Article(id=1149780468469560151, tenantId=1146029695717560320, journalId=1146123166801305609, issueId=1149780466032669506, articleNumber=null, orderNo=null, doi=10.12404/j.issn.1671-1815.2403297, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1714924800000, receivedDateStr=2024-05-06, revisedDate=1735833600000, revisedDateStr=2025-01-03, acceptedDate=null, acceptedDateStr=null, onlineDate=1752058625571, onlineDateStr=2025-07-09, pubDate=1744041600000, pubDateStr=2025-04-08, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1752058625571, onlineIssueDateStr=2025-07-09, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1752058625571, creator=13701087609, updateTime=1752058625571, updator=13701087609, issue=Issue{id=1149780466032669506, tenantId=1146029695717560320, journalId=1146123166801305609, year='2025', volume='25', issue='10', pageStart='3969', pageEnd='4395', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=0, createTime=1752058624990, creator=13701087609, updateTime=1768456644259, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1218558743898411553, tenantId=1146029695717560320, journalId=1146123166801305609, issueId=1149780466032669506, language=EN, specialIssueTitle=, coverIllustrator=, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1218558743898411554, tenantId=1146029695717560320, journalId=1146123166801305609, issueId=1149780466032669506, language=CN, specialIssueTitle=, coverIllustrator=, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=4118, endPage=4128, ext={EN=ArticleExt(id=1149780468763161433, articleId=1149780468469560151, tenantId=1146029695717560320, journalId=1146123166801305609, language=EN, title=Analysis of Fault Acoustic Signal Characteristics of Full Ceramic Angular Contact Ball Bearings, columnId=1156262732765717457, journalTitle=Science Technology and Engineering, columnName=Papers·Mechanical and Instrumental Industry, runingTitle=null, highlight=null, articleAbstract=

To solve the problem of bearing fault and complex sound field environment, taking H7009C full ceramic angular contact ball bearing as the research object, the dynamic analysis model of full ceramic angular contact ball bearing was established, and the error of theoretical calculation and simulation of rolling body was compared to verify the validity of the model. Based on the transient dynamic analysis of the influence of inner ring fault on the bearing dynamic characteristics, the surface SPL (sound pressure level) of bearings caused by different faults was calculated, and the SPL characteristics of high-speed bearings were compared under the action of variable speed and variable load. The results show that the sound pressure level of the faulty inner ring bearing increases with the increase of speed, and increases first and then decreases with the increase of load. When the ratio of the lowest sound pressure level frequency to the vibration frequency is close to 0.75 or the ratio of the highest sound pressure level frequency to the vibration frequency is close to 4, it can be identified as an inner ring fault.

, correspAuthors=Xue YANG, authorNote=null, correspAuthorsNote=null, copyrightStatement=null, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=null, magXml=null, pdfUrl=null, pdf=null, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=null, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=null, mapNumber=null, authorCompany=null, fund=null, authors=null, authorsList=Hai-peng YAN, Meng-lin LIU, Xue YANG, Zhi-ying QIN, Sai LANG), CN=ArticleExt(id=1149780521519116814, articleId=1149780468469560151, tenantId=1146029695717560320, journalId=1146123166801305609, language=CN, title=全陶瓷角接触球轴承故障声信号特性分析, columnId=1156262732954461139, journalTitle=科学技术与工程, columnName=论文·机械、仪表工业, runingTitle=null, highlight=null, articleAbstract=

针对轴承故障及其声场环境较为复杂的问题,以H7009C型全陶瓷角接触球轴承为研究对象,建立了全陶瓷角接触球轴承的动力学分析模型,并对比滚动体理论计算与仿真模拟的误差来验证模型的有效性。基于瞬态动力学分析内圈故障对轴承动态特性的影响,计算轴承由于存在不同故障产生的表面声压级,对比变转速和变载荷作用下高速轴承的声压级特性。研究表明:内圈故障轴承的声压级随着转速的增加而增大,同时也随着载荷的增加呈现出先增大后减小的变化趋势;当最低声压级频率与振动频率之比接近0.75或最高声压级频率与振动频率之比接近4时,即可识别为内圈故障。

