Article(id=1241049265900941456, tenantId=1146029695717560320, journalId=1227999626482147330, issueId=1241049258309251153, articleNumber=null, orderNo=null, doi=10.16579/j.issn.1001.9669.2025.06.002, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1695312000000, receivedDateStr=2023-09-22, revisedDate=1701792000000, revisedDateStr=2023-12-06, acceptedDate=null, acceptedDateStr=null, onlineDate=1773818802571, onlineDateStr=2026-03-18, pubDate=1749916800000, pubDateStr=2025-06-15, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1773818802571, onlineIssueDateStr=2026-03-18, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1773818802571, creator=13701087609, updateTime=1773818802571, updator=13701087609, issue=Issue{id=1241049258309251153, tenantId=1146029695717560320, journalId=1227999626482147330, year='2025', volume='47', issue='6', pageStart='1', pageEnd='158', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1773818800761, creator=13701087609, updateTime=1773819014967, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1241050156821434987, tenantId=1146029695717560320, journalId=1227999626482147330, issueId=1241049258309251153, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1241050156821434988, tenantId=1146029695717560320, journalId=1227999626482147330, issueId=1241049258309251153, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=11, endPage=16, ext={EN=ArticleExt(id=1241049267675132059, articleId=1241049265900941456, tenantId=1146029695717560320, journalId=1227999626482147330, language=EN, title=Research on Circular plot analysis method and gear fault intelligent diagnosis based on time synchronous averaging, columnId=1228282191914926752, journalTitle=Journal of Mechanical Strength, columnName=Vibration·Noise·Monitoring·Diagnosis, runingTitle=null, highlight=null, articleAbstract=

Gear’s Circular plot is a result presentation method which needs to be combine with time synchronous averaging (TSA), which can clearly display gear meshing vibration waveform extracted by TSA. Aiming at the problem of parameter setting of gear’s Circular plot and lack of the quantitative index, Fi index for waveform edge recognition and Yi index based on Hu-moments were proposed. Firstly, TSA algorithm was used to extract the gear meshing vibration signal, and the upper and lower edges of the vibration signal waveform were determined by calculating the minimum Fi index. Secondly,Circular plot of gears were drawn by the upper and lower edge parameters. Then, the Circular plot of the gear was divided into four parts, and Yi index of the Circular plot was obtained by calculating Hu-moments of the picture after segmentation. Finally,based on the Yi and Fi indices extracted from the gear Circular plot, a K-nearest neighbors (KNN) classifier was utilized to classify the gear vibration signals. The results show that there is a significant difference between the Yi and Fi indices of the vibration signals of normal gears and those of abnormal gears. By combining with the KNN classifier,it is possible to distinguish between normal and abnormal gear signals,which proves the effectiveness of this method.

, correspAuthors=null, authorNote=null, correspAuthorsNote=
ZHANG Kun, E-mail:
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齿轮Circular图是用于与时域同步平均(Time Synchronous Averaging, TSA)相结合的一种结果呈现方法,可以将TSA提取到的齿轮啮合振动波形直观、清晰地展现出来。针对齿轮Circular图绘制参数设置和其缺少量化指标的问题,提出了用于波形边缘识别的Fi指标和基于Hu氏不变矩的Yi指标。首先,使用TSA算法提取出齿轮啮合振动信号,通过计算最小Fi指标确定振动信号波形的上、下边缘;其次,利用上、下边缘参数绘制齿轮Circular图;再次,将齿轮Circular图分割为4个部分,通过计算分割后图片的Hu氏不变矩得到齿轮Circular图的Yi指标;最后,基于从齿轮Circular图中提取出的YiFi指标,使用K最近邻(K-Nearest Neighbor, KNN)分类器对齿轮振动信号进行分类。仿真信号及齿轮断齿、裂纹故障信号的处理结果表明了该方法的有效性。

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张坤(通信作者),男,1991年生,河北张家口人,博士,讲师;主要研究方向为机械故障诊断、现代信号处理方法等;E-mail:
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胥永刚,男,1975年生,河北沧州人,博士,教授;主要研究方向为机械故障诊断、现代信号处理方法等;E-mail:

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胥永刚,男,1975年生,河北沧州人,博士,教授;主要研究方向为机械故障诊断、现代信号处理方法等;E-mail:

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胥永刚,男,1975年生,河北沧州人,博士,教授;主要研究方向为机械故障诊断、现代信号处理方法等;E-mail:

