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CN-122016300-A - Gear vibration testing method and device for two-stage transmission press

CN122016300ACN 122016300 ACN122016300 ACN 122016300ACN-122016300-A

Abstract

The application provides a gear vibration testing method and device of a secondary transmission press, belonging to the technical field of press vibration testing and state monitoring, wherein an acceleration sensor and a cam sensor are arranged; the method comprises the steps of collecting vibration signals and angle signals under various working conditions, preprocessing the vibration signals, carrying out angle domain resampling to output angle domain stable signals, carrying out time domain and frequency domain analysis on the angle domain stable signals, outputting time domain characteristic indexes, meshing frequency and frequency domain characteristic parameters, carrying out band-pass filtering on the angle domain stable signals to extract high-frequency signals, calculating envelope spectrum to output envelope characteristic parameters, analyzing sideband characteristics on two sides of meshing frequency, obtaining rules of change of the meshing characteristics along with time, outputting sideband and time frequency characteristic parameters, carrying out gear meshing health evaluation based on the characteristic parameters, and calculating comprehensive health indexes to quantitatively evaluate the meshing state of gears. The application realizes non-invasive monitoring, accurately diagnoses gear faults and improves equipment operation reliability.

Inventors

  • WANG ZHIHUI
  • JIAO XIAOHAN
  • SONG HONGNING
  • WANG KUNKUN

Assignees

  • 济南二机床集团有限公司

Dates

Publication Date
20260512
Application Date
20251205

Claims (10)