, correspAuthors=杨雪, authorNote=null, correspAuthorsNote=
* 杨雪(1978—),女,汉族,河北石家庄人,硕士,讲师。研究方向:智能运维、故障诊断与预测。E-mail:
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闫海鹏(1987—),男,汉族,辽宁葫芦岛人,博士,副教授。研究方向:机械系统状态监测与故障诊断技术。E-mail:

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闫海鹏(1987—),男,汉族,辽宁葫芦岛人,博士,副教授。研究方向:机械系统状态监测与故障诊断技术。E-mail:

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闫海鹏(1987—),男,汉族,辽宁葫芦岛人,博士,副教授。研究方向:机械系统状态监测与故障诊断技术。E-mail:

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figureFileBig=FRvZcpNPdhDx77rTB5pLhQ==, tableContent=null), ArticleFig(id=1218525112941331353, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1149780468469560151, language=CN, label=图18, caption=变转速下的声压级云图, figureFileSmall=RFAzLOYODjqUIUGPM1zcLQ==, figureFileBig=FRvZcpNPdhDx77rTB5pLhQ==, tableContent=null), ArticleFig(id=1218525113067160479, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1149780468469560151, language=EN, label=Fig.19, caption=Frequency domain diagram of sound pressure level at variable speed, figureFileSmall=lBq5MAc7Nq9fL+1cm2ghiw==, figureFileBig=+HF/gcU6P2wV6PaO3SDELA==, tableContent=null), ArticleFig(id=1218525113205572521, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1149780468469560151, language=CN, label=图19, caption=变转速下的声压级频域图, figureFileSmall=lBq5MAc7Nq9fL+1cm2ghiw==, figureFileBig=+HF/gcU6P2wV6PaO3SDELA==, tableContent=null), ArticleFig(id=1218525113339790258, 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Structural parameters

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参数 数值
外径/mm 75
内径/mm 45
轴承宽度/mm 16
滚动体直径/mm 8.731
滚动体数目 17
初始触角/(°) 15
保持架外径/mm 63.5
保持架宽度/mm 14
兜孔直径/mm 8.9
), ArticleFig(id=1218525113692111818, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1149780468469560151, language=CN, label=表1, caption=

结构参数

, figureFileSmall=null, figureFileBig=null, tableContent=
参数 数值
外径/mm 75
内径/mm 45
轴承宽度/mm 16
滚动体直径/mm 8.731
滚动体数目 17
初始触角/(°) 15
保持架外径/mm 63.5
保持架宽度/mm 14
兜孔直径/mm 8.9
), ArticleFig(id=1218525113889244112, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1149780468469560151, language=EN, label=Table 2, caption=

Material main performance parameters

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元件名称 弹性模量/Pa 密度/(kg·m-3) 材料
滚动体 3.20×1011 3 200 Si3N4
内圈 2.19×1011 6 000 ZrO2
外圈 2.19×1011 6 000 ZrO2
保持架 3.80×109 1 370 PEEK
), ArticleFig(id=1218525113981518807, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1149780468469560151, language=CN, label=表2, caption=

材料主要性能参数

, figureFileSmall=null, figureFileBig=null, tableContent=
元件名称 弹性模量/Pa 密度/(kg·m-3) 材料
滚动体 3.20×1011 3 200 Si3N4
内圈 2.19×1011 6 000 ZrO2
外圈 2.19×1011 6 000 ZrO2
保持架 3.80×109 1 370 PEEK
), ArticleFig(id=1218525114094765019, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1149780468469560151, language=EN, label=Table 3, caption=

Comparison of revolution speed

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周期/s 实际转速/
(r·min-1)
理论转速/
(r·min-1)
差值百分
比/%
0.034 1 764.7 1 933.7 8.74
), ArticleFig(id=1218525114224788452, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1149780468469560151, language=CN, label=表3, caption=

