JP4581860B2 - Machine equipment abnormality diagnosis apparatus and abnormality diagnosis method - Google Patents

Description

The present invention, mechanical equipment, for example, relates to an abnormality diagnosis apparatus and an abnormality diagnosis method of the component you rotate used in the reduction gear and the electric motor or wind turbine and railway vehicles and the like, in particular, of the component abnormality presence or aura, or the abnormal The present invention relates to an abnormality diagnosis apparatus and an abnormality diagnosis method for mechanical equipment that specifies a part.

  Conventionally, after rotating parts such as railway vehicles and wind turbines for power generation are used for a certain period, bearings and other rotating parts are regularly inspected for abnormalities such as damage and wear. This periodic inspection is carried out by disassembling the mechanical device in which the rotating parts are incorporated, and the person in charge finds damage and wear generated in the rotating parts by visual inspection. And the main defects found in the inspection are in the case of bearings, indentations caused by the biting of foreign matter, peeling due to rolling fatigue, other wear, etc., in the case of gears, missing teeth and wear, etc. In the case of a wheel, there is wear such as a flat, and in any case, if irregularities or wear that is not found in a new article is found, it is replaced with a new one.

  Various methods for diagnosing abnormalities of rotating parts in an actual operating state without disassembling a mechanical device incorporating the rotating parts have been proposed (see, for example, Patent Documents 1 to 5). As the most general one, as described in Patent Document 1, an accelerometer is installed in the bearing portion, the vibration acceleration of the bearing portion is measured, and further, FFT (Fast Fourier Transform) processing is performed on this signal. Thus, there is known a method of performing diagnosis by extracting a signal of vibration generation frequency components.

In the apparatus described in Patent Document 4, a temperature sensor is mounted on a bearing box in a railway vehicle, and when the detected temperature rises above a reference value, an abnormal signal is issued to the cab, or the temperature is measured from the ground side and the bearing is measured. Anomaly monitoring is performed. Further, in the device described in Patent Document 5, in a general mechanical device, the state of the bearing is constantly monitored by a vibration or temperature sensor, and when each value rises above a reference value, an abnormality alarm is output, Or stop working.
JP 2002-22617 A JP 2003-202276 A Japanese Patent Laid-Open No. 2004-257836 JP 9-79915 A Japanese Patent Laid-Open No. 11-125244

However, in the method of disassembling the entire mechanical equipment and visually inspecting the person in charge, a great deal of labor is required for the disassembling work for removing the rotating body from the apparatus and the assembling work for reassembling the inspected rotating body into the apparatus again. There is a problem that the maintenance cost of the apparatus is greatly increased.

Further, there is a possibility such that would put never been dent before the test when reassemble the rotating body, the inspection itself causes produce a defect of the rotating body. Further, since a large number of bearings are visually inspected within a limited time, there is a problem that a possibility of overlooking a defect remains. Furthermore, the determination of the degree of the defect also varies depending on the individual, and parts are exchanged even if there is substantially no defect, resulting in a wasteful cost.

  Further, in the abnormality diagnosis method described in Patent Document 1, the vibration generation frequency component is calculated based on the rotational speed. However, when the actual rotational speed cannot be directly captured, the rotational speed data used for the calculation is actually If there is a deviation from the rotational speed, there is a problem that the diagnostic accuracy deteriorates.

  Furthermore, in the apparatus described in Patent Document 4, since the presence or absence of an abnormality is determined based on whether or not the temperature of the bearing has increased to a reference value or higher, the degree of damage is already severe when an abnormality is detected. In many cases, it cannot be used continuously, and there is a problem that the machine must be stopped urgently.

  In addition, the apparatus described in Patent Document 5 has a problem that even if an abnormality alarm is issued and the operation of the mechanical device stops, there is a problem that the abnormal part cannot be specified, and malfunction due to the influence of noise or the like. There is a problem that stable operation is hindered, such as generating an abnormal alarm.

  Furthermore, in machinery and equipment using a large number of bearings as rotating parts, if the inner and outer diameters and width dimensions of the bearings are the same, they may be used even if the internal design dimension specifications are different. In this case, if the design dimensions of the bearing are different, the set values used for the abnormality diagnosis of the bearing are also different, and the diagnosis becomes complicated. For this reason, there is a problem that parts having the same design dimensions may be incorporated in a specific part, resulting in poor work efficiency during assembly.

  The present invention has been made in view of the above-described circumstances, and its purpose is to identify the presence or absence of an abnormality and an abnormal portion while ensuring diagnostic accuracy even when the actual rotational speed cannot be directly captured. An object of the present invention is to provide an abnormality diagnosis apparatus and abnormality diagnosis method for mechanical equipment. Another object of the present invention is to provide an abnormality diagnosis apparatus for mechanical equipment that can identify the presence / absence of an abnormality and an abnormal part even if a plurality of rotating parts having different design dimension specifications are incorporated in an arbitrary part. It is to provide.

