基于振动分析的气门间隙异常故障诊断
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摘要
在发动机各种类型故障中与气门间隙异常相关的故障占了很大比例,所以针对此类型故障的诊断具有重要意义。本文以DA462型发动机为研究对象,对于基于振动分析的气门间隙异常故障诊断进行了分析和研究。
在本论文中,以发动机结构及运转特性等分析为基础,确定了燃烧激励、活塞敲击激励、惯性力激励、气门落座冲击和气门开启节流冲击为发动机的主要激励源,并且分析了发动机振动的传播路径;结合本课题的研究内容,合理的选择了燃烧激励响应和排气门开闭激励响应作为故障特征信号;通过详细地研究振动信号分析方法,采用了时域分析和频域分析相结合的信号分析方法。
在分析了现代振动测试技术的基础上,成功的搭建了一套实用的振动信号测试系统,通过实验,验证了该系统能够准确的获得故障特征信号。采用双排不进的气门间隙调整法将气门间隙调整为0.15mm、0.25mm、0.35mm和0.45mm,其中0.15mm为正常间隙,用其它的数值模拟气门间隙异常。通过本课题搭建的测试系统测得不同转速和不同间隙下的振动信号,总结出发动机转速对故障特征信号的影响情况,以及不同间隙对故障特征信号的影响程度;通过理论分析确定故障特征信号的频带,再观察这个频带随间隙调整的变化状况,这样通过对实测故障信号和正常信号的对比分析,提出了一种行之有效的内燃机故障诊断方法。
通过对DA462型发动机的实验验证,证明了本课题提出的基于振动分析的气门间隙异常的故障诊断方法,具有简单、准确和实用性强的特点。
Abnormal fault of Internal Combustion Engine valves clearance have the very big percent in various type of Internal Combustion Engine faults, so it has important meaning to make diagnosis of this kind fault. This paper take the DA 462 type engine as research object, putting forward diagnosis method based on vibration analysis according to abnormal state of valves clearance.
In this paper, author take analysis such as the Internal Combustion Engine structure and the operation characteristic as the foundation, making sure that the combustion excitation ,the piston slap excitation, the inertia force encourage, the valve falling impact and throttle impact when valve opens act as main excitation source, and analyze the propagation path of engine vibration. Combining this subject study, choose response of the combustion excitation and exhaust valve excitation as fault characteristic signal. Through studying the method of analyzing vibration signal in details, adopt the method of signal analysis combining the time domain analysis together with the frequency domain analysis. Basing on the analysis of modern vibrate measuring and testing techniques, built a set of practical vibration signal measuring and testing system successfully. Through the experiment, verify that this system can get fault characteristic signal accurately. Adopt the method of“shuang pai bu jin”to adjust the valve clearance data which are 0.15 mm,0.25 mm,0.35 mm and 0.45 mm. Among those data, normal clearance is 0.15mm, using the other data to simulate abnormal state of valve clearance. Using the measuring and testing system that was built for my subject, we can get the vibration signal in condition of different rotation speed and valve clearance, making conclusion that different rotation speed and valve clearance influence on the degree of the characteristic signal. The frequency band of the fault characteristic signal through the theories analysis is taken certainly, in next step observing range of frequency band’s variation when we adjust clearance data, then we can judge the size of the valve clearance in the light of time domain and frequency domain’s wave figure of fault characteristic signal .
在本论文中,以发动机结构及运转特性等分析为基础,确定了燃烧激励、活塞敲击激励、惯性力激励、气门落座冲击和气门开启节流冲击为发动机的主要激励源,并且分析了发动机振动的传播路径;结合本课题的研究内容,合理的选择了燃烧激励响应和排气门开闭激励响应作为故障特征信号;通过详细地研究振动信号分析方法,采用了时域分析和频域分析相结合的信号分析方法。
在分析了现代振动测试技术的基础上,成功的搭建了一套实用的振动信号测试系统,通过实验,验证了该系统能够准确的获得故障特征信号。采用双排不进的气门间隙调整法将气门间隙调整为0.15mm、0.25mm、0.35mm和0.45mm,其中0.15mm为正常间隙,用其它的数值模拟气门间隙异常。通过本课题搭建的测试系统测得不同转速和不同间隙下的振动信号,总结出发动机转速对故障特征信号的影响情况,以及不同间隙对故障特征信号的影响程度;通过理论分析确定故障特征信号的频带,再观察这个频带随间隙调整的变化状况,这样通过对实测故障信号和正常信号的对比分析,提出了一种行之有效的内燃机故障诊断方法。
通过对DA462型发动机的实验验证,证明了本课题提出的基于振动分析的气门间隙异常的故障诊断方法,具有简单、准确和实用性强的特点。
Abnormal fault of Internal Combustion Engine valves clearance have the very big percent in various type of Internal Combustion Engine faults, so it has important meaning to make diagnosis of this kind fault. This paper take the DA 462 type engine as research object, putting forward diagnosis method based on vibration analysis according to abnormal state of valves clearance.
