高速電主軸動(dòng)態(tài)加載可靠性試驗(yàn)及其故障診斷研究
發(fā)布時(shí)間：2019-02-09 14:28
【摘要】：數(shù)控機(jī)床作為裝備制造業(yè)的基礎(chǔ)和關(guān)鍵設(shè)備,其性能與質(zhì)量反映了一個(gè)國(guó)家制造業(yè)水平的高低。目前,可靠性水平是我國(guó)數(shù)控機(jī)床行業(yè)的技術(shù)瓶頸之一,因此,提高國(guó)產(chǎn)數(shù)控機(jī)床整機(jī)及其關(guān)鍵功能部件的可靠性水平勢(shì)在必行。高速電主軸作為數(shù)控機(jī)床關(guān)鍵功能部件之一,通常是數(shù)控機(jī)床功率輸出的核心部件,是目前制約我國(guó)數(shù)控機(jī)床整機(jī)可靠性水平的薄弱環(huán)節(jié)。因此,國(guó)產(chǎn)電主軸的可靠性水平亟待提高。本文以國(guó)產(chǎn)高速電主軸為研究對(duì)象,提出了考慮維修成本的電主軸FMECA方法,并根據(jù)現(xiàn)場(chǎng)可靠性試驗(yàn)數(shù)據(jù),對(duì)電主軸進(jìn)行故障分析;以機(jī)床實(shí)際工況的載荷數(shù)據(jù)為依據(jù),編制了電主軸多維動(dòng)態(tài)載荷譜,進(jìn)而設(shè)計(jì)并開展了電主軸可靠性試驗(yàn);為實(shí)現(xiàn)電主軸工作時(shí)的徑向跳動(dòng)及軸向竄動(dòng)的狀態(tài)監(jiān)測(cè),提出了一種基于加速度時(shí)-頻域混合積分的電主軸振動(dòng)監(jiān)測(cè)方法;最后,提出了一種基于S變換改進(jìn)閾值去噪的電主軸故障診斷方法,并進(jìn)行了實(shí)例驗(yàn)證。本文的主要工作和研究成果如下:(1)論述了國(guó)內(nèi)外數(shù)控機(jī)床電主軸可靠性技術(shù)的發(fā)展和研究現(xiàn)狀,闡述了電主軸可靠性試驗(yàn)技術(shù)研究的背景及意義。對(duì)國(guó)內(nèi)外電主軸的故障分析、電主軸靜力加載及載荷譜加載的可靠性試驗(yàn)技術(shù)進(jìn)行了探討,綜合評(píng)述了基于電主軸可靠性試驗(yàn)臺(tái)的電主軸性能監(jiān)測(cè)技術(shù)及故障診斷技術(shù);在上述工作基礎(chǔ)上,給出了本文關(guān)于電主軸可靠性試驗(yàn)及故障診斷研究的技術(shù)路線。(2)基于電主軸系統(tǒng)的組成結(jié)構(gòu)與功能原理,對(duì)電主軸進(jìn)行子系統(tǒng)劃分。從電主軸故障模式分析入手,結(jié)合危害性分析的方法,對(duì)現(xiàn)場(chǎng)可靠性試驗(yàn)得到的故障數(shù)據(jù)進(jìn)行了分析。針對(duì)傳統(tǒng)危害度計(jì)算中存在的問(wèn)題,即忽略了企業(yè)維修電主軸故障時(shí)付出的成本,提出一種考慮維修成本的危害度計(jì)算方法,并進(jìn)行了危害度分析,得到了危害度最高的電主軸單元子系統(tǒng),最終結(jié)果表明,該方法彌補(bǔ)了傳統(tǒng)FMECA方法的不足,為電主軸可靠性試驗(yàn)、可靠性設(shè)計(jì)及可靠性增長(zhǎng)提供了參考依據(jù)。(3)設(shè)計(jì)并開展了基于多維載荷譜動(dòng)態(tài)加載的電主軸可靠性試驗(yàn)。鑒于以往載荷譜編制方法只能將切削力、扭矩、轉(zhuǎn)速分別作譜,忽略了切削力、扭矩、轉(zhuǎn)速間的對(duì)應(yīng)關(guān)系,與實(shí)際工況不符的問(wèn)題,提出電主軸的多維載荷譜編制思想。依據(jù)加工中心的現(xiàn)場(chǎng)載荷數(shù)據(jù),分析并計(jì)算了切削力及切削扭矩。將切削力及切削扭矩按照輕載、輕中載、中載、中重載及重載,轉(zhuǎn)速按低速、中速、高速分別進(jìn)行分級(jí),編制了包含轉(zhuǎn)速、軸向力、徑向力、扭矩及相對(duì)循環(huán)次數(shù)的多維載荷譜。最終,在電主軸試驗(yàn)臺(tái)受載范圍內(nèi)設(shè)計(jì)并開展了電主軸的可靠性試驗(yàn),包括空運(yùn)轉(zhuǎn)試驗(yàn)、靜載試驗(yàn)及基于多維載荷譜動(dòng)態(tài)加載的可靠性試驗(yàn),并進(jìn)行了電主軸可靠性評(píng)估。(4)針對(duì)數(shù)控機(jī)床切削作業(yè)時(shí)難以實(shí)時(shí)監(jiān)測(cè)其徑向跳動(dòng)、軸向竄動(dòng)的問(wèn)題,提出了一種基于加速度傳感器的時(shí)-頻域混合積分的監(jiān)測(cè)方法。對(duì)加速度信號(hào)進(jìn)行高通濾波時(shí)域積分后,再經(jīng)過(guò)低頻截止頻域積分,得到電主軸振動(dòng)位移,即電主軸的徑向跳動(dòng)與軸向竄動(dòng)。通過(guò)與Lab VIEW同步采集的數(shù)據(jù)進(jìn)行積分誤差檢驗(yàn)表明,經(jīng)時(shí)-頻域混合積分法處理的結(jié)果與實(shí)測(cè)數(shù)據(jù)一致性較好。同時(shí)與簡(jiǎn)單二次時(shí)域積分法、簡(jiǎn)單二次頻域積分法、低頻截止頻域積分法、多項(xiàng)式擬合時(shí)域積分法以及高通濾波時(shí)域積分法等五種方法進(jìn)行了對(duì)比處理,試驗(yàn)結(jié)果表明,時(shí)-頻域混合積分法得到的位移信號(hào)積分誤差較小,更貼近實(shí)測(cè)位移信號(hào),可以用于監(jiān)測(cè)加工中心電主軸工作時(shí)的徑向跳動(dòng)及軸向竄動(dòng)。(5)提出了一種基于S變換改進(jìn)閾值去噪的電主軸故障診斷方法。在傳統(tǒng)閾值算法的基礎(chǔ)上,引入矯正參數(shù),并結(jié)合S變換對(duì)故障特征頻率進(jìn)行提取,進(jìn)而判斷故障類型,最終實(shí)現(xiàn)電主軸故障診斷。基于高速電主軸可靠性試驗(yàn)的振動(dòng)數(shù)據(jù),采用S變換改進(jìn)閾值去噪法對(duì)電主軸轉(zhuǎn)子摩擦、不對(duì)中及機(jī)械松動(dòng)等三種故障進(jìn)行了診斷與識(shí)別。同時(shí)采用FFT、STFT以及HHT等三種故障診斷方法對(duì)故障數(shù)據(jù)進(jìn)行處理,與S變換改進(jìn)閾值去噪結(jié)果進(jìn)行對(duì)比表明,FFT容易出現(xiàn)故障特征提取過(guò)度的問(wèn)題,HHT則不能全面、精確地進(jìn)行提取故障特征,而由于故障信號(hào)信噪比太差,STFT最不適用于電主軸故障診斷。對(duì)比分析結(jié)果證明了S變換改進(jìn)閾值去噪方法在電主軸故障診斷中的優(yōu)越性。
[Abstract]:As the base and key equipment of the equipment manufacturing industry, the performance and quality of the NC machine tool reflect the level of a country's manufacturing industry. At present, the reliability level is one of the technical bottleneck of the NC machine tool industry in China, so it is imperative to improve the reliability level of the whole machine and key functional parts of the home-made NC machine tool. As one of the key functional parts of NC machine, the high-speed electric spindle is usually the core part of the power output of the numerical control machine, which is the weak link that restricts the