齿轮箱行星轮系故障诊断与原因分析

Fault Diagnosis and Cause Analysis of Planetary Gear Trains in Gearboxes

综合运用振动信号分析、内窥镜检查、宏观观察、金相分析、扫描电镜(Scanning Electron Microscopy,SEM)分析、能谱仪分析(Energy Dispersive Spectroscopy,EDS)和力学性能试验等多种技术手段,针对某型号风电齿轮箱出现的沿齿槽径向开裂现象进行了故障诊断与原因分析。通过振动信号分析发现异常振动,并通过频谱分析和时域特征提取了确定异常振动的特征;通过内窥镜检查确认故障位置,拆解后利用SEM检测确认裂纹源存在一块大尺寸夹杂物,并通过EDS明确了夹杂物的成分;进一步分析确定齿轮贯穿性开裂的整个过程,通过综合分析确定了故障原因和位置,为设备维护提供了科学依据,并为提高生产效率、延长设备寿命、降低故障损失和维修成本提供了参考。

Comprehensively utilizing various technical means,such as vibration signal analysis,endoscopy,macroscopic observation,metallographic analysis,scanning electron microscopy(SEM)analysis,energy dispersive spectroscopy(EDS)analysis,and mechanical performance experiments,a fault diagnosis and cause analysis were conducted for the radial cracking phenomenon along the tooth groove of a certain type of wind power gearboxes.The abnormal vibration was revealed through vibration signal analysis,and the characteristics of abnormal vibration was determined through spectrum analysis and time domain feature extraction.The fault location was confirmed through endoscopic inspection.After disassembly,SEM inspection were used to confirm the presence of a large-sized inclusion at the crack source,and the composition of the inclusion was determined through EDS,further analyzing and determining the entire process of gear penetration cracking.By comprehensive analysis,the cause and location of the fault were determined,which provides scientific basis for equipment maintenance,and improves production efficiency and equipment life,while reducing fault loss and maintenance costs.