Article(id=1202984228507054505, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1202984226762219866, articleNumber=1009-5438(2022)03-0068-05, orderNo=null, doi=null, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1648483200000, receivedDateStr=2022-03-29, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1764743390442, onlineDateStr=2025-12-03, pubDate=1656086400000, pubDateStr=2022-06-25, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1764743390442, onlineIssueDateStr=2025-12-03, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1764743390442, creator=13701087609, updateTime=1764743390442, updator=13701087609, issue=Issue{id=1202984226762219866, tenantId=1146029695717560320, journalId=1185652524569653253, year='2022', volume='48', issue='3', pageStart='1', pageEnd='98', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1764743390026, creator=13701087609, updateTime=1764744768237, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1202990007461049256, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1202984226762219866, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1202990007461049257, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1202984226762219866, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=68, endPage=72, ext={EN=ArticleExt(id=1202984228779684270, articleId=1202984228507054505, tenantId=1146029695717560320, journalId=1185652524569653253, language=EN, title=Establishment of Self Diagnosis Model for Rolling Bearing Faults Based on Wavelet Packet Decomposition, columnId=1187100786392711543, journalTitle=Science & Technology of Baotou Steel, columnName=Equipment and Automation, runingTitle=null, highlight=null, articleAbstract=

In the paper, the scheme of establishing a self diagnosis model for high speed rolling bearing is proposed considering the complexity of rolling bearing fault diagnosis and combining with the difficulties of rolling bearing fault diagnosis for equipment on site. The original vibration signal of rolling bearing for high speed gear box is decomposed using the wavelet packet, then frequency domain signals in different frequency bands in decomposed original vibration signal are reconstructed and the characteristics of shock pulse energy for rolling bearing fault of reconstructed frequency domain signals are extracted respectively. The extraction of characteristics for rolling bearing fault of high speed gear box is realized and they are used for establishing the self diagnosis model for high speed rolling bearing through comparing the characteristics of impact energy for rolling bearing extracted from each frequency band after reconstruction as well as extracting frequency band signals sensitive to energy changes aiming at different types of rolling bearings.

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考虑滚动轴承故障诊断的复杂性,结合现场设备滚动轴承故障诊断的痛点,文章提出了一种高速滚动轴承自诊断模型建立方案。利用小波包分解高速齿轮箱滚动轴承原始振动信号,再将分解后的原始振动信号中不同频带内的频域信号进行重构,分别对重构的频域信号提取滚动轴承故障冲击脉冲能量特征,通过对比重构后各频段提取的滚动轴承冲击能量特征,针对不同类型的滚动轴承提取能量变化敏感的频带信号,实现对高速齿轮箱滚动轴承故障特征的提取并用于建立高速滚动轴承故障自诊断模型。

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宁中赫(1987-),男,内蒙古包头市人,硕士,工程师,现从事设备运行管理工作。

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宁中赫(1987-),男,内蒙古包头市人,硕士,工程师,现从事设备运行管理工作。

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宁中赫(1987-),男,内蒙古包头市人,硕士,工程师,现从事设备运行管理工作。

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基于小波包分解建立滚动轴承故障自诊断模型
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宁中赫 , 贺天成
包钢科技 | 设备与自动化 2022,48(3): 68-72
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包钢科技 | 设备与自动化 2022, 48(3): 68-72
基于小波包分解建立滚动轴承故障自诊断模型
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宁中赫, 贺天成
作者信息
  • 内蒙古包钢钢联股份有限公司长材厂,内蒙古 包头 014010
  • 宁中赫(1987-),男,内蒙古包头市人,硕士,工程师,现从事设备运行管理工作。

Establishment of Self Diagnosis Model for Rolling Bearing Faults Based on Wavelet Packet Decomposition
Zhong-he Ning, Tian-cheng He
Affiliations
  • Long Products Plant of Inner Mongolia Baotou Steel Union Co., Ltd., Baotou 014010, Inner Mongolia Autonomous Region, China
出版时间: 2022-06-25
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考虑滚动轴承故障诊断的复杂性,结合现场设备滚动轴承故障诊断的痛点,文章提出了一种高速滚动轴承自诊断模型建立方案。利用小波包分解高速齿轮箱滚动轴承原始振动信号,再将分解后的原始振动信号中不同频带内的频域信号进行重构,分别对重构的频域信号提取滚动轴承故障冲击脉冲能量特征,通过对比重构后各频段提取的滚动轴承冲击能量特征,针对不同类型的滚动轴承提取能量变化敏感的频带信号,实现对高速齿轮箱滚动轴承故障特征的提取并用于建立高速滚动轴承故障自诊断模型。