The object of the present invention is achieved by the following constitution.
(1) once equipped with rolling parts, an abnormality diagnosis device for machinery and equipment,
At least one detector that outputs a vibration signal generated from the mechanical equipment as an electrical signal;
The frequency analysis of the waveform of the electrical signal is performed, the frequency component of the measured spectrum data obtained by the frequency analysis and the frequency component caused by the rotating component are compared and verified with an allowable width, and based on the verification result, A signal processing unit for determining the presence / absence and abnormality of the rotating part; and
Equipped with a,
The permissible width includes at least a region having an upper limit value and a lower limit value calculated from a rotational speed of the rotating component and internal design dimension specifications of a plurality of rotating parts having different internal design dimension specifications of the rotating component. Dividing into one region, obtaining a center value of each of the divided regions, and at least one allowable width of an arbitrary size given to the center value;
The apparatus according to claim 1, wherein the signal processing unit compares and collates the frequency component of the measured spectrum data with the frequency component caused by the rotating component for each of the at least one allowable width.
(2) the allowable width, the abnormality diagnosis apparatus for machinery according to (1) said frequency components increases as the harmonic component.
( 3 ) The apparatus for diagnosing machine equipment abnormality according to (1) or (2), wherein the allowable width is increased or decreased according to a frequency band of the frequency component.
( 4 ) The abnormality diagnosis device for mechanical equipment according to (1) , wherein the allowable width is increased or decreased according to a rotation speed.
(5) The signal processing unit performs at least one of the amplification processing and filter processing on the detected signals, any and performs envelope processing to the processed waveform (1) to (4) An apparatus for diagnosing abnormalities in mechanical equipment according to claim 1.
( 6 ) In addition to the sensor that detects vibration generated from the mechanical equipment, the detection unit includes at least one of a sensor that detects the temperature of the mechanical equipment and a rotational speed sensor that detects the rotational speed of the rotating component. The apparatus for diagnosing abnormality of mechanical equipment according to any one of (1) to ( 5 ), comprising an integrated sensor housed in a single casing.
( 7 ) The mechanical equipment includes a bearing that is the rotating component and a bearing box that fixes the bearing.
The apparatus for diagnosing abnormality of mechanical equipment according to ( 6 ), wherein the integrated sensor is fixed to a flat portion of the bearing box.
( 8 ) The abnormality diagnosis device according to any one of (1) to ( 7 ), further including data transmission means for transmitting a determination result by the signal processing unit.
( 9 ) The abnormality diagnosis device according to any one of (1) to ( 8 ), further including a microcomputer that performs processing by the signal processing unit and processing for outputting the determination result to a control system.
( 10 ) The mechanical equipment abnormality diagnosis apparatus according to any one of (1) to ( 9 ), wherein the mechanical equipment is a railway vehicle bearing device.
( 11 ) The machine equipment abnormality diagnosis apparatus according to any one of (1) to ( 9 ), wherein the machine equipment is a wind turbine bearing device.
( 12 ) The machine equipment abnormality diagnosis apparatus according to any one of (1) to ( 9 ), wherein the machine equipment is a machine tool spindle bearing device.
(13 ) A method for diagnosing abnormalities in mechanical equipment, including rotating parts,
Detecting vibration signals generated from the mechanical equipment and outputting them as electrical signals;
Analyzing the frequency of the waveform of the detected signal;
An upper limit value and a lower limit value calculated from internal design dimension specifications of a plurality of rotary parts having internal design dimension specifications different from the rotational speed of the rotary part with respect to the frequency component caused by the rotary parts. Dividing the region into at least one region, obtaining a center value of each of the divided regions, and setting at least one allowable width having an arbitrary size given to the center value;
Comparing the frequency component of the measured spectrum data obtained by the frequency analysis and the frequency component caused by the rotating component for each at least one allowable width; and
Determining the presence / absence and abnormality of the rotating part based on the comparison result in the comparison step;
An abnormality diagnosis method for mechanical equipment, comprising:
Note that dividing the region having the upper limit value and the lower limit value calculated from the rotation speed of the rotating component and the design dimension specifications of the rotating component into at least one region means that the region is not divided.

  According to the abnormality diagnosis device and abnormality diagnosis method for a mechanical device of the present invention, the frequency component of the measured spectrum data obtained by frequency analysis and the frequency component caused by the component are compared and collated with a variable tolerance, Since the presence / absence of an abnormality of the part and the abnormal part are determined based on the collation result, when the actual rotational speed cannot be directly captured, the rotational speed data used for the calculation deviates from the actual rotational speed. Even if it occurs, the presence / absence of an abnormality and the specification of the abnormal part can be accurately performed.

Further, according to the abnormality diagnosis device and an abnormality diagnosis method of the machinery of the present invention, without disassembling the machinery it rotates a simple components are incorporated to identify the abnormal presence or absence and the abnormal site It is possible to reduce the time and effort required for disassembling and assembling the apparatus, and it is possible to prevent damage to the parts due to disassembly and assembling.