公转转速对比情况

, figureFileSmall=null, figureFileBig=null, tableContent=
周期/s 实际转速/
(r·min-1)
理论转速/
(r·min-1)
差值百分
比/%
0.034 1 764.7 1 933.7 8.74
), ArticleFig(id=1218525114317063149, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1149780468469560151, language=EN, label=Table 4, caption=

Comparison of rotational speed

, figureFileSmall=null, figureFileBig=null, tableContent=
周期/s 实际转速/
(r·min-1)
理论转速/
(r·min-1)
差值百分
比/%
0.003 93 15 267.2 15 156.3 0.73
), ArticleFig(id=1218525114468058098, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1149780468469560151, language=CN, label=表4, caption=

自转转速对比情况

, figureFileSmall=null, figureFileBig=null, tableContent=
周期/s 实际转速/
(r·min-1)
理论转速/
(r·min-1)
差值百分
比/%
0.003 93 15 267.2 15 156.3 0.73
), ArticleFig(id=1218525114589692923, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1149780468469560151, language=EN, label=Table 5, caption=

Relationship of vibration frequency and acoustic frequency

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故障元件 振动频
率/Hz
最低声压级
频率/Hz
最高声压级
频率/Hz
内圈 fi 0.75fi 4fi
), ArticleFig(id=1218525114673579009, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1149780468469560151, language=CN, label=表5, caption=

振动频率与声学频率的关系

, figureFileSmall=null, figureFileBig=null, tableContent=
故障元件 振动频
率/Hz
最低声压级
频率/Hz
最高声压级
频率/Hz
内圈 fi 0.75fi 4fi
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全陶瓷角接触球轴承故障声信号特性分析
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闫海鹏 , 刘孟林 , 杨雪 * , 秦志英 , 郎赛
科学技术与工程 | 论文·机械、仪表工业 2025,25(10): 4118-4128
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科学技术与工程 | 论文·机械、仪表工业 2025, 25(10): 4118-4128
全陶瓷角接触球轴承故障声信号特性分析
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闫海鹏 , 刘孟林, 杨雪* , 秦志英, 郎赛
作者信息
  • 河北科技大学机械工程学院, 石家庄 050018
  • 闫海鹏(1987—),男,汉族,辽宁葫芦岛人,博士,副教授。研究方向:机械系统状态监测与故障诊断技术。E-mail:

通讯作者:

* 杨雪(1978—),女,汉族,河北石家庄人,硕士,讲师。研究方向:智能运维、故障诊断与预测。E-mail:
Analysis of Fault Acoustic Signal Characteristics of Full Ceramic Angular Contact Ball Bearings
Hai-peng YAN , Meng-lin LIU, Xue YANG* , Zhi-ying QIN, Sai LANG
Affiliations
  • School of Mechanical Engineering, Hebei University of Science and Technology, Shijiazhuang 050018, China
出版时间: 2025-04-08 doi: 10.12404/j.issn.1671-1815.2403297
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针对轴承故障及其声场环境较为复杂的问题,以H7009C型全陶瓷角接触球轴承为研究对象,建立了全陶瓷角接触球轴承的动力学分析模型,并对比滚动体理论计算与仿真模拟的误差来验证模型的有效性。基于瞬态动力学分析内圈故障对轴承动态特性的影响,计算轴承由于存在不同故障产生的表面声压级,对比变转速和变载荷作用下高速轴承的声压级特性。研究表明:内圈故障轴承的声压级随着转速的增加而增大,同时也随着载荷的增加呈现出先增大后减小的变化趋势;当最低声压级频率与振动频率之比接近0.75或最高声压级频率与振动频率之比接近4时,即可识别为内圈故障。

