脂润滑球轴承噪声寿命试验技术研究
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摘要
轴承的噪声寿命是一个表征轴承质量的重要指标,它与产品设计、材料、工艺以及加工过程中的质量控制手段等诸多因素有关,又是一个综合性指标。随着人们对家电产品性能要求的提高,对轴承的质量要求也越来越高,所以提供一种评估家电轴承噪声寿命的试验方法显得非常重要。
本文以江门机械设备有限公司轴承噪声寿命试验机的设计为背景,考虑到试验机的自动化程度、试验精度和系统稳定性的要求,给出了以LabVIEW软件为主要开发平台的轴承噪声寿命试验机监控系统的设计方案。主要研究内容为：试验机机械部分设计：传动系统设计、电气硬件系统设计；主电路的设计和测控部分的设计；振动信号的分析和处理等三大部分。
整个系统的关键点是转速的控制、温度的控制以及对采集信号的分析处理方法。转速的控制主要是通过变频器和LabVIEW的通讯来实现速度的实时控制。试验中对轴承加热的温度控制采用PID无极调温的方法实现。对波形的分析与处理主要是在时域、频域以及时频域的分析方法,包括调用Matlab进行混合编程实现经验模态分解的轴承故障分析方法。
该测试系统以LabVIEW为平台开发的模块化测试系统实现了监测、控制、故障诊断、管理等功能。并实现了自动化,因此该试验平台的开发对工业中评估轴承的噪声寿命具有重大意义。
Bearing noise life is an important indicator of representing its quality. It is related with the materials, processing technology and quality control methods, and many other factors, and also a comprehensive indicator. With the improvement of home appliances'performance which people require, the requirements of bearing quality is getting high and high, so it is very important to provide a test method of bearing noise life assessment.
In this paper, take the design of bearing noise life testing machine, jiangmen mach- inery and equipment Co., Ltd as the background. Given the automation of the testing machine, testaccuracy and the requriement of system stability, it provides life test bearing noise monitoring and control system design which bases on the Labview. There are more than three parts in this paper such as the design of tester mechanical parts, the design of transmission system and electric hardware system, the design of main circuit and the measurement and control part, the vibration signal analysis and processing.
The key point of the whole system is speed control, temperature control and analysis of the collected signal processing methods. Speed control and LabVIEW mainly through the drive speed of communication to achieve real-time control. Test the temperature of the bearing heating thermostat control methods used to achieve PID Promise. Analysis and treatment of the waveform mainly in the time domain, frequency domain and time-frequency domain analysis methods, including calling Matlab programming experience in mixed mode decomposition analysis of bearing failure.
This test system for the platform development in LabVIEW modular test system realizes the monitoring, control, fault diagnosis and management, and other functions. And it realized automation. It is of great significance to assess bearing noise life in industry.
本文以江门机械设备有限公司轴承噪声寿命试验机的设计为背景,考虑到试验机的自动化程度、试验精度和系统稳定性的要求,给出了以LabVIEW软件为主要开发平台的轴承噪声寿命试验机监控系统的设计方案。主要研究内容为：试验机机械部分设计：传动系统设计、电气硬件系统设计；主电路的设计和测控部分的设计；振动信号的分析和处理等三大部分。
整个系统的关键点是转速的控制、温度的控制以及对采集信号的分析处理方法。转速的控制主要是通过变频器和LabVIEW的通讯来实现速度的实时控制。试验中对轴承加热的温度控制采用PID无极调温的方法实现。对波形的分析与处理主要是在时域、频域以及时频域的分析方法,包括调用Matlab进行混合编程实现经验模态分解的轴承故障分析方法。
该测试系统以LabVIEW为平台开发的模块化测试系统实现了监测、控制、故障诊断、管理等功能。并实现了自动化,因此该试验平台的开发对工业中评估轴承的噪声寿命具有重大意义。
Bearing noise life is an important indicator of representing its quality. It is related with the materials, processing technology and quality control methods, and many other factors, and also a comprehensive indicator. With the improvement of home appliances'performance which people require, the requirements of bearing quality is getting high and high, so it is very important to provide a test method of bearing noise life assessment.
In this paper, take the design of bearing noise life testing machine, jiangmen mach- inery and equipment Co., Ltd as the background. Given the automation of the testing machine, testaccuracy and the requriement of system stability, it provides life test bearing noise monitoring and control system design which bases on the Labview. There are more than three parts in this paper such as the design of tester mechanical parts, the design of transmission system and electric hardware system, the design of main circuit and the measurement and control part, the vibration signal analysis and processing.