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Application Research of Computers201027(8):2895-2898.(In Chinese), articleTitle=Research of bullet engraving automated comparison optimization method based on second moment invariants, refAbstract=null)], funds=[Fund(id=1241049295399482077, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241049265900941456, awardId=52405083, language=EN, fundingSource=Young Scientists Fund of the National Natural Science Foundation of China(52405083), fundOrder=null, country=null), Fund(id=1241049295550477024, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241049265900941456, awardId=52405083, language=CN, fundingSource=国家自然科学基金青年基金项目(52405083), fundOrder=null, country=null)], companyList=[AuthorCompany(id=1241049282032234911, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241049265900941456, xref=1., ext=[AuthorCompanyExt(id=1241049282040623521, tenantId=1146029695717560320, journalId=1227999626482147330, 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ArticleFig(id=1241049287921037910, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241049265900941456, language=EN, label=Fig.2, caption=Gear Circular plot, figureFileSmall=GqtmmwwTTcMeqSZEwCZ+2g==, figureFileBig=mAGYyTdANjDdLjxS/sObeA==, tableContent=null), ArticleFig(id=1241049288059449949, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241049265900941456, language=CN, label=图2, caption=齿轮Circular图, figureFileSmall=GqtmmwwTTcMeqSZEwCZ+2g==, figureFileBig=mAGYyTdANjDdLjxS/sObeA==, tableContent=null), ArticleFig(id=1241049288206250593, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241049265900941456, language=EN, label=Fig.3, caption=Profile recognition base on Fi index, figureFileSmall=4ESJGlAcrzzkNUDrIpYRsA==, figureFileBig=wnWNxm92rnlqWgeql5ioXg==, tableContent=null), ArticleFig(id=1241049289997218410, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241049265900941456, language=CN, label=图3, caption=Fi指标轮廓识别, figureFileSmall=4ESJGlAcrzzkNUDrIpYRsA==, figureFileBig=wnWNxm92rnlqWgeql5ioXg==, tableContent=null), ArticleFig(id=1241049290680889968, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241049265900941456, language=EN, label=Fig.4, caption=Segmentation diagram of Circular plots of gears, figureFileSmall=cDhmea/yj0/Xy2Ksuhm5pw==, figureFileBig=1dtzpQSXXpvrl/eKUpe8QQ==, tableContent=null), ArticleFig(id=1241049290836079222, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241049265900941456, language=CN, label=图4, caption=齿轮Circular图分割示意图, figureFileSmall=cDhmea/yj0/Xy2Ksuhm5pw==, figureFileBig=1dtzpQSXXpvrl/eKUpe8QQ==, tableContent=null), ArticleFig(id=1241049290940936827, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241049265900941456, language=EN, label=Fig.5, caption=Classification boundary of the training set, figureFileSmall=I0RARWCadxCsOqigEwxwuw==, 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figureFileSmall=mWNXcvuViTs9fZCPlJccdw==, figureFileBig=sD6HYRqudhGFg0YS+6/yBA==, tableContent=null), ArticleFig(id=1241049292375388850, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241049265900941456, language=EN, label=Tab.1, caption=

Fi index of normal and faulty gears

, figureFileSmall=null, figureFileBig=null, tableContent=
齿轮类型 Type of gearsFi
正常齿轮1 Normal gear 11.044 0
正常齿轮2 Normal gear 21.516 4
断齿齿轮1 Broken tooth gear 119.100 3
断齿齿轮2 Broken tooth gear 2225.936 2
), ArticleFig(id=1241049292639630006, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241049265900941456, language=CN, label=表1, caption=

正常齿轮与故障齿轮的Fi指标

, figureFileSmall=null, figureFileBig=null, tableContent=
齿轮类型 Type of gearsFi
正常齿轮1 Normal gear 11.044 0
正常齿轮2 Normal gear 21.516 4
断齿齿轮1 Broken tooth gear 119.100 3
断齿齿轮2 Broken tooth gear 2225.936 2
), ArticleFig(id=1241049294384460473, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241049265900941456, language=EN, label=Tab.2, caption=

Hu-moments of rotation,translation and shrink of Circular plots

, figureFileSmall=null, figureFileBig=null, tableContent=
类型Typeφ1φ2
参照Standard0.012 26.992 9×10-6
旋转Rotate0.012 26.904 6×10-6
平移Translation0.012 26.993 4×10-6
缩小Shrink0.012 36.882 6×10-6
), ArticleFig(id=1241049294535455425, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241049265900941456, language=CN, label=表2, caption=