全陶瓷角接触球轴承  /  轴承故障  /  载荷  /  转速  /  声压级

To solve the problem of bearing fault and complex sound field environment, taking H7009C full ceramic angular contact ball bearing as the research object, the dynamic analysis model of full ceramic angular contact ball bearing was established, and the error of theoretical calculation and simulation of rolling body was compared to verify the validity of the model. Based on the transient dynamic analysis of the influence of inner ring fault on the bearing dynamic characteristics, the surface SPL (sound pressure level) of bearings caused by different faults was calculated, and the SPL characteristics of high-speed bearings were compared under the action of variable speed and variable load. The results show that the sound pressure level of the faulty inner ring bearing increases with the increase of speed, and increases first and then decreases with the increase of load. When the ratio of the lowest sound pressure level frequency to the vibration frequency is close to 0.75 or the ratio of the highest sound pressure level frequency to the vibration frequency is close to 4, it can be identified as an inner ring fault.

Full ceramic angular contact ball bearings  /  bearing failure  /  load  /  speed  /  sound pressure level
闫海鹏, 刘孟林, 杨雪, 秦志英, 郎赛. 全陶瓷角接触球轴承故障声信号特性分析. 科学技术与工程, 2025 , 25 (10) : 4118 -4128 . DOI: 10.12404/j.issn.1671-1815.2403297
Hai-peng YAN, Meng-lin LIU, Xue YANG, Zhi-ying QIN, Sai LANG. Analysis of Fault Acoustic Signal Characteristics of Full Ceramic Angular Contact Ball Bearings[J]. Science Technology and Engineering, 2025 , 25 (10) : 4118 -4128 . DOI: 10.12404/j.issn.1671-1815.2403297
轴承凭借高速、承压能力强等优势,大规模应用旋转机械领域。据统计,旋转机械中,约30%的机械故障与轴承损坏有关[1]。因此对轴承进行故障诊断意义重大。