In this paper, author take analysis such as the Internal Combustion Engine structure and the operation characteristic as the foundation, making sure that the combustion excitation ,the piston slap excitation, the inertia force encourage, the valve falling impact and throttle impact when valve opens act as main excitation source, and analyze the propagation path of engine vibration. Combining this subject study, choose response of the combustion excitation and exhaust valve excitation as fault characteristic signal. Through studying the method of analyzing vibration signal in details, adopt the method of signal analysis combining the time domain analysis together with the frequency domain analysis. Basing on the analysis of modern vibrate measuring and testing techniques, built a set of practical vibration signal measuring and testing system successfully. Through the experiment, verify that this system can get fault characteristic signal accurately. Adopt the method of“shuang pai bu jin”to adjust the valve clearance data which are 0.15 mm,0.25 mm,0.35 mm and 0.45 mm. Among those data, normal clearance is 0.15mm, using the other data to simulate abnormal state of valve clearance. Using the measuring and testing system that was built for my subject, we can get the vibration signal in condition of different rotation speed and valve clearance, making conclusion that different rotation speed and valve clearance influence on the degree of the characteristic signal. The frequency band of the fault characteristic signal through the theories analysis is taken certainly, in next step observing range of frequency band’s variation when we adjust clearance data, then we can judge the size of the valve clearance in the light of time domain and frequency domain’s wave figure of fault characteristic signal .
引文
[1] 曹龙汉.柴油机智能故障诊断技术[M].北京:国防工业出版社,2005,1:68～71
[2] 曹龙汉.柴油机智能化故障诊断技术研究[D].重庆:重庆大学 2001
[3] 屈梁生,何正嘉.机械故障诊断学[M].上海:上海科学技术出版社,1986,12
[4] 裴峻峰,杨其俊.机械故障诊断技术[M].北京:石油大学出版社,1997,1
[5] J.Antoni,J.Daniere,F.Guillet.Effective vibration analysis of IC engines using cyclostationarity[J] . Part I-A methodology for condition monitoring . Journal of Sound andVibration,2002,257(5):815～837
[6] 李国华,张永忠.机械故障诊断[M].北京:化学工艺出版社,1999,2:3～4
[7] 胡以怀,杨叔子,刘永长.柴油机磨损故障振动诊断机理的研究[J].天津:内燃机学报,2005,1
[8] 王晓武,杨建国.利用振动参数监测和诊断柴油机滑动主轴承磨损状态的研究[M].北京:国防工业出版社,2000,6
[9] 张培林,李国章,何忠波.利用缸盖振动信号诊断气门机构故障[J].太原:测试技术学报,2000,12(1):41～46
[10] Zunmin Geng,Jin Chen,J.Barry Hull.Analysis of engine vibration and design of an applicable diagnosising approach[J].International Journal of Mechanical Science,2003,45:1391～1410
[11] J.Antoni,J.Daniere,F.Guillet.Effective vibration analysis of IC engines using Cyclost -ationarity[J].Part II-New results on the reconstruction of the cylinder pressures.Journal of Sound and Vibration,2002,257(5):839～856