reliability level of the whole machine in China. Therefore, the reliability level of the domestic electric spindle needs to be improved. In this paper, using the domestic high-speed electric spindle as the research object, an electric spindle FMECA method considering the maintenance cost is put forward, and the fault analysis of the electric spindle is carried out according to the data of the on-site reliability test, the multi-dimensional dynamic load spectrum of the electric spindle is prepared based on the load data of the actual working condition of the machine tool, so as to design and carry out the reliability test of the electric spindle, and provides an electric spindle vibration monitoring method based on the acceleration time-frequency domain mixing integral to realize the state monitoring of the radial run-out and the axial movement during the work of the electric spindle, and finally, An electric spindle fault diagnosis method based on S-transform to improve the threshold de-noising is proposed, and the example verification is carried out. The main work and research results of this paper are as follows: (1) The development and research status of the reliability technology of the electric spindle of the NC machine at home and abroad are discussed, and the background and significance of the research on the reliability test technology of the electric spindle are described. The fault analysis of the main electric spindle at home and abroad, the static loading of the electric spindle and the reliability test technology of the load spectrum loading are discussed, and the performance monitoring technology and the fault diagnosis technology of the electric spindle based on the reliability test stand of the electric spindle are comprehensively reviewed. On the basis of the above work, The technical route of the reliability test and fault diagnosis of the electric spindle is given in this paper. (2) Based on the composition structure and functional principle of the electric spindle system, the sub-system of the electric spindle is divided. Based on the analysis of the failure mode of the electric spindle, the fault data obtained from the on-site reliability test is analyzed by means of the method of hazard analysis. Aiming at the problems existing in the calculation of the traditional hazard degree, that is, the cost of the failure of the maintenance electric spindle of the enterprise is ignored, a method for calculating the hazard degree of the maintenance cost is put forward, the harm degree analysis is carried out, the electric spindle unit sub-system with the highest harm degree is obtained, and the final result is that, The method overcomes the shortcomings of the traditional FMECA method, and provides a reference basis for the reliability test, the reliability design and the reliability growth of the electric spindle. (3) The reliability test of the electric spindle based on the dynamic loading of the multi-dimensional load spectrum is designed and carried out. In view of the previous load spectrum method, the cutting force, the torque and the rotating speed can be respectively used as the spectrum, the corresponding relation between the cutting force, the torque and the rotating speed is ignored, and the problem that the actual working condition is not in conformity with the actual working condition is ignored, and the multi-dimensional load spectrum preparation method of the electric spindle is put forward. According to the field load data of the machining center, the cutting force and cutting torque are analyzed and calculated. The cutting force and cutting torque are classified according to the light load, the light medium load, the medium load, the medium heavy load