The key point of the whole system is speed control, temperature control and analysis of the collected signal processing methods. Speed control and LabVIEW mainly through the drive speed of communication to achieve real-time control. Test the temperature of the bearing heating thermostat control methods used to achieve PID Promise. Analysis and treatment of the waveform mainly in the time domain, frequency domain and time-frequency domain analysis methods, including calling Matlab programming experience in mixed mode decomposition analysis of bearing failure.
This test system for the platform development in LabVIEW modular test system realizes the monitoring, control, fault diagnosis and management, and other functions. And it realized automation. It is of great significance to assess bearing noise life in industry.
引文
[1]刘奇,蒋兴奇NSK家电轴承的初期静音及静音寿命[J]轴承2003,241-44
[2]苗学问,王大伟,洪杰.滚动轴承寿命理论的发展[J].轴承2008.(3)：47-52
[3]Y.Wang,M.Hadfield.Rolling Contact Fatigue Failure Modes ofLubricated Silicon Nitride in Relation to Ring Crack Defects.Wear,1999,225(2):1284-1292
[4]SHIGEO SHIMIZU; KAZUO TSUCHIYA Probabilistic Stress-Life (P-S-N) Study on Bearing Steel Using Alternating Torsion Life Test[J] Tribology Transactions 2009,52(6)
[5]李兴林,张仰平等.轴承疲劳寿命试验技术发展趋势[J]轴承2005(2),42-43
[6]李兴林,张燕辽等.滚动轴承寿命试验机及其试验技术的现状及发展[J].试验技术及试验机2007.(3)：15
[7]李兴林轴承寿命性能试验技术现状及发展[J]MC现代零部件.2007(2)44-47
[8]李兴林,等.国外滚动轴承疲劳寿命试验的现状及其发展趋势[J].轴承1995.(12)：3036
[9]高静.轴承疲劳寿命试验故障诊断系统及实现[D]大连海事大学2005
[10]华容等信号分析与处理[M]高等教育出版社2004第一版
[11]廖伯瑜,机械故障诊断基础,第1版,1995年,冶金工业出版社,86-95
[12]古毅,振动测量的发展现状,现代计量测试,1997(5)
[13]杨咸启,冯启民.轴承异音模态与实验研究[J]振动工程学报2004(8)831-834
[14]禹德伟,宋剑虹.轴承振动加速度和异常声检测新方法[J].轴承2008(7)：35-37
[15]S.Hogmar,S.Jacobson and O.Wanstrand.Universal Test for Friction.Wear and Lubrication,1998,Swedish Patent DNR 98020 17-5
[16]NSK轴承手册.机械工业出版社[M].2004.6 300-301
[17]廖林清,谢明等流量守恒定律在皮带传送中的应用[J]机械传动2010.9：33-38
[18]张安华.机电设备状态监测与故障诊断技术[M].西安：西北工业大学出版社,1995：68-69
[19]萧汉年.机械工况监测与故障诊断[M].北京：人民交通出版社,1994：18-20
[20]马草原,郭双强李国欣基于labview的串口调试与数据分析[J]工矿自动化 2008.84-6
[21]VFM-D台达变频器使用手册[M]2008.43-47
[22]徐晓东、郑对元等LabVIEW8.5常用功能与编程实例精讲[M].电子工业出版社
[23]钟绍俊等LabVIEW与三菱变频器的通讯实现[J].微计算机信息,2006,22
[24]刘君华.基于LabVIEW的虚拟仪器设计[M].北京：电子工业出版社,2003.
[25]姚建成,杨洪涛基于LabVIEW的温度自动控制PID算法的实现[J]龙岩学院学报2006(12)40-44
[26]汪敏生LabVIEW基础教程[M]成都：电子工业出版社2002
[27]侯国屏,叶齐鑫.LabVIEW7.1编程与虚拟仪器设计[M].北京：清华大学出版社,2005.
[28]肖亚克.基于虚拟仪器技术的温度和光照测量[J].国外电子测量技术,2004,(5)：33-35.
[29]刘金琨.先进PID控制MATLAB仿真[M].北京：电子工业出版社,2004.
[30]宋坚华,宋延熙,张文俊.实用微机测控应用技术[M].广州：广东科技出版社,1991.