机械系统在运行过程中难免会因为各组合部件的振动而产生噪声,进行声学信号处理,为轴承的故障分析提供了参考[2]。声学信号检测故障可以通过非接触式方法来实现,泛化性优于基于模型和数据驱动的故障诊断方法[3-4]。相关学者对轴承声学故障诊断有深入研究:滕繁荣等[5]开发出参数驱动学习的声学故障诊断方式。闫海鹏等[6]分析了全陶瓷球轴承在重载、冲击载荷、干摩擦状态以及低温环境下的声压级。Wu等[7]采用三维等波束宽度波束形成阵列提轴承的声压级,既保证监测数据的有效性,又提高故障诊断的可靠性。王树杰等[8]提出了基于自适应的最大相关峭度反卷积的故障诊断方法,实现了基于声信号的轴承故障诊断。王冉等[9]提出了一种具有非接触测量优势的基于声成像与卷积神经网络的故障诊断方法,并用轴承试验台的声阵列数据验证了该方法的有效性与可靠性。张楠等[10]开展了基于2D-MUSIC算法L型声阵列的轴承故障定位理论仿真研究,实现了对阵列参数的优化,提高了故障定位分辨率。沙云东等[11]提出了一种基于小波包分解、峭度值指标和希尔伯特包络解调相结合的故障特征提取方法,有效实现了特征信息的精准提取,提高了故障诊断准确率。
尽管上述研究均围绕于声学的故障诊断方法以及不同工况下轴承声压级的深入分析,但多数研究主要是侧重于算法层面的故障诊断探索。即使有部分仿真研究,但也并未与轴承故障进行联系。更为关键的是,已有文献中只注重于声信号进行研究,而忽略了振动与声信号间潜在的关系。故本文研究以H7009C型全陶瓷角接触球轴承为研究对象,对轴承进行特性分析以获取其在故障条件下的振动响应参数,利用LMS Virtual.Lab声学分析软件建立轴承的边界元模型,并将振动响应参数输入模型中,对故障轴承在变载荷和变转速工况下的声压级进行仿真分析,为基于振声特性的轴承故障诊断提供参考。
以H7009C型全陶瓷角接触球轴承为研究对象,对其内圈施加深度为0.7 mm形状不规则的故障,如表1图1所示。
基于ANSYS Workbench分析软件,分别导入正常和故障轴承模型,并对其进行相应的材料参数设置,如表2所示。
通过对滚动体的理论计算速度与仿真模拟结果进行比较,判断模型系数设置的合理性及方法的可行性。结合高速滚动球轴承外圈固定、内圈高速旋转的特点,得到滚动体的公转和自转速度,公式为
ω c = ω 2 ( 1 - λ c o s α )
ω r = ω 2 1 λ - λ c o s 2 α
式中:ω为内圈旋转转速;λ=d/D,其中D为轴承节圆直径,d为滚动体直径;ωc为滚动体轨道速度;ωr为滚动体绕自身轴线的转速。
表1参数并按内圈速度4 500 r/min求解出滚动体公转转速为1 933.7 r/min,自转转速为15 156.3 r/min。
基于瞬态动力学分析模块进行动态仿真,当轴承内圈转速达到4 500 r/min时,滚动体的理论转速与仿真转速对比结果分别如表3表4所示。
表3表4可知,滚动体自转与公转时的仿真结果与理论值的误差较小,故建立的动态有限元模型是可靠的,可用于轴承动态特性分析。通过在轴承动态特性分析过程中获得故障条件下的振动速度和位移参数,可以实现轴承声压(级)的计算。
轴承内圈作为主要的旋转元件,其运转状态对整个轴承系统起着至关重要的影响。因此研究内圈故障的动态特性是很有意义的。首先对内圈故障时的应力进行分析,再与正常轴承进行对比,能更加直观地发现特性,如图2所示。
图2可知,正常轴承的最大应力值约为18 MPa,内圈故障轴承的最大应力值小于正常轴承,约为12 MPa。原因可能是运转速度达到最高引起应力突然增加,转速稳定后又瞬间下降导致的。但大部分时间段内的应力值显然是故障轴承高于正常轴承,此现象证明了内圈应力随着故障的产生而逐渐增大。
此外,当轴承发生内圈故障时对轴承其他元件进行应力分析也是很有必要的,如图3所示。
图3可知,滚动体受到的应力最大,外圈次之,保持架最小。最大应力约为20 MPa,最小约为1 MPa,3个轴承元件的应力变化分层较明显,且滚动体元件的应力幅值较于其他两者分布更广,此现象说明滚动体在内圈故障时受到的影响最大。因此,研究内圈故障动态特性时,可从滚动体的位移与速度两个角度展开分析,如图4所示。
对比图4(a)图4(b)可知,在0~0.06 s内,内圈故障与正常轴承的滚动体位移曲线差别并不明显,0.06 s后,即转速达到最大并稳定后,内圈故障轴承的滚动体位移周期在逐渐变大,而正常轴承的滚动体位移周期却变化不大。经计算,内圈故障轴承的滚动体位移周期为0.021 81 s,而正常轴承的只有0.016 82 s,表明当轴承内圈发生损坏时,其滚动体的位移周期会发生明显增大的现象,原因可能是内圈故障位置会对滚动体产生减速效果,使其运行速度变慢。