  1. 1. The gear vibration testing method of the two-stage transmission press machine comprises a flywheel, a high-speed gear box connected with the flywheel, a low-speed gear box connected with an output shaft of the high-speed gear box, a crank block mechanism driven by a crankshaft output by the low-speed gear box and a balancer cylinder for balancing the weight of a slide block in the crank block mechanism, wherein a cam sensor for detecting the rotation angle position of the crankshaft is arranged on the crankshaft, and the method is characterized by comprising the following steps: s1, arranging a plurality of groups of three-way acceleration sensors on the outer walls of a high-speed gear box and a low-speed gear box, and simultaneously leading out cam sensor signals so as to realize synchronous acquisition of vibration signals and crank shaft angle signals; S2, under the running state of the secondary press, setting combined working conditions of different balancer wind pressures and different slider speeds, and collecting vibration signals and crankshaft angle signals under each working condition in a multichannel synchronous mode; S3, performing anti-aliasing filtering, trending and band-pass filtering processing on the acquired vibration signals, and performing angular domain resampling by using the crank shaft angle signals to output angular domain stable signals; s4, performing time domain analysis and frequency domain analysis on the angular domain stationary signal, and outputting a time domain characteristic index, a gear pair meshing frequency and a frequency domain characteristic parameter; S5, carrying out band-pass filtering on the angle domain stationary signal to extract a high-frequency signal, carrying out Hilbert transformation envelope demodulation on the high-frequency signal, extracting a gear meshing impact envelope signal, and calculating an envelope spectrum output envelope characteristic parameter; s6, analyzing sideband features on two sides of meshing frequency of the gear pair, acquiring a law of time variation of the meshing features of the gear by using a time-frequency analysis method, and outputting sideband and time-frequency feature parameters; S7, carrying out gear engagement health evaluation based on the time domain characteristic index, the frequency domain characteristic parameter, the envelope characteristic parameter, the sidebands and the time-frequency characteristic parameter, and calculating the comprehensive health index HI so as to quantitatively evaluate the gear engagement state.
  2. 2. The gear vibration testing method of a two-stage transmission press according to claim 1, wherein step S1 comprises the specific steps of: s11, arranging a group of three-way acceleration sensors right above the left front end, the left rear end, the right front end and the right rear end cover of the low-speed gear box respectively, wherein the sensitive axes of the three-way acceleration sensors are perpendicular to the mounting surface; S12, arranging a group of three-way acceleration sensors right above a jackshaft bearing gland of the high-speed gear box; S13, connecting pulse signals of the cam sensors to a rotating speed channel of the signal acquisition system through shielding wires, and connecting all three-way acceleration sensors to a vibration channel of the signal acquisition system.
  3. 3. The gear vibration testing method of a two-stage transmission press according to claim 2, wherein step S2 comprises the specific steps of: s21, setting the wind pressure of the balancer as three wind pressure working conditions of standard wind pressure, low wind pressure and high wind pressure; s22, setting at least three different sliding block running speeds under each wind pressure working condition; s23, synchronously acquiring vibration signals of all three-way acceleration sensors and crank shaft angle signals of the cam sensors according to preset sampling frequency under each wind pressure and speed combination working condition, wherein continuous acquisition time meets a time length threshold.
  4. 4. The gear vibration testing method of a two-stage transmission press according to claim 3, wherein the step S3 comprises the specific steps of: S31, sequentially performing anti-aliasing filtering and linear trend removal item processing on the original vibration according to a preset cut-off frequency signal; s32, setting a band-pass filter according to the estimated gear meshing frequency range for filtering; S33, resampling the vibration signal of the filtered time domain into an angular domain stable signal with equal angular intervals by adopting a cubic spline interpolation method based on the acquired crank shaft angle signal; in particular, for a time series Corresponding vibration signal Interval of structure, three-degree polynomial of structure Second derivative of third order polynomial The following set of equations is satisfied: Wherein, the Is the sum of time The corresponding crank axle is provided with an equal angular coordinate, 、 、 And Respectively three times, two times, one time and constant time Corresponding coefficients; setting a target interpolation point (K=1, 2,., N) N is N uniform angle points per revolution, and the interpolated angular domain stationary signal is obtained by solving the system of equations 。
  5. 5. The gear vibration testing method of a two-stage transmission press according to claim 4, wherein step S4 comprises the specific steps of: S41, calculating an angular domain stationary signal Peak of (2) Root mean square value Peak factor Kurtosis of the sum As a time domain characteristic index; Wherein μ is the angular domain stationary signal Is the mean value of the angle domain stationary signal N is the number of sampling points, The vibration signal amplitude corresponding to the nth angular sampling point, N being the sampling point sequence number of the angular domain stationary signal, n=1, 2, 3. S42, stabilizing signals in diagonal domain Performing fast Fourier transform to obtain frequency spectrum, and identifying and extracting meshing frequency of gear pair from the frequency spectrum : Wherein, the For the number of teeth of the gear, Rotating the crankshaft; S43, calculating frequency domain characteristic parameters: Frequency multiplication amplitude ratio ; Concentration of energy Wherein A 1 is the meshing fundamental frequency of the gear pair in the frequency spectrum Is the frequency doubling of the meshing frequency in the frequency spectrum, A 2 A 3 is the frequency tripled of the meshing frequency in the spectrum A 4 is four times the frequency of the meshing frequency in the frequency spectrum Is a function of the magnitude of (a).
