CN116878867A - Fault diagnosis method for mining speed reducer - Google Patents

Abstract

A fault diagnosis method for a mining reducer, including: testing the standard operating data of the mining reducer in each input torque section on a loading test bench in advance, and establishing the standards corresponding to each input torque section. The mapping relationship of the operating data can obtain the standard operating data map of the mining reducer during normal operation; among which, the operating data is the data collected by the sensor on the mining reducer; when the mining reducer is running, the data from the reducer is The actual input torque is obtained from the drive system, and the actual operating data at this time is obtained from the sensor of the mining reducer; the fault of the mining reducer is diagnosed based on the actual operating data, actual input torque and standard operating data map. This solution can improve the accuracy of reducer fault diagnosis.

Description

Fault diagnosis method of mining reducer

Technical field

The invention relates to the technical field of scraper conveyor equipment, and in particular to a fault diagnosis method for a mining reducer.

Background technique

Intelligent mining technology in coal mines is developing rapidly. As a key equipment for raw coal mining and transportation in underground coal mine working surfaces, scraper conveyors have developed slowly in automation and intelligent technology. Especially the reducer of the scraper conveyor, as the core transmission component of the scraper conveyor, the operating data of the reducer is the key to the automation and intelligence of the scraper conveyor. Whether its operation is normal plays an important role in the raw coal transportation efficiency of the scraper conveyor. Therefore, when the reducer fails, it is crucial to diagnose the fault quickly, so that the corresponding fault treatment can be carried out as soon as possible according to the diagnosed fault, thereby ensuring the normal operation of the reducer.

At present, when the reducer fault diagnosis and analysis are performed based on the monitored reducer operating data, the judgment is usually made based on a single operating data, such as only setting thresholds such as operating temperature, bearing temperature, and bearing vibration amplitude. However, the influencing factors on the operation of the reducer are complex. Similarly, the operating data that will show abnormal changes when it fails is not single. That is, there is usually an inherent relationship between operating parameters. Based on a single operating data The fault diagnosis results obtained are less reliable. In addition, there are many types of reducer failures. As long as the type of reducer failure is accurately diagnosed, targeted troubleshooting measures can be implemented to handle the fault quickly and accurately. However, the current method based on a single operating data Fault diagnosis methods are difficult to accurately diagnose various fault types. Therefore, the current reducer fault diagnosis method has low accuracy.

Contents of the invention

In view of this, in view of the above shortcomings, it is necessary to propose a fault diagnosis method for mining reducers to improve the accuracy of reducer fault diagnosis.

The embodiment of the present invention provides a fault diagnosis method for a mining reducer, which includes:

Test the standard operating data corresponding to each input torque section of the mining reducer on the loading test bench in advance, and establish the mapping relationship between each input torque section and the corresponding standard operating data to obtain the normal operation of the mining reducer. The standard operating data chart at that time; among which, the operating data is the data collected by the sensor on the mining reducer;

When the mining reducer is running, the actual input torque is obtained from the reducer drive system, and the actual operating data at this time is obtained from the sensor of the mining reducer;

According to the actual operating data, actual input torque and the standard operating data map, the fault of the mining reducer is diagnosed.

Preferably, the operating data includes: bearing vibration amplitude, gear vibration amplitude, input shaft swing, bearing temperature, gear oil temperature, oil level, oil quality, input seal, output seal, cooling water temperature, cooling water pressure and cooling water flow.

Preferably, the standard operating data corresponding to the torque value of the actual input torque in the standard operating data map includes: standard bearing temperature, standard cooling water flow rate, standard cooling water temperature and standard oil level;

Diagnosing the fault of the mining reducer based on the actual operating data, actual input torque and the standard operating data map includes:

Step A1: Determine whether it is satisfied: the actual input torque in the obtained operating data is less than the first torque ratio of the reducer's rated torque, and the actual bearing temperature in the actual operating data has increased to no less than the first temperature within the preset time. threshold; if yes, perform step A2; otherwise, continue to monitor the operating data; wherein the first temperature threshold is greater than the standard bearing temperature;

Step A2: Determine whether it is satisfied: the actual cooling water flow rate is reduced by a first flow rate ratio compared with the standard cooling water flow rate, the actual cooling water temperature is greater than the standard cooling water temperature, and other operating data are located in the standard operating data map. Corresponding normal range; if yes, then the fault diagnosis of the mining reducer is excessive bearing temperature caused by reduced cooling water flow; if not, perform step A3;

Step A3: Determine whether: the actual cooling water temperature is greater than the standard cooling water temperature, the actual oil level is lower than the first oil level ratio of the standard oil level, and other operating data are located in the corresponding standard operating data map. The normal range; if so, the fault diagnosis of the mining reducer is excessive bearing temperature caused by insufficient gear oil.