  Further, according to the abnormality diagnosis apparatus and abnormality diagnosis method for a mechanical device of the present invention, at least one region having an upper limit value and a lower limit value calculated from the rotation speed of the rotating component and the design dimension specifications of the rotating component is provided. The center value of each of the divided regions is obtained and compared and collated with at least one allowable width of an arbitrary size given to the center value. Can be specified in the presence or absence of an abnormality or an abnormal part even when the is incorporated in an arbitrary part or when the rotational speed of the rotating component fluctuates.

  Hereinafter, an abnormality diagnosis apparatus for machine equipment according to each embodiment of the present invention will be described in detail with reference to the drawings.

(First embodiment)
First, with reference to FIGS. 1-4, the abnormality diagnosis apparatus of the mechanical installation of 1st Embodiment is demonstrated. As shown in FIG. 1, the abnormality diagnosis apparatus detects a signal generated from the machine facility 10 and determines a state such as an abnormality of the machine facility 10 from an electrical signal output from the detection unit 20. The controller 30 includes a signal processing unit 32 and a control unit 34 that drives and controls the machine facility 10, and an output device 40 such as a monitor and an alarm device.

  The mechanical equipment 10 is provided with a rolling bearing 12 that is a rotating part. The rolling bearing 12 includes an inner ring 14 that is a rotating ring fitted around a rotating shaft (not shown), and a housing (not shown). An outer ring 16 that is a fixed ring fitted into the inner ring 14, a ball 18 that is a plurality of rolling elements disposed between the inner ring 14 and the outer ring 16, and a cage (not shown) that holds the ball 18 in a freely rolling manner. ).

  The detection unit 20 includes a sensor 22 that detects vibration generated from the mechanical equipment 10 during operation. The sensor 22 is fixed near the outer ring of the housing by bolt fixing, bonding, bolt fixing and bonding, or embedding with a molding material. In addition, in the case of bolt fixation, you may make it provide a rotation stop function. Further, when the sensor 22 is molded, the waterproof property is achieved and the vibration proofing property against external vibration is improved, so that the reliability of the sensor 22 itself can be drastically improved.

  The sensor 22 may be any sensor that can detect vibration, such as a vibration sensor, an AE (acoustic emission) sensor, an ultrasonic sensor, a shock pulse sensor, and the like, acceleration, speed, strain, stress, displacement type, etc. Any device that can convert the vibration into an electrical signal may be used. Further, when attaching to a mechanical device having a lot of noise, it is preferable to use an insulating type because it is less affected by noise. Further, when the sensor 22 uses a vibration detection element such as a piezoelectric element, the element may be molded into plastic or the like. In addition, the mechanical equipment 10 of the present embodiment can detect vibrations of gears and wheels (both not shown) in addition to the rolling bearing 12 by the sensor 22.

  Further, the detection unit 20 may be an integrated sensor in which a sensor 22 that detects vibration generated from mechanical equipment, and a temperature sensor and a rotational speed sensor that detect the temperature of the mechanical equipment are housed in a single casing. Good. In this case, the integrated sensor is preferably fixed to a flat portion of a bearing box that fixes the rolling bearing 12 (see FIG. 8). The temperature sensor may be a temperature fuse of a type in which, when the temperature reaches a certain specified value, the bimetal contact is separated or the contact is blown to cause no conduction. As a result, when a temperature equal to or higher than a specified value is detected, the temperature fuse is not turned on, so that an abnormality can be detected.

  The controller 30 including the signal processing unit 32 and the control unit 34 is configured by a microcomputer (IC chip, CPU, MPU, DSP, etc.), and receives an electrical signal from the sensor 22 via the data transmission means 24. .

  As shown in FIG. 2, the signal processing unit 32 includes a data storage / distribution unit 50, a rotation analysis unit 52, a filter processing unit 54, a vibration analysis unit 56, a comparison determination unit 58, and an internal data storage unit 60. The data storage / distribution unit 50 receives and temporarily stores the electrical signal from the sensor 22 and the electrical signal related to the rotational speed, and collects and distributes the signal to one of the analysis units 52 and 56 according to the type of the signal. It has a function. Various signals are A / D converted into digital signals by an A / D converter (not shown) before being sent to the data storage / distribution unit 50, amplified by an amplifier (not shown), and then sent to the data storage / distribution unit 50. Note that the order of A / D conversion and amplification may be reversed.

  The rotation analysis unit 52 calculates the rotation speed of the inner ring 14, that is, the rotation shaft, based on an output signal from a sensor (not shown) that detects the rotation speed, and transmits the calculated rotation speed to the comparison determination unit 58. . When the detection element is composed of an encoder attached to the inner ring 14 and a magnet and a magnetic detection element attached to the outer ring 16, the signal output from the detection element depends on the shape and rotational speed of the encoder. A corresponding pulse signal is obtained. The rotation analysis unit 52 has a predetermined conversion function or conversion table corresponding to the shape of the encoder, and calculates the rotation speed of the inner ring 14 and the rotation shaft from the pulse signal according to the function or table.

