基于虚拟仪器的旋转机械主轴故障在线监测系统研究

On-line monitoring system for rotation mechanical spindle fault based on virtual instrument

针对机床主轴状态直接影响加工产品精度及刀具寿命的问题,对加工过程中的主轴故障状态监测技术进行了研究,提出了一种基于虚拟仪器的旋转机械主轴故障在线监测系统。该系统以主轴振动、转速及温度为监测信号,采用了时域分析、频域分析和小波包分析相结合的信号处理技术,提取了能反映主轴运行状态的特征参数,建立了基于模糊C均值聚类算法的主轴故障识别模型,通过计算当前故障特征参数与模型中已知状态的隶属度来判断主轴状态;最后,采用了基于虚拟仪器技术的Lab VIEW软件作为编程工具,设计了一套旋转机械主轴故障在线监测与诊断系统软件,并在实际机床中进行了理论验证和实例验证。研究结果表明,该系统可在线实时识别主轴的冲击、摩擦、松动、不平衡等故障,具有速度快、效率高的特点,平均准确率达99%。

Aiming that spindle running state of machine tool during working has a great influence on product precision,cut tool lifetime,spindle condition monitoring technology during the process of machining was studied. A spindle condition monitoring and diagnosis system for rotator machine was established. The vibration,speed and temperature signal of rotator machine were selected as monitoring signal,the effective fault characteristic which was sensitive to spindle fault was extracted by signal analysis techniques,including time domain analysis,frequency domain analysis and wavelet packet analysis technology,a recognition model based on fuzzy C-means clustering algorithm was established,the condition of spindle can be detected by calculating the membership between the unknown samples and known state. Finally,a spindle condition monitoring and diagnosis software was designed by Lab VIEW which is a virtual instrument programming tool,and the theoretical analysis and instance validation were carried on in the actual machine tool. The results indicate that the faults of the spindle included Impact,Friction,Loose and Imbalance,can be classified and identified by this system,and has high recognition success rate,up to 99%,and it has the features of fast and efficiently.