Preferably, the standard operating data corresponding to the torque value of the actual input torque in the standard operating data map includes: standard gear oil temperature, standard cooling water flow rate, standard cooling water temperature and standard oil level;

Diagnosing the fault of the mining reducer based on the actual operating data, actual input torque and the standard operating data map includes:

Step B1: Determine whether it is satisfied: the actual input torque in the obtained operating data is less than the second torque ratio of the rated torque of the reducer, and the actual gear oil temperature in the actual operating data has increased to no less than the second torque ratio within the preset time. temperature threshold; if yes, perform step B2; otherwise, continue to monitor the operating data; wherein the second temperature threshold is greater than the standard gear oil temperature;

Step B2: Determine whether it is satisfied: the actual cooling water flow rate is reduced by a second flow rate ratio compared with the standard cooling water flow rate, the actual cooling water temperature is greater than the standard cooling water temperature, and other operating data are located in the standard operating data map. Corresponding normal range; if yes, then the fault diagnosis of the mining reducer is excessive gear oil temperature caused by reduced cooling water flow; if not, perform step B3;

Step B3: Determine whether the actual cooling water temperature is greater than the standard cooling water temperature, the actual oil level is lower than the second oil level ratio of the standard oil level, and other operating data are located in the corresponding standard operating data map. The normal range; if so, the fault diagnosis of the mining reducer is excessive gear oil temperature caused by insufficient gear oil.

Preferably, diagnosing the fault of the mining reducer based on the actual operating data, actual input torque and the standard operating data map includes: if oil leakage is detected in the input seal or the output seal If so, the fault diagnosis of the mining reducer is seal failure.

Preferably, the standard operating data corresponding to the torque value of the actual input torque in the standard operating data map includes: standard bearing temperature, standard input shaft swing, standard bearing vibration amplitude, standard oil quality, standard gear oil temperature, Standard cooling water flow, standard cooling water temperature and standard oil level;

Diagnosing the fault of the mining reducer based on the actual operating data, actual input torque and the standard operating data map includes:

Step C1: Determine whether it is satisfied: the actual input torque in the obtained operating data is less than the third torque ratio of the reducer's rated torque, and the actual bearing temperature has increased to no less than the third temperature threshold within the preset time; if so, perform steps C2; otherwise, continue to monitor the operating data; wherein the third temperature threshold is greater than the standard bearing temperature;

Step C2: Determine whether it is satisfied: the actual input shaft swing is greater than the standard input shaft swing by a first swing ratio, and the actual bearing vibration amplitude is greater than the standard bearing vibration amplitude by a first vibration ratio; if yes, execute step C3, otherwise Execute step C4;

Step C3: Determine whether the actual oil quality contains more metal particles than the standard oil quality; if so, the fault diagnosis of the mining reducer is a bearing failure caused by metal impurities entering the bearing track; otherwise, the mining reducer The fault diagnosis of the reducer was bearing fatigue failure;

Step C4: Determine whether it is satisfied: the actual gear oil temperature has increased to no less than the fourth temperature threshold within the preset time, the actual cooling water flow rate is reduced by a third flow rate ratio compared with the standard cooling water flow rate, and the actual cooling water temperature is greater than the standard cooling water flow rate. The water temperature, and other operating data are within the corresponding normal range in the standard operating data map; if yes, the fault diagnosis of the mining reducer is bearing failure caused by reduced cooling water flow; if not, perform step C5;

Step C5: Determine whether the seal failure failure of the reducer has been diagnosed, and the actual oil level is lower than the third oil level ratio of the standard oil level; if so, the fault diagnosis of the mining reducer is based on Bearing failure caused by insufficient gear oil.

Preferably, the standard operating data corresponding to the torque value of the actual input torque in the standard operating data map includes: standard input shaft swing, standard bearing vibration amplitude, and standard oil quality;

Diagnosing the fault of the mining reducer based on the actual operating data, actual input torque and the standard operating data map includes:

D1: Determine whether the actual input torque in the obtained operating data is less than the fourth torque ratio of the reducer's rated torque; if so, proceed to step D2; otherwise, continue to monitor the operating data;

D2: Determine whether it is satisfied: the actual input shaft swing has a regular band that is larger than the standard input shaft swing by a second swing ratio, the actual bearing vibration amplitude has a regular band that is larger than the standard bearing vibration amplitude by a second vibration ratio, and other The operating data is within the normal range corresponding to the standard operating data chart; if so, the fault diagnosis of the mining reducer is gear failure caused by defects in the tooth surface of the gear part; if not, proceed to step D3;

D3: Determine whether there are more metal particles in the actual oil quality than the standard oil quality; if so, the fault diagnosis of the mining reducer is gear failure caused by pitting corrosion on the gear tooth surface.

Preferably, the standard operating data corresponding to the torque value of the actual input torque in the standard operating data map includes: standard oil quality;

Diagnosing the fault of the mining reducer based on the actual operating data, actual input torque and the standard operating data map includes:

E1: Determine whether the actual oil quality has increased metal particle content or metal particle size compared to the standard oil quality; if so, the fault diagnosis of the mining reducer is caused by gear wear, bearing raceway or gear tooth surface metal peeling The gear oil has deteriorated; otherwise, proceed to step E2;

E2: Determine whether the actual oil quality has increased water content compared to the standard oil quality; if so, the fault diagnosis of the mining reducer is gear oil deterioration caused by cooler leakage; if not, proceed to step E3;

E3: Determine whether it is satisfied: the actual oil quality has a viscosity decay greater than the first viscosity ratio compared to the standard oil quality, and the actual gear oil temperature has not changed; if so, the fault diagnosis of the mining reducer is gear oil deterioration.

