CN-121994481-A - Health monitoring system of speed reducer

CN121994481ACN 121994481 ACN121994481 ACN 121994481ACN-121994481-A

Abstract

The invention discloses a health monitoring system of a speed reducer, and belongs to the field of monitoring of mechanical equipment states. The intelligent monitoring device comprises a sensor module, a data acquisition module, a data processing module, an early warning module and a display module, wherein the sensor module comprises a displacement sensor, a pressure sensor, a rotating speed sensor, a vibration sensor and a temperature sensor, the displacement sensor and the pressure sensor are arranged at the position of a brake piston of a speed reducer and used for monitoring the displacement and the braking pressure of the piston in real time, and the rotating speed sensor is arranged at the output end of the speed reducer and used for monitoring the output rotating speed of the speed reducer. The real-time monitoring of the key parameters of the speed reducer is realized through multi-sensor fusion, potential faults can be found in time, and the fundamental transition from passive maintenance to active early warning and from planned maintenance to predictive maintenance is realized. The brake performance and the friction plate wear degree are accurately estimated through the joint monitoring of the brake piston displacement and the pressure, and the early fault diagnosis is realized through the spectrum analysis of the vibration signals.

Inventors

WU YAN
MA SHIZHEN
CHENG HE

Assignees

徐州迈科思机械科技有限公司

Dates

Publication Date: 20260508
Application Date: 20260302

Claims (8)

1. The health monitoring system of the speed reducer is characterized by comprising a sensor module, a data acquisition module, a data processing module, an early warning module and a display module, wherein the sensor module comprises a displacement sensor, a pressure sensor, a rotating speed sensor, a vibration sensor and a temperature sensor, the displacement sensor and the pressure sensor are arranged at the position of a brake piston of the speed reducer and used for monitoring the displacement and the braking pressure of the piston in real time, the rotating speed sensor is arranged at the output end of the speed reducer and used for monitoring the output rotating speed of the speed reducer, the vibration sensor is arranged at a shell of the speed reducer and used for acquiring vibration signals, the temperature sensor is arranged inside the speed reducer and used for monitoring the working temperature of the speed reducer, the data acquisition module is connected with the sensor module and used for acquiring real-time data of the sensors, the data processing module is connected with the data acquisition module and internally provided with a data processing algorithm and used for analyzing and calculating the acquired data and comparing the data with a preset threshold value or a theoretical curve, the early warning module is connected with the data processing module and used for generating early warning signals according to comparison results, and the display module is used for displaying running state information and early warning prompts of the speed reducer.
2. The health monitoring system of a speed reducer according to claim 1, wherein the data processing module comprises a brake performance analysis unit, the brake performance analysis unit is used for comparing and analyzing a theoretical curve of brake pressure and piston displacement according to piston displacement data monitored by a displacement sensor and brake pressure data monitored by a pressure sensor, the theoretical curve formula is that P=K×n× (11+Δl)/A, wherein P is brake pressure, K is spring stiffness, n is the number of springs, Δl is piston displacement, A is piston area, when positive displacement Δl reaches 2.0mm, the system judges that the brake pressure is more than or equal to 9MPa, if the system pressure is less than 9MPa, and when the system pressure is more than or equal to 10.5MPa and Δl is less than 4.0mm, the spring stiffness is judged to be larger.
3. The health monitoring system of the speed reducer according to claim 1, wherein the data processing module comprises a friction plate abrasion monitoring unit, the friction plate abrasion monitoring unit is used for judging the abrasion degree according to negative displacement data and braking pressure data by combining the relation between the abrasion quantity of the friction plate and the braking pressure, the system is judged to be safe when the negative displacement delta is less than or equal to 4mm and the system pressure is more than or equal to 4.8MPa, insufficient braking torque or too small spring force is indicated when the negative displacement delta is less than or equal to 4mm and the braking moment is indicated to be too large when the negative displacement delta is less than or equal to 4.8MPa, and the friction plate abrasion quantity is indicated to be replaced when the negative displacement delta is more than or equal to 4 mm.
4. The health monitoring system of a speed reducer according to claim 1, wherein the data processing module comprises a speed calculating unit, the speed calculating unit calculates real-time speed per hour of the vehicle according to an output rotation speed n monitored by a rotation speed sensor through a formula v= 0.3014 ×n, wherein the unit of V is km/h, the early warning module sets different overspeed thresholds according to a vehicle load state, and prompts overspeed if V is more than 10km/h when the vehicle is fully loaded, and prompts overspeed if V is more than 18km/h when the vehicle is not loaded with goods.
5. The health monitoring system of the speed reducer according to claim 1, wherein the data processing module comprises a temperature monitoring unit, the temperature monitoring unit is used for carrying out multistage judgment according to real-time temperature t monitored by a temperature sensor, the early warning module is used for sending out buzzing prompt when t is less than or equal to-20 ℃ or t is more than or equal to 80 ℃, the early warning module is used for sending out risk warning when t is less than or equal to-40 ℃ or t is more than or equal to 130 ℃, and the temperature abnormality prompt comprises lubrication state abnormality, overload and abnormal friction warning and sealing system protection.
6. The health monitoring system of the speed reducer according to claim 1, wherein the data processing module comprises a vibration analysis unit, the vibration analysis unit collects vibration signals and spectrograms in the early operation period of the system, a reference database of the amplitude range of the vibration signals is built, in the operation process, the vibration signals are collected in real time and compared with the reference database, when the amplitude of the vibration signals exceeds a preset range, the early warning module sends out buzzing reminding, and the speed reducer speed ratio conversion is combined with a rotating speed sensor to analyze the state of a gear, so that early fault diagnosis and state assessment are achieved.
7. The health monitoring system of a speed reducer according to claim 1, wherein the data processing module comprises a data storage unit, the data storage unit is used for storing real-time data acquired by the sensor, analysis comparison results and historical operation data, a speed reducer operation state database is gradually formed, a data basis is provided for subsequent artificial intelligent analysis, and the data processing module further comprises a driving mileage calculation unit, and the driving mileage calculation unit is used for calculating and recording the total driving mileage of the vehicle according to real-time speed and driving time.
8. The health monitoring system of the speed reducer is characterized in that the early warning module comprises an acoustic prompt unit and a visual prompt unit, when the system detects abnormality or risk, the acoustic prompt unit gives out a buzzing alarm, the visual prompt unit flashes and prompts through a display module, the early warning level is divided into a warning level and a warning level according to the abnormality degree, the warning level corresponds to the temperature exceeding the range of-20 ℃ to 80 ℃ or the amplitude of a vibration signal is abnormal, the warning level corresponds to the temperature exceeding the range of-40 ℃ to 130 ℃, the braking torque is insufficient or the abrasion loss of a friction plate is overlarge.