[31]黄文虎,夏松波,刘瑞岩.设备故障诊断原理、技术及应用.北京：科学出版社,1997：55-58
[32]张晨罡.基于经验模态分解的滚动轴承诊断方法研究[D]郑州大学2007
[33]高静.轴承疲劳寿命试验故障诊断系统及实现[D]大连海事大学2005
[34]应怀樵,波形和频谱分析与随机数据处理,第1版,1985,中国铁道出版社,32-69
[35]Zhizhang Chen, Ney.M.M. On the Relationship Between the Time-Domain and Frequency-Domain TLM Methods[J]. IEEE Antennas and Wireless Propagation Letters 2888,7
[36]] Ruqiang Yan, Robert X. Gao. Hilbert-Huang Transform-Based VibrationSignal Analysis for Machine Health Monitoring.IEEE Transaction onInstrumentation and Measurement,2006, Vol.55:2320-2329
[37]Norden E Huang,Zheng Shen,Steven R Long, etal The Empirical Mode Decomposition and the Hilbert Spectrum for Nonlinear Non-Stationary Time Series Analysis[J]. Proc R Soc Lond A.1998(454):903-995
[38]于德介,程军圣.EMD方法在齿轮故障诊断中的应用.湖南大学学报(自然科学版),2002,29(6)：48-51
[39]胡劲松.面向旋转机械故障诊断的经验模态分解时频分析方法及实验研究.浙江大学[D],2003
[40]李力等编著.机械信号处理及其应用.华中科技大学出版社[M].2007.8：190-206
[41]陈锡辉等编著.LabVIEW8.20程序设计从入门到精通.清华大学出版社[M].2007
[42]赵玲,苏维军.一种LabVIEW调用Mat lab的方法[J],北京工商大学学报：自然科学版,2009.3：23-25
[43]付瑶、王新军等.EMD信号处理方法LabVIEW和Mat lab中的实现.北京机械工业学院学报[J].2008.23(2)：22-26
[44]李辉,郑海起,唐力伟.声测法和经验模态分解在轴承故障诊断中的应用[J].中国电机工程学报,2006,26(15)：124-127
[45]Fei Bao, Xinlong Wang, Zhiyong Tao etc.EMD-based extraction of modulated cavitation noise[J]. Mechanical Systems & Signal Processing.2010,24(7)
[46]焦卫东,朱有剑.基于EMD与倒频谱分析的轴承故障诊断[J].机电工程,2009.26(2)：18-20
[47]Feng Zhipeng, Chu Fulei. Transient hydraulic pressure fluctuation signal analysis of hydroturbine based on Hilbert-Huang transform [J]. Proceedings of the CSEE,2005, 25(10):111-115.
[48]张晨罡.基于经验模态分解的滚动轴承诊断方法研究[D]郑州大学2007
[2]苗学问,王大伟,洪杰.滚动轴承寿命理论的发展[J].轴承2008.(3)：47-52
[3]Y.Wang,M.Hadfield.Rolling Contact Fatigue Failure Modes ofLubricated Silicon Nitride in Relation to Ring Crack Defects.Wear,1999,225(2):1284-1292
[4]SHIGEO SHIMIZU; KAZUO TSUCHIYA Probabilistic Stress-Life (P-S-N) Study on Bearing Steel Using Alternating Torsion Life Test[J] Tribology Transactions 2009,52(6)
[5]李兴林,张仰平等.轴承疲劳寿命试验技术发展趋势[J]轴承2005(2),42-43
[6]李兴林,张燕辽等.滚动轴承寿命试验机及其试验技术的现状及发展[J].试验技术及试验机2007.(3)：15
[7]李兴林轴承寿命性能试验技术现状及发展[J]MC现代零部件.2007(2)44-47
[8]李兴林,等.国外滚动轴承疲劳寿命试验的现状及其发展趋势[J].轴承1995.(12)：3036
[9]高静.轴承疲劳寿命试验故障诊断系统及实现[D]大连海事大学2005
[10]华容等信号分析与处理[M]高等教育出版社2004第一版
[11]廖伯瑜,机械故障诊断基础,第1版,1995年,冶金工业出版社,86-95
[12]古毅,振动测量的发展现状,现代计量测试,1997(5)
[13]杨咸启,冯启民.轴承异音模态与实验研究[J]振动工程学报2004(8)831-834
[14]禹德伟,宋剑虹.轴承振动加速度和异常声检测新方法[J].轴承2008(7)：35-37
[15]S.Hogmar,S.Jacobson and O.Wanstrand.Universal Test for Friction.Wear and Lubrication,1998,Swedish Patent DNR 98020 17-5
[16]NSK轴承手册.机械工业出版社[M].2004.6 300-301
[17]廖林清,谢明等流量守恒定律在皮带传送中的应用[J]机械传动2010.9：33-38
[18]张安华.机电设备状态监测与故障诊断技术[M].西安：西北工业大学出版社,1995：68-69
[19]萧汉年.机械工况监测与故障诊断[M].北京：人民交通出版社,1994：18-20
[20]马草原,郭双强李国欣基于labview的串口调试与数据分析[J]工矿自动化 2008.84-6
[21]VFM-D台达变频器使用手册[M]2008.43-47
[22]徐晓东、郑对元等LabVIEW8.5常用功能与编程实例精讲[M].电子工业出版社
[23]钟绍俊等LabVIEW与三菱变频器的通讯实现[J].微计算机信息,2006,22
[24]刘君华.基于LabVIEW的虚拟仪器设计[M].北京：电子工业出版社,2003.