  The filter processing unit 54 extracts only a predetermined frequency band corresponding to the natural frequency from the vibration signal based on the natural frequency of the rolling bearing 12, which is a rotating component, a gear, a wheel, or the like, and extracts an unnecessary frequency band. Remove. This natural frequency can be easily obtained by vibrating the rotating part as an object to be measured by the striking method and analyzing the frequency of the vibration detector attached to the object to be measured or the sound generated by the striking. When the object to be measured is a rolling bearing, the natural frequency due to any of the inner ring, outer ring, rolling element, cage, etc. is given. In general, there are a plurality of natural frequencies of mechanical parts, and the amplitude level at the natural frequencies is high, so the sensitivity of measurement is good.

  The vibration analysis unit 56 performs frequency analysis of vibration generated in the bearing 12, the gears, and the wheels based on the output signal from the sensor 22. Specifically, the vibration analysis unit 56 is an FFT calculation unit that calculates a frequency spectrum of a vibration signal, and calculates a frequency spectrum of vibration based on an FFT algorithm. The calculated frequency spectrum is transmitted to the comparison determination unit 58. Further, the vibration analysis unit 56 may perform absolute value processing and envelope processing as preprocessing for performing FFT, and convert only to frequency components necessary for diagnosis. The vibration analysis unit 56 also outputs the envelope data after the envelope processing to the comparison determination unit 58 as necessary.

  The comparison / determination unit 58 compares and collates the frequency component caused by the rolling bearing 12, the gear, and the wheel with the frequency component of the actually measured spectrum data of vibration by the vibration analysis unit 56 with a variable tolerance. In the present embodiment, the comparison / determination unit 58 calculates a reference value (for example, sound pressure level or voltage level) from the measured spectrum data, while using the relational expressions shown in FIGS. The frequency (vibration generation frequency) due to the sound is calculated, and the sound pressure level (or voltage level) in the range where the variable tolerance is given to the vibration generation frequency is extracted from the measured spectrum data and compared with the reference value. ing. Furthermore, the comparison / determination unit 58 specifies the presence / absence of an abnormality and an abnormal part based on the determination result.

  The calculation of the vibration generation frequency may be performed before this, and when the same diagnosis has been performed before, the data may be stored in the internal data storage unit 60 and used. Further, design specification data of each rotating part used for calculation is input and stored in advance.

  In addition, the variable tolerance in the comparison and verification may be set so as to increase as the frequency component becomes higher. If the frequency component is linked to the target frequency band or rotation speed, the change in the actual rotation speed (railway It is possible to cope with changes due to the effects of wheel wear on the vehicle.

  Then, the determination result in the comparison / determination unit 58 may be stored in the internal data storage unit 60 such as a memory or HDD, or may be transmitted to the output device 40 via the data transmission unit 42. Further, the determination result may be output to the control unit 34 that controls the operation of the drive mechanism of the mechanical equipment 10 and a control signal corresponding to the determination result may be fed back.

  Further, the output device 40 may display the determination result on a monitor or the like in real time, or may notify the abnormality using an alarm device such as a light or a buzzer when an abnormality is detected. The data transmission means 24 and 42 only need to be able to transmit and receive signals accurately, may be wired, or may be wireless using a network.

  Next, a specific example of the abnormality diagnosis processing flow based on the vibration signal will be described with reference to FIG.

  First, the sensor 31 detects the vibration of each rotating component (step S101). The detected vibration signal is converted into a digital signal by the A / D converter (step S102), amplified by a predetermined amplification factor (step S103), and then corresponding to the natural frequency of the rotating component by the filter processing unit 54. Filter processing for extracting only the predetermined frequency band is performed (step S104). Thereafter, the vibration analysis unit 56 performs envelope processing on the digital signal after the filter processing (step S105), and obtains the frequency spectrum of the digital signal after the envelope processing (step S106).

  Next, from the relational expressions shown in FIG. 4 and FIG. 5, the vibration generation frequency generated due to the abnormality of each rotating component is obtained based on the rotation speed signal (step S107), and the allowable width variable with respect to the obtained frequency. The sound pressure level in the abnormal frequency band of each rotating part having a bearing (in the case of the rolling bearing 12, the bearing flaw component Sx, that is, the inner ring flaw component Si, the outer ring flaw component So, the rolling element flaw component Sb and the cage component Sc) In the case of a gear, the gear scratch component Sg corresponding to the meshing, and in the case of a rotating body such as a wheel, the wear and unbalance component Sr) of the rotating body are obtained (step S108).

  On the other hand, a reference value (for example, sound pressure level or voltage level) used for abnormality diagnosis is calculated from the frequency spectrum obtained by the vibration analysis unit 56 (step S109). Here, the reference value may be an effective value or a peak value of a digital signal of actually measured spectrum data at an arbitrary time, or may be calculated based on these values.

  Next, the comparison between the sound pressure level (or voltage level) of the abnormal frequency band of each rotating component calculated in step S108 and the reference value calculated in step S109 is divided for each rotating component having a different design specification. (Step S110). When all the components do not match, it is determined that there is no abnormality in the rotating component (step S111). On the other hand, if any of the components match, it is determined that there is an abnormality and the abnormal part is specified (step S112), and the comparison result is sent to the control unit 34 or the output device 40 such as a monitor or alarm device. Output (step S113).

