CN105510025A - Intelligent gear failure detection device and its detection method - Google Patents
Intelligent gear failure detection device and its detection method Download PDFInfo
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- CN105510025A CN105510025A CN201510884005.XA CN201510884005A CN105510025A CN 105510025 A CN105510025 A CN 105510025A CN 201510884005 A CN201510884005 A CN 201510884005A CN 105510025 A CN105510025 A CN 105510025A
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- 238000001514 detection method Methods 0.000 title claims abstract description 22
- 238000000034 method Methods 0.000 claims description 10
- 229910000831 Steel Inorganic materials 0.000 claims description 7
- 239000010959 steel Substances 0.000 claims description 7
- 230000002159 abnormal effect Effects 0.000 abstract 1
- 238000010586 diagram Methods 0.000 description 5
- 230000006698 induction Effects 0.000 description 4
- 238000012544 monitoring process Methods 0.000 description 4
- 230000006378 damage Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000012423 maintenance Methods 0.000 description 2
- 238000005272 metallurgy Methods 0.000 description 2
- 230000007115 recruitment Effects 0.000 description 2
- 230000005540 biological transmission Effects 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 230000008034 disappearance Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000005039 memory span Effects 0.000 description 1
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Classifications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M13/00—Testing of machine parts
- G01M13/02—Gearings; Transmission mechanisms
- G01M13/021—Gearings
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B7/00—Measuring arrangements characterised by the use of electric or magnetic techniques
- G01B7/02—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring length, width or thickness
- G01B7/06—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring length, width or thickness for measuring thickness
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- General Physics & Mathematics (AREA)
- Transmission And Conversion Of Sensor Element Output (AREA)
Abstract
The invention discloses an intelligent gear failure detection device and a detection method thereof, wherein the device comprises: the magnetic component is arranged on the outer side or the inner side of the gear teeth of the gear, the Hall element is arranged between the gear teeth of the gear and the magnetic component, and the processor is connected with the output end of the Hall element; when the gear rotates, gear teeth of the gear pass through the Hall elements one by one, the Hall elements sense the magnetic field change caused by the gear teeth passing through and output electric signals to the processor, and the processor acquires the time of each gear tooth passing through the Hall elements according to the high-low level change of the received electric signals so as to know the thickness state of the gear teeth. The invention can monitor the working state of the gear, find the abnormal condition of the gear in working in time and give a warning to avoid unnecessary loss.
Description
Technical field
The present invention relates to a kind of intelligent gear failure pick-up unit and detection method thereof.
Background technology
Gear is widely used in as important actuated element in the various plant equipment such as machinery, metallurgy, mine, automobile, its operating condition directly affect equipment serviceable life and with safety in production closely bound up.Gear is in transmission and motion process, there is rubbing wear and raise with temperature in Gear Contact surface, finally cause gear failure, especially the industry such as mine, metallurgy under load effect, the load that gear bears at work is very large, and service condition is harsh, more easily gear failure occurs.But due to the working environment rather harsh of equipment, therefore people is for carrying out detection difficult.If can the duty of Real-Time Monitoring gear, Timeliness coverage problem place, just can avoid the burst accident caused because of gear failure, the security incident such as caused because coal mine machinery middle gear lost efficacy.
Summary of the invention
The present invention is directed to the proposition of above problem, and develop a kind of intelligent gear failure pick-up unit and detection method thereof.
Technological means of the present invention is as follows:
A kind of intelligent gear failure pick-up unit, comprising: the magnetic part outside the gear teeth being arranged on gear or inside the gear teeth, the processor being arranged on the gear teeth of gear and the Hall element between described magnetic part and being connected with described Hall element output terminal; When described pinion rotation, the gear teeth that this gear has are one by one through described Hall element, described Hall element senses the changes of magnetic field that described gear teeth process is brought and exports electric signal to described processor, described processor obtains each gear teeth through the time of described Hall element according to the low and high level change of the electric signal received, and then knows the uniform configuration of the described gear teeth;
Further, when having the gear teeth through out-of-date in the certain limit apart from described Hall element, described Hall element exports high level, when not having the gear teeth through out-of-date in the certain limit apart from described Hall element, and described Hall element output low level;
Further, described processor compared the duration of each high level signal that described Hall element exports and the first preset durations, when the duration of arbitrary high level signal is less than the first preset durations, described processor output device signal out of service, this equipment is the equipment comprising described gear;
Further, described processor compared the duration of each low level signal that described Hall element exports and the second preset durations, when the duration of arbitrary low level signal higher than the second preset durations time, described processor exports break of gear tooth alerting signal;
In addition, described device also comprises the display be connected with described processor, and this display is used for the uniform configuration of each gear teeth that processor is known and shows the break of gear tooth alerting signal that processor exports; Described magnetic part is magnet steel; Described Hall element is Hall element; Described processor is single-chip microcomputer.
A kind of intelligent gear failure detection method, comprises the steps:
Step 1: configuration magnetic part is outside the gear teeth of gear or inside the gear teeth, and configuration Hall element is between the gear teeth and described magnetic part of gear; Described Hall element is connected with processor;
Step 2: when described pinion rotation, the gear teeth that this gear has are one by one through described Hall element, and described Hall element senses the changes of magnetic field that described gear teeth process is brought and exports electric signal to described processor;
Step 3: described processor obtains each gear teeth through the time of described Hall element according to the low and high level change of the electric signal received, and then knows the uniform configuration of the described gear teeth;
Further, when having the gear teeth through out-of-date in the certain limit apart from described Hall element, described Hall element exports high level, when not having the gear teeth through out-of-date in the certain limit apart from described Hall element, and described Hall element output low level;
In addition, also comprise the steps: after step 3
Described processor compared the duration of each high level signal that described Hall element exports and the first preset durations, when the duration of arbitrary high level signal is less than the first preset durations, described processor output device signal out of service, this equipment is the equipment comprising described gear;
In addition, also comprise the steps: after step 3
Described processor compared the duration of each low level signal that described Hall element exports and the second preset durations, when the duration of arbitrary low level signal higher than the second preset durations time, described processor exports break of gear tooth alerting signal;
Further,
Described magnetic part is magnet steel; Described Hall element is Hall element; Described processor is single-chip microcomputer;
Also comprise the steps: after step 3
The break of gear tooth alerting signal that uniform configuration and the processor of each gear teeth that processor is known go out is shown.