Preferably, the standard operating data corresponding to the torque value of the actual input torque in the standard operating data map includes: standard oil quality, standard cooling water pressure and standard cooling water flow rate;

Diagnosing the fault of the mining reducer based on the actual operating data, actual input torque and the standard operating data map includes:

F1: Determine whether the actual oil quality is greater than the water content of the standard oil quality; if so, the fault diagnosis of the mining reducer is cooler leakage; otherwise, proceed to step F2;

F2: Determine whether it is satisfied: the actual cooling water flow gradually decreases relative to the standard cooling water flow within a period of time, and the actual cooling water pressure does not change relative to the standard cooling water pressure; if so, the mining reducer The fault diagnosis is that the inner diameter of the cooling pipe is reduced due to scale formation in the cooling pipe; if not, proceed to step F3;

F3: Determine whether it is satisfied: the reduction of the actual cooling water flow within the preset time is greater than the fourth flow ratio, and the actual cooling water pressure has not changed relative to the standard cooling water pressure; if so, then the mining reducer has The fault was diagnosed as particulate matter flowing into the cooling pipe.

Preferably, the fault diagnosis method further includes: optimizing the standard operating data map according to the data of each fault diagnosis and the accuracy of the fault diagnosis.

In the fault diagnosis method of the mining reducer provided by the embodiment of the present invention, the standard operating data corresponding to each input torque segment is first tested in the loading test bench, so that the corresponding relationship between each input torque and the standard operating data can be established. Further, when the mining reducer is running, the actual operating data is obtained from the sensor of the mining reducer, and the actual input torque at this time is also obtained. In this way, fault diagnosis of the mining reducer can be realized based on the actual input torque and the difference between the corresponding actual operating data and the standard operating data map. It can be seen that this solution uses multi-dimensional data such as sensor data and system data to comprehensively diagnose and analyze mining reducer faults. It can more accurately determine the type and cause of the fault and improve the accuracy of fault diagnosis. .

Description of the drawings

Figure 1 is a flow chart of a fault diagnosis method for a mining reducer.

Detailed ways

In order to more clearly illustrate the technical solutions of the embodiments of the present invention, a brief introduction will be made below to the drawings required to be used in the embodiments. Obviously, the drawings in the following description are some embodiments of the present invention, which are of great significance to this field. Ordinary technicians can also obtain other drawings based on these drawings without exerting creative work.

As shown in Figure 1, an embodiment of the present invention provides a fault diagnosis method for a mining reducer, which may include the following steps:

Step 1: Test the standard operating data corresponding to each input torque segment of the mining reducer on the loading test bench in advance, and establish the mapping relationship between each input torque segment and the corresponding standard operating data to obtain the mining deceleration The standard operating data chart of the normal operation of the reducer; among which, the operating data is the data collected by the sensor on the mining reducer;

Step 2: When the mining reducer is running, obtain the actual input torque from the reducer drive system, and at the same time obtain the actual operating data at this time from the sensor of the mining reducer;

Step 3: Diagnose the fault of the mining reducer based on the actual operating data, actual input torque and standard operating data map.

For the reducer of the coal mine scraper conveyor, the main faults that are prone to occur are bearing failure, gear failure, seal failure, gear oil temperature is too high, bearing temperature is too high, oil quality deterioration, cooling failure, etc.

The operating data of the reducer can mainly consist of two parts: the operating data collected by the sensor and the data directly obtained from the reducer drive system. Among them, the reducer operating data obtained by the sensor mainly includes bearing vibration amplitude, gear vibration amplitude, input shaft swing, bearing temperature, gear oil temperature, oil level, oil quality (color, acid value, moisture, kinematic viscosity, particle contamination degree and sludge content, etc.), input seal, output seal, cooling water temperature, cooling water pressure and cooling water flow rate, etc. The operating data of the reducer directly obtained from the reducer drive system can mainly include the speed of the reducer and the input torque. The input shaft torque is an important indicator for judging the failure of the reducer.

When the reducer is operating normally, the operating data of the reducer obtained by the sensor and the rotational speed obtained by the drive system remain unchanged. The load of the scraper conveyor changes with the change of coal transportation volume and coal loading position, and the input torque of the reducer also changes in real time. Parameters such as bearing and gear transmission vibration, bearing temperature, gear oil temperature, etc. are closely related to the input torque of the reducer. Closely related, as the input torque of the reducer changes, the related bearing and gear transmission vibration, bearing temperature, lubricating oil temperature, etc. also change. Therefore, this program uses input torque as the main parameter. First, the operating data corresponding to each input torque segment under normal working conditions is tested on the test bench, and further fault diagnosis analysis is performed based on the changes in actual operating data.

In step 1, when obtaining the standard operating data map through the test bench, you can consider dividing the input torque of the reducer into multiple segments, and test the bearing and gear transmission vibration, input shaft swing, and input shaft vibration corresponding to each torque segment on the loading test bench. Operating data such as bearing temperature, gear oil temperature, oil level, oil quality, input and output seals, cooling water temperature and pressure, and flow rate form an operating data curve and set the data floating range to form changes in normal operating parameters of each series of reducers. The interval map is used as the initial value and basis for fault judgment to determine whether the operating status data of the reducer is normal during actual use.

