基于稀疏信号分解的自适应时变滤波器及其在齿轮故障诊断中的应用

提出一种新的自适应时变滤波器设计方法,并将其应用于变速齿轮箱齿轮故障诊断中.齿轮箱振动信号频率成分复杂,特别是多级变速齿轮箱,存在多个啮合频率,而齿轮箱齿轮故障诊断的核心是获取啮合频率的调制状态.在非平稳转速下,如何从复杂振动信号中提取包络调制信号是齿轮箱故障诊断需要解决的关键问题.基于多尺度线调频基(Multi-scale chirplet)的稀疏信号分解方法可以有效地提取频率呈曲线变化的信号分量,适合于载波频率的提取,以该载波频率为滤波器的中心频率,转频的倍频为滤波带宽,设计滤波中心频率曲线变化的自适应时变滤波器,可以有效地将多个包络调制信号分别提取出来,进而可以对变速多级齿轮箱齿轮进行故障诊断.提出的自适应滤波器可以根据信号本身的特点自动改变滤波中心频率和滤波带宽,对信号进行滤波,保留信号的有用频率成分,抑制无用成分.仿真算例和应用实例说明了方法的有效性.     

基于时变零相位滤波的变转速滚动轴承故障诊断

针对变转速下齿轮箱中滚动轴承故障调制特征的提取与分离,提出了基于时变零相位滤波的变转速滚动轴承故障诊断方法。该方法先用线调频小波路径追踪(CPP)算法从齿轮箱滚动轴承故障振动信号中估计出齿轮啮合频率,由啮合频率除以齿数得到齿轮箱的转速,同时,采用Hilbert包络解调方法获取轴承故障振动信号的包络信号;然后根据获取的转速信息设计各阶时变零相位滤波器;再采用各时变零相位滤波器对包络信号进行分析,获取各调制信号;最后,利用转速信号对求取的各调制信号进行阶次分析,并根据各阶次谱来诊断滚动轴承故障。算法仿真和应用实例分析表明,该方法可有效提取和分离变速齿轮箱中滚动轴承的各阶故障调制特征。     

基于时变滤波与CWT的齿轮箱无转速计阶次跟踪

针对转频波动工况下复杂齿轮箱系统振动信号中各啮合阶次成分相互干扰,导致对啮合频率估计困难的情况,提出一种基于时变滤波与连续小波变换(CWT)结合的无转速计阶次跟踪齿轮箱故障诊断技术。基于短时傅里叶变换(STFT)设置时变滤波器;通过时变滤波及连续小波变换(CWT),获得平滑的瞬时频率估计(IFE);再基于Vold-Kalman滤波(VKF)获得参考轴相位。该方法获得的阶次谱与计算阶次跟踪(COT)相当。最后,结合快速谱峭度算法可准确判断故障齿轮位置。通过仿真和实验表明,无转速计方法能为强噪声转速明显波动工况下的机械故障诊断提供一种新的有效手段。     

基于多尺度线调频基稀疏信号分解的齿轮故障信号阶比分析

针对变转速齿轮箱故障振动信号调制边频带难以识别的问题,提出一种基于多尺度线调频基稀疏信号分解的阶比分析方法.该方法先采用基于多尺度线调频基的稀疏信号分解方法对齿轮箱振动信号进行分解,提取齿轮的啮合分量与调制边频分量,由啮合分量的时频分布曲线得到瞬时转频估计,再基于获得的瞬时转频对啮合分量与调制边频分量之和进行等角度重采样,将非平稳的分量信号转化为平稳信号,对重采样后的信号进行阶比分析,诊断齿轮故障.与传统的直接对齿轮箱故障振动信号进行阶比分析的方法比较,结果表明,提出的基于多尺度线调频基稀疏信号分解的阶比分析方法抗噪性强,调制边频带识别效果好.仿真算例与应用实例验证了本方法的有效性.     

齿轮箱中滚动轴承故障振动信号的提取

应用一种自适应滤波技术,即自适应谱线增强技术从齿轮箱的振动信号中提取滚动轴承故障振动信号.实例表明,该方法能够有效地排除齿轮啮合振动等干扰噪声,提高轴承故障振动信号的信噪比,有利于准确诊断齿轮箱中滚动轴承的故障.     