内圈故障与正常轴承滚动体的Z向速度变化曲线如图5所示。对比图5(a)图5(b)可知,二者最大速度出现的时间几乎一致,均约为0.08 s,但正常轴承的速度幅值大于内圈故障轴承,原因可能是同一时间点,滚动体遇到故障位置而导致速度比正常小很多。正常轴承滚动体速度在运转速度达到最高值时也到达了最高点,但其他阶段速度幅值都较小,说明正常轴承在运转时振动波动存在但不太明显,而内圈故障轴承在0.07~0.11 s,速度波动较为明显,其幅值显然也高于正常轴承,这表明轴承在运转过程中,发生内圈故障产生的振动会更加明显,冲击也会随之增大。
陶瓷材料刚度大,较于全钢轴承来说,对声压级的吸收能力较差,在特殊工况下轴承声压级的变化比较复杂,且不同运行状态下的噪声特性也有很大差异。因此,声学特征能够反映出轴承的运行状态[6]
由于声压级可以定量的描述声音的大小,因此,本文研究采用线性声压级来评价噪声的大小[12],公式为
S P L ( P ) = 20 l g p ( P ) p r e f
式(3)中:SPL(P)为场点P的声压级;p(P)为场点P的声压;pref为参考声压。
通过设置声学边界条件、建立模型场点和模型材料赋予完成声压级的仿真,具体流程如图6所示。
由于声学有限元的计算往往是要求局限于一个封闭的空间,且需要将封闭空间离散成一个个实体的网格,从而实现计算实体网格内部的声场,而声学边界元法则没有这些束缚[13],使用起来更加方便。
声学边界元BEM法是以边界划分为基础来表达单元内法向位移及声压级的节点与单元的,其网格只能用三角形网格划分[14],并要求边界元网格单元要小于或等于计算频率波长的1/6[15],公式为
l c 6 f m a x
式(4)中:c为声速;l为声学边界元网格单元;fmax为计算频率。
设置计算频率为3 000 Hz,根据式(4)计算出网格单元尺寸为18.9 mm,得到边界元模型如图7所示。通过改变网格密度来进行网格无关性验证,进而得到该模型的网格节点数为5 780,单元数为11 294,可用于研究轴承在故障条件下的振动响应,进而检测轴承的健康状态,其步骤如下:首先,在模型的边界上选择场点,其通常对应于结构表面,而在这些场点上需要考虑结构的边界条件,如位移等;其次,引入轴承故障模型,利用边界元法求解在场点上的位移、速度等参数得到轴承在故障条件下的振动响应;最后,通过分析振动响应且与健康轴承对比,进而判断轴承是否发生故障及故障类型。
根据有限元与边界元的相对映射关系,即振声映射关系,将有限元的数据转移到边界元上,进而完成后续声压级的计算。由于两种网格处于交叉并存的状态,其节点与单元可能会发生冲突而导致数据转移失败。因此,在数据转移之前应进行两种网格的节点与单元冲突排查,然后运用函数插值的振声映射方法将有限元的数据顺利转移到边界元上来,两者关系如图8所示。
最终目标节点的数值,公式为
P T a r g e t = i = 1 N P i s o u r c e d i i = 1 N 1 d i
式(5)中:PTarget为最终目标节点数;N为影响的节点数;Pi为源节点数值;di为数据映射的半径。
将数据按步骤进行声振映射转移操作,利用LMS Virtual.Lab中的Data Transfer Soulution Set命令完成转移,转移后的位移如图9所示。
为研究轴承结构的声压级,场点的建立十分重要。轴承通常位于结构的关键支持部位,因此场点的选择需要考虑到轴承的几何布局。本文研究以结构件居中放置的方式,球形场点设置半径为150 mm,距离结构非常近,优点是能精确得到噪声数值,并将Number of Elements on Equator/4数量设置为20,能更准确保证计算的精确性,如图10所示。利用场点在模型中的振动响应通过频域分析可以反映出各零件的故障频率,从而提供对轴承健康状况的监测。
声压级云图作为一种将声场中声压级空间分布可视化的工具[16]。通过分析云图中的空间分布,可以确定声源的位置,进而推断出存在的故障位置。以空气为声波传播介质,利用建立的轴承球形场点网格进行计算,得到正常和内圈故障轴承声压级云图分别如图11图12所示。
