动压支承相结合的方式作为轴承振动检测仪的主轴支承系统,相对于国内常用的同类型轴承振动测量仪,主轴在轴向上的承载能力从250N提高到1400N,主轴端而跳动从原来的3μm提高到现在的0.5um；采用PCI数据采集卡、labview软件、PC机作为轴承振动数据的采集分析系统,检查项目可以根据需求设计和添加,升级方便,只需更改Labview程序即可达到要求。
本课题的研究成果已应用于实际生产,提高了轴承测量的精确度、降低对操作工人的要求。同时本研究成果还可以应用于其他类型轴承的振动检测设备中。
Along with the rapid development of the industry in our country, the demand for the quantity of the tapered roller bearing will increase a lot, meanwhile, the demand for its quality will increase a lot, too. However, the bearing vibrometer, which is presently used to qualify the quality of the bearing in domestics, is still basically designed and manufactured according to the standards of2001. Due to accepting the international standards in our country, now the formal bearing vibrometer exists many deficiencies, such as unsufficient bearing capacity of the main spindle, fewer testing projects, difficult upgrading problems, and so on.
Developed the bearing vibrometer for tapered roller bearing with outside diameter from30mm to140mm. It is vital to improve the accuracy of the bearing's testing and the quality of its production.
The main contents of this paper include:
(1) Designing the scheme of bearing vibrometer for tapered roller bearing based on function and the sturcture of bearing vibrometer by using the computer aid design (CAD). By using the method of theoretical calculation and experienced design, developed the spindle system of bearing vibrometer.
(2) Made a discussion and research about the theory of the diagnosis of the bearing faults, combined virtual instrument with data acquisition as the tool to extract and analyze the bearing vibration signals, and applied the related theory to the design of Labview software. Calculated the parameters of the bearing and automatically judged the quality level of the bearing. Adopted the man-machine engineering technology in the control system.
(3) Using the developed equipment to carry out the loading force experiment to demonstrate the bearing capacity of the bearing, and using the contrasted experiment between soft testing and simulation electricity box testing to verify the feasibility and accuracy of the collection and analysis system.
Combined with the actual demands, the spindle bearing system is put up as that the main spindle is supported by hydrostatic bearing in the axial direction and hydrodynamic journal bearing in the radial direction. Compared to the same type of bearing vibrometer commonly used in domestic country, the bearing capacity of the spindle in the axial direction is promoted to1400N from the original250N and the face runout of the spindle is improved to0.5μm from the original3μm. m. Using the PCI data acquisition card, virtual instrument, computer as the collection and analysis system of the bearing vibration data. The testing projects can be designed and enlarged according to the demands, upgrading will be convenient, it can be achieved just by changing the Labview program.
The research on the subject has been used in actual production, ensuring the quality of powder liner, and it increased production efficiency. Meanwhile the results of this study can also be applied to other manufacturing powder metallurgy products.
引文
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[6]杨晓蔚,李红涛.滚动轴承振动与噪声的相关性解析[J].轴承,2011(7)：53-56.
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[19]孙立明,史龙武,陈原.深沟球轴承振动峰值、波峰因数与异常声关系的试验分析[J].河南科技大学学报,2007,28(6)：10-12.
[20]圆锥滚子轴承振动测量仪[EB/OL]. [2012-4-13].http://www.d1kh.com/product_6.htm.
[21]S7910圆锥滚子轴承振动测量仪[EB/OL]. [2012-4-13].http://www.yr8.cn/products.html.
[22]王家亮.关于S0910型轴承振动测量仪的使用问题[J].检测技术：44-48.
[23]方振全.速度型轴承振动测量仪[J].轴承,1987(6)：30-34.
[24]Vibration tester MVU 150A/B/C[EB/OL].[2012-4-13].http://www.skf.com/portal/skf/home /products?contentld=346001 &lang=en.
[25]R.M.Rodriguez, C.Cristalli, N.Paone. Comparative study between laser vibrometer and accelerometer measurements for mechanical fault detection of electric motors. Fifth International Conference on Vibration Measurements by Laser Techniques.
[26]唐照民,李质芳,诸文俊等.机械设计[M].西安:西安交通大学出版社,1998.
[27]蹼良贵,纪名刚.机械设计[M].北京：高等教育出版社,2006.
[28]庞志成.液体气体静压技术[M].哈尔滨：黑龙江人民出版社,1981.
[29]陈燕生.液体静压支承原理和设计[M].北京：国防工业出版社,1980.
[30]黄金,杨岩,黄世国,钱怀文.液体动压轴承特性分析的实验方法研究[J].重庆工学院学报,2001,15(2)：58-61.