Circular图旋转、平移和缩小的Hu氏不变矩

, figureFileSmall=null, figureFileBig=null, tableContent=
类型Typeφ1φ2
参照Standard0.012 26.992 9×10-6
旋转Rotate0.012 26.904 6×10-6
平移Translation0.012 26.993 4×10-6
缩小Shrink0.012 36.882 6×10-6
), ArticleFig(id=1241049294619341508, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241049265900941456, language=EN, label=Tab.3, caption=

Hu-moments of normal and faulty gear’s Circular plot after segmentation

, figureFileSmall=null, figureFileBig=null, tableContent=
Circular图类型
Type of Circular plots
位置
Position
φ1φ2
正常齿轮
Normal gear
左上角
Upper left
0.014 81.585 2×10-4
右上角
Upper right
0.014 41.506 6×10-4
左下角
Lower left
0.013 41.270 5×10-4
右下角
Lower right
0.014 81.575 2×10-4
故障齿轮
Faulty gear
左上角
Upper left
0.014 51.345 3×10-4
右上角
Upper right
0.012 69.981 1×10-5
左下角
Lower left
0.014 01.302 0×10-4
右下角
Lower right
0.005 91.956 7×10-7
), ArticleFig(id=1241049294778725062, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241049265900941456, language=CN, label=表3, caption=

正常齿轮、故障齿轮Circular图分割后的Hu氏不变矩

, figureFileSmall=null, figureFileBig=null, tableContent=
Circular图类型
Type of Circular plots
位置
Position
φ1φ2
正常齿轮
Normal gear
左上角
Upper left
0.014 81.585 2×10-4
右上角
Upper right
0.014 41.506 6×10-4
左下角
Lower left
0.013 41.270 5×10-4
右下角
Lower right
0.014 81.575 2×10-4
故障齿轮
Faulty gear
左上角
Upper left
0.014 51.345 3×10-4
右上角
Upper right
0.012 69.981 1×10-5
左下角
Lower left
0.014 01.302 0×10-4
右下角
Lower right
0.005 91.956 7×10-7
), ArticleFig(id=1241049295156212434, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241049265900941456, language=EN, label=Tab.4, caption=

Yi index of normal and faulty gears with broken tooth

, figureFileSmall=null, figureFileBig=null, tableContent=
齿轮类型 Type of gearsYi
正常齿轮1 Normal gear 11.125 8
正常齿轮2 Normal gear 21.163 5
断齿齿轮1 Broken tooth gear 15.322 9
断齿齿轮2 Broken tooth gear 2208.018
), ArticleFig(id=1241049295252681432, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241049265900941456, language=CN, label=表4, caption=

正常齿轮与故障齿轮的Yi指标

, figureFileSmall=null, figureFileBig=null, tableContent=
齿轮类型 Type of gearsYi
正常齿轮1 Normal gear 11.125 8
正常齿轮2 Normal gear 21.163 5
断齿齿轮1 Broken tooth gear 15.322 9
断齿齿轮2 Broken tooth gear 2208.018
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基于时域同步平均的Circular图分析方法及齿轮故障智能诊断研究
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胥永刚 1 , 张翼飞 1 , 孙国栋 2 , 张坤 1
机械强度 | 振动·噪声·监测·诊断 2025,47(6): 11-16
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机械强度 | 振动·噪声·监测·诊断 2025, 47(6): 11-16
基于时域同步平均的Circular图分析方法及齿轮故障智能诊断研究
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胥永刚1 , 张翼飞1, 孙国栋2, 张坤1
作者信息
  • 1.北京工业大学 先进制造技术北京市重点实验室,北京 100124
  • 2.山东省科学技术情报研究院,济南 250101
  • 胥永刚,男,1975年生,河北沧州人,博士,教授;主要研究方向为机械故障诊断、现代信号处理方法等;E-mail:

通讯作者:

