基于阶比分析方法的主减速器总成故障诊断技术研究
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摘要
汽车主减速器总成作为汽车驱动桥的核心组成部分,其性能的好坏,对驱动桥的性能以及对整车的行驶性能都会有直接的影响。分析和研究主减速器总成的性能是保障汽车质量的一个重要环节。针对汽车主减速器总成振动信号的特征分析有多种不同的方法,其中阶比分析是比较重要的一种。本文针对主减速器总成振动信号特征的分析主要手段—阶比分析技术,进行了系统而全面的研究。
本文首先阐述了汽车主减速器总成测试的重要意义,对国内外故障诊断发展现状进行了分析。接着对汽车主减速器总成振动信号产生的原理以及振动信号的特征进行了详细剖析。从原理上揭示了汽车主减速器总成的振动特征以及振动信号的基本形式。
其次,本文针对汽车主减速器总成振动信号的特征,进行了以阶比分析为核心的各种分析方法的详细阐述。详细介绍了各种阶比跟踪方法的原理以及基于C#编程平台的算法实现。通过对阶比分析与频谱分析的对比分析,深入阐述了阶比分析中抗混叠滤波以及降噪问题,并且将频谱分析过程中的有效方法引入到阶比分析中来,达到了快速准确提取故障特征的目的。另外针对阶比分析的不足—不能反映角度域信息的特点,提出了阶比分析和小波分析结合的“阶比—小波”分析方法。针对非定比传动系统的阶比分析方法进行了一定程度的探讨。
最后,参考目前国内外汽车主减速器总成测试系统的设计方法以及总结本文所阐述的各种信号分析方法,提出了以阶比分析为核心的阶比分析系统的设计方法。通过对汽车主减速器总成生产现场测试的数据分析,表明了基于阶比分析方法的故障检测具有正确性和科学性。
Main reducer is one of the most important modules of drive train. It’s capability would affect the function of axle and vehicle. To analyse the measurement method of main reducer is an improtant thing for automobile.There are lots of means for failure analysis, but order analysis algorithm is the most suitable method for main reducer fault diagnosis. So, this article focuses on this algorithm, and introduces the theory systemically.
First of all, the meaning of measurement for main reducer is introduced. And the development situation of fault diagnosis is also be involved in the article. Additionaly, the vibration theory and signal features of main reducer are introduced. Here we explain the the vibration reasons and make a summary of the signal type.
Subsequently, various methods of dealing with the signal of vibration which base on order analysis algorithm are arised. Every order tracking method is explaned in detail, from the theory to arithmetic. Through the comparison of power spectrum analysis and order spectrum analysis, an in-depth study about the filter method and some efficient analytical methods are done. Some important means for power spectrum analysis are brought forward to use for order spectrum analysis. Besides, a new method -“Order-Wavelet”method is advanced to supply a gap of order analysis algorithm.And, the discussion is done here about how to use order analysis for the variable transimission ratio machine.
Finally, a fault diagnosis systerm for main reducer is put forword based on the arithmetics before-mentioned and some cases from home and abroad. Subsequently, a practical case that the vibration detection system is used in is introduced. And we can find out that the order analysis algorithm is a good method for main reducer fault diagnosis through the test data result.
本文首先阐述了汽车主减速器总成测试的重要意义,对国内外故障诊断发展现状进行了分析。接着对汽车主减速器总成振动信号产生的原理以及振动信号的特征进行了详细剖析。从原理上揭示了汽车主减速器总成的振动特征以及振动信号的基本形式。
其次,本文针对汽车主减速器总成振动信号的特征,进行了以阶比分析为核心的各种分析方法的详细阐述。详细介绍了各种阶比跟踪方法的原理以及基于C#编程平台的算法实现。通过对阶比分析与频谱分析的对比分析,深入阐述了阶比分析中抗混叠滤波以及降噪问题,并且将频谱分析过程中的有效方法引入到阶比分析中来,达到了快速准确提取故障特征的目的。另外针对阶比分析的不足—不能反映角度域信息的特点,提出了阶比分析和小波分析结合的“阶比—小波”分析方法。针对非定比传动系统的阶比分析方法进行了一定程度的探讨。
最后,参考目前国内外汽车主减速器总成测试系统的设计方法以及总结本文所阐述的各种信号分析方法,提出了以阶比分析为核心的阶比分析系统的设计方法。通过对汽车主减速器总成生产现场测试的数据分析,表明了基于阶比分析方法的故障检测具有正确性和科学性。
Main reducer is one of the most important modules of drive train. It’s capability would affect the function of axle and vehicle. To analyse the measurement method of main reducer is an improtant thing for automobile.There are lots of means for failure analysis, but order analysis algorithm is the most suitable method for main reducer fault diagnosis. So, this article focuses on this algorithm, and introduces the theory systemically.