  As described above, in this embodiment, the frequency component of the measured spectrum data obtained by frequency analysis and the frequency component caused by the rotating component are compared and collated with a variable tolerance, and the abnormality of the rotating component is determined based on the collation result. If the actual rotational speed cannot be directly captured and the rotational speed data used for the calculation is different from the actual rotational speed, the presence / absence of the abnormality is determined. And an abnormal part can be identified with high accuracy.

  In addition, according to the abnormality diagnosis device and abnormality diagnosis method for a mechanical device of the present invention, it is possible to specify the presence or absence of abnormality and the location of the abnormality without disassembling a mechanical device incorporating a rotating component with a simple configuration. It is possible to reduce the time and effort required for disassembling and assembling the apparatus, and it is possible to prevent damage to the parts due to disassembling and assembling.

  Furthermore, according to the abnormality diagnosis device and abnormality diagnosis method for a mechanical device of the present embodiment, the signal processing unit is configured by a microcomputer, so that the signal processing unit is unitized, and the abnormality diagnosis device can be downsized and modules Can be achieved.

  Next, with reference to FIG. 6, the abnormality diagnosis apparatus and abnormality diagnosis method for mechanical equipment according to the second embodiment of the present invention will be described in detail. In addition, about the part equivalent to 1st Embodiment, the same code | symbol is attached | subjected and description is abbreviate | omitted or simplified.

  In the present embodiment, the processing in the comparison / determination unit 58 of the signal processing unit 32 is different from that of the first embodiment. As shown in the processing flow of the present embodiment in FIG. 6, steps S201 to S206 are performed in the same manner as steps S101 to S106 in the first embodiment.

  Next, from the relational expressions shown in FIGS. 4 and 5, the vibration generation frequency generated due to the abnormality of each rotating component is obtained based on the rotation speed signal (step S207). Then, an allowable width that is an area having an upper limit frequency and a lower limit frequency of a damage component of the rotating component in each specification calculated from the rotational speed of the rotating component and the design dimension specification of the rotating component, and the center frequency of the width Is calculated (step S208). In step S208, if necessary, the allowable width is divided into one or more widths, a center frequency for each width is obtained, and an allowable width having an arbitrary width with respect to the center frequency is obtained. give. Note that the allowable width may be set so as to increase corresponding to the frequency band.

  Thereafter, the sound pressure level in the abnormal frequency band of the rotating part having an allowable range with respect to the frequency obtained in step S207 (in the case of the rolling bearing 12, the bearing flaw component Sx, that is, the inner ring flaw component Si, the outer ring flaw component, So, the rolling element scratch component Sb and the cage component Sc, in the case of gears, the gear scratch component Sg corresponding to meshing, and in the case of a rotating body such as a wheel, the wear and unbalance component Sr) of the rotating body. Obtained (step S209).

  On the other hand, as in the first embodiment, a reference value (for example, sound pressure level or voltage level) used for abnormality diagnosis is calculated from the frequency spectrum obtained by the vibration analysis unit 56 (step S210), and calculated in step S209. The comparison of the sound pressure level (or voltage level) in the abnormal frequency band of each rotating component and the reference value calculated in step S210 is performed in order for each rotating component having a different design specification (step S211). . In step S211, the process is repeated as many times as the frequency tolerance is divided.

  When all the components do not match, it is determined that there is no abnormality in the rotating component (step S212). On the other hand, if any of the components match, it is determined that there is an abnormality and the abnormal part is specified (step S213), and the comparison result is sent to the control unit 34 or the output device 40 such as a monitor or alarm device. Output (step S214).

  When there is an abnormality in the rotating component, when the allowable width is divided in step S208, it may be determined that there is an abnormality in any of the divided allowable widths. For this reason, for example, when performing diagnosis for two allowable widths, in step S211, the diagnosis with the second width is not performed when it is determined that there is an abnormality as a result of the diagnosis with the first width. It is also possible to perform diagnosis in the second width after diagnosing normality in the first width.

  As shown in the relational expressions in FIG. 4 and FIG. 5, the vibration generation frequency generated due to the abnormality of each rotating part in step S209 is given by the rotational speed and design dimension specifications. The original difference hinders accurate diagnosis. For this reason, setting the permissible width as in step S208 means that the rotating component includes a plurality of rotating components having different design dimension specifications, or the actual rotation speed signal cannot be directly captured, and the rotating component rotates. This is effective when the speed fluctuates.

  For example, even when the actual rotational speed signal cannot be directly captured, the fluctuation range of the rotational speed when rotating at a constant rotational speed may be known. In this case, based on the lower limit rotational speed and the upper limit rotational speed, the characteristic frequency component resulting from the damage of the rotating component is calculated to obtain the allowable range. If the allowable range is large, the frequency component other than the damaged component of the rotating component is obtained. , And the diagnostic accuracy deteriorates. Therefore, the permissible width is divided as necessary, the center frequency for each divided width is obtained, and a permissible width having an arbitrary size is provided for the center frequency, and the permissible width is divided. By comparing and collating several minutes, highly accurate diagnosis is possible without being affected by fluctuations in the rotational speed.