[12] 夏勇,商斌梁,张振仁等.神经网络在内燃机故障诊断中的应用研究[J].西安:机械科学与技术,2000,19(1):107～109
[13] 徐章遂,房立清,米东等.基于神经网络的柴油机燃油系统故障诊断[J].上海:内燃机工程,2001,18(3):32～35
[14] Y.Gao,R.B.Randall.Reconstruction of Diesel Engine Cylinder Pressure Using a Time Domain Smoothing Technique.Mechanical Systems and Signal Processing,1999,13(5):709～722
[15] 房立清,米东,徐章遂等.基于奇异谱分析的发动机燃油系统故障诊断[J].天津:燃烧科学与技术,2003,9(2):108～111
[16] 李志敏,王义,宋希庚等.内燃机主轴承磨损故障的振动监测方法研究[J].天津:内燃机学报,2000,18(2):203～206
[17] 贾继德,徐寅生.利用振动信号诊断气门挺杆响故障[J].大同:车用发动机,2000,1:36~39
[18] 刘世元,杜润生,杨叔子.内燃机缸盖振动信号的特性与诊断应用研究[J].武汉:华中理工大学学报,1999,27(7):48～50
[19] K.Hammond,P.R.White.The Analysis of Non-stationary Signals Using Time -frequency Mechods[J].Journal of Sound and Vibration,1996,190(3):419～447
[20] Olivier Rioul,Patrick Flandrin.Time-Scale Energy Distributions:A General Class Extending Wavelet Transforms[J].IEEE Transactions on Signal Processing,1992,40(7)
[21] Ljubisa Stankovic,Johann F.Bohme.Time-frequency analysis of multiple resonances in combustion engine signals[J].Signal Processing,1999,79:15-28
[22] 郑海波,李志远,陈心昭等.基于时频分析的发动机异响特征分析及故障诊断研究[J].天津:内燃机学报,2002,20(3):267～272
[23] 陈基明.小波分析基础[M].上海:上海大学出版社,2002,12
[24] 贾继德,孔凡让,李志远等.基于时频分析的内燃机曲轴轴承磨损故障的诊断研究[J].合肥:中国科学技术大学学报,2003,33(6):709～717
[25] 张安华.机电设备状态监测与故障诊断技术[M].西安:西安工业大学出版社,1995,4～5
[26] Lixiang Shen,Francis E.H.Tay,Liangsheng Qu et al.Fault Diagnosis Using Rough Sets Theory.Computers in Industry,2000,43:61～72
[27] Olivier Rioul,Patrick Flandrin.Time-Scale Energy Distributions:A General Class Extending Wavelet Transforms[J].IEEE Transactions on Signal Processing,1992,40(7)
[28] 冯志鹏,宋希庚,薛冬新.基于粗糙集与神经网络集成的内燃机故障诊断[J].天津:内燃机学报,2003,21(1):75～80
[29] 何勇,鲍一丹.基于神经网络的发动机故障多媒体诊断专家系统[J].天津:内燃机学报,2001,19(3):245～248
[30] 郑君里,应启珩,杨为理.信号与系统[M].北京:高等教育出版社,1981,5
[31] 芮坤生.信号分析与处理[M].北京:高等教育出版社,1993
[32] 姜建国,曹建中,高玉明.信号与系统分析基础[M].北京:清华大学出版社,1994,2
[33] 时友芬,郑捷,王持志.信号与系统原理[M].北京:北京邮电学院出版社,1993,1
[34] 沈寿林,张英堂,张中民.利用振动信号诊断发动机气门间隙异常故障[J].石家庄:军械工程学院学报, 1998,10(1)
[35] 余成波.内燃机振动控制及应用[M].北京:国防工业出版社,1997,25～27
[36] 周龙保.内燃机学[M].北京:机械工业出版社.1999
[37] 王敏智,周恒昌.微型汽车构造与维修(发动机辑)[M]:人民交通出版社.1993,6
[38] 陈家瑞.汽车构造(上册)[M]:人民交通出版社.1996,74~75
[39] 黄贤武,郑筱霞.传感器实际应用电路设计[M].北京:电子科技大学出版社,1997,6
[40] 何正嘉,刘雄,屈梁生.信号平均处理原理和应用[M].北京:信号处理,1986,2(4):236- 243
[2] 曹龙汉.柴油机智能化故障诊断技术研究[D].重庆:重庆大学 2001
[3] 屈梁生,何正嘉.机械故障诊断学[M].上海:上海科学技术出版社,1986,12
[4] 裴峻峰,杨其俊.机械故障诊断技术[M].北京:石油大学出版社,1997,1
[5] J.Antoni,J.Daniere,F.Guillet.Effective vibration analysis of IC engines using cyclostationarity[J] . Part I-A methodology for condition monitoring . Journal of Sound andVibration,2002,257(5):815～837
[6] 李国华,张永忠.机械故障诊断[M].北京:化学工艺出版社,1999,2:3～4
[7] 胡以怀,杨叔子,刘永长.柴油机磨损故障振动诊断机理的研究[J].天津:内燃机学报,2005,1