First of all, the meaning of measurement for main reducer is introduced. And the development situation of fault diagnosis is also be involved in the article. Additionaly, the vibration theory and signal features of main reducer are introduced. Here we explain the the vibration reasons and make a summary of the signal type.
Subsequently, various methods of dealing with the signal of vibration which base on order analysis algorithm are arised. Every order tracking method is explaned in detail, from the theory to arithmetic. Through the comparison of power spectrum analysis and order spectrum analysis, an in-depth study about the filter method and some efficient analytical methods are done. Some important means for power spectrum analysis are brought forward to use for order spectrum analysis. Besides, a new method -“Order-Wavelet”method is advanced to supply a gap of order analysis algorithm.And, the discussion is done here about how to use order analysis for the variable transimission ratio machine.
Finally, a fault diagnosis systerm for main reducer is put forword based on the arithmetics before-mentioned and some cases from home and abroad. Subsequently, a practical case that the vibration detection system is used in is introduced. And we can find out that the order analysis algorithm is a good method for main reducer fault diagnosis through the test data result.
引文
[1]王雨佳.中国汽车业能否后来居上.新财经,2009,3:22～46
[2]漓沙.从AutomotiveTestingExpoChina看未来汽车测试技术发展.技术与市场,2008,34～35
[3]姚桂艳,孙丽媛,程秀芳,薛全会.机械故障诊断技术的研究现状及发展趋势.河北理工学院学报,2005,8:35～37
[4] KenjiK.Evaluation and Improvement of Vehicle Roll Behavior[J].SAE Paper 970093:25～35
[5]朱元佳.汽车变速箱在线快速故障诊断技术研究[D].同济大学硕士学位论文,2007:2～3
[6]俞峰、刘学军.虚拟仪器及其应用.电气时代,2003年第二期,60～62
[7]陆林吉,饶家明.虚拟仪器讲座[J].电子技术,2000,4:44～47
[8]黄明俊,赵伟,侯国屏等.,虚拟仪器技术—现代电工电子测量仪器的发展方向[J].电工电能新技术,1998,3:26～29
[9]李青霞,任焱唏.虚拟仪器综述[J].现代科学仪器,1999,4:10～12
[10]尹安东.车辆变速箱故障诊断的发展现状与展望.农机化研究,2005,5:280～282
[11]陈家瑞.汽车构造下册(第二版).机械工业出版社,2005,3:117～157
[12]丁康,李巍华,朱小勇.齿轮及齿轮箱故障诊断实用技术.机械工业出版社,2005,5
[13]刘景军.斜齿轮啮合刚度的计算.武钢职工大学学报,2001,6:33～36
[14]卫丽.齿轮传动动载荷沿啮合线分布规律的研究[D].太原理工大学硕士学位论文,2006:13～16
[15]胡磊.汽车主减速器螺旋锥齿轮参数化建模与有限元分析[D].武汉理工大学硕士学位论文,2008:39～42
[16]陈克兴.设备状态检测与故障诊断技术.北京:科学技术文献出版社,1991
[17]樊永生.机械设备诊断的现代信号处理方法.北京:国防工业出版社,2009
[18]陈刚.齿轮和滚动轴承故障的振动诊断[D].西北工业大学硕士学位论文,2007:12～15
[19]何正嘉.机械设备非平稳信号的故障诊断原理及应用.北京:高等教育出版社,2001
[20]科恩.时-频分析:理论与应用.西安:西安交通大学出版社,1998
[21]张祥春.面向旋转机械的虚拟式阶比分析仪的研究[D].重庆大学硕士学位论文,2006:42～45
[22] Jones D.L.and Baraniuk R.G. A simple scheme for adapting time-frequency representations. Signal Processing, IEEE Transactions, 1994, 42(12):3530~ 3535
[23] Jones D.L. and Bariniuk R.G. An adaptive optimal-kernel time-frequency representation. Signal Processing, IEEE Transactions, 1995, 43(10):2361~ 2371
