嵌入式传感器的齿轮裂纹故障诊断

Gear crack fault diagnosis based on embedded sensors

针对传统的齿轮箱体振动信号的故障诊断,提出了一种新的测试方法,即把传感器直接安装在齿轮箱体内的齿轮体上,缩短了振动信号的传递路径,有效降低了振动信号在传递过程中幅值衰减,能诊断出齿轮传动系统的早期故障。为验证该方法的有效性,对齿根2 mm裂纹的故障齿轮传动系统进行了动力学仿真和实验验证,结果发现从齿轮体上的振动信号中能成功诊断出齿轮裂纹的早期故障,而箱体上的振动信号则不能体现故障特征。这充分说明了振动信号在经过复杂的传递路径后导致幅值衰减和频率成分丢失,微弱的故障信息被削弱。这为齿轮箱的早期微弱故障的诊断提供了一种有效的方法。

Being different from the traditional fault diagnosis method based on a gearbox’s vibration signals,a new test method with sensors installed directly on a gear inside a gearbox was proposed here. Thus,gear vibration signals’ amplitude attenuation was reduced effectively due to shortening vibration signals’ transmission path,early faults in gear transmission systems could be detected. In order to verify the effectiveness of the proposed method,a faulty gear transmission system with a 2 mm crack on one of its gear tooth roots were simulated dynamically and tested,respectively.The results showed that vibration signals measured with embedded sensors can be used to detect effectively the early fault of this crack while vibration signals measured on this gearbox cannot reveal this crack fault; in fact,after vibration signals passing through a complex transmission path,their amplitudes are attenuated and parts of their frequency components are lost,so the weak fault information is diminished. This study provided an effective method for diagnosis of gearbox early weak faults.