张坤(通信作者),男,1991年生,河北张家口人,博士,讲师;主要研究方向为机械故障诊断、现代信号处理方法等;E-mail:
Research on Circular plot analysis method and gear fault intelligent diagnosis based on time synchronous averaging
Yonggang XU1 , Yifei ZHANG1, Guodong SUN2, Kun ZHANG1
Affiliations
  • 1.Beijing Key Laboratory of Advanced Manufacturing Technology, Beijing University of Technology, Beijing 100124, China
  • 2.Shandong Institute of Scientific and Technical Information, Jinan 250101, China
出版时间: 2025-06-15 doi: 10.16579/j.issn.1001.9669.2025.06.002
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齿轮Circular图是用于与时域同步平均(Time Synchronous Averaging, TSA)相结合的一种结果呈现方法,可以将TSA提取到的齿轮啮合振动波形直观、清晰地展现出来。针对齿轮Circular图绘制参数设置和其缺少量化指标的问题,提出了用于波形边缘识别的Fi指标和基于Hu氏不变矩的Yi指标。首先,使用TSA算法提取出齿轮啮合振动信号,通过计算最小Fi指标确定振动信号波形的上、下边缘;其次,利用上、下边缘参数绘制齿轮Circular图;再次,将齿轮Circular图分割为4个部分,通过计算分割后图片的Hu氏不变矩得到齿轮Circular图的Yi指标;最后,基于从齿轮Circular图中提取出的YiFi指标,使用K最近邻(K-Nearest Neighbor, KNN)分类器对齿轮振动信号进行分类。仿真信号及齿轮断齿、裂纹故障信号的处理结果表明了该方法的有效性。

齿轮箱  /  齿轮Circular图  /  特征指标  /  智能故障诊断

Gear’s Circular plot is a result presentation method which needs to be combine with time synchronous averaging (TSA), which can clearly display gear meshing vibration waveform extracted by TSA. Aiming at the problem of parameter setting of gear’s Circular plot and lack of the quantitative index, Fi index for waveform edge recognition and Yi index based on Hu-moments were proposed. Firstly, TSA algorithm was used to extract the gear meshing vibration signal, and the upper and lower edges of the vibration signal waveform were determined by calculating the minimum Fi index. Secondly,Circular plot of gears were drawn by the upper and lower edge parameters. Then, the Circular plot of the gear was divided into four parts, and Yi index of the Circular plot was obtained by calculating Hu-moments of the picture after segmentation. Finally,based on the Yi and Fi indices extracted from the gear Circular plot, a K-nearest neighbors (KNN) classifier was utilized to classify the gear vibration signals. The results show that there is a significant difference between the Yi and Fi indices of the vibration signals of normal gears and those of abnormal gears. By combining with the KNN classifier,it is possible to distinguish between normal and abnormal gear signals,which proves the effectiveness of this method.