小波包分解  /  滚动轴承  /  自诊断  /  瞬时冲击信号

In the paper, the scheme of establishing a self diagnosis model for high speed rolling bearing is proposed considering the complexity of rolling bearing fault diagnosis and combining with the difficulties of rolling bearing fault diagnosis for equipment on site. The original vibration signal of rolling bearing for high speed gear box is decomposed using the wavelet packet, then frequency domain signals in different frequency bands in decomposed original vibration signal are reconstructed and the characteristics of shock pulse energy for rolling bearing fault of reconstructed frequency domain signals are extracted respectively. The extraction of characteristics for rolling bearing fault of high speed gear box is realized and they are used for establishing the self diagnosis model for high speed rolling bearing through comparing the characteristics of impact energy for rolling bearing extracted from each frequency band after reconstruction as well as extracting frequency band signals sensitive to energy changes aiming at different types of rolling bearings.

wavelet packet decomposition  /  rolling bearing  /  self diagnosis  /  temporary impact signal
宁中赫, 贺天成. 基于小波包分解建立滚动轴承故障自诊断模型. 包钢科技, 2022 , 48 (3) : 68 -72 .
Zhong-he Ning, Tian-cheng He. Establishment of Self Diagnosis Model for Rolling Bearing Faults Based on Wavelet Packet Decomposition[J]. Science & Technology of Baotou Steel, 2022 , 48 (3) : 68 -72 .
在冶金行业的齿轮箱、大型风机及水泵中滚动轴承应用十分广泛,一旦滚动轴承损坏,轻则使设备轴承室镗孔磨损,重则会导致齿轮箱齿轮打齿、风机断轴等严重后果,若轴承故障不能及时发现,维修费用也会大幅提高。现阶段各大钢企通过在重要设备上安装足够的传感器,获取实时、批量的振动、温度数据。针对重要设备状态诊断模型的建立方面都处于起步阶段。目前工业大数据发展迅猛,在旋转设备故障诊断方面,故障诊断模型主要分为机理模型和算法模型两类,笔者认为未来在旋转设备智能诊断方面,一定是基于机理模型的智能AI模型。本文提出了一种基于小波包分解自诊断高速滚动轴承故障的机理模型,解决现场旋转设备滚动轴承维护的痛点,做到高速滚动轴承缺陷早发现,早干预,将高速滚动轴承故障消灭在萌芽状态。
小波包分解能对信号进行全面的时频分解,更有效地反映信号的瞬时时频特征,从而可以更加有效地提取信号的冲击特征[1]。将采集的原始加速度信号通过小波包3次分解,并利用滚动轴承缺陷产生的冲击脉冲频带宽这一特性来实现系统自动诊断转速大于1 000 r/min设备滚动轴承缺陷,比如高速线材锥箱、增速机、吐丝机及高速齿轮箱、风机、水泵等。
小波包分解可以同时对低频部分信号、高频部分信号进行分解,而且这种分解既无冗余,也无疏漏,因此对包含大量低频、中频及高频信号中的信息能够进行更好的时频局部化分析,如图1所示。
其中,SSS、SdS、SSd和Sdd为第三层节点的低频系数,而dSS、ddS、dSd和ddd为第三层节点的高频系数[2]
采集长材厂2#线高速区22架锥箱振动加速度原始数据,通过MATLAB仿真绘制的小波包树,如图2所示。
将原始加速度数据3次分解,得到8个频段数据。目前长材厂诊断高速区设备采集的加速度信号设置是:分析频宽10 000 Hz,谱线数6 400线,信号采样点数为16 384,分解到第3层离散点数为2 048,故n=2 048。每个频率段的频率区间是10 000 Hz/8=1 250 Hz。笔者理解小波包也是个很好的滤波器,且每个频段有一定的宽度,这样就算转速波动,不会影响轴承缺陷的整体判断。
通过提取55个缺陷滚动轴承的振动信号,探索滚动轴承缺陷特征冲击能量分布。
