发动机台架试验在线图像可视铁谱磨损监测系统研究与开发

Research and Development of On-line Visual Ferrography Wear Monitoring System for Engine Bench Tests

在线图像可视铁谱(on-line visual ferrography,OLVF)是一种获得润滑油磨粒在线铁谱的技术,为实现发动机台架试验的实时磨损监测,应用OLVF模块开发了发动机台架试验在线磨损监测硬件系统,并在Windows XPE系统下采用Visual C#语言开发了监测软件。实现了OLVF模块流道图像的实时检测,并利用基于磨粒谱片的磨粒百分遮光面积指数(index of particle covered area,IPCA)绘制磨损趋势曲线。将系统应用于某型号柴油机台架进行了实机试验,试验结果表明:在线磨损监测硬件系统能够稳定可靠工作,使无效数据比例仅为0.3%;并在发动机拉缸前捕获到大片磨粒(IPCA=912),及时发现异常磨损信号,实现了发动机台架试验的磨损实时监测和故障早期预警。

In order to realize real-time wear monitoring of engine bench tests, on-line visual ferrography （OLVF） module was applied to develop on-line wear monitoring system for engine bench tests and a monitoring software was developed on the Windows XPE platform by using Visual C#. With which the real-time images in the channel of OLVF module were captured and the index of particle covered area （IPCA） of ferrograms was adopted to plot wear trend curves. The practical test was conducted by utilizing the monitoring system on a diesel engine bench. The experimental results show that the system can run stabily and reliably and the invalid data ratio is only 0. 3%. A large particle （IPCA= 912） was captured before occurrence of scuffing and abnormal wear signals. The system can achieve real-time wear monitoring and early fault warning for engine bench tests.