Gearbox  /  Gear Circular plot  /  Characteristic index  /  Intelligent fault diagnosis
胥永刚, 张翼飞, 孙国栋, 张坤. 基于时域同步平均的Circular图分析方法及齿轮故障智能诊断研究. 机械强度, 2025 , 47 (6) : 11 -16 . DOI: 10.16579/j.issn.1001.9669.2025.06.002
Yonggang XU, Yifei ZHANG, Guodong SUN, Kun ZHANG. Research on Circular plot analysis method and gear fault intelligent diagnosis based on time synchronous averaging[J]. Journal of Mechanical Strength, 2025 , 47 (6) : 11 -16 . DOI: 10.16579/j.issn.1001.9669.2025.06.002
旋转机械使用各种类型的旋转部件,如电动机、轴、轴承和齿轮等,均是复杂多自由度系统的典型例子[1]。旋转机械中的旋转部件可以视为多个振动源,其物理振动可能相互耦合[2]。在振动信号采集中,振动传感器通常安装在机械的外露表面,因此所收集的振动信号往往是多个振动源混合的结果。受其他机械部件的干扰,故障部件引起的瞬态振动信号隐藏在测量信号中,不容易在原始振动信号的波形中被识别[3],如何从多振动源耦合信号中提取故障元件的振动信号是故障诊断领域面临的一个关键问题[4]。齿轮箱在许多工业应用中的机械动力传输系统中发挥着重要作用[5]。据统计,80%的传动机械故障是由齿轮故障引起的,齿轮故障约占旋转机械故障的10%。因此,齿轮箱的故障检测和诊断是工业维护的重要任务之一[6]
齿轮Circular图方法是一种在工业领域常用的齿轮振动信号展示技术,该方法可将齿轮振动信号绘制在极坐标域,使得信号波形呈现出类似于齿轮外观的特征;时域同步平均(Time Synchronous Averaging,TSA)算法能够有效地提取出目标齿轮旋转一周的啮合振动信号。因此,学者们常将齿轮Circular图方法与TSA算法相结合使用。理想情况下,正常齿轮的振动信号波形与正弦波形相近,振动波形的波峰数对应齿轮齿数。当齿轮发生故障时,振动波形相应部分的幅值将会增大。因此,绘制出与齿轮齿形相似的齿轮Circular图,有利于对齿轮故障进行可视化分析。
特征提取是智能故障诊断(Intelligent Fault Diag-nosis, IFD)的重要步骤,而IFD是基于机器学习理论,如人工神经网络(Artificial Neural Netwok, ANN)、支持向量机(Support Vector Machine, SVM)和深度神经网络(Deep Neural Network, DNN)在机器故障诊断中的应用[7],完整的IFD流程包括:①数据采集;②特征提取;③健康状态识别。特征提取有助于消除冗余信息,进一步改善诊断结果,因此特征提取是必要的[8]。在故障特征提取的研究中,胥永刚等[9]将近似熵应用在故障诊断领域,利用小波包分解技术将信号分解到不同尺度的频带内,再对各频带内的近似熵进行对比分析,验证了近似熵可以有效监测故障的发生和发展的假设。相较于选择机器学习分类器,选择合适的特征指标更有助于提高智能故障诊断的识别率。CUI等[10]计算信号特征指标,使用邻域成分分析(Neighborhood Compo-nent Analysis, NCA)从特征指标中筛选出合适的指标,用K最近邻(K-Nearest Neighbor, KNN)分类器对信号进行分类,提高了风力发电机轴承健康状态分类准确率,但并未继续深入研究信号特征指标的提取问题。根据监测对象计算出更具区分度的特征指标有利于将故障特征量化,提高智能故障诊断的成功率。
本文提出了用于波形边缘识别的Fi指标和基于Hu氏不变矩的Yi指标。首先,使用TSA算法提取出齿轮旋转一周的振动信号,根据齿轮齿数对齿轮旋转一周的振动信号进行分割,计算被分割信号的最小Fi值,选择出TSA信号波形的最佳上、下轮廓;然后,将TSA信号绘制为齿轮Circular图,将齿轮Circular图均匀分割为4个部分,计算各个部分的Hu氏不变矩,根据各个部分Hu氏不变矩的差异构建Yi指标;最后,将提取的特征指标输入KNN分类器,对齿轮振动信号进行分类。研究结果表明,所提指标在正常齿轮和故障齿轮之间区分度高,可以应用于齿轮故障的智能诊断。
TSA是一种可以消除与信号分段周期无关的信号分量,并提取与信号分段周期相关的周期信号的算法。设齿轮运行所产生的振动信号x(n)由周期性的齿轮啮合振动信号和其他干扰产生的噪声组成。周期信号x(n)的周期为T,数据点总数为N,每个周期的数据点数为NTx(n)由齿轮啮合振动信号s(n)和白噪声ξ(n)组成,即