基于VMD阶比跟踪的变转速齿轮箱齿轮故障特征提取

针对变转速工况下齿轮箱齿轮阶比信号互相干扰故障特征难以提取的问题,提出了基于VMD(Variational Mode Decomposition)和阶比跟踪技术结合的齿轮箱齿轮故障特征提取方法。该方法通过计算阶比跟踪技术对振动信号进行角域重采样;获得重采样信号后,利用VMD按照中心阶比不同,自适应地将重采样信号分解,再利用峭度准则从IMF(Intrinsic Mode Function)分量中选取出故障信号;最后对故障信号进行快速谱峭图处理和滤波平方包络解调。通过变转速下齿轮箱的齿轮故障试验和对比分析,表明该方法能有效提取出变转速下齿轮箱的齿轮故障特征,且降噪效果明显,特征突出,适用于变转速齿轮箱的齿轮故障特征提取。     

基于ATF与ASAD的变转速齿轮故障诊断

针对变工况、强噪声状态下齿轮的故障特征难以提取的问题,提出了一种基于自适应时变滤波(Adaptive time-varying filtering,ATF)与角域同步平均降噪(Angle domain synchronous average denoising,ASAD)的齿轮故障诊断方法.将ASAD与ATF相结合,对降噪后的信号进行阶次谱分析,并通过阶次谱中的调制边频带即可诊断齿轮局部故障.通过分析模拟数据及变转速齿轮箱试验台的数据表明,该方法对变转速状态下的齿轮振动信号有很好的信号分析自适应性,不仅能很好地滤除噪声干扰,提升通带内的噪声抑制效果,且能有效凸显变转速下的齿轮故障特征.     

VMD和奇异差分谱在齿轮早期故障诊断中的应用

针对齿轮故障振动信号的多分量、多频率调制特性且早期故障振动信号信噪比低,故障特征微弱难以提取的问题,提出了基于变分模态分解(Variational Mode Decomposition,VMD)和奇异值差分谱的故障诊断方法。首先对采集到的齿轮故障振动信号进行VMD分解,得到一系列窄带本征模态分量(band-limited intrinsic mode functions,BLIMFS),由于噪声的干扰,从各个模态分量的频谱中很难对故障做出正确的判断;然后根据相关系数准则,选取与原始信号相关系数较大的分量构建Hankel矩阵并进行奇异值分解,求取奇异值差分谱,从差分谱中确定重构信号的有效阶次对信号进行降噪处理;最后对降噪处理后的信号进行Hilbert包络谱分析,即可从中准确地识别出齿轮的故障特征频率。仿真信号和齿轮箱齿轮故障模拟实验结果表明,该方法能够有效地降低噪声的影响,准确地提取到齿轮微弱的故障特征信息。     

基于EMD和Hilbert解调的齿轮箱故障诊断

针对复杂的齿轮箱振动信号难以提取出故障特征频率的问题,提出了一种将希尔伯特包络解调技术与经验模式分解(EMD)相结合的分析方法。首先对齿轮箱的故障信号进行了EMD分解,得到了本征模态函数(IMF分量),再对IMF分量进行了包络解调,得到了其调制信号,结合调制信号的频率成分可初步判断出齿轮箱中出现故障的齿轮;然后根据IMF分量与初始信号之间相关系数的大小,选择相关系数较大的分量重构信号,相当于对初始信号进行滤波;最后对重构的信号以啮合频率及其倍频为中心频率进行了带通滤波,对得到的信号进行了包络解调分析,再次进行了故障诊断,以验证故障诊断的准确性。整个过程通过对齿轮箱实测故障信号的分析加以验证。研究结果表明,该方法能够准确地提取出齿轮箱的故障特征频率,从而可以对齿轮箱故障进行有效地诊断。     

基于MODWPT和MCKD的滚动轴承早期故障诊断

针对齿轮啮合强振动干扰下滚动轴承微弱故障特征提取难的问题，提出一种最大重叠离散小波包变换(MODWPT)和最大相关峭度解卷积(MCKD)相结合的滚动轴承早期故障诊断方法。首先采用MODWPT方法将复杂的轴承故障振动信号分解为若干分量，然后依据峭度准则，选取峭度较大的分量进行MCKD滤波，最后对滤波后所得信号做Hilbert包络分析，将包络谱呈现的频率特征与理论故障特征频率相比较，识别故障特征，实现故障诊断。通过轴承故障的仿真及实验研究，并对比单一MCKD方法和EMD-MED方法的提取效果，说明该方法可以在一定程度上抑制齿轮啮合强振动及噪声的干扰，增强并有效提取出滚动轴承早期低频微弱故障特征。     

Gearbox fault diagnosis using adaptive zero phase time-varying filter based on multi-scale chirplet sparse signal decomposition

When used for separating multi-component non-stationary signals, the adaptive time-varying filter(ATF) based on multi-scale chirplet sparse signal decomposition(MCSSD) generates phase shift and signal distortion. To overcome this drawback, the zero phase filter is introduced to the mentioned filter, and a fault diagnosis method for speed-changing gearbox is proposed. Firstly, the gear meshing frequency of each gearbox is estimated by chirplet path pursuit. Then, according to the estimated gear meshing frequencies, an adaptive zero phase time-varying filter(AZPTF) is designed to filter the original signal. Finally, the basis for fault diagnosis is acquired by the envelope order analysis to the filtered signal. The signal consisting of two time-varying amplitude modulation and frequency modulation(AM-FM) signals is respectively analyzed by ATF and AZPTF based on MCSSD. The simulation results show the variances between the original signals and the filtered signals yielded by AZPTF based on MCSSD are 13.67 and 41.14, which are far less than variances (323.45 and 482.86) between the original signals and the filtered signals obtained by ATF based on MCSSD. The experiment results on the vibration signals of gearboxes indicate that the vibration signals of the two speed-changing gearboxes installed on one foundation bed can be separated by AZPTF effectively. Based on the demodulation information of the vibration signal of each gearbox, the fault diagnosis can be implemented. Both simulation and experiment examples prove that the proposed filter can extract a mono-component time-varying AM-FM signal from the multi-component time-varying AM-FM signal without distortion.     

基于自混合干涉的齿轮箱故障诊断技术

将激光自混合干涉（SMI）技术用于齿轮箱的故障检测,设计出一种新的齿轮箱故障检测传感器。采用QL65D5SA型半导体激光自混合传感器、冯哈勃2342l012CR空心杯减速电机自带的行星齿轮箱,搭建了行星齿轮箱故障SMI检测系统,并对行星轮Z1做断齿故障实验。通过对时域波形的分析,可以找到额定转频下的12个冲击点;通过对齿轮箱故障信号傅里叶频谱的分析,发现故障齿轮的啮合频率周围出现与故障齿轮特征频率和行星架转频呈整数倍关系的边带,且啮合频率处的波形幅值明显增大,这些都与齿轮副的理论振动模型相符合。     

基于振动信号的齿轮箱故障诊断

主齿轮箱是某船重要动力设备,需要对其进行经常性监测。测量了某船1#和2#主齿轮箱的振动加速度信号,比较了两齿轮箱振动信号的时间历程曲线和频谱,发现2#齿轮箱频谱最大幅值约为1#齿轮箱的2.5倍,而且该谱值对应的频率接近于啮合频率。在啮合频率附近对所测信号进行了带通滤波,对滤波后的窄带信号进行了Hilbert变换,得到了该窄带信号的包络。两齿轮箱的包络信号差异明显,1#齿轮箱包络信号的频谱频率成分丰富,而2#齿轮箱包络信号的频谱具有突出的单一频率成分。结果表明2#齿轮箱存在轻微的故障。而油液分析的结果也表明,2#齿轮箱的磨损大于1#齿轮箱,说明了采用的振动分析方法的合理性。     

基于线调频小波路径追踪阶比跟踪算法的齿轮箱故障诊断研究

针对阶比跟踪转速获取硬件方法需要额外安装转速测量设备,软件方法精度不高、抗噪能力弱的问题,提出基于线调频小波路径追踪瞬时频率估计的齿轮箱阶比跟踪故障诊断方法。该方法利用基于线调频小波路径追踪瞬时频率估计算法适于分解频率呈曲线变化的非平稳信号的特点,采用其对齿轮箱的啮合频率分量进行估计以获取转速信号,依据转速信号对等时间间隔采样信号进行等角度重采样,将非平稳信号转化为角域平稳信号,得到振动信号的阶次谱,判断齿轮箱故障。仿真算例与应用实例表明上述方法在瞬时频率估计方面具有精度高和抗噪能力强的优点,可以根据信号自身的特点自适应的选择基函数,准确地对转速进行估计,其与阶比跟踪算法的结合能有效诊断齿轮箱故障。     

The envelope order spectrum based on generalized demodulation time–frequency analysis and its application to gear fault diagnosis