In one embodiment, the standard operating data corresponding to the torque value of the actual input torque in the standard operating data map includes: standard bearing temperature, standard cooling water flow rate, standard cooling water temperature and standard oil level; step 3 is based on the actual When diagnosing mining reducer faults using operating data, actual input torque and standard operating data charts, the details may include:

Step A1: Determine whether it is satisfied: the actual input torque in the obtained operating data is less than the first torque ratio of the reducer's rated torque, and the actual bearing temperature in the actual operating data has increased to no less than the first temperature threshold within the preset time; If so, perform step A2; otherwise, continue to monitor the operating data; where the first temperature threshold is greater than the standard bearing temperature;

Step A2: Determine whether it is satisfied: the actual cooling water flow rate is reduced by the first flow rate ratio compared with the standard cooling water flow rate, the actual cooling water temperature is greater than the standard cooling water temperature, and other operating data are within the corresponding normal range in the standard operating data chart; if yes , then the fault diagnosis of the mining reducer is excessive bearing temperature caused by reduced cooling water flow; if not, proceed to step A3;

Step A3: Determine whether it is satisfied: the actual cooling water temperature is greater than the standard cooling water temperature, the actual oil level is lower than the first oil level ratio of the standard oil level, and other operating data are within the corresponding normal range in the standard operating data chart; if so, The fault diagnosis of the mining reducer is excessive bearing temperature caused by insufficient gear oil.

In this embodiment, if the first torque ratio is 85%, the reducer operates at 80% of the rated torque, and its operating temperature increases from 75°C to 82°C in a short period of time. At this time, it can be seen that the fault is that the bearing operating temperature is too high. Furthermore, if it is found that the cooling water flow of the reducer has been reduced by 15%, the cold zone water temperature has increased to more than 65°C, and other parameters are within the normal range, then it can be judged that the cooling water flow is too low, and the cold water intake temperature is too high, which will cause cooling If there is scale in the pipe, the inner diameter of the cooling pipe will decrease after long-term use, and the flow rate will gradually decrease. That is, at this time, it can be judged that the fault of the reducer operating temperature being too high is caused by the reduction of cooling water flow rate; if the operating temperature of the reducer bearing changes from 75℃ in a short time increased to 82°C, the cooling water flow rate of the reducer did not change, the cooling water temperature increased to more than 65°C, and other parameters were within the normal range. It can be judged that the gear oil of the reducer is too low, because the oil in the reducer is dynamic during the working process. , cannot be monitored in real time, so the oil level sensor can be used to monitor the oil volume after shutdown to determine whether the bearing temperature is too high due to insufficient gear oil. In addition, if the operating temperature of the reducer bearing increases from 75°C to 82°C in a short period of time, which is less than the maximum value of 85°C at rated torque, and the torque increases from 80% of rated torque to 99%, and other parameters are normal, it is an increase in operating torque. The temperature rises normally after.

In practical applications, different causes may lead to the occurrence of the same fault, which makes it more difficult to analyze and find the cause of the fault. In this embodiment, torque is used as the main parameter, and by analyzing the changes of other operating parameters relative to the standard operating data in the standard operating data map, not only can the fault type of excessive bearing temperature be analyzed, but also the cause of the fault can be determined. Is the cause caused by reduced cooling water flow or insufficient gear oil? This saves time for subsequent troubleshooting.

In one embodiment, the standard operating data corresponding to the torque value of the actual input torque in the standard operating data map includes: standard gear oil temperature, standard cooling water flow rate, standard cooling water temperature and standard oil level;

Diagnose mining reducer faults based on actual operating data, actual input torque and standard operating data charts, including:

Step B1: Determine whether it is satisfied: the actual input torque in the obtained operating data is less than the second torque ratio of the reducer's rated torque, and the actual gear oil temperature in the actual operating data has increased to no less than the second temperature threshold within the preset time. ; If yes, execute step B2; otherwise, continue to monitor the operating data; where the second temperature threshold is greater than the standard gear oil temperature;

Step B2: Determine whether it is satisfied: the actual cooling water flow rate is reduced by a second flow rate ratio compared to the standard cooling water flow rate, the actual cooling water temperature is greater than the standard cooling water temperature, and other operating data are within the normal range corresponding to the standard operating data chart; if yes , then the fault diagnosis of the mining reducer is that the gear oil temperature is too high caused by the reduction of cooling water flow; if not, proceed to step B3;

Step B3: Determine whether it is satisfied: the actual cooling water temperature is greater than the standard cooling water temperature, the actual oil level is lower than the second oil level ratio of the standard oil level, and other operating data are within the corresponding normal range in the standard operating data chart; if so, The fault diagnosis of the mining reducer is excessive gear oil temperature caused by insufficient gear oil.

In this example, if the reducer operates at 80% of the rated torque, the gear oil temperature increases from 65°C to 74°C in a short period of time. At the same time, it is found that the cooling water flow rate of the reducer decreases by 15%, and the cooling water temperature increases to 65°C. ℃ or above, and other parameters are within the normal range, then it can be judged that the gear oil temperature is too high and the fault is caused by the reduction of cooling water flow; if the reducer operating temperature increases from 65°C to 74°C in a short period of time, the reducer cooling water flow does not change , the cooling water temperature increases to above 65°C, and other parameters are within the normal range. It can be initially judged that the reducer gear oil is insufficient. Furthermore, it is necessary to use the oil level sensor to monitor the oil volume after shutting down to determine whether the gear oil temperature is too high due to insufficient gear oil.