[25]姚建成,杨洪涛基于LabVIEW的温度自动控制PID算法的实现[J]龙岩学院学报2006(12)40-44
[26]汪敏生LabVIEW基础教程[M]成都：电子工业出版社2002
[27]侯国屏,叶齐鑫.LabVIEW7.1编程与虚拟仪器设计[M].北京：清华大学出版社,2005.
[28]肖亚克.基于虚拟仪器技术的温度和光照测量[J].国外电子测量技术,2004,(5)：33-35.
[29]刘金琨.先进PID控制MATLAB仿真[M].北京：电子工业出版社,2004.
[30]宋坚华,宋延熙,张文俊.实用微机测控应用技术[M].广州：广东科技出版社,1991.
[31]黄文虎,夏松波,刘瑞岩.设备故障诊断原理、技术及应用.北京：科学出版社,1997：55-58
[32]张晨罡.基于经验模态分解的滚动轴承诊断方法研究[D]郑州大学2007
[33]高静.轴承疲劳寿命试验故障诊断系统及实现[D]大连海事大学2005
[34]应怀樵,波形和频谱分析与随机数据处理,第1版,1985,中国铁道出版社,32-69
[35]Zhizhang Chen, Ney.M.M. On the Relationship Between the Time-Domain and Frequency-Domain TLM Methods[J]. IEEE Antennas and Wireless Propagation Letters 2888,7
[36]] Ruqiang Yan, Robert X. Gao. Hilbert-Huang Transform-Based VibrationSignal Analysis for Machine Health Monitoring.IEEE Transaction onInstrumentation and Measurement,2006, Vol.55:2320-2329
[37]Norden E Huang,Zheng Shen,Steven R Long, etal The Empirical Mode Decomposition and the Hilbert Spectrum for Nonlinear Non-Stationary Time Series Analysis[J]. Proc R Soc Lond A.1998(454):903-995
[38]于德介,程军圣.EMD方法在齿轮故障诊断中的应用.湖南大学学报(自然科学版),2002,29(6)：48-51
[39]胡劲松.面向旋转机械故障诊断的经验模态分解时频分析方法及实验研究.浙江大学[D],2003
[40]李力等编著.机械信号处理及其应用.华中科技大学出版社[M].2007.8：190-206
[41]陈锡辉等编著.LabVIEW8.20程序设计从入门到精通.清华大学出版社[M].2007
[42]赵玲,苏维军.一种LabVIEW调用Mat lab的方法[J],北京工商大学学报：自然科学版,2009.3：23-25
[43]付瑶、王新军等.EMD信号处理方法LabVIEW和Mat lab中的实现.北京机械工业学院学报[J].2008.23(2)：22-26
[44]李辉,郑海起,唐力伟.声测法和经验模态分解在轴承故障诊断中的应用[J].中国电机工程学报,2006,26(15)：124-127
[45]Fei Bao, Xinlong Wang, Zhiyong Tao etc.EMD-based extraction of modulated cavitation noise[J]. Mechanical Systems & Signal Processing.2010,24(7)
[46]焦卫东,朱有剑.基于EMD与倒频谱分析的轴承故障诊断[J].机电工程,2009.26(2)：18-20
[47]Feng Zhipeng, Chu Fulei. Transient hydraulic pressure fluctuation signal analysis of hydroturbine based on Hilbert-Huang transform [J]. Proceedings of the CSEE,2005, 25(10):111-115.
[48]张晨罡.基于经验模态分解的滚动轴承诊断方法研究[D]郑州大学2007