  Therefore, according to the abnormality diagnosis apparatus and abnormality diagnosis method of the present embodiment, the region having the upper limit value and the lower limit value calculated from the rotational speed of the rotating component and the design dimension specifications of the rotating component is divided into at least one region. Since the center value of each of the divided areas is obtained and compared and collated with at least one allowable width of an arbitrary size given to the center value, a plurality of rotating parts having different design dimensions can be arbitrarily selected. Even if it is incorporated into this part or the rotational speed of the rotating component fluctuates, the presence or absence of an abnormality or the part of the abnormality can be reliably identified, and a highly accurate diagnosis is possible. In addition, this saves the trouble of having to incorporate parts with the same specifications as before, and even when parts with different specifications are incorporated, the diagnosis is possible, improving work efficiency and effective. Maintenance is possible.

The abnormality diagnosis of the present embodiment is also effective in the case of a mechanical device that includes a plurality of rotating parts having different design dimension specifications and the rotational speed of the rotating parts varies.
Further, in the bearing abnormality diagnosis, each frequency component shown in FIG. 4 is a multiplication of the rotation frequency. Therefore, if the bearing specifications are known in advance, the center is not calculated without calculating the lower limit and the upper limit frequency due to the rotation speed fluctuation. It is also possible to determine the frequency.
Furthermore, the abnormality diagnosis of the present embodiment is not applied only to the frequency spectrum on which the envelope processing is performed, and any method for diagnosing the presence / absence of a frequency component resulting from damage to the rotating component from the rotational speed information. It is also applicable to.

  Next, with reference to FIG. 7, the abnormality diagnosis apparatus and abnormality diagnosis method for mechanical equipment according to the third embodiment of the present invention will be described in detail. In addition, about the part equivalent to 1st Embodiment, the same code | symbol is attached | subjected and description is abbreviate | omitted or simplified.

This embodiment is a single processing unit that combines a detection unit including a sensor 22 and a signal processing unit including a microcomputer 50 in an abnormality diagnosis device for a mechanical facility 70 including a plurality of rolling bearings 12 and 12. 80 is incorporated in the bearing device of the rolling bearing 12. As a result, the abnormality diagnosis apparatus can perform management in a centralized manner, so that efficient monitoring is possible. Further, it is preferable to incorporate a single processing unit in the bearing device because there is a merit that the entire device becomes compact. In addition, this single processing unit may be incorporated in mechanical equipment for compactness, or a single processing unit may be configured for a plurality of rolling bearings.
Other configurations and operations are the same as those in the first and second embodiments, and the processing flow of the signal processing unit may be either in the first or second embodiment.

In addition, this invention is not limited to the said embodiment, In the range which does not deviate from the summary of this invention, it can change suitably.
Machinery of the present invention include long as having a you rotating component is abnormal diagnosed, bearing system for a railway vehicle, the wind turbine support bearing assembly, a machine tool spindle bearing device.

  For example, as shown in FIG. 8, the railway vehicle bearing device 90 supports the axle shaft 90 rotatably with respect to a bearing box 92 constituting a part of the railway vehicle carriage via the double row tapered roller bearing 12. In addition, the detection units 20 and 20 are fixed to the radial load area of the bearing housing 92 and the vibration of the bearing housing 92 is detected to perform abnormality diagnosis. If the bearing raceway surface is damaged, the collision force generated when the rolling element passes through the damaged portion is larger in the load zone than in the no-load zone, so the detection unit 20 is fixed on the load zone side. This makes it possible to detect vibration with high sensitivity.

As the component you rotate, rolling bearings, gears, axles, may be a rotating component such as a ball screw, may be a component that generates a periodic vibration by injury.

Further, the signal detected by the detection unit, sound, vibration, ultrasound (AE), stress, displacement, include distortion, etc., in these signals, when there is a defect or abnormality in mechanical equipment that includes a rotating unit products , Including a signal component indicating the defect or abnormality.

  Specific examples of abnormality diagnosis of rotating parts using the machine equipment abnormality diagnosis apparatus and method of the present invention will be described below.

(Test 1)
FIG. 9 shows the result of frequency analysis after envelope processing of housing vibration when a single row deep groove bearing with a defect on the outer ring raceway surface actually rotates at 2430 min ⁻¹ . However, the rotational speed data used for the calculation is 2400 min ⁻¹ , and there is a deviation from the actual rotational speed. In the figure, the solid line indicates the envelope frequency spectrum based on the actually measured vibration data, and the dotted line indicates the reference value. Further, each shaded range shows a frequency component and its harmonics resulting from the outer ring damage based on the rotational speed of 2400 min ^−1, and the allowable range of comparison and collation is increased corresponding to the frequency band. As a result, since the peak exceeding the reference value matches the frequency component resulting from damage to the outer ring having a variable tolerance, it can be diagnosed that the outer ring of the bearing is damaged.