and the heavy load, and the rotating speed is respectively graded according to the low speed, the medium speed and the high speed, and the multi-dimensional load spectrum including the rotation speed, the axial force, the radial force, the torque and the relative cycle time is prepared. Finally, the reliability test of the electric spindle is carried out in the load range of the electric spindle test bed, including the air transfer test, the static load test and the reliability test based on the dynamic loading of the multi-dimensional load spectrum, and the reliability evaluation of the electric spindle is carried out. (4) It is difficult to monitor the radial runout and axial movement of the numerical control machine in real time, and a method for monitoring the time-frequency domain mixed integral based on the acceleration sensor is put forward. after the time-domain integral of the acceleration signal is high-pass filtered, the vibration displacement of the electric spindle is obtained through the low-frequency cut-off frequency domain integral, namely, the radial jump and the axial movement of the electric main shaft. The integration error test of the data collected with the Lab VIEW shows that the result of the time-domain mixed integration method is better with the measured data. At the same time, compared with the simple quadratic time-domain integral method, the simple quadratic frequency-domain integral method, the low-frequency cut-off frequency-domain integration method, the polynomial fitting time-domain integral method and the high-pass filtering time-domain integral method, the experimental results show that, and the displacement signal integration error obtained by the time-frequency domain mixing integration method is small, is closer to the measured displacement signal, and can be used for monitoring the radial runout and the axial movement of the machining center electric spindle during the work. (5) An electric spindle fault diagnosis method based on S-transform to improve the threshold de-noising is proposed. On the basis of the traditional threshold algorithm, the correction parameter is introduced, and the fault characteristic frequency is extracted in combination with the S transformation, and then the fault type is judged, and the fault diagnosis of the electric spindle is finally realized. Based on the vibration data of the reliability test of the high-speed electric spindle, the method of S-transform to improve the threshold de-noising method is used to diagnose and identify the three faults such as the friction, the non-centering and the mechanical loosening of the electric spindle. in that same time, three fault diagnosis methods such as FFT, STFT and HHT are adopted to process the fault data, and compared with the improvement threshold de-noising result of the S-transform, the problem that the FFT is prone to fault feature extraction is solved, and the HHT can not comprehensively and accurately extract the fault characteristic, Because the signal-to-noise ratio of the fault signal is too poor, the STFT is most suitable for the fault diagnosis of the electric spindle. The comparative analysis results show the superiority of the S-transform improved threshold de-noising method in the fault diagnosis of the electric spindle.
【學(xué)位授予單位】：吉林大學(xué)
【學(xué)位級(jí)別】：博士
【學(xué)位授予年份】：2016
【分類號(hào)】：TG659
本文編號(hào)：2419051