图11可知,早期运行阶段,即Occurrence为100时,声压级云图呈现非常规律划分的状态,此时最高声压级为53.1 dB;稳定运行阶段,即Occurrence为230时,声压级云图呈现上下两端逐渐变红且面积增大的现象,此时最高声压级为53.7 dB,证实了正常轴承在运行期间振动变化平稳、噪声小的特性。
图12可知,轻微故障阶段与显著故障阶段的辐射云图形状非常相似,只是显著故障阶段的曲线密集,但总体趋势保持一致。随着仿真时间的增加,下端部的蓝色云图逐渐增多,而上端部的红色云图逐渐向上推移,原因可能是随时间的增加,轴承内圈的损伤加剧,导致引发更大的振动,进而使轴承的声压级逐渐升高。从数值角度来看,随着时间的增加,从Occurrence100到Occurrence296的声压级由57.2 dB增加至65.1 dB,与正常轴承相比,其声压级变化幅度较大。
为了更深层次探讨轴承的声压级特性,又研究了正常轴承与内圈故障轴承在时域与频域中的变化情况。其中,设置转速4 000 r/min、载荷1 000 N,时域计算的最终时间为0.12 s,频域计算的最高频率为3 000 Hz,并分别选取正常轴承Node ID为893 295和内圈故障轴承Node ID为18 893时的场点位置,经处理得到正常和内圈故障轴承时域与频域上的变化情况如图13图14所示。
图13(a)可知,声压级随时间的增大而上升,当时间为0.01 s时声压级约为100 dB,在0.04 s时声压级基本达到最高值,后续呈现上下波动的状态。原因可能是仿真过程中声源持续发声,导致声压随时间增长而不断累积增加,进而造成声压级上升。由图13(b)可知,声压级随频率的增加先增大后减小再增大。原因可能是仿真初期的剧烈抖动冲击导致振动加剧,声压级上升,当仿真趋于稳定后,声压级又迅速降低,但后续随着转速的增加,振动再次加剧,进而导致声压级再次增大。
图14(a)可知,声压级随时间增加而上升,对比图13(a),其到达声压级最高值的时间与正常轴承相似,约为0.04 s。从声压级幅值来看,其略大于正常轴承且最低声压级幅值的平均值明显低于正常轴承。由图14(b)可知,开始阶段出现振动冲击增大、噪声升高的现象,后续呈先减小后增大的变化趋势,在400 Hz处出现声压级最低值,约为53 dB,在2 400 Hz处出现声压级最高值,约为95 dB。正常轴承的最低声压级约为30 dB,最高约为90 dB。通过对比正常与内圈故障轴承的声压级发现,内圈故障轴承的声压级无论是最低值还是最高值均高于正常轴承,原因可能是内圈故障轴承存在的划痕等损伤会导致轴承在运转过程中产生额外的摩擦和振动,从而导致产生更高的声压级。
设置转速4 000 r/min,轴承内圈故障状态下1 000、2 000、3 000 N共3种载荷分布。经仿真分析处理后得到变载荷下的轴承辐射声压级云图,如图15图16所示。
图12(a)、15(a)和16(a)发现,声压级由载荷从低到高分别为57.2、73.8、66 dB。可见,声压级并非随载荷增大而增大,而是先增大后减小,原因可能是载荷为3 000 N时的前中期声波或振动速度较慢导致的。从云图形状来看,前期分布较为均匀规律,但随载荷的增大,显著故障阶段的云图形状也越发杂乱无规律。
对于变载对轴承声压级的影响分析,只需考虑声压级随频率的变化情况,如图17所示。
图17可知,声压级随载荷的增大而升高,载荷3 000 N时基本一直处于最高声压级位置,而载荷2 000 N时的最低声压级比载荷1 000 N时还要低。原因可能是测点位置不完全相同而产生的结果。
设置载荷为1 000 N,轴承内圈故障状态下的转速分别为4 000、6 000、8 000 r/min。经仿真分析处理后得到变转速下的轴承辐射声压级云图,如图18所示。
对比图12(a)图18可知,转速由低到高的声压级数值分别为57.2、76.3、94.7 dB。可见,声压级随着转速的升高而增加,且增加的速度快、跨度大。从云图形状来看,3种转速下的辐射云图形状分布均较为规律,呈现出分层阶梯的状态。
经处理得到声压级随频率的变化曲线,如图19所示。由图19可知,声压级随转速的增加而上升,原因可能是转速升高,导致滚动体与滚道间的接触力增加,进而产生更高的声压级。大约从250 Hz开始,声压级幅值显著上升,到2 400 Hz时声压级最高,约为96 dB。8 000 r/min时的声压级始终处于较高位置,4 000 r/min时的最低声压级处于较低位置,这表明转速越高对声压级的影响也越大。