In one embodiment, diagnosing the fault of the mining reducer based on actual operating data, actual input torque and standard operating data maps includes: if the input seal or output seal detects oil leakage, then the mining reducer The fault diagnosis was seal failure.

In this embodiment, if the input or output seal detects oil leakage, it can be known that a seal failure occurs. In addition, the degree of seal failure can be further determined based on the oil volume and the speed of oil volume change, and whether it needs to be replaced in time. At the same time, the oil level sensor needs to be used to monitor the oil volume after shutdown to determine whether to replenish gear oil.

In one embodiment, the standard operating data corresponding to the torque value of the actual input torque in the standard operating data map includes: standard bearing temperature, standard input shaft swing, standard bearing vibration amplitude, standard oil quality, standard gear oil temperature, Standard cooling water flow, standard cooling water temperature and standard oil level;

Diagnose mining reducer faults based on actual operating data, actual input torque and standard operating data charts, including:

Step C1: Determine whether it is satisfied: the actual input torque in the obtained operating data is less than the third torque ratio of the reducer's rated torque, and the actual bearing temperature has increased to no less than the third temperature threshold within the preset time; if so, perform steps C2; otherwise, continue to monitor the operating data; where the third temperature threshold is greater than the standard bearing temperature;

Step C2: Determine whether it is satisfied: the actual input shaft swing is greater than the standard input shaft swing by a first swing ratio, and the actual bearing vibration amplitude is greater than the standard bearing vibration amplitude by a first vibration ratio; if yes, execute step C3, otherwise Execute step C4;

Step C3: Determine whether the actual oil quality has more metal particles than the standard oil quality; if so, the fault diagnosis of the mining reducer is a bearing failure caused by metal impurities entering the bearing track; otherwise, the fault of the mining reducer The fault diagnosis was bearing fatigue failure;

Step C4: Determine whether it is satisfied: the actual gear oil temperature has increased to no less than the fourth temperature threshold within the preset time, the actual cooling water flow rate is reduced by a third flow rate ratio compared with the standard cooling water flow rate, and the actual cooling water temperature is greater than the standard cooling water temperature. , and other operating data are within the corresponding normal range in the standard operating data chart; if yes, the fault diagnosis of the mining reducer is bearing failure caused by reduced cooling water flow; if not, proceed to step C5;

Step C5: Determine whether the seal failure of the reducer has been diagnosed, and the actual oil level is lower than the third oil level ratio of the standard oil level; if so, the fault diagnosis of the mining reducer is due to insufficient gear oil. Caused bearing failure.

In this embodiment, if the reducer operates at 80% of the rated torque and the bearing temperature increases from 110°C to 125°C within a few seconds, it can be determined that a bearing failure has occurred. Furthermore, if it is found that the input shaft swing and bearing vibration amplitude increase by more than 20%, and metal particles are detected in the oil quality monitoring, it can be determined that metal impurities have entered the bearing raceway, causing bearing failure; if the input shaft swing and bearing vibration amplitude are found to increase, It can be judged that the bearing fatigue failure is greater than 20% or if there is a regular band that increases by more than 20%, and no changes are found in other monitoring data. For example, if the reducer operates at 80% of the rated torque and the bearing temperature increases from 110°C to 120°C in a short period of time, it is found that the gear oil temperature increases from 75°C to 78°C in a short period of time, and the reducer cooling water flow decreases by 15%. If the zone water temperature increases to above 65°C and other parameters are within the normal range, it can be judged that the cooling water flow is too small, and the cold water temperature is too high, which will cause scale to form in the cooling pipe. Long-term use will reduce the inner diameter of the cooling pipe and reduce the flow rate. gradually decreases. It can be judged that the fault of excessive operating temperature of the reducer is caused by the reduction of cooling water flow, which in turn leads to the bearing failure; if it is detected that the reducer has a seal failure fault and other parameters are within the normal range, it can be preliminarily judged that the reducer There is too little gear oil. You need to use the oil level sensor to monitor the oil amount after shutting down to determine whether the bearing failure is caused by too little gear oil. If the torque increases from 80% of the rated torque to 99%, the bearing and gear transmission will vibrate, rotate, etc. If the parameters are within the normal range, the temperature rises normally after the working torque increases. If the reducer operates at 80% of the rated torque and the bearing temperature increases to 115°C, and other parameters are within the normal range, it is initially judged that the bearing temperature is too high and needs to be observed. If the bearing temperature does not change significantly for a long time, it can be used normally.