[24] Mallat S. and Zhang Z. Adaptive time-frequency decomposition with matching pursuits. Proceedings of the IEEE-SP International Symposium, Victoria, BC, Canada, 1992, IEEE-SP, 1992:7~10
[25] Mallat S. and Zhang Z. Adaptive time-frequency transform, Acoustics, Speech, and Signal Processing, Minneapolis, MN, USA, 1993, ICASSP-93, 3, 1993:241~244
[26]文红举.基于计算机的阶比分析关键技术研究[D].上海大学硕士学位论文,2006:8～12
[27] National Instruments.LabVIEW Order Analysis Toolset User Manual, August 2005 Edition
[28]赵晓平,张令弥,郭勤涛.旋转机械阶比跟踪技术研究进展综述.地震工程与工程振动,2008,12:213～219
[29]纪跃波,郭瑜.阶比分析技术的发展应用与展望.现代制造工程,2007年第11期:123～126
[30] Bossley KM, Mckendrick RJ.Hybrid. Computed order tracking [J]. Mechanical Systems and Signal Processing , 1999, 13 (4) : 627～641
[31]杨炯明,秦树人,季忠.旋转机械阶比分析技术中阶比采样实现方式的研究.中国机械工程,2005,2:249～253
[32] Qin Shuren, Guo Yu. The Order Tracking of Rotating Machinery Based on Instantaneous Frequency Estimation.Proceedings of SPIE 2002, Ancona, Italy, 2002
[33] Qian S, Chen D. Joint Time-frequency Analysis. IEEE Signal Processing Magazine, 1999, 16(2) :52～67
[34] Boashash B. Interpreting and Estimating the Instantaneous Frequency of a Signal-Part 1: Fundamentals. Proc. IEEE, 1992 , 80 (4) : 520～538
[35] Boashash B. Interpreting and Estimating the Instantaneous Frequency of a Signal - Part 2 : Algorithms and Applications, Proc. IEEE, 1992, 80 (4) : 540～568
[36]宋文健.阶比分析方法的研究[D].燕山大学硕士学位论文,2006:41～47
[37]郭瑜,秦树人,汤宝平.基于分段重叠零相位滤波的阶比跟踪滤波法.振动工程学报,2003,12:399～403
[38]王力,张冰,徐伟.基于MATLAB复调制ZOOM-FFT算法的分析和实现.船舶电子工程,2006,4:119～121
[39]赵霞,熊小伏,郭珂.用细化频谱技术分析断路器操动机构振动信号[J].电力系统自动化,2003 ,(12) :37～40
[40]丁康,谢明,张彼德等.基于复解析带通滤波器的复调制细化谱分析原理和方法[J].振动工程学报, 2001 , 14 (1):30～35
[41]赵志军.基于阶次分析与振速法的汽车主减速器在线质量检测的研究[D].合肥工业大学硕士学位论文,2009:25～26
[42]胡惠英,吴善培.小波去噪在语音识别中的应用.北京邮电大学学报,1999,9:31～34
[43] Mallat S. Theory formulti-resolution signal decomposition: The wavelet rep -resentation [J]. IEEE Transactions on Pattern Analysis and Machine Intelligence, 1989, 11 (7): 674- 693
[44]文莉,刘正士,葛运建.小波去噪的几种方法.合肥工业大学学报(自然科学版),2002,4:167～172
[45]王红忠,徐寒梅,周漪清.齿轮故障诊断专家系统的研究与实现.邵阳学院学报(自然科学版),2006,3:26～28
[46]关惠玲,韩捷.设备故障诊断专家系统原理与实践.机械工业出版社,2000,8
[47]张彼德.齿轮箱振动分析及故障诊断[D].重庆大学硕士学位论文,1999:48～55
[2]漓沙.从AutomotiveTestingExpoChina看未来汽车测试技术发展.技术与市场,2008,34～35
[3]姚桂艳,孙丽媛,程秀芳,薛全会.机械故障诊断技术的研究现状及发展趋势.河北理工学院学报,2005,8:35～37
[4] KenjiK.Evaluation and Improvement of Vehicle Roll Behavior[J].SAE Paper 970093:25～35
[5]朱元佳.汽车变速箱在线快速故障诊断技术研究[D].同济大学硕士学位论文,2007:2～3
[6]俞峰、刘学军.虚拟仪器及其应用.电气时代,2003年第二期,60～62
[7]陆林吉,饶家明.虚拟仪器讲座[J].电子技术,2000,4:44～47
[8]黄明俊,赵伟,侯国屏等.,虚拟仪器技术—现代电工电子测量仪器的发展方向[J].电工电能新技术,1998,3:26～29
[9]李青霞,任焱唏.虚拟仪器综述[J].现代科学仪器,1999,4:10～12
[10]尹安东.车辆变速箱故障诊断的发展现状与展望.农机化研究,2005,5:280～282
[11]陈家瑞.汽车构造下册(第二版).机械工业出版社,2005,3:117～157
[12]丁康,李巍华,朱小勇.齿轮及齿轮箱故障诊断实用技术.机械工业出版社,2005,5
[13]刘景军.斜齿轮啮合刚度的计算.武钢职工大学学报,2001,6:33～36
[14]卫丽.齿轮传动动载荷沿啮合线分布规律的研究[D].太原理工大学硕士学位论文,2006:13～16
