铁路客车轴承磨合机加装智能声学诊断系统研究

Study on Installation of the Intelligent Acoustic Diagnosis System on the Bearing Running-in Machine for Railway Passenger Cars

为进一步确保铁路客车上线运行安全,客车轮轴在组装完成后,须在磨合机上进行磨合试验来对轴承组装状态进行检验。目前,磨合试验对转速、时间和温升的卡控标准均已明确,且能够通过磨合机设备自身性能实现,但磨合过程中产生的异音、卡滞现象,主要依靠检修人员耳听、手摸来判断,准确率全靠经验和感觉,效率和兑现率低,预报标准无法统一和量化,存在误判和漏判风险。因此如何通过检测手段使轴承磨合机在磨合试验过程中自动判断异音、卡滞现象,且更加真实地模拟铁路客车在实际线路上运行的状态,需要借鉴铁路运输业成熟的技术来实现。基于此,文章提出了在现有客车轴承磨合机上增加智能声学诊断系统的设想,以高频共振解调技术、统计因子法相结合的诊断技术,对故障轴承声学信号特征进行了综合性的判定,实现了客车滚动轴承故障的监测;对异音、卡滞现象予以量化,提供在轮轴磨合试验过程中综合判断轴承故障的手段,达到“机控”目的,给现场安全生产提供了技术保障。

To further ensure the operation safety of railway passenger cars on track,after assembly,the axles of the passenger car shall receive the running-in test on the running-in machine to verify the bearing assembly state.At present,the control criteria of the running-in test for rotating speed,time and temperature rise are clear and can be realized through the own performance of the running-in machine.However,the phenomena of abnormal noise and blockage arising during the running-in are mainly judged by maintenance personnel through listening and touching,so the accuracy rate completely depends on their experience and feeling,the efficiency and rate of fulfillment are low,the prediction criteria can’t be unified and quantified,and risks of erroneous or missed judgement exist.Therefore,in order to allow the bearing running-in machine to automatically judge the phenomena of abnormal noise and blockage during the running-in test with testing methods and simulate the operation state of railway passenger cars on real tracks more truly,it’s necessary to learn from the proven technologies in the railway transport industry.On this basis,the article proposes the concept of installing an intelligent acoustic diagnosis system on the existing bearing running-in machine for passenger cars.The system can make a comprehensive judgement of the acoustic signal characteristics of the faulty bearing with the diagnosis technology combining the high-frequency resonance demodulation technology and the statistical factor method so as to realize the monitoring of the faults of rolling bearings of passenger cars;and it can quantify the phenomena of abnormal noise and blockage and provide a way for comprehensive judgement of bearing faults during the axle running-in test so as to achieve the goal of“mechanical control”and provide a technical guarantee for the safe production on site.