面向行星轮系复合故障诊断的非接触扭振测量与残余振动分析方法

A non-contact torsional vibration measurement and residue analysis method for compound fault diagnosis of planetary gearing train

  • 摘要: 行星齿轮传动系统广泛应用于工业领域, 由于其结构紧凑、复杂,长期服役时机械部件易发生故障。行星轮系结构与运动形式远比定轴轮系复杂,基于固定测点的振动状态监测技术面临多激励源并存和传递路径时变的挑战,难以满足复合故障诊断需求,特别是行星轮早期故障与轴承故障耦合时。为解决此问题,提出了利用激光多普勒测振技术的非接触扭振监测与残余振动分析方法。将激光入射点设置在低速轴表面,直接获取轮系扭振信息。为减轻测量噪声对故障特征提取的影响,提出了基于倒谱分析的软阈值编辑和中值滤波方法,分别抑制伪振动和随机性脉冲噪声。针对复合故障的不同特点,逐步剥离扭振信号中的残余宽带响应与残余啮合边带分量,一方面,对倒谱短通得到的宽带响应进行优化滤波,以提取轴承故障的二阶循环平稳特征;另一方面,提出了基于相位自解调的阶次域重采样方法,通过重构不同阶的啮合边带残余信号,以凸显齿轮故障特征。通过行星轮齿面剥落与太阳轮轴承滚道剥落故障注入试验,证明了所提方法可有效实现行星轮系复合故障的非接触诊断,与经典柔性同步平均法和箱体振动信号的分析结果相比,所提方法在不同转速下对行星轮早期故障的识别效果更优。

     

    Abstract: Planetary gear transmission systems are extensively used in industrial applications. Due to their compact and complex configurations, mechanical components are prone to failure during long-term operation. Compared to fixed-axis gear systems, planetary gear systems exhibit multiple excitation sources and time-varying signal transmission paths stemming from their intricate structural and kinematic characteristics. Consequently, condition monitoring techniques based on fixed vibration measurement points face significant challenges in compound fault diagnosis, especially when a planet gear fault is coupled with a bearing fault. To address these issues, this study proposes a non-contact torsional vibration monitoring and residual vibration analysis method utilizing laser doppler vibrometry (LDV). The laser beam is positioned on the low-speed shaft surface to directly acquire torsional vibration information from the gear system. To mitigate the impact of measurement noise on fault feature extraction, a hybrid denoising strategy combining cepstrum-based soft-threshold editing and median filtering is developed to suppress pseudo-vibration artifacts and random impulse noise, respectively. For different types of compound faults, a progressive residual vibration decomposition framework is established. This framework systematically peels off residual broadband response and residual meshing sideband components from the torsional vibration signal. Specifically, optimized filtering is applied to the broadband response obtained via cepstrum short-pass to extract the second-order cyclostationary features of bearing faults. Concurrently, a phase self-demodulation-based order domain resampling method is proposed to highlight gear fault features by reconstructing meshing sideband residual signals of different orders. Experiments involving tooth spalling on planetary gears and raceway spalling on the sun gear bearing demonstrate that the proposed method can effectively achieve non-contact compound fault diagnosis for planetary gear systems. Compared to conventional flexible synchronous averaging and accelerometer-based methods, the proposed approach exhibits superior performance in early-stage planet gear fault detection under varying speeds.

     

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