式中,n=1,2,…,N。将x(n)以周期T分为P段,每段信号的数据点数为NTNNT关系可表示为式(3),第p(p=1,2,…,P)段信号可表示为式(4)。
式中,nT=1,2,…,NT。将P段信号相加,鉴于白噪声的不相干特性,可以得到
设TSA计算后的信号为
由式(7)可知,经过TSA降噪后,信号x'(nT)中的白噪声是原来信号x(n)中白噪声的,信噪比(Signal-to-Noise Ratio, SNR)则提高了倍,且分段数P越多SNR越高,如图1所示。
TSA应用于齿轮箱振动信号的优点在于其能够将齿轮啮合振动的波形提取出来,并且改变分段信号的点数NT可以获得齿轮箱中不同齿轮啮合振动的波形。此外,除了分段数据点数外,TSA不需要设置其他参数。齿轮箱振动信号经过TSA处理后得到目标齿轮旋转一周的啮合振动信号,将该信号加上一个大小合适的常数,然后在极坐标域绘制出来,即可得到齿轮Circular图。图2所示为由某型号风力涡轮机齿轮振动信号绘制出的齿轮Circular图。
TSA的齿轮Circular图中的波峰数量与齿轮齿数相对应,且其形状与齿轮相似,能够直观地区分出齿轮故障信号,定位故障位置。这有助于在未来搭建的在线监测系统中实时观察齿轮振动信号的变化。
将使用TSA算法提取到的齿轮旋转一周的振动信号均分为k份,k=z-1。其中,z为齿轮的齿数。该分割方法的目的是保证每一个区间内都有齿轮振动信号的波峰和波谷落入。计算出每一个区间内振动信号的最大值与最小值,将每一个区间振动信号的最大值构建为一个最大值序列,将振动信号的最小值构建为一个最小值序列。再分别计算最大值序列的峰峰值和最小值序列的峰峰值,令r为两个峰峰值中较小峰峰值的一半。再计算每一个区间以该区间的最大值为上轮廓、最小值为下轮廓时,其他区间的最大值和最小值落入±r轮廓范围内的数量k'。当其他区间最大值和最小值落入轮廓±r范围内的数量最大时,将该轮廓确定为最佳轮廓。计算出最佳轮廓之后,将齿轮旋转一周的振动信号加上其最小值的绝对值与下轮廓的绝对值之和,将其绘制在极坐标域,得到图2(a)所示的齿轮Circular图。图3中横实线为在齿轮旋转一周振动信号中识别出的上轮廓和下轮廓,横虚线为轮廓±r范围的边界。各个区间振动信号波形最大值和最小值落入轮廓±r范围的个数为k',k'的最大值为2k。由正常齿轮的振动信号计算的k'接近于2k;而由断齿齿轮的振动信号计算的k'会明显小于2k。根据此特性可以构建出一个无量纲指标Fi,即
由式(8)可知,k'越小,Fi指标的值越大。构建Fi指标的意义在于Fi指标的大小不会受到齿轮齿数z的影响;当k'接近2k时,Fi指标会趋近于1。这样构建出的指标可以更容易地被机器学习分类方法区分。取从3 MW风力涡轮机测得的两段正常齿轮信号和两段故障齿轮信号,使用TSA算法提取出齿轮旋转一周的振动信号,将由信号计算出的Fi值列入表1中。由表1可知,正常齿轮的Fi值更加接近于1,故障齿轮的Fi值远远大于1,这一结果与预期结果相符。
Hu氏不变矩是一种提取灰度图像特征的方法,由HU于1962年首先提出。文献[11]中给出了连续函数矩的定义和矩的基本性质。WONG等[12]进一步给出了离散情况下各阶矩的计算方法,不变矩算法是一种通过提取具有平移、旋转和比例因子不变性的数学特征来解决集合失真问题的方法[13]
设有一个二元函数f(vw),对于任意的正整数ijf(vw)在平面上的(i+j)阶矩为
对于二值图像,在平面上的(i+j)阶矩为
式中,f(vw)为图像在坐标点(vw)上的灰度。
mij依赖于图像在坐标中的位置,不具备平移不变性,(i+j)阶中心矩μij满足平移不变性,其定义为
式中,分别为图像质心的横坐标和纵坐标。
μij进行正则化处理,得到ηij的计算式为
式中,ηij满足平移和伸缩不变性,但不满足旋转不变性。HU通过研究分析得到了7个完备的2阶和3阶不变矩φ1~φ7,它们在连续图像条件下可保持平移、缩放和旋转不变,具体定义为
实际上,在对图片的识别过程中,只有φ1φ2的不变性保持得比较好,其他的几个不变矩带来的误差比较大。有学者认为只有基于2阶矩的不变矩对二维物体的描述才真正具有旋转、缩放和平移不变性[14]φ1φ2刚好都是由2阶矩组成)。表2给出了对图2(b)进行旋转、平移和缩小后的φ1φ2表2中的结果验证了该观点。
φ1为表示图像发散程度的度量指标,图像的发散程度越大,则φ1越大。φ2为表示图像对称性的度量指标,图像的对称性越好,则φ2越小。如图4所示,根据Circular图的特点,可以将Circular图均分为4份,然后分别计算相应的Hu氏不变矩。表3为将图2中正常齿轮和故障齿轮Circular图分割后计算得到的Hu氏不变矩。
表3可知,故障齿轮Circular图分割后的Hu氏不变矩之间有着较大的差异,而正常齿轮Circular图分割后的Hu氏不变矩之间的差异较小。因此,可以通过这种差异构建式(14)中的指标β,为