  6. 6. The method for testing gear vibration of a two-stage transmission press according to claim 5, wherein step S5 comprises the specific steps of: S51, setting a bandpass filter constructed with the target center frequency and bandwidth, and stabilizing signals from the angular domain by using the constructed bandpass filter Extracting high-frequency resonance signals; s52, for high-frequency resonance signals Envelope demodulation is carried out through Hilbert transformation to obtain an envelope signal, and the specific steps are as follows: For high frequency resonance signals Performing Hilbert transform to obtain high-frequency resonance signal Orthogonal components of (2) The transformation formula is: Wherein p.v. represents the cauchy principal value integral; by applying high-frequency resonance signals Orthogonal component to Hilbert transform Combination, structure analysis signal : Wherein j is an imaginary unit; Calculating an analytic signal Is the envelope signal : S53, performing fast Fourier transform on the envelope signal to obtain an envelope spectrum, and calculating an envelope impact factor : 。
  7. 7. The method for testing gear vibration of a two-stage transmission press according to claim 6, wherein step S6 comprises the specific steps of: s61, identifying meshing frequency of gear pair from frequency spectrum The distance between two sides is the crankshaft rotation frequency Is a sideband family of (2); S62, calculating the ratio of total energy of the front third-order sidebands in the sideband family to main frequency energy based on the amplitude information of the frequency spectrum to serve as the sideband energy ratio : K is the sideband order, and k=1, 2 and 3 are taken, namely the front third-order sidebands are summed; At a frequency equal to the engagement frequency Adding k times of crankshaft rotation frequency Is used to determine the sideband amplitude of (a), At a frequency equal to the engagement frequency Subtracting k times the frequency of rotation Is a sideband amplitude of (a); For the engaged frequency Is a magnitude of (a); S63, analyzing the angle domain stationary signal by adopting short-time Fourier transform, generating a time-frequency distribution map by selecting a preset window function length and an overlapping rate so as to identify the maximum value of the energy of the impact signal in a preset crank angle interval corresponding to the loading stage of the press, and recording as time-frequency impact energy 。
  8. 8. The method for testing gear vibration of a two-stage transmission press according to claim 7, wherein step S7 comprises the specific steps of: S71, root mean square value in time domain characteristic index Peak factor Kurtosis degree Frequency multiplication amplitude ratio in frequency domain characteristic parameters And envelope impact factor in envelope characteristic parameters Respectively comparing and normalizing the parameters with corresponding parameters in a healthy baseline state, wherein a normalization formula is as follows: Wherein, the As a value of the current parameter(s), As a value of the baseline parameter(s), Is the normalized parameter value; s72, calculating a comprehensive health index HI through weighted fusion, wherein the calculation formula is as follows: Wherein, the The normalized root mean square value is represented, Representing the peak factor after normalization, The kurtosis after normalization is represented, Representing the normalized frequency multiplication amplitude ratio, Representing the normalized envelope impact factor, 、 、 、 、 Is a weight coefficient and satisfies ; S73, according to the comprehensive health index Evaluating gear state, setting a first health index threshold Second health index threshold Third health index threshold ; Wherein, the The state evaluation rule is: If it is Judging that the gear engagement state is normal; If it is Judging that the gear engagement state is slightly uneven; If it is Judging the gear engagement state to be moderate abrasion; If it is The gear engagement state is determined to be severely abnormal.
  9. 9. The method according to claim 8, wherein in step S71, the sideband energy ratio in the sideband characteristic parameter is also set Time-frequency impact energy as time-frequency characteristic parameter Normalizing; And the integrated health index at step S72 Adding corresponding weighting terms in a calculation formula And (3) with And (2) and : Wherein, the To normalize the sideband energy ratio, Is normalized time-frequency impact energy.
  10. 10. The gear vibration testing device of the two-stage transmission press comprises a flywheel, a high-speed gear box connected with the flywheel, a low-speed gear box connected with an output shaft of the high-speed gear box, a crank slider mechanism driven by a crankshaft output by the low-speed gear box and a balancer cylinder for balancing the weight of a slider in the crank slider mechanism, wherein a cam sensor for detecting the rotation angle position of the crankshaft is arranged on the crankshaft, and the gear vibration testing device is characterized by comprising: The sensor arrangement and synchronization module is used for arranging a plurality of groups of three-way acceleration sensors on the outer walls of the high-speed gear box and the low-speed gear box and simultaneously leading out cam sensor signals so as to realize synchronous acquisition of vibration signals and crank shaft angle signals; The multi-working-condition synchronous acquisition module is used for setting combined working conditions of different balancer wind pressures and different slider speeds under the running state of the secondary press and acquiring vibration signals and crankshaft angle signals under each working condition in a multi-channel synchronous mode; The signal preprocessing module is used for performing anti-aliasing filtering, trending and band-pass filtering processing on the acquired vibration signals, and performing angular domain resampling by using the crank shaft angle signals to output angular domain stable signals; The time-frequency characteristic extraction module is used for carrying out time domain analysis and frequency domain analysis on the angular domain stable signal and outputting a time domain characteristic index, a gear pair meshing frequency and a frequency domain characteristic parameter; The envelope demodulation analysis module is used for carrying out band-pass filtering on the angle domain stationary signal to extract a high-frequency signal, carrying out Hilbert transformation envelope demodulation on the high-frequency signal, extracting a gear meshing impact envelope signal, and calculating an envelope spectrum output envelope characteristic parameter; The sideband and time-frequency analysis module is used for analyzing sideband characteristics of two sides of meshing frequency of the gear pair, acquiring a law of time variation of the meshing characteristics of the gear by adopting a time-frequency analysis method, and outputting sideband and time-frequency characteristic parameters; the health state evaluation module is used for carrying out gear engagement health evaluation based on the time domain characteristic index, the frequency domain characteristic parameter, the envelope characteristic parameter, the sidebands and the time-frequency characteristic parameter, and calculating the comprehensive health index HI so as to quantitatively evaluate the gear engagement state.