In one embodiment, the standard operating data corresponding to the torque value of the actual input torque in the standard operating data map includes: standard input shaft swing, standard bearing vibration amplitude, and standard oil quality;

Diagnose mining reducer faults based on actual operating data, actual input torque and standard operating data charts, including:

D1: Determine whether the actual input torque in the obtained operating data is less than the fourth torque ratio of the reducer's rated torque; if so, proceed to step D2; otherwise, continue to monitor the operating data;

D2: Determine whether it is satisfied: the actual input shaft swing has a regular band that is larger than the standard input shaft swing by a second swing ratio, the actual bearing vibration amplitude has a regular band that is larger than the standard bearing vibration amplitude by a second vibration ratio, and other The operating data is within the normal range corresponding to the standard operating data chart; if so, the fault diagnosis of the mining reducer is gear failure caused by defects in the tooth surface of the gear part; if not, proceed to step D3;

D3: Determine whether there are more metal particles in the actual oil quality than the standard oil quality; if so, the fault diagnosis of the mining reducer is gear failure caused by pitting corrosion on the gear tooth surface.

In this embodiment, if the reducer operates at 80% of the rated torque, and it is found that the input shaft swing and bearing vibration amplitude increase by more than 20% in regular bands, and other parameters are within the normal range, it is preliminarily determined that there is a defect in the tooth surface of the gear. ; If it is found that the shaft swing and bearing vibration amplitude increase irregularly by more than 20%, and metal particles are detected in the oil quality monitoring, it can be judged that there are pitting corrosion and other defects on the tooth surface of the gear.

In one embodiment, the standard operating data corresponding to the torque value of the actual input torque in the standard operating data map includes: standard oil quality;

Diagnose mining reducer faults based on actual operating data, actual input torque and standard operating data charts, including:

E1: Determine whether the actual oil quality has an increase in metal particle content or metal particle size compared to the standard oil quality; if so, the fault diagnosis of the mining reducer is gear wear, bearing raceway or gear tooth surface metal peeling. The oil has deteriorated; otherwise, proceed to step E2;

E2: Determine whether the actual oil quality has increased water content compared to the standard oil quality; if so, the fault diagnosis of the mining reducer is gear oil deterioration caused by cooler leakage; if not, proceed to step E3;

E3: Determine whether it is satisfied: the viscosity decay of the actual oil quality compared to the standard oil quality is greater than the first viscosity ratio, and the actual gear oil temperature does not change; if so, the fault diagnosis of the mining reducer is gear oil deterioration.

In this embodiment, if the oil quality monitors changes in metal particle content or particle size, it can be determined that gear wear, bearing raceway or gear tooth surface metal peeling has occurred; if the water content is monitored to increase, cooling can be determined There is leakage in the device; if the viscosity decay is detected and the change exceeds 30%, and the gear oil temperature does not change, it can be judged that the gear oil has deteriorated; if the viscosity decay is detected, the change exceeds 10%, and the torque increases from 80% of the rated torque 99%, if the gear oil temperature increases from 75° to 82° in a short period of time, it is a normal change in the viscosity of the gear oil after the temperature rises.

In one embodiment, the standard operating data corresponding to the torque value of the actual input torque in the standard operating data map includes: standard oil quality, standard cooling water pressure and standard cooling water flow rate;

Diagnose mining reducer faults based on actual operating data, actual input torque and standard operating data charts, including:

F1: Determine whether the actual oil quality has increased water content compared to the standard oil quality; if so, the fault diagnosis of the mining reducer is cooler leakage; otherwise, proceed to step F2;

F2: Determine whether it is satisfied: the actual cooling water flow gradually decreases relative to the standard cooling water flow over a period of time, and the actual cooling water pressure does not change relative to the standard cooling water pressure; if so, then the fault diagnosis of the mining reducer It is the reduction in the inner diameter of the cooling pipe due to scale formation in the cooling pipe; if not, proceed to step F3;

F3: Determine whether it is satisfied: the reduction of the actual cooling water flow within the preset time is greater than the fourth flow ratio, and the actual cooling water pressure has not changed relative to the standard cooling water pressure; if so, then the fault diagnosis of the mining reducer The particles flow into the cooling tube.

In this embodiment, if the oil quality is monitored and the water content increases, it can be determined that the cooler is leaking; if the cooling water flow rate of the cooler gradually decreases over a long period of time and the pressure does not change, it can be determined that scale is formed in the cooling pipe of the cooler. , the inner diameter of the cooling pipe decreases; if the cooling water flow rate of the cooler decreases by more than 15% within a few seconds and the pressure does not change, it can be determined that particulate matter has flowed into the cooling pipe.

It can be seen from the above embodiments that this solution not only realizes the diagnosis of common faults of the scraper conveyor reducer and improves the accuracy of fault diagnosis by analyzing various operating data, but also specifically analyzes the causes of various faults. s reason. In this way, this provides a quick diagnosis and troubleshooting solution for situations where the same fault occurs due to different reasons, which can greatly improve the efficiency of subsequent fault handling.

In addition, in one embodiment, the fault diagnosis method can further optimize the standard operating data map based on the data of each fault diagnosis and the accuracy of the fault diagnosis. In this way, through data accumulation, each parameter judgment value and parameter change interval of whether the reducer is operating normally are gradually optimized, thereby making the standard operating data map more accurate, more reliable as a reference standard, and further improving the accuracy of fault diagnosis.

Modules or units in the device of the embodiment of the present invention can be merged, divided, and deleted according to actual needs. What is disclosed above is only the preferred embodiment of the present invention. Of course, it cannot be used to limit the scope of the present invention. Those of ordinary skill in the art can understand all or part of the processes for implementing the above embodiments and make decisions according to the claims of the present invention. Equivalent changes still fall within the scope of the invention.