[Abstract]:As the base and key equipment of the equipment manufacturing industry, the performance and quality of the NC machine tool reflect the level of a country's manufacturing industry. At present, the reliability level is one of the technical bottleneck of the NC machine tool industry in China, so it is imperative to improve the reliability level of the whole machine and key functional parts of the home-made NC machine tool. As one of the key functional parts of NC machine, the high-speed electric spindle is usually the core part of the power output of the numerical control machine, which is the weak link that restricts the reliability level of the whole machine in China. Therefore, the reliability level of the domestic electric spindle needs to be improved. In this paper, using the domestic high-speed electric spindle as the research object, an electric spindle FMECA method considering the maintenance cost is put forward, and the fault analysis of the electric spindle is carried out according to the data of the on-site reliability test, the multi-dimensional dynamic load spectrum of the electric spindle is prepared based on the load data of the actual working condition of the machine tool, so as to design and carry out the reliability test of the electric spindle, and provides an electric spindle vibration monitoring method based on the acceleration time-frequency domain mixing integral to realize the state monitoring of the radial run-out and the axial movement during the work of the electric spindle, and finally, An electric spindle fault diagnosis method based on S-transform to improve the threshold de-noising is proposed, and the example verification is carried out. The main work and research results of this paper are as follows: (1) The development and research status of the reliability technology of the electric spindle of the NC machine at home and abroad are discussed, and the background and significance of the research on the reliability test technology of the electric spindle are described. The fault analysis of the main electric spindle at home and abroad, the static loading of the electric spindle and the reliability test technology of the load spectrum loading are discussed, and the performance monitoring technology and the fault diagnosis technology of the electric spindle based on the reliability test stand of the electric spindle are comprehensively reviewed. On the basis of the above work, The technical route of the reliability test and fault diagnosis of the electric spindle is given in this paper. (2) Based on the composition structure and functional principle of the electric spindle system, the sub-system of the electric spindle is divided. Based on the analysis of the failure mode of the electric spindle, the fault data obtained from the on-site reliability test is analyzed by means of the method of hazard analysis. Aiming at the problems existing in the calculation of the traditional hazard degree, that is, the cost of the failure of the maintenance electric spindle of the enterprise is ignored, a method for calculating the hazard degree of the maintenance cost is put forward, the harm degree analysis is carried out, the electric spindle unit sub-system with the highest harm degree is obtained, and the final result is that, The method overcomes the shortcomings of the traditional FMECA method, and provides a reference basis for the reliability test, the reliability design and the reliability growth of the electric spindle. (3) The reliability test of the electric spindle based on the dynamic loading of the multi-dimensional load spectrum is designed and carried out. In view of the previous load spectrum method, the cutting force, the torque and the rotating speed can be respectively used as the spectrum, the corresponding relation between the cutting force, the torque and the rotating speed is ignored, and the problem that the actual working condition is not in conformity with the actual working condition is ignored, and the multi-dimensional load spectrum preparation method of