Description

Gear vibration testing method and device for two-stage transmission press Technical Field The application belongs to the technical field of vibration testing and state monitoring of presses, and particularly relates to a gear vibration testing method and device of a secondary transmission press. Background Mechanical presses are used as the core mechanical equipment for metal forming, and their transmission systems are generally composed of multi-stage gears, cranks and linkage mechanisms. The stability of the gear engagement state directly influences the transmission precision, the motion stability and the stamping quality of the whole machine. Because the press bears periodic impact load in the working process, the gear pair is extremely easy to have the problems of fluctuation of meshing rigidity, abrasion of tooth surfaces, assembly deviation and the like, thereby causing meshing vibration and abnormal sound and even causing fatigue damage of the gear. The traditional gear detection method is mostly dependent on static precision measurement or running noise subjective evaluation, and is difficult to accurately identify the formation of abnormal meshing and early faults. The existing vibration testing method can acquire acceleration or speed signals, but under the complex working condition of a press machine with high impact and strong background noise, the measured signal is complex in component, the signal-to-noise ratio is low, and effective fault characteristic information is often submerged. In addition, the existing method is limited to macroscopic analysis of the whole frequency spectrum, and lack of deep analysis of specific frequency components (such as meshing frequency, sidebands, resonance frequency bands and the like) generated in the gear meshing process leads to insensitivity to potential faults such as early tooth surface damage, meshing stiffness change and the like, so that accurate state evaluation and early warning are difficult to realize. Therefore, a high signal-to-noise ratio vibration test method capable of effectively extracting and analyzing the dynamic characteristics of gear engagement under the operating condition of a press is needed to realize real-time quantitative evaluation and early fault identification of the gear engagement state. Disclosure of Invention In a first aspect, an embodiment of the present application provides a gear vibration testing method for a secondary transmission press, where the secondary transmission press includes a flywheel, a high-speed gear box connected to the flywheel, a low-speed gear box connected to an output shaft of the high-speed gear box, a crank block mechanism driven by a crankshaft output from the low-speed gear box, and a balancer cylinder for balancing a weight of a slider in the crank block mechanism, and a cam sensor for detecting a rotational angle position of the crankshaft is disposed on the crankshaft, and the method includes the steps of: s1, arranging a plurality of groups of three-way acceleration sensors on the outer walls of a high-speed gear box and a low-speed gear box, and simultaneously leading out cam sensor signals so as to realize synchronous acquisition of vibration signals and crank shaft angle signals; S2, under the running state of the secondary press, setting combined working conditions of different balancer wind pressures and different slider speeds, and collecting vibration signals and crankshaft angle signals under each working condition in a multichannel synchronous mode; S3, performing anti-aliasing filtering, trending and band-pass filtering processing on the acquired vibration signals, and performing angular domain resampling by using the crank shaft angle signals to output angular domain stable signals; s4, performing time domain analysis and frequency domain analysis on the angular domain stationary signal, and outputting a time domain characteristic index, a gear pair meshing frequency and a frequency domain characteristic parameter; S5, carrying out band-pass filtering on the angle domain stationary signal to extract a high-frequency signal, carrying out Hilbert transformation envelope demodulation on the high-frequency signal, extracting a gear meshing impact envelope signal, and calculating an envelope spectrum output envelope characteristic parameter; s6, analyzing sideband features on two sides of meshing frequency of the gear pair, acquiring a law of time variation of the meshing features of the gear by using a time-frequency analysis method, and outputting sideband and time-frequency feature parameters; S7, carrying out gear engagement health evaluation based on the time domain characteristic index, the frequency domain characteristic parameter, the envelope characteristic parameter, the sidebands and the time-frequency characteristic parameter, and calculating the comprehensive health index HI so as to quantitatively evaluate the gear engagement state. Further, the specific steps of step