Claims (10)

1. A fault diagnosis method for a mining speed reducer, comprising:

the method comprises the steps of testing standard operation data corresponding to each input torque section of the mining speed reducer on a loading test bed in advance, and establishing a mapping relation between each input torque section and the corresponding standard operation data to obtain a standard operation data map when the mining speed reducer normally operates; the operation data are data acquired by a sensor on the mining speed reducer;

when the mining speed reducer operates, acquiring actual input torque from a speed reducer driving system, and simultaneously acquiring actual operation data from a sensor of the mining speed reducer;

and diagnosing the fault of the mining speed reducer according to the actual operation data, the actual input torque and the standard operation data map.

2. The fault diagnosis method of a mining retarder according to claim 1, wherein the operation data includes: bearing vibration amplitude, gear vibration amplitude, input shaft oscillation, bearing temperature, gear oil temperature, oil level, oil quality, input seal, output seal, cooling water temperature, cooling water pressure and cooling water flow.

3. The fault diagnosis method of a mining speed reducer according to claim 2, wherein the standard operation data corresponding to the torque value of the actual input torque in the standard operation data map includes: standard bearing temperature, standard cooling water flow, standard cooling water temperature and standard oil level;

The diagnosis of the fault of the mining speed reducer according to the actual operation data, the actual input torque and the standard operation data map comprises the following steps:

step A1: judging whether the following conditions are satisfied: the actual input torque in the obtained operation data is smaller than a first torque proportion of rated torque of the speed reducer, and the actual bearing temperature in the actual operation data is increased to be not smaller than a first temperature threshold value within preset time; if yes, executing the step A2; otherwise, continuing to monitor the operation data; wherein the first temperature threshold is greater than the standard bearing temperature;

step A2: judging whether the following conditions are satisfied: the actual cooling water flow is reduced by a first flow proportion compared with the standard cooling water flow, the actual cooling water temperature is greater than the standard cooling water temperature, and other operation data are located in a normal range corresponding to the standard operation data map; if yes, diagnosing that the bearing temperature is too high due to the fact that the cooling water flow is reduced by the fault of the mining speed reducer; if not, executing the step A3;

step A3: judging whether the following conditions are satisfied: the actual cooling water temperature is higher than the standard cooling water temperature, the actual oil level is lower than the first oil level proportion of the standard oil level, and other operation data are located in a normal range corresponding to the standard operation data map; if yes, the fault of the mining speed reducer is diagnosed as the too high temperature of the bearing caused by the fact that the gear oil is less.

4. The fault diagnosis method of a mining speed reducer according to claim 2, wherein the standard operation data corresponding to the torque value of the actual input torque in the standard operation data map includes: standard gear oil temperature, standard cooling water flow, standard cooling water temperature and standard oil level;

the diagnosis of the fault of the mining speed reducer according to the actual operation data, the actual input torque and the standard operation data map comprises the following steps:

step B1: judging whether the following conditions are satisfied: the actual input torque in the obtained operation data is smaller than a second torque proportion of rated torque of the speed reducer, and the actual gear oil temperature in the actual operation data is increased to be not smaller than a second temperature threshold value within a preset time; if yes, executing the step B2; otherwise, continuing to monitor the operation data; wherein the second temperature threshold is greater than the standard gear oil temperature;

step B2: judging whether the following conditions are satisfied: the actual cooling water flow rate is reduced by a second flow rate ratio compared with the standard cooling water flow rate, the actual cooling water temperature is higher than the standard cooling water temperature, and other operation data are located in a normal range corresponding to the standard operation data map; if yes, diagnosing that the gear oil temperature caused by the reduction of the cooling water flow is too high due to the fault of the mining speed reducer; if not, executing the step B3;

Step B3: judging whether the following conditions are satisfied: the actual cooling water temperature is higher than the standard cooling water temperature, the actual oil level is lower than the second oil level proportion of the standard oil level, and other operation data are located in a normal range corresponding to the standard operation data map; if yes, the fault of the mining speed reducer is diagnosed as the excessive high temperature of the gear oil caused by the low gear oil.

5. The fault diagnosis method of a mining speed reducer according to claim 2, wherein the diagnosing the fault of the mining speed reducer based on the actual operation data, actual input torque, and the standard operation data map comprises: and if the input seal or the output seal monitors oil leakage, diagnosing the fault of the mining speed reducer as seal failure.