On the other hand, FIG. 10 shows a case where the tolerance for comparison and collation is fixed (1 Hz) under the same conditions as in FIG. As a result, since the peak exceeding the reference value does not coincide with the frequency component due to the outer ring damage, it may be determined that there is no abnormality. That is, it can be seen that if the difference between the actual rotational speed and the rotational speed used for diagnosis is large, a large deviation occurs in the harmonic component of the generated frequency, which affects the diagnostic accuracy.
From these results, it can be seen that by performing abnormality diagnosis based on the first embodiment, the presence / absence of abnormality of the rotating component and the specification of the abnormal part can be performed with high accuracy.

(Test 2)
Next, three types (A, B, C) tapered rollers with the same inner and outer diameter dimensions (bearing outer diameter: 220 mm, bearing inner diameter: 120 mm, bearing width: 150 mm) but different internal design specifications as rotating parts Bearings were prepared, each outer ring raceway surface of these bearings was made defective, and individual bearings were incorporated into the housing. Then, vibration generated when the inner ring is rotated at 200 min ⁻¹ is detected by a piezoelectric insulation type acceleration sensor attached to the housing, the amplified signal is subjected to frequency analysis (envelope analysis), and the processing flow in the second embodiment Based on the comparison.

  FIG. 11 shows the result of frequency analysis after envelope processing for the vibration of the housing when the three types of bearings are rotated. Here, the solid line is an envelope frequency spectrum based on the measured vibration data, and the dotted line indicates a reference value.

Further, each shaded range includes an allowable width with respect to the center frequency of the lower limit frequency and the upper limit frequency of the frequency component due to the outer ring damage based on the rotational speed 200 min ⁻¹ and the internal specifications of the three types of bearings (A, B, C). The harmonic width is shown, and the allowable range for comparison is increased corresponding to the frequency band.

In this test, the frequency component resulting from damage to the outer ring based on the bearing specifications is calculated from FIG. 4, the center frequency f _CL1 between the lower limit frequency and the upper limit frequency is obtained, and an allowable width Δf with respect to the center frequency f _CL1 is provided. . Further, the allowable width Δf is set to 2 Hz, and this allowable width is set to be large corresponding to the frequency band.

  From these results, there are multiple peaks that differ in frequency but exceed the reference value in any bearing, and those peaks are included in the frequency attributed to the outer ring damage shown in the shaded area. Any bearing with different specifications can diagnose that the outer ring is damaged.

On the other hand, FIG. 12 shows a case where the abnormality diagnosis of the second embodiment is applied to a normal bearing that is not damaged. The specifications of this bearing are the same as those of the bearing A.
From the results shown in FIG. 12, in a normal bearing, a remarkable peak exceeding the reference value is not included in the frequency caused by the outer ring damage indicated by the shaded area, so that the outer ring is diagnosed as not damaged. Can do.

(Test 3)
Next, when the internal design specifications are the same but the rotation speed slightly varies, a test is performed using the processing flow of the second embodiment.

13, with a defect in the outer ring raceway surface of the tapered roller bearing, detected by piezoelectric Isolated acceleration sensor attached to the housing the vibration generated when rotating the inner ring 200 min ^-1 and 170Min ^-1, after amplification It is the result of having compared the signal of this by frequency analysis (envelope analysis). Further, in FIG. 13, each shaded range indicates the allowable width with respect to the center frequency of the frequency component caused by damage to the outer ring based on the bearing internal specifications corresponding to the lower limit rotational speed and the upper limit rotational speed of the rotational speed fluctuation, and the harmonic width thereof. Therefore, the tolerance of comparison and collation is increased corresponding to the frequency band. Further, this shaded area depends on the fluctuation range of the rotational speed, and is set so that the shaded area becomes wider when the rotational fluctuation width is large.

In this state, the abnormality diagnosis may be performed based on the presence or absence of components included in the shaded range. However, if the shaded range is widened, a frequency component other than the bearing damage component is also included, and thus the diagnosis accuracy may be deteriorated. For this reason, in this test, the corresponding shaded area is divided into two areas (A, B), the center frequency (f _CLA , f _CLB ) corresponding to the area width is calculated, and the tolerance for the center frequency is calculated. A width Δf is provided.

Specifically, in this test, the lower limit and the upper limit frequency and the center frequency thereof are obtained based on the fluctuation range of the rotation speed of 170 to 200 min ⁻¹ , the allowable width Δf is 2 Hz, and this allowable width is the frequency band. It is set large corresponding to.

As a result, when the rotation speed is 200 min ^−1, no peak due to damage appears in region A, but since a peak appears in region B, it can be determined that the outer ring is damaged. On the other hand, when the rotation speed is 170 min ⁻¹ , since a peak due to damage appears in the region A, it can be determined that the outer ring is damaged even if no peak appears in the region B.