Owing to have employed technique scheme, intelligent gear failure pick-up unit provided by the invention and detection method thereof, can realize the duty monitoring gear, the unusual condition in Timeliness coverage working gear is also warned, to avoid unnecessary loss; In the application places of some bad environments, manual detection is very difficult, employing the present invention can when not taking gear case apart, the machinery and equipment worked under rugged surroundings is detected, convenient and swift, save recruitment cost, and then according to gear practical working situation, machine maintenance equipment, avoids the further destruction causing gear case because of broken teeth, prevents the burst accident caused because of gear failure.
Accompanying drawing explanation
Fig. 1 is the structural representation of device of the present invention;
Fig. 2 is the structured flowchart of device of the present invention;
Fig. 3 is the process flow diagram of the method for the invention;
Fig. 4 is the circuit connection diagram of the present invention with the Hall element of magnetic part;
Fig. 5 is the characteristic electron schematic diagram of Hall element of the present invention;
Fig. 6 is the signal schematic representation that gear of the present invention does not exist that gear teeth thickness reduces or in the situation that fractures, Hall element exports;
Fig. 7 is the signal schematic representation that gear of the present invention exists that Hall element exports in gear teeth thickness reduction situation;
Fig. 8 is the signal schematic representation that gear of the present invention exists that Hall element exports in break of gear tooth situation.
In figure: 1, gear, 2, the gear teeth, 3, Hall element, 4, magnetic part.
Embodiment
The intelligent gear failure pick-up unit of one as depicted in figs. 1 and 2, comprising: the magnetic part 4 outside the gear teeth 2 being arranged on gear 1 or inside the gear teeth 2, the processor being arranged on the gear teeth 2 of gear 1 and the Hall element 3 between described magnetic part 4 and being connected with described Hall element 3 output terminal; When described gear 1 rotates, the gear teeth 2 that this gear 1 has are one by one through described Hall element 3, described Hall element 3 senses the changes of magnetic field that the described gear teeth 2 process is brought and exports electric signal to described processor, described processor obtains each gear teeth 2 through the time of described Hall element 3 according to the low and high level change of the electric signal received, and then knows the uniform configuration of the described gear teeth 2; Further, when having the gear teeth 2 through out-of-date in the certain limit apart from described Hall element 3, described Hall element 3 exports high level, when not having the gear teeth 2 through out-of-date in the certain limit apart from described Hall element 3, and described Hall element 3 output low level; Further, described processor compared the duration of each high level signal that described Hall element 3 exports and the first preset durations, when the duration of arbitrary high level signal is less than the first preset durations, described processor output device signal out of service, this equipment is the equipment comprising described gear 1; Further, described processor compared the duration of each low level signal that described Hall element 3 exports and the second preset durations, when the duration of arbitrary low level signal higher than the second preset durations time, described processor exports the gear teeth 2 and to fracture alerting signal; In addition, described device also comprises the display be connected with described processor, and this display is used for showing to the uniform configuration of each gear teeth 2 that processor is known and to the gear teeth 2 that processor the exports alerting signal that fractures; Described magnetic part 4 is magnet steel; Described Hall element 3 is Hall element; Described processor is single-chip microcomputer; Described magnetic part 4 is magnet steel; Described Hall element 3 is Hall element; Described processor is single-chip microcomputer; Described device also comprises the power Vcc for powering to Hall element 3, for the mu balanced circuit powering to described processor, and for giving the display power supply of described monitor power supply.
The intelligent gear failure detection method of one as shown in Figure 3, comprises the steps:
Step 1: configuration magnetic part 4 is outside the gear teeth 2 of gear 1 or inside the gear teeth 2, and configuration Hall element 3 is between the gear teeth 2 and described magnetic part 4 of gear 1; Described Hall element 3 is connected with processor;
Step 2: when described gear 1 rotates, the gear teeth 2 that this gear 1 has are one by one through described Hall element 3, and described Hall element 3 senses the changes of magnetic field that the described gear teeth 2 process is brought and exports electric signal to described processor;
Step 3: described processor obtains each gear teeth 2 through the time of described Hall element 3 according to the low and high level change of the electric signal received, and then knows the uniform configuration of the described gear teeth 2;
Further, when having the gear teeth 2 through out-of-date in the certain limit apart from described Hall element 3, described Hall element 3 exports high level, when not having the gear teeth 2 through out-of-date in the certain limit apart from described Hall element 3, and described Hall element 3 output low level; In addition, also comprise the steps: that described processor compared the duration of each high level signal that described Hall element 3 exports and the first preset durations after step 3, when the duration of arbitrary high level signal is less than the first preset durations, described processor output device signal out of service, this equipment is the equipment comprising described gear 1; In addition, also comprise the steps: that described processor compared the duration of each low level signal that described Hall element 3 exports and the second preset durations after step 3, when the duration of arbitrary low level signal higher than the second preset durations time, described processor exports the gear teeth 2 and to fracture alerting signal; Further, described magnetic part 4 is magnet steel; Described Hall element 3 is Hall element; Described processor is single-chip microcomputer; Also comprise the steps: that the gear teