基于油液監(jiān)測和灰色理論的變速箱磨損損傷評估及預(yù)測
發(fā)布時間：2018-12-14 17:46
【摘要】：變速箱作為工程機械的關(guān)鍵傳動部件,其工作環(huán)境惡劣、載荷變化大、作業(yè)中循環(huán)動作頻繁,從而導(dǎo)致故障頻發(fā)。研究表明,80%的變速箱零部件都是因磨損而失效,又因為變速箱的關(guān)鍵零部件一般為無冗余設(shè)計,一旦發(fā)生故障往往引發(fā)嚴重的事故。因此,為了對變速箱的運行狀態(tài)和磨損趨勢有一個宏觀、準確的把握,很有必要研究變速箱磨損損傷評估技術(shù)和磨損量預(yù)測方法,以實現(xiàn)對變速箱運行狀態(tài)、磨損類型和磨損程度的監(jiān)控與預(yù)測。本文以推土機變速箱為研究對象,基于油液監(jiān)測技術(shù)和灰色系統(tǒng)理論研究變速箱磨損損傷評估技術(shù)和磨損量預(yù)測方法,主要研究內(nèi)容如下:(1)基于油液監(jiān)測技術(shù)進行了推土機變速箱磨損狀態(tài)評估的實際試驗研究。首先深入分析了變速箱的組成結(jié)構(gòu)、主要磨損件、零部件構(gòu)成元素和磨損磨粒特性,為應(yīng)用油液監(jiān)測技術(shù)進行變速箱磨損損傷評估奠定基礎(chǔ)。之后,綜合應(yīng)用黏度分析、光譜分析和鐵譜分析三種技術(shù),對SD16型推土機變速箱內(nèi)零部件的磨損狀態(tài)和潤滑油的污染情況進行了評估試驗研究,所得結(jié)論與實際檢修結(jié)果一致。該研究實現(xiàn)了變速箱磨損損傷部位、損傷類型、箱體密封情況以及油液潤滑狀態(tài)的判定,證明了油液監(jiān)測技術(shù)實際應(yīng)用的可行性與準確性。(2)建立了基于灰色GM(1,1)模型修正的變速箱磨損量灰色預(yù)測模型。選取推土機變速箱油液鐵譜分析數(shù)據(jù)作為輸入特征信息,綜合考慮預(yù)測數(shù)據(jù)序列的非等間隔性、換油干擾等影響因素,在灰色預(yù)測理論中引入修正因子λ,建立修正的變速箱磨損量預(yù)測模型。經(jīng)后驗差法驗證表明,該模型預(yù)測精度為一級精度。最后,逐步搜索最優(yōu)λ值,實例分析表明,當(dāng)λ=0.992時,修正后模型能實現(xiàn)三步準確預(yù)測,而原始灰色GM(1,1)預(yù)測模型只能實現(xiàn)一步準確預(yù)測,修正后模型提高了變速箱磨損量的預(yù)測精度。(3)設(shè)計并搭建了變速箱故障診斷試驗臺,并基于試驗臺在線黏度傳感器研究了 15W40 CF-4型潤滑油的黏溫特性。為消除現(xiàn)場跟蹤取樣數(shù)據(jù)易隨天氣、推土機工作環(huán)境、操作人員水平等因素波動的影響,本文設(shè)計并搭建了變速箱故障診斷試驗臺。該試驗臺是通過潤滑系統(tǒng)安裝的在線黏度傳感器來實時監(jiān)測某一工況溫度下油液的黏度,但該黏度并不是標(biāo)準換油黏度。在實際工程應(yīng)用中,需根據(jù)潤滑油的黏溫特性方程將某一溫度的黏度轉(zhuǎn)換成國家標(biāo)準100℃時的換油黏度。為研究15W40 CF-4型潤滑油黏溫特性的變化規(guī)律,本文應(yīng)用Andrade方程、Walther方程和Vogel方程對新油、在用油和廢油在40℃～100℃時的運動黏度數(shù)據(jù)進行回歸擬合,從擬合度和擬合標(biāo)準差兩個方面,分析和比較了3種黏溫方程的擬合精度。分析表明,用Vogel方程來描述該潤滑油的黏溫特性更加準確,為在線監(jiān)測的實時黏度換算提供了依據(jù)。
[Abstract]:As the key transmission part of construction machinery, the gearbox has a bad working environment, great load variation and frequent cyclic operation, which leads to frequent faults. The research shows that 80% of the gearbox parts fail because of wear and tear, and because the key parts of the gearbox are generally non-redundant design, once the fault occurs, it often leads to serious accidents. Therefore, in order to have a macroscopic and accurate grasp of the running state and wear trend of the gearbox, it is necessary to study the gearbox wear damage assessment technology and the method of predicting the wear quantity in order to realize the running state of the gearbox. Monitoring and prediction of wear type and wear degree. This paper takes the gearbox of bulldozer as the research object, based on the oil monitoring technology and the grey system theory, studies the gearbox wear damage assessment technology and the wear quantity forecast method. The main contents are as follows: (1) based on the oil monitoring technology, the actual experimental research on the evaluation of the wear status of the bulldozer gearbox is carried out. Firstly, the structure of gearbox, main wear parts, component elements and wear abrasive characteristics of gearbox are analyzed in depth, which lays a foundation for the application of oil monitoring technology to the gearbox wear damage assessment. After that, the wear status of parts in the gearbox of SD16 bulldozer and the pollution of lubricating oil are evaluated by using three techniques, viscosity analysis, spectrum analysis and ferrography analysis. The results are in agreement with the actual inspection and repair results. In this study, the gearbox wear damage location, damage type, sealing condition of the box and oil lubrication state are determined. The feasibility and accuracy of the application of oil monitoring technology are proved. (2) the grey prediction model of gearbox wear quantity based on grey GM (1t1) model is established. The iron-spectrum analysis data of bulldozer gearbox oil are selected as input characteristic information. Considering the influence factors such as the non-equal interval of prediction data sequence and oil exchange interference, the correction factor 位 is introduced into the grey prediction theory. A modified gearbox wear prediction model was established. The prediction accuracy of the model is proved to be a first order precision by a posteriori method. Finally, the optimal 位 value is searched step by step. The case analysis shows that the modified model can realize the three-step accurate prediction when 位 = 0.992, while the original grey GM (1 ~ 1) prediction model can only realize the one-step accurate prediction. The modified model improves the accuracy of the gearbox wear prediction. (3) the gearbox fault diagnosis test-bed is designed and built, and the viscosity and temperature characteristics of 15W40 CF-4 lubricating oil are studied based on the on-line viscosity sensor of the gearbox. In order to eliminate the influence of weather, bulldozer working environment and operator level on tracking sampling data, a gearbox fault diagnosis test-bed is designed and built in this paper. The on-line viscosity sensor installed in the lubricating system is used to monitor the viscosity of oil at a certain operating temperature in real time, but the viscosity is not the standard viscosity of oil exchange. In practical engineering application, the viscosity of a certain temperature should be converted into the oil exchange viscosity at 100 鈩，
本文編號：2379045
[Abstract]:As the key transmission part of construction machinery, the gearbox has a bad working environment, great load variation and frequent cyclic operation, which leads to frequent faults. The research shows that 80% of the gearbox parts fail because of wear and tear, and because the key parts of the gearbox are generally non-redundant design, once the fault occurs, it often leads to serious accidents. Therefore, in order to have a macroscopic and accurate grasp of the running state and wear trend of the gearbox, it is necessary to study the gearbox wear damage assessment technology and the method of predicting the wear quantity in order to realize the running state of the gearbox. Monitoring and prediction of wear type and wear degree. This paper takes the gearbox of bulldozer as the research object, based on the oil monitoring technology and the grey system theory, studies the gearbox wear damage assessment technology and the wear quantity forecast method. The main contents are as follows: (1) based on the oil monitoring technology, the actual experimental research on the evaluation of the wear status of the bulldozer gearbox is carried out. Firstly, the structure of gearbox, main wear parts, component elements and wear abrasive characteristics of gearbox are analyzed in depth, which lays a foundation for the application of oil monitoring technology to the gearbox wear damage assessment. After that, the wear status of parts in the gearbox of SD16 bulldozer and the pollution of lubricating oil are evaluated by using three techniques, viscosity analysis, spectrum analysis and ferrography analysis. The results are in agreement with the actual inspection and repair results. In this study, the gearbox wear damage location, damage type, sealing condition of the box and oil lubrication state are determined. The feasibility and accuracy of the application of oil monitoring technology are proved. (2) the grey prediction model of gearbox wear quantity based on grey GM (1t1) model is established. The iron-spectrum analysis data of bulldozer gearbox oil are selected as input characteristic information. Considering the influence factors such as the non-equal interval of prediction data sequence and oil exchange interference, the correction factor 位 is introduced into the grey prediction theory. A modified gearbox wear prediction model was established. The prediction accuracy of the model is proved to be a first order precision by a posteriori method. Finally, the optimal 位 value is searched step by step. The case analysis shows that the modified model can realize the three-step accurate prediction when 位 = 0.992, while the original grey GM (1 ~ 1) prediction model can only realize the one-step accurate prediction. The modified model improves the accuracy of the gearbox wear prediction. (3) the gearbox fault diagnosis test-bed is designed and built, and the viscosity and temperature characteristics of 15W40 CF-4 lubricating oil are studied based on the on-line viscosity sensor of the gearbox. In order to eliminate the influence of weather, bulldozer working environment and operator level on tracking sampling data, a gearbox fault diagnosis test-bed is designed and built in this paper. The on-line viscosity sensor installed in the lubricating system is used to monitor the viscosity of oil at a certain operating temperature in real time, but the viscosity is not the standard viscosity of oil exchange. In practical engineering application, the viscosity of a certain temperature should be converted into the oil exchange viscosity at 100 鈩，
本文編號：2379045
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