Damage extent identification method of typical rolling bearing faults based on acoustic emission multi-parameter fusion
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摘要:
针对滚动轴承典型故障损伤程度难识别的问题，以声发射参数分析和波形流分析方法为基础，结合时间到达特征指数（TAFI）、计数、撞击数、能量以及引入故障特征频率功率峰值与其相邻倍频间频带内平均功率比值的无量纲参数故障因子，提出了一种基于声发射多参数融合的滚动轴承典型故障损伤程度识别方法。为验证该方法对滚动轴承典型故障损伤程度的识别效果，搭建了滚动轴承典型故障模拟试验台，开展试验并采集了线切割严重损伤和点蚀微弱损伤两种缺陷的滚动轴承声发射信号，对相同转速工况下测得的典型故障轴承与健康轴承的声发射信号应用本文提出的方法进行识别。结果表明：声发射特征参数TAFI可以初步判定轴承是否存在故障，计数和撞击数可有效识别滚动轴承的故障类型；特征参数能量可有效识别外圈故障和滚动体故障滚动轴承的不同损伤程度，引入故障因子参量来表征不同缺陷滚动轴承的损伤程度，通过线切割和点蚀缺陷1～5倍频故障因子数值上的差异，有效识别了典型故障滚动轴承的不同损伤程度，弥补了特征参数能量对内圈故障损伤程度识别的不足。该方法可有效识别滚动轴承典型故障的不同损伤程度。
Abstract:In view of the problem in identifying the damage extent of typical rolling bearing faults, based on acoustic emission parameter analysis and waveform flow analysis methods, the time arrival feature index (TAFI), count, number of hits and energy were combined, and the non-dimensional parameter fault factor as the ratio of the peak power of the fault characteristic frequency to the average power in the frequency band between its adjacent octave was introduced. An identification method of the damage extent for typical rolling bearing faults based on acoustic emission multi-parameter fusion was proposed. In order to verify the identification effect of this method on the damage extent of typical rolling bearing faults, a test bench for simulating typical rolling bearing faults was built. Test was carried out and the acoustic emission signals of rolling bearing with two defects of serious damage caused by wire-cutting and weak damage caused by pitting caused were collected. The identification method proposed was applied to the acoustic emission signals of typical faulty bearings and healthy bearings measured under the same speed conditions. The results showed that the acoustic emission characteristic parameter TAFI can preliminarily determine whether the bearing was faulty, the count and number of hits can effectively identify the fault types of rolling bearings. The characteristic parameter energy can effectively identify different damage extents of the rolling bearing with outer ring fault and rolling element fault. The fault factor parameter was introduced to characterize the damage degree of rolling bearings with different defects, and the different damage extents of rolling bearing with typical faults were effectively identified through the numerical differences of the fault factors of 1−5 times fault characteristic frequency between wire-cutting and pitting defects, which made up for the lack of fault damage extent identification of inner ring fault with characteristic parameter energy. This method can effectively identify different damage extents of typical rolling bearing faults.
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Key words:
- acoustic emission /
- multi-parameter fusion /
- rolling bearing /
- typical fault /
- damage extent /
- fault factor
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图 1 声发射信号特征参数定义图
Figure 1. Characteristic parameter definition of acoustic emission signal
图 4 滚动轴承典型故障损伤程度识别流程
Figure 4. Identification process of damage extent of typical rolling bearing faults
图 12 典型故障及健康轴承计数对时间经历图
Figure 12. Counting-time history graph of different faulty bearings
图 13 典型故障及健康轴承撞击数对幅值分布图
Figure 13. Hit number-amplitude distribution map of different faulty bearings
图 14 典型故障及健康轴承能量对时间经历图
Figure 14. Energy-time history graph of different faulty bearings
图 15 不同损伤状态典型故障轴承平均计数
Figure 15. Average count of typical fault bearings under different damage states
图 16 不同损伤状态典型故障轴承平均能量
Figure 16. Average energy of typical fault bearings under different damage states
图 17 不同损伤状态典型故障轴承撞击总数
Figure 17. Total number of impacts of typical fault bearings under different damage states
图 24 轴承故障不同损伤状态的故障因子
Figure 24. Fault factors of bearing fault in different damage states
表 1 试验轴承的几何参数
Table 1. Geometric parameters of the test bearing
参数 数值及说明 轴承型号 NJ204EM 节径/mm 33.5 接触角/（°） 0 滚动体个数 12 滚动体直径/mm 6 
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表 2 不同损伤状态典型故障轴承的声发射参数统计
Table 2. Acoustic emission parameter statistics of typical fault bearings under different damage states
损伤
状态故障
类型计数
平均值能量平均值/
（mV·µs）撞击
总数健康 无故障 2.10 0.42 20 线切割
缺陷内圈 71.30 2.27 234 滚动体 169.67 466.03 841 外圈 281.90 825.03 625 点蚀缺陷 内圈 15.58 0.97 53 滚动体 51.35 30.94 721 外圈 186.48 48.29 236
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表 3 840 r/min转速下轴承线切割与点蚀损伤故障特征频率理论值
Table 3. Theoretical value of fault characteristic frequency of bearing linear cutting and pitting damage at 840 r/min speed
故障类型 故障特征频率理论值/Hz 外圈 ${f_{\text{o}}} = 60.91$ 滚动体 ${f_{\text{b}}} = 30.25$ 内圈 ${f_{\text{i}}} = 99.04$
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表 4 故障特征频率及倍频对应峰值和附近平均峰值
Table 4. Fault characteristic frequency and frequency doubling corresponding peak and nearby average peak
10−3 W 特征
频率变量值 外圈 滚动体 内圈 线切割故障 点蚀故障 线切割故障 点蚀故障 线切割故障 点蚀故障 1倍频 D2 4.22 1.78 59.7 1.65 0.0189 0.176 D 0.78 0.81 9.0 0.58 0.0070 0.120 2倍频 D2 3.71 1.24 62.7 1.66 0.0185 0.123 D 0.78 0.65 10.1 0.49 0.0069 0.079 3倍频 D2 2.38 1.18 47.3 1.20 0.0148 0.098 D 0.76 0.57 9.2 0.48 0.0055 0.069 4倍频 D2 2.78 1.03 43.3 1.23 0.0153 0.089 D 0.77 0.47 9.1 0.48 0.0056 0.059 5倍频 D2 2.29 0.72 28.4 0.0128 0.090 D 0.75 0.38 9.0 0.47 0.0053 0.063
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表 5 不同损伤状态典型故障轴承的故障因子
Table 5. Fault factors of typical fault bearings under different damage states
故障类型 损伤状态 $ {\lambda _1} $ $ {\lambda _2} $ $ {\lambda _3} $ $ {\lambda _4} $ $ {\lambda _5} $ 外圈 线切割 5.38 4.75 3.13 3.63 3.05 点蚀 2.19 1.92 2.08 2.22 1.88 滚动体 线切割 6.67 6.21 5.16 4.74 3.16 点蚀 2.84 3.40 2.51 2.55 1.00 内圈 线切割 2.71 2.69 2.67 2.75 2.41 点蚀 1.46 1.56 1.43 1.50 1.43
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