Description

Health monitoring system of speed reducer Technical Field The invention relates to state monitoring of mechanical equipment, in particular to a health monitoring system of a speed reducer. Background The hub speed reducer is used as a key link of a core hub and power transmission of a heavy engineering equipment transmission system, and the running state of the hub speed reducer directly determines the performance and safety of the whole machine. As a core execution component of the driving terminal, once the wheel-side speed reducer fails, the wheel-side speed reducer directly causes the vehicle or equipment to lose part or all of driving force and effective braking force, so that serious equipment damage and safety accidents are caused. Particularly, in key equipment such as mining dump trucks, large cranes and the like, unexpected shutdown can be caused by sudden faults of a speed reducer, so that the whole production line is interrupted, high shutdown loss, emergency maintenance cost and productivity loss are generated, and the overall progress and operation benefit of projects are seriously influenced. In the prior art, the monitoring of the speed reducer mainly relies on manual inspection and periodic maintenance, and the problems that the monitoring is not timely, the problems cannot be found in real time, the predictive maintenance capability is insufficient and the like exist in the mode. Although some devices are provided with simple sensors, most of the devices are single parameter monitoring, and the devices lack comprehensive analysis capability on multiple parameters such as braking performance, friction plate abrasion, vibration characteristics and the like, so that accurate state evaluation and fault early warning are difficult to realize. Therefore, developing a set of health monitoring system capable of implementing real-time state monitoring and intelligent early warning on the wheel-side speed reducer becomes an indispensable technical guarantee means for guaranteeing the safety of heavy equipment, preventing major accidents, realizing predictive maintenance and guaranteeing economic operation. Disclosure of Invention The invention aims to provide a health monitoring system of a speed reducer, which realizes comprehensive monitoring and fault early warning of the running state of the speed reducer through multi-sensor fusion and intelligent algorithm analysis. The health monitoring system of the speed reducer comprises a sensor module, a data acquisition module, a data processing module, an early warning module and a display module, wherein the sensor module comprises a displacement sensor, a pressure sensor, a rotating speed sensor, a vibration sensor and a temperature sensor, the displacement sensor and the pressure sensor are arranged at the position of a brake piston of the speed reducer and used for monitoring the displacement and the braking pressure of the piston in real time, the rotating speed sensor is arranged at the output end of the speed reducer and used for monitoring the output rotating speed of the speed reducer, the vibration sensor is arranged in a shell of the speed reducer and used for acquiring vibration signals, the temperature sensor is arranged in the speed reducer and used for monitoring the working temperature of the speed reducer, the data acquisition module is connected with the sensor module and used for acquiring real-time data of the sensors, the data processing module is connected with the data acquisition module and used for carrying out analysis calculation on the acquired data and comparison with a preset threshold value or a theoretical curve, the early warning module is connected with the data processing module and used for generating early warning signals according to comparison results, and the display module is used for displaying running state information and early warning prompts of the speed reducer. Further, the data processing module comprises a brake performance analysis unit, wherein the brake performance analysis unit is used for comparing and analyzing according to piston displacement data monitored by a displacement sensor and brake pressure data monitored by a pressure sensor and a theoretical curve of brake pressure and piston displacement, a theoretical curve formula is that P=K multiplied by n multiplied by (11+Deltal)/A, wherein P is brake pressure, K is spring stiffness, n is spring quantity, deltal is piston displacement, A is piston area, when positive displacement Deltal reaches 2.0mm, a system judges that the brake pressure is more than or equal to 9MPa, if the system pressure is less than 9MPa, the spring stiffness is smaller, and when the system pressure is more than or equal to 10.5MPa and Deltal is less than 4.0mm, the spring stiffness is larger. Further, the data processing module comprises a friction plate abrasion monitoring unit, the friction plate abrasion monitoring unit judges the abrasion degree according to negativ