[15]胡磊.汽车主减速器螺旋锥齿轮参数化建模与有限元分析[D].武汉理工大学硕士学位论文,2008:39～42
[16]陈克兴.设备状态检测与故障诊断技术.北京:科学技术文献出版社,1991
[17]樊永生.机械设备诊断的现代信号处理方法.北京:国防工业出版社,2009
[18]陈刚.齿轮和滚动轴承故障的振动诊断[D].西北工业大学硕士学位论文,2007:12～15
[19]何正嘉.机械设备非平稳信号的故障诊断原理及应用.北京:高等教育出版社,2001
[20]科恩.时-频分析:理论与应用.西安:西安交通大学出版社,1998
[21]张祥春.面向旋转机械的虚拟式阶比分析仪的研究[D].重庆大学硕士学位论文,2006:42～45
[22] Jones D.L.and Baraniuk R.G. A simple scheme for adapting time-frequency representations. Signal Processing, IEEE Transactions, 1994, 42(12):3530~ 3535
[23] Jones D.L. and Bariniuk R.G. An adaptive optimal-kernel time-frequency representation. Signal Processing, IEEE Transactions, 1995, 43(10):2361~ 2371
[24] Mallat S. and Zhang Z. Adaptive time-frequency decomposition with matching pursuits. Proceedings of the IEEE-SP International Symposium, Victoria, BC, Canada, 1992, IEEE-SP, 1992:7~10
[25] Mallat S. and Zhang Z. Adaptive time-frequency transform, Acoustics, Speech, and Signal Processing, Minneapolis, MN, USA, 1993, ICASSP-93, 3, 1993:241~244
[26]文红举.基于计算机的阶比分析关键技术研究[D].上海大学硕士学位论文,2006:8～12
[27] National Instruments.LabVIEW Order Analysis Toolset User Manual, August 2005 Edition
[28]赵晓平,张令弥,郭勤涛.旋转机械阶比跟踪技术研究进展综述.地震工程与工程振动,2008,12:213～219
[29]纪跃波,郭瑜.阶比分析技术的发展应用与展望.现代制造工程,2007年第11期:123～126
[30] Bossley KM, Mckendrick RJ.Hybrid. Computed order tracking [J]. Mechanical Systems and Signal Processing , 1999, 13 (4) : 627～641
[31]杨炯明,秦树人,季忠.旋转机械阶比分析技术中阶比采样实现方式的研究.中国机械工程,2005,2:249～253
[32] Qin Shuren, Guo Yu. The Order Tracking of Rotating Machinery Based on Instantaneous Frequency Estimation.Proceedings of SPIE 2002, Ancona, Italy, 2002
[33] Qian S, Chen D. Joint Time-frequency Analysis. IEEE Signal Processing Magazine, 1999, 16(2) :52～67
[34] Boashash B. Interpreting and Estimating the Instantaneous Frequency of a Signal-Part 1: Fundamentals. Proc. IEEE, 1992 , 80 (4) : 520～538
[35] Boashash B. Interpreting and Estimating the Instantaneous Frequency of a Signal - Part 2 : Algorithms and Applications, Proc. IEEE, 1992, 80 (4) : 540～568
[36]宋文健.阶比分析方法的研究[D].燕山大学硕士学位论文,2006:41～47
[37]郭瑜,秦树人,汤宝平.基于分段重叠零相位滤波的阶比跟踪滤波法.振动工程学报,2003,12:399～403
[38]王力,张冰,徐伟.基于MATLAB复调制ZOOM-FFT算法的分析和实现.船舶电子工程,2006,4:119～121
[39]赵霞,熊小伏,郭珂.用细化频谱技术分析断路器操动机构振动信号[J].电力系统自动化,2003 ,(12) :37～40
[40]丁康,谢明,张彼德等.基于复解析带通滤波器的复调制细化谱分析原理和方法[J].振动工程学报, 2001 , 14 (1):30～35
[41]赵志军.基于阶次分析与振速法的汽车主减速器在线质量检测的研究[D].合肥工业大学硕士学位论文,2009:25～26
[42]胡惠英,吴善培.小波去噪在语音识别中的应用.北京邮电大学学报,1999,9:31～34
[43] Mallat S. Theory formulti-resolution signal decomposition: The wavelet rep -resentation [J]. IEEE Transactions on Pattern Analysis and Machine Intelligence, 1989, 11 (7): 674- 693
[44]文莉,刘正士,葛运建.小波去噪的几种方法.合肥工业大学学报(自然科学版),2002,4:167～172
[45]王红忠,徐寒梅,周漪清.齿轮故障诊断专家系统的研究与实现.邵阳学院学报(自然科学版),2006,3:26～28
[46]关惠玲,韩捷.设备故障诊断专家系统原理与实践.机械工业出版社,2000,8
[47]张彼德.齿轮箱振动分析及故障诊断[D].重庆大学硕士学位论文,1999:48～55