6. The fault diagnosis method of a mining speed reducer according to claim 5, wherein the standard operation data corresponding to the torque value of the actual input torque in the standard operation data map includes: standard bearing temperature, standard input shaft oscillation, standard bearing oscillation amplitude, standard oil quality, standard gear oil temperature, standard cooling water flow, standard cooling water temperature and standard oil level;

The diagnosis of the fault of the mining speed reducer according to the actual operation data, the actual input torque and the standard operation data map comprises the following steps:

step C1: judging whether the following conditions are satisfied: the actual input torque in the obtained operation data is smaller than a third torque proportion of rated torque of the speed reducer, and the actual bearing temperature is increased to be not smaller than a third temperature threshold value within preset time; if yes, executing the step C2; otherwise, continuing to monitor the operation data; wherein the third temperature threshold is greater than the standard bearing temperature;

step C2: judging whether the following conditions are satisfied: the actual input shaft swing is increased by a first swing proportion compared with the standard input shaft swing, and the actual bearing vibration amplitude is increased by a first vibration proportion compared with the standard bearing vibration amplitude; if yes, executing the step C3, otherwise executing the step C4;

step C3: judging whether the actual oil quality is more than the standard oil quality by metal particles; if yes, diagnosing the fault of the mining speed reducer as bearing failure caused by the fact that metal impurities enter a bearing track; otherwise, diagnosing the faults of the mining speed reducer as bearing fatigue failure;

step C4: judging whether the following conditions are satisfied: the actual gear oil temperature is increased to be not less than a fourth temperature threshold value within preset time, the actual cooling water flow is reduced by a third flow proportion compared with the standard cooling water flow, the actual cooling water temperature is greater than the standard cooling water temperature, and other operation data are located in a normal range corresponding to the standard operation data map; if yes, diagnosing the faults of the mining speed reducer as bearing failure caused by the reduction of cooling water flow; if not, executing the step C5;

Step C5: judging whether the speed reducer has been diagnosed as having the failure of the seal, and the actual oil level is lower than the third oil level proportion of the standard oil level; if yes, the fault of the mining speed reducer is diagnosed as the bearing failure caused by less gear oil.

7. The fault diagnosis method of a mining speed reducer according to claim 2, wherein the standard operation data corresponding to the torque value of the actual input torque in the standard operation data map includes: standard input shaft swing, standard bearing vibration amplitude and standard oil quality;

the diagnosis of the fault of the mining speed reducer according to the actual operation data, the actual input torque and the standard operation data map comprises the following steps:

d1: judging whether the actual input torque in the acquired operation data is smaller than a fourth torque proportion of rated torque of the speed reducer; if yes, executing the step D2; otherwise, continuing to monitor the operation data;

d2: judging whether the following conditions are satisfied: the actual input shaft swing has a regular wave band with a second swing proportion increased compared with the standard input shaft swing, the actual bearing vibration amplitude has a regular wave band with a second vibration proportion increased compared with the standard bearing vibration amplitude, and other operation data are located in a normal range corresponding to the standard operation data map; if yes, diagnosing the fault of the mining speed reducer as the gear failure caused by the defect of the tooth surface of the gear part; if not, executing the step D3;

D3: judging whether the actual oil quality is more than the standard oil quality; if yes, diagnosing the fault of the mining speed reducer as the gear failure caused by pitting of the gear tooth surface.

8. The fault diagnosis method of a mining speed reducer according to claim 2, wherein the standard operation data corresponding to the torque value of the actual input torque in the standard operation data map includes: standard oil quality;

the diagnosis of the fault of the mining speed reducer according to the actual operation data, the actual input torque and the standard operation data map comprises the following steps:

e1: judging whether the metal particle content or the metal particle size of the actual oil quality is increased compared with that of the standard oil quality; if yes, diagnosing the fault of the mining speed reducer as gear abrasion, and gear oil deterioration caused by metal peeling of a bearing raceway or a gear tooth surface; otherwise, executing the step E2;

e2: judging whether the water content of the actual oil quality is increased compared with that of the standard oil quality; if yes, diagnosing the fault of the mining speed reducer as deterioration of the gear oil caused by leakage of the cooler; if not, executing the step E3;

e3: judging whether the following conditions are satisfied: the viscosity decay of the actual oil is larger than the first viscosity proportion compared with the standard oil, and the temperature of the actual gear oil is unchanged; if yes, diagnosing the fault of the mining speed reducer as the deterioration of the gear oil.

9. The fault diagnosis method of a mining speed reducer according to claim 2, wherein the standard operation data corresponding to the torque value of the actual input torque in the standard operation data map includes: standard oil quality, standard cooling water pressure and standard cooling water flow;

the diagnosis of the fault of the mining speed reducer according to the actual operation data, the actual input torque and the standard operation data map comprises the following steps:

f1: judging whether the water content of the actual oil quality is increased compared with that of the standard oil quality; if yes, diagnosing the fault of the mining speed reducer as cooler leakage; otherwise, executing the step F2;

f2: judging whether the following conditions are satisfied: the actual cooling water flow rate is gradually reduced relative to the standard cooling water flow rate in a period of time, and the actual cooling water pressure is unchanged relative to the standard cooling water pressure; if yes, diagnosing the fault of the mining speed reducer as the reduction of the inner diameter of the cooling pipe caused by scale formation in the cooling pipe; if not, executing the step F3;

f3: judging whether the following conditions are satisfied: the decrement of the actual cooling water flow in the preset time is larger than the fourth flow proportion, and the actual cooling water pressure is unchanged relative to the standard cooling water pressure; if yes, diagnosing the fault of the mining speed reducer as particulate matters flowing into the cooling pipe.

10. The fault diagnosis method of a mining speed reducer according to any one of claims 1 to 9, characterized in that the fault diagnosis method further comprises: and optimizing the standard operation data map according to the data of fault diagnosis and the accuracy of fault diagnosis.