4种齿轮Circular图的β指标各有不同,但是由故障齿轮经分割后的Circular图得到的4个β指标的差异明显大于由正常齿轮Circular图分割后得到的β指标的差异。令每个齿轮Circular图分割后的β指标为β=[β1β2β3β4],其中,β1β2β3β4分别为齿轮Circular图的左上角、右上角、左下角、右下角对应的β指标。在此基础之上,构建一个Yi指标,为
式中,max(β)为指标β的最大值;min(β)为指标β的最小值。表4中列出了由3 MW风力涡轮机测得的正常齿轮与故障齿轮振动信号的齿轮Circular图的Yi指标。由表4可知,正常齿轮的Yi值更加接近于1,故障齿轮的Yi值远大于1。这一结果与预期结果相符。
KNN分类器是使用训练数据集的k个最近邻找出未知对象所属类别的算法。当要找出某个未知数据点所属的类别时,需要先找出k'个最近邻,然后进行多数表决。KNN算法可以用于分类和回归问题,因此可以用于齿轮Circular图的分类。KNN算法的流程如下:
1)计算已知类别数据集中的点与当前点之间的距离。
2)按距离递增的次序排序。
3)选取与当前点距离最小的k'个点。
4)统计前k'个点所在的类别出现的频率。
5)返回前k'个点出现频率最高的类别作为当前点的预测分类。
根据正常齿轮和故障齿轮的振动特性,构建一个包含2 000组数据的训练集,其中正常齿轮数据与故障齿轮数据各1 000组。将数据集作为KNN分类器的训练集,设置最近邻个数k为5,训练后得到图5所示的分类边界。其中,方框表示正常齿轮,三角形表示故障齿轮。
本文数据来自声学和振动数据库和PHM09挑战数据集。声学和振动数据库中齿轮箱振动数据为在3 MW风力涡轮机小齿轮上进行的径向振动测量所得。对于故障案例,初始振动读数显示高振动水平,机器在一周后停止,发现小齿轮故障,如图6所示。其他来自相同型号的不同风力涡轮机的小齿轮没有已知故障。齿轮在振动测量时的转速为1 800 r/min,设置径向加速度测试通道和转速测试通道2个通道,采样频率为97 656 Hz,采集长度为6 s。PHM09挑战数据集代表通用工业齿轮箱的数据,齿轮箱使用的为斜齿轮,该齿轮箱共有输入轴、中间轴、输出轴3个传动轴。输入轴齿轮为16齿斜齿轮,中间轴上有1个48齿斜齿轮和1个24齿斜齿轮,输出轴齿轮为40齿斜齿轮。图7为齿轮箱内部细节图,使用数据集中的齿轮裂纹故障数据验证本文所提方法。
该数据集共有24组数据,其中包含15组正常齿轮数据、1组裂纹齿轮数据和8组断齿齿轮数据。使用TSA算法提取其啮合振动信号,将其绘制为齿轮Circular图,提取Fi指标和Yi指标。使用第3节中训练的KNN分类器对数据进行分类,结果如图8所示。其中,白色数据标记为来自风机齿轮箱的振动信号,黑色数据标记为来自PHM09的齿轮箱振动信号。由图8可知,正常齿轮数据和故障齿轮数据可以被训练出的KNN分类器正确分类。由此可知,Fi指标和Yi指标适用于齿轮Circular图的特征提取。
1)提出了FiYi指标,用于齿轮Circular图的绘制和从中提取出可以区分正常齿轮与故障齿轮的特征值。
2)通过两组仿真信号和两组工业信号验证了FiYi指标在KNN分类器中的分类效果,结果表明:使用KNN分类器可以将正常齿轮与故障齿轮的FiYi指标区分开。
3)将基于齿轮Circular图的FiYi指标与KNN分类器应用于齿轮箱的故障诊断,可以有效地提取故障信息。
综上所述,所提方法可以实现齿轮异常检测,为齿轮故障特征量化提取方法的研究提供参考。
  • 国家自然科学基金青年基金项目(52405083)
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2025年第47卷第6期
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doi: 10.16579/j.issn.1001.9669.2025.06.002
  • 接收时间:2023-09-22
  • 首发时间:2026-03-18
  • 出版时间:2025-06-15
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  • 收稿日期:2023-09-22
  • 修回日期:2023-12-06
基金
Young Scientists Fund of the National Natural Science Foundation of China(52405083)
国家自然科学基金青年基金项目(52405083)
作者信息
    1.北京工业大学 先进制造技术北京市重点实验室,北京 100124
    2.山东省科学技术情报研究院,济南 250101

通讯作者:

张坤(通信作者),男,1991年生,河北张家口人,博士,讲师;主要研究方向为机械故障诊断、现代信号处理方法等;E-mail:
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