[8] 王晓武,杨建国.利用振动参数监测和诊断柴油机滑动主轴承磨损状态的研究[M].北京:国防工业出版社,2000,6
[9] 张培林,李国章,何忠波.利用缸盖振动信号诊断气门机构故障[J].太原:测试技术学报,2000,12(1):41～46
[10] Zunmin Geng,Jin Chen,J.Barry Hull.Analysis of engine vibration and design of an applicable diagnosising approach[J].International Journal of Mechanical Science,2003,45:1391～1410
[11] J.Antoni,J.Daniere,F.Guillet.Effective vibration analysis of IC engines using Cyclost -ationarity[J].Part II-New results on the reconstruction of the cylinder pressures.Journal of Sound and Vibration,2002,257(5):839～856
[12] 夏勇,商斌梁,张振仁等.神经网络在内燃机故障诊断中的应用研究[J].西安:机械科学与技术,2000,19(1):107～109
[13] 徐章遂,房立清,米东等.基于神经网络的柴油机燃油系统故障诊断[J].上海:内燃机工程,2001,18(3):32～35
[14] Y.Gao,R.B.Randall.Reconstruction of Diesel Engine Cylinder Pressure Using a Time Domain Smoothing Technique.Mechanical Systems and Signal Processing,1999,13(5):709～722
[15] 房立清,米东,徐章遂等.基于奇异谱分析的发动机燃油系统故障诊断[J].天津:燃烧科学与技术,2003,9(2):108～111
[16] 李志敏,王义,宋希庚等.内燃机主轴承磨损故障的振动监测方法研究[J].天津:内燃机学报,2000,18(2):203～206
[17] 贾继德,徐寅生.利用振动信号诊断气门挺杆响故障[J].大同:车用发动机,2000,1:36~39
[18] 刘世元,杜润生,杨叔子.内燃机缸盖振动信号的特性与诊断应用研究[J].武汉:华中理工大学学报,1999,27(7):48～50
[19] K.Hammond,P.R.White.The Analysis of Non-stationary Signals Using Time -frequency Mechods[J].Journal of Sound and Vibration,1996,190(3):419～447
[20] Olivier Rioul,Patrick Flandrin.Time-Scale Energy Distributions:A General Class Extending Wavelet Transforms[J].IEEE Transactions on Signal Processing,1992,40(7)
[21] Ljubisa Stankovic,Johann F.Bohme.Time-frequency analysis of multiple resonances in combustion engine signals[J].Signal Processing,1999,79:15-28
[22] 郑海波,李志远,陈心昭等.基于时频分析的发动机异响特征分析及故障诊断研究[J].天津:内燃机学报,2002,20(3):267～272
[23] 陈基明.小波分析基础[M].上海:上海大学出版社,2002,12
[24] 贾继德,孔凡让,李志远等.基于时频分析的内燃机曲轴轴承磨损故障的诊断研究[J].合肥:中国科学技术大学学报,2003,33(6):709～717
[25] 张安华.机电设备状态监测与故障诊断技术[M].西安:西安工业大学出版社,1995,4～5
[26] Lixiang Shen,Francis E.H.Tay,Liangsheng Qu et al.Fault Diagnosis Using Rough Sets Theory.Computers in Industry,2000,43:61～72
[27] Olivier Rioul,Patrick Flandrin.Time-Scale Energy Distributions:A General Class Extending Wavelet Transforms[J].IEEE Transactions on Signal Processing,1992,40(7)
[28] 冯志鹏,宋希庚,薛冬新.基于粗糙集与神经网络集成的内燃机故障诊断[J].天津:内燃机学报,2003,21(1):75～80
[29] 何勇,鲍一丹.基于神经网络的发动机故障多媒体诊断专家系统[J].天津:内燃机学报,2001,19(3):245～248
[30] 郑君里,应启珩,杨为理.信号与系统[M].北京:高等教育出版社,1981,5
[31] 芮坤生.信号分析与处理[M].北京:高等教育出版社,1993
[32] 姜建国,曹建中,高玉明.信号与系统分析基础[M].北京:清华大学出版社,1994,2
[33] 时友芬,郑捷,王持志.信号与系统原理[M].北京:北京邮电学院出版社,1993,1
[34] 沈寿林,张英堂,张中民.利用振动信号诊断发动机气门间隙异常故障[J].石家庄:军械工程学院学报, 1998,10(1)
[35] 余成波.内燃机振动控制及应用[M].北京:国防工业出版社,1997,25～27
[36] 周龙保.内燃机学[M].北京:机械工业出版社.1999
[37] 王敏智,周恒昌.微型汽车构造与维修(发动机辑)[M]:人民交通出版社.1993,6
[38] 陈家瑞.汽车构造(上册)[M]:人民交通出版社.1996,74~75
[39] 黄贤武,郑筱霞.传感器实际应用电路设计[M].北京:电子科技大学出版社,1997,6
[40] 何正嘉,刘雄,屈梁生.信号平均处理原理和应用[M].北京:信号处理,1986,2(4):236- 243