The generalized demodulation time–frequency analysis is a novel signal processing method, which is particularly suitable for the processing of multi-component amplitude-modulated and frequency-modulated (AM–FM) signals as it can decompose a multi-component signal into a set of single-component signals whose instantaneous frequencies own physical meaning. While fault occurs in gear, the vibration signals measured from gearbox would exactly display AM–FM characteristics. Therefore, targeting the modulation feature of gear vibration signal in run-ups and run-downs, a fault diagnosis method in which generalized demodulation time–frequency analysis and envelope order spectrum technique are combined is put forward and applied to the transient analysis of gear vibration signal. Firstly the multi-component vibration signal of gear is decomposed into some mono-component signals using the generalized demodulation time–frequency analysis approach; secondly the envelope analysis is performed to each single-component signal; thirdly each envelope signal is re-sampled in angle domain; finally the spectrum analysis is applied to each re-sampled signal and the corresponding envelope order spectrum can be obtained. Furthermore, the gear working condition can be identified according to the envelope order spectrum. The analysis results from the simulation and experimental signals show that the proposed algorithm was effective in gear fault diagnosis.     

基于包络加窗同步平均的行星齿轮箱特征提取

行星齿轮箱由于行星轮通过效应、太阳轮与行星架的旋转及时变工况,导致其振动响应存在时变传递路径及非平稳性等特点,且传统的同步平均将不能直接应用于行星齿轮箱。笔者在国外加窗同步平均的基础上提出一种能有效克服时变传递路径及非平稳性的基于包络信号角域加窗同步平均的行星齿轮箱故障特征提取方法。首先,基于谱峭度提取出行星齿轮箱振动信号的包络信号;其次,再利用计算阶比跟踪技术对包络信号进行等角度重采样,行星架每旋转一圈,选择合适的窗函数对角域信号进行多齿宽加窗截取;最后,验证齿轮啮合齿序特征,根据重排齿序对加窗信号进行重构振动分离信号,对振动分离信号进行角域同步平均,提取行星齿轮箱故障特征。行星齿轮箱故障实测信号分析表明,该方法能有效提取行星齿轮箱故障特征。     

Adaptive filtering based system for extracting gearbox condition feature from the measured vibrations

Vibration signals measured from a gearbox are complex multi-component signals, generated by tooth meshing, gear shaft rotation, gearbox resonance vibration signatures and a substantial amount of noise. This article presents a novel scheme for extracting gearbox fault features using adaptive filtering techniques for enhancing condition features, meshing frequency sidebands. A modified least mean square (LMS) algorithm is developed and validated using only one accelerometer, instead of using two accelerometers in traditional arrangement, as the main signal and a desired signal is artificially generated from the measured shaft speed and gear meshing frequencies. The proposed scheme is applied to a signal simulated from gearbox frequencies with a numerous values of step size. Findings confirm that 10⁻⁵ step size invariably produces more accurate results and there has been a substantial improvement in signal clarity (better signal-to-noise ratio); which make meshing frequency sidebands more discernible. The developed scheme is validated via a number of experiments carried out using two-stage helical gearbox for a pair of healthy gears and one pair suffering from a tooth breakage with severity fault 1 (25% tooth removal), and fault 2 (50% tooth removal) under loads (0%, and 80% of the total load). The experimental results show remarkable improvements and enhance gear fault features. This paper illustrates that the new approach offers a more effective way to detect early faults.     

Application of Instantaneous Rotational Speed to Detect Gearbox Faults Based on Double Encoders

Considerable studies have been carried out on fault diagnosis of gears, with most of them concentrated on conventional vibration analysis. However, besides the complexity of gear dynamics, the diagnosis results in terms of vibration signal are easily misjudged owing to the interference of sensor position or other components. In this paper, an alternative gearbox fault detection method based on the instantaneous rotational speed is proposed because of its advantages over vibration analysis. Depending on the timer/counter-based method for the pulse signal of the optical encoder, the varying rotational speed can be obtained e ectively. Owing to the coupling and meshing of gears in transmission, the excitations are the same for the instantaneous rotational speed of the input and output shafts. Thus, the di erential signal of instantaneous rotational speeds can be adopted to eliminate the e ect of the interference excitations and extract the associated feature of the localized fault e ectively. With the experiments on multistage gearbox test system, the di erential signal of instantaneous speeds is compared with other signals. It is proved that localized faults in the gearbox generate small angular speed fluctuations, which are measurable with an optical encoder. Using the di erential signal of instantaneous speeds, the fault characteristics are extracted in the spectrum where the deterministic frequency component and its harmonics corresponding to crack fault characteristics are displayed clearly.