It is the schematic of the abnormality diagnosis apparatus which is 1st Embodiment of this invention. It is a block diagram of the signal processing part of FIG. It is a flowchart which shows the processing flow of the abnormality diagnosis method which is 1st Embodiment of this invention. It is a figure which shows the relationship between the site | part of the damage | wound of a bearing, and the vibration generation frequency which originates in a damage | wound. It is a figure for demonstrating the relational expression of the abnormal vibration frequency which generate | occur | produces by meshing | engagement of a gearwheel. It is a flowchart which shows the processing flow of the abnormality diagnosis method which is 2nd Embodiment of this invention. It is the schematic of the abnormality diagnosis apparatus which is 2nd Embodiment of this invention. It is sectional drawing of the bearing apparatus for rail vehicles which is a mechanical installation with which the detection part of the abnormality diagnosis apparatus was integrated. It is a figure for demonstrating abnormality diagnosis of the test 1 of an Example. It is a figure for demonstrating the conventional abnormality diagnosis. It is a figure for demonstrating abnormality diagnosis of the test 2 of an Example. It is another figure for demonstrating abnormality diagnosis of the test 2 of an Example. It is a figure for demonstrating abnormality diagnosis of the test 3 of an Example.

Explanation of symbols

10,70 Machine equipment 12 Rolling bearings (Rotating parts)
20 detection unit 22 sensor 30 controller 32 signal processing unit 34 control unit 40 output device 50 data storage / distribution unit 52 rotation analysis unit 54 filter processing unit 56 vibration analysis unit 58 comparison determination unit 60 internal data storage unit

Claims (13)

  An apparatus for diagnosing abnormalities in mechanical equipment, including rotating parts
  At least one detector that outputs a vibration signal generated from the mechanical equipment as an electrical signal;
  The frequency analysis of the waveform of the electrical signal is performed, the frequency component of the measured spectrum data obtained by the frequency analysis and the frequency component caused by the rotating component are compared and verified with an allowable width, and based on the verification result, A signal processing unit for determining the presence / absence and abnormality of the rotating part; and
With
  The permissible width includes at least a region having an upper limit value and a lower limit value calculated from a rotational speed of the rotating component and internal design dimension specifications of a plurality of rotating components having different internal design dimension specifications of the rotating component. Dividing into one region, obtaining a center value of each of the divided regions, and at least one allowable width of an arbitrary size given to the center value;
  The apparatus according to claim 1, wherein the signal processing unit compares and collates the frequency component of the measured spectrum data with the frequency component caused by the rotating component for each of the at least one allowable width.   The apparatus for diagnosing abnormality of mechanical equipment according to claim 1, wherein the allowable width increases as the frequency component becomes a harmonic component.   The apparatus according to claim 1 or 2, wherein the allowable width is increased or decreased according to a frequency band of the frequency component.   The apparatus for diagnosing abnormalities in mechanical equipment according to claim 1, wherein the allowable width is increased or decreased according to a rotation speed.   The machine according to claim 1, wherein the signal processing unit performs at least one of amplification processing and filtering processing on the detected signal, and performs envelope processing on the processed waveform. Equipment abnormality diagnosis device.   In addition to a sensor that detects vibrations generated from the mechanical equipment, the detection unit includes at least one of a temperature sensor that detects the temperature of the mechanical equipment and a rotational speed sensor that detects the rotational speed of the rotating component. An abnormality diagnosis apparatus for a mechanical facility according to any one of claims 1 to 5, further comprising an integrated sensor housed in the housing.   The mechanical facility includes a bearing that is the rotating part and a bearing box that fixes the bearing.
  The abnormality diagnosis device for a mechanical facility according to claim 6, wherein the integrated sensor is fixed to a flat portion of the bearing box.   The abnormality diagnosis apparatus according to claim 1, further comprising a data transmission unit configured to transmit a determination result by the signal processing unit.   The abnormality diagnosis device according to claim 1, further comprising a microcomputer that performs processing by the signal processing unit and processing for outputting the determination result to a control system.   The machine equipment abnormality diagnosis device according to claim 1, wherein the machine equipment is a railway vehicle bearing device.   The machine equipment abnormality diagnosis device according to claim 1, wherein the machine equipment is a wind turbine bearing device.   The machine equipment abnormality diagnosis device according to claim 1, wherein the machine equipment is a machine tool spindle bearing device.   An abnormality diagnosis method for machine equipment, equipped with rotating parts,
  Detecting vibration signals generated from the mechanical equipment and outputting them as electrical signals;
  Analyzing the frequency of the waveform of the detected signal;
  An upper limit value and a lower limit value calculated from internal design dimension specifications of a plurality of rotary parts having internal design dimension specifications different from the rotational speed of the rotary part with respect to the frequency component caused by the rotary parts. Dividing the region into at least one region, obtaining a center value of each of the divided regions, and setting at least one allowable width having an arbitrary size given to the center value;
  Comparing the frequency component of the measured spectrum data obtained by the frequency analysis and the frequency component caused by the rotating component for each at least one allowable width; and
  Determining whether or not there is an abnormality in the rotating part based on the comparison result in the comparison step, and an abnormal part;
An abnormality diagnosis method for mechanical equipment, comprising:

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