[31]伍良生,刘振宇等.带过渡深腔的动压轴承的优化设计与试验[J].机械工程学报.2006,42(11)：144-149.
[32]钟洪,张冠坤.液体静压动静压轴承设计使用手册[M].电子工业出版社,2006.
[33]陈芳华,章有良,严思思,张根源.滚动轴承振动测量方法新国标解析[J].轴承,2011(3):60-63.
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[2]A.Dzwonkowski, L.Swedrowski. Motor Bearing Diagnostics Performed by means of Laser Vibrometer [JL 2011 IEEE:482-486
[3]尹念东.虚拟仪器技术及其应用前景[J].计量与测试技术,2002(6)：34-36.
[4]李兴林,沈云同等.轴承振动(速度)噪声测试技术现状与发展[J].现代零部件,2005(2-3)：90-93
[5]卢锡鸣.滚动球轴承振动噪音缺陷的分析和研究[J].装备制造技术,2009(5)：14-17.
[6]杨晓蔚,李红涛.滚动轴承振动与噪声的相关性解析[J].轴承,2011(7)：53-56.
[7]Dhany Arifianto. Source Separation using Independent Component Analysis Techniques for Machine Fault Detection in the presence of Background Noise[C].20112nd International Conference on Instrumentation Control and Automation,15-17 November 2011, Bandung, Indonesia.
[8]夏新涛.滚动轴承振动与噪声的研究现状与发展[J].MC现代零部件,2004(3-4):47-49.
[9]武和雷,朱善俺等.一种新型数字式滚动轴承故障诊断系统[J].仪器仪表学报,2002,23,(3)：687-689.
[10]武和雷,朱善安等.滚动轴承故障诊断虚拟仪器系统[J].轴承,2002(12)：34-39.
[11]章国士.轴承振动速度的测量及其电路[J].机电工程,1994(3)：12-14.
[12]荆学东,徐滨士等.虚拟仪器技术及其应用[J].陕西科技大学学报,2007(2)：128-131.
[13]侯剑波.数字AGC电路设计[J].现代电子技术,2006(15)：72-77.
[14]程佩青.数字信号处理教程[M].北京：清华大学出版社,2000.
[15]陈锡辉,张银鸿Labview8.20程序设计从入门到精通[M].北京：清华大学出版社,2009.
[16]李伟,吴庆华,张训华.基于虚拟仪器的滚动轴承振动故障诊断系统[J].湖北工业大学学报,2007,22(2)：35-38.
[17]Wang.C, Gao.R.X. Virtual instrumentation for integrated bearing condition monitoring[J]. Instrumentation and Measurement Teehnology Conference.Proceedings of the 16thIEEE.1999, Volume2:667-672
[18]李兴林,陈芳华,沈云同等.滚动轴承振动、噪音和异音测试系统技术研究[J].哈尔滨轴承,2003,24(2)：37-41.
[19]孙立明,史龙武,陈原.深沟球轴承振动峰值、波峰因数与异常声关系的试验分析[J].河南科技大学学报,2007,28(6)：10-12.
[20]圆锥滚子轴承振动测量仪[EB/OL]. [2012-4-13].http://www.d1kh.com/product_6.htm.
[21]S7910圆锥滚子轴承振动测量仪[EB/OL]. [2012-4-13].http://www.yr8.cn/products.html.
[22]王家亮.关于S0910型轴承振动测量仪的使用问题[J].检测技术：44-48.
[23]方振全.速度型轴承振动测量仪[J].轴承,1987(6)：30-34.
[24]Vibration tester MVU 150A/B/C[EB/OL].[2012-4-13].http://www.skf.com/portal/skf/home /products?contentld=346001 &lang=en.
[25]R.M.Rodriguez, C.Cristalli, N.Paone. Comparative study between laser vibrometer and accelerometer measurements for mechanical fault detection of electric motors. Fifth International Conference on Vibration Measurements by Laser Techniques.
[26]唐照民,李质芳,诸文俊等.机械设计[M].西安:西安交通大学出版社,1998.
[27]蹼良贵,纪名刚.机械设计[M].北京：高等教育出版社,2006.
[28]庞志成.液体气体静压技术[M].哈尔滨：黑龙江人民出版社,1981.
[29]陈燕生.液体静压支承原理和设计[M].北京：国防工业出版社,1980.
[30]黄金,杨岩,黄世国,钱怀文.液体动压轴承特性分析的实验方法研究[J].重庆工学院学报,2001,15(2)：58-61.
[31]伍良生,刘振宇等.带过渡深腔的动压轴承的优化设计与试验[J].机械工程学报.2006,42(11)：144-149.
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