图3图4所示,因为内滑道和滚动体缺陷在测试信号上都会出现大量的的调制信息,所以在分析能量的分布上可以放在一起讨论[3]。两种缺陷产生的冲击都会激起宽频带能量,但是因为调制的信息不同,内滑道缺陷高能量的分布会更宽一些,滚动体缺陷的高能量分布相对于内滑道会较窄一些。这是分辨内滑道缺陷及滚动体缺陷的相对明显的特征。两种缺陷都存在调制信息,在能量的分布形态上类似于正态分布图。
图5所示,轴承外滑道缺陷体现在加速度信号上是轴承外滑道特征频率及其高次谐波处出现能量,并且缺陷产生的冲击同样会激起宽频带的能量[3]。在能量带的分布上体现为各频段均有能量出现,虽然在个别频段上会出现高能量,但是整体的能量带分布相对均匀。以分析频宽10 kHz、频段间隔1 250 Hz为例,若在高转速下出现外环特征频率大于1 458.3 Hz的情况,6X特征频率会跨频带出现,也就是说不考虑最后一个频段的情况下,外环特征频率大于1 458.3 Hz后其谐波开始出现跨频带的情况。这就需要在诊断高转速运行轴承外滑道缺陷时,针对能量跨频段出现这一情况相应调整系统需要捕捉的小波包分解重构后的能量频段。
滚动轴承保持架缺陷的特点是冲击脉冲的间隔周期相对较长,而且冲击脉冲能量不均匀[4]。针对以上特点,目前通过小波包分解对比能量带分布还无法识别其早期缺陷,但轴承保持架缺陷发展到后期时可以识别出轴承故障。
在MATLAB仿真中使用小波包分解与重构,结合高速滚动轴承(大于1 000 r/min)冲击能量分布特征研究滚动轴承故障诊断模型的方法。本文采用高速线材生产线现场实际测试的滚动轴承外滑道早期缺陷数据进行分析,以验证基于小波包分解提取高速齿轮箱故障信号频域特征并用于建立滚动轴承故障诊断模型的方法的有效性[4]。测试轴承为角接触轴承,转速为3 834 r/min,采样频率为25 600 Hz,选用角接触轴承处采集到的滚动轴承振动加速度信号的16 384个采样点作分析,其原始时域波形如图6所示[5]
将原始滚动轴承振动加速度信号用小波包将其3次分解,对节点顺序按照频率递增进行重排序,对小波节点进行重构,并分别绘制第3层各个节点重构后的信号频谱。原始振动信号3次小波包分解后得到8个频段,第3层离散点数为2 048,每个频率段的频率区间是10 000 Hz/8=1 250 Hz[6]。缺陷轴承各频段频谱能量及频谱形态如图7所示。
求取小波包分解第3层0节点、1节点、2节点、3节点、4节点、5节点、6节点、7节点的小波包系数,然后求取小波包分解后各个频段的能量及能量占比。缺陷轴承频段能量分布及占比如图8所示。
为了更好地对比该诊断模型的有效性,针对高速线材在相同架次、相同位置上新更换角接触轴承的振动信号,采用与上述缺陷轴承相同的信号处理方法,如图9所示。
通过对比,可以发现,缺陷滚动轴承与正常滚动轴承的振动信号在频段能量分布及占比上有显著差别。能量在小波包分解第3层(3,3)(3,4)(3,5)(3,6)(3,7)变化明显。
经过信号处理后,对比图8图9滚动轴承频段能量分布及占比图,缺陷轴承能量在小波包分解第3层(3,3)(3,4)(3,5)(3,6)(3,7)明显高于正常轴承。这种简化的诊断模型可以跳过讨论复杂的轴承缺陷特征识别,其优点是不需要轴承特征频率。在状态监测系统中,基于小波包分解的自诊断模型,针对滚动轴承缺陷,系统可以自动提取符合滚动轴承缺陷的振动信号特征,比如在上述的角接触轴承缺陷中,系统只要抓住频带(3,4)(3,5)(3,6)(3,7)的能量及能量占比便可以自动识别滚动轴承缺陷。
(1)利用小波包分解,通过对比各频段能量分布来实现高速滚动轴承缺陷的识别,将自诊断模型尽可能简化为频段及频段能量占比。
(2)针对不同类型及尺寸大小的滚动轴承,根据其不同的共振频率,该诊断模型可以随时调整系统预警所关注的频带位置。
(3)小波包分解是很好的滤波器,在齿轮箱的高速滚动轴承自诊断中,针对齿轮啮合频率及其谐波所在的频段,只要提前做好标记,系统便可自行分辨是滚动轴承缺陷还是齿轮啮合冲击,可以避免状态监测系统误报警。
(4)基于小波包分解的滚动轴承自诊断模型用于辅助诊断的巨大作用,在经过大量训练后,针对不同类型、不同尺寸大小的滚动轴承预警会更加精准,这样在监测大量高速设备时,只需要很少的振动分析师就会完成大量的滚动轴承诊断工作。在诊断风机及水泵滚动轴承方面,不用考虑齿啮合能量,滚动轴承自诊断模型会相对容易建立,可以在包钢内部推广。
参考文献 引证文献
排序方式:
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2022年第48卷第3期
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  • 接收时间:2022-03-29
  • 首发时间:2025-12-03
  • 出版时间:2022-06-25
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  • 收稿日期:2022-03-29
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    内蒙古包钢钢联股份有限公司长材厂,内蒙古 包头 014010
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2种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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