针对内圈的故障识别,将从不同的方位出发,通过声压级的变化来深入研究。选取同一场点的不同节点位置来模拟不同方位,而声压级主要研究随不同方位频率的变化情况。因此,轴承内圈发生故障时,不同场点位置处的声压级频域曲线如图20所示。其中,选取的场点Node ID分别为17 619、18 384。
图20可知,两个不同方位频域曲线的总体变化趋势均为先上升再下降,只是上升速度不同。从数值角度分析,18 384位置处的曲线在600 Hz左右时出现声压级最小值,约为43 dB,而17 619位置处的曲线在700 Hz左右时出现声压级最小值,约为53 dB。基于此,得出内圈故障轴承的最低声压级范围为40~60 dB,其出现的频段范围为500~800 Hz。两者声压级达到最高时出现的位置则相同,约为2 650 Hz,最高值均约为97 dB,而在3 000 Hz处的声压级有所下降,约为82 dB。从故障特征频率角度分析,声压级特征频率位置可以由轴承内圈故障特征频率来表示,由于最低声压级频率以频段形式存在,且最低值更靠近频段中数据较小的一侧,为此选取较小数据作为主要研究对象,并根据故障频率计算方法得到轴承内圈故障时的特征频率为664.7 Hz,进而得到内圈故障时振动与声学频率的关系,如表5所示。
表5可知,当最低声压级频率与振动频率之比接近0.75或最高声压级频率与振动频率之比接近4时,可推测可能存在轴承内圈故障,若非此种关系,则可能为其他故障类型。
通过建立全陶瓷角接触球轴承存在内圈故障的有限元模型,研究了变载荷和变转速对轴承声压级的影响以及内圈故障的判别方法,构建了声信号与振动二者之间的联系,打破了以往只注重声信号单一维度的研究,并得出以下结论。
(1)通过分析变转速与变载荷情况下高速轴承的声压级特性,得到了运转轴承声压级与多变工况的关系,当转速恒为4 000 r/min时,内圈故障的声压级随着载荷的增加呈现出先增大后减小的变化趋势,其值按载荷由小到大分别为57.2、73.8、66 dB;当载荷恒为1 000 N时,内圈故障的声压级随着转速的增加而增大,其值按转速由小到大分别为57.2、76.3、94.7 dB。
(2)通过内圈故障特征总结出了声压级与特征频率的关系,当最低声压级频率与振动频率之比接近0.75或最高声压级频率与振动频率之比接近4时,即可识别为内圈故障。这一发现为后续轴承故障位置的检测提供了重要依据,推动了轴承故障诊断技术的发展。
  • 河北省自然科学基金(E2021208004)
  • 河北省教育厅青年基金(QN2021061)
  • 河北省省级科技计划(20310803D)
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2025年第25卷第10期
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doi: 10.12404/j.issn.1671-1815.2403297
  • 接收时间:2024-05-06
  • 首发时间:2025-07-09
  • 出版时间:2025-04-08
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  • 收稿日期:2024-05-06
  • 修回日期:2025-01-03
基金
河北省自然科学基金(E2021208004)
河北省教育厅青年基金(QN2021061)
河北省省级科技计划(20310803D)
作者信息
    河北科技大学机械工程学院, 石家庄 050018

通讯作者:

* 杨雪(1978—),女,汉族,河北石家庄人,硕士,讲师。研究方向:智能运维、故障诊断与预测。E-mail:
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2种不同金属材料的力学参数

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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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