the electric spindle is put forward. According to the field load data of the machining center, the cutting force and cutting torque are analyzed and calculated. The cutting force and cutting torque are classified according to the light load, the light medium load, the medium load, the medium heavy load and the heavy load, and the rotating speed is respectively graded according to the low speed, the medium speed and the high speed, and the multi-dimensional load spectrum including the rotation speed, the axial force, the radial force, the torque and the relative cycle time is prepared. Finally, the reliability test of the electric spindle is carried out in the load range of the electric spindle test bed, including the air transfer test, the static load test and the reliability test based on the dynamic loading of the multi-dimensional load spectrum, and the reliability evaluation of the electric spindle is carried out. (4) It is difficult to monitor the radial runout and axial movement of the numerical control machine in real time, and a method for monitoring the time-frequency domain mixed integral based on the acceleration sensor is put forward. after the time-domain integral of the acceleration signal is high-pass filtered, the vibration displacement of the electric spindle is obtained through the low-frequency cut-off frequency domain integral, namely, the radial jump and the axial movement of the electric main shaft. The integration error test of the data collected with the Lab VIEW shows that the result of the time-domain mixed integration method is better with the measured data. At the same time, compared with the simple quadratic time-domain integral method, the simple quadratic frequency-domain integral method, the low-frequency cut-off frequency-domain integration method, the polynomial fitting time-domain integral method and the high-pass filtering time-domain integral method, the experimental results show that, and the displacement signal integration error obtained by the time-frequency domain mixing integration method is small, is closer to the measured displacement signal, and can be used for monitoring the radial runout and the axial movement of the machining center electric spindle during the work. (5) An electric spindle fault diagnosis method based on S-transform to improve the threshold de-noising is proposed. On the basis of the traditional threshold algorithm, the correction parameter is introduced, and the fault characteristic frequency is extracted in combination with the S transformation, and then the fault type is judged, and the fault diagnosis of the electric spindle is finally realized. Based on the vibration data of the reliability test of the high-speed electric spindle, the method of S-transform to improve the threshold de-noising method is used to diagnose and identify the three faults such as the friction, the non-centering and the mechanical loosening of the electric spindle. in that same time, three fault diagnosis methods such as FFT, STFT and HHT are adopted to process the fault data, and compared with the improvement threshold de-noising result of the S-transform, the problem that the FFT is prone to fault feature extraction is solved, and the HHT can not comprehensively and accurately extract the fault characteristic, Because the signal-to-noise ratio of the fault signal is too poor, the STFT is most suitable for the fault diagnosis of the electric spindle. The comparative analysis results show the superiority of the S-transform improved threshold de-noising method in the fault diagnosis of the electric spindle.
【學(xué)位授予單位】：吉林大學(xué)
【學(xué)位級(jí)別】：博士
【學(xué)位授予年份】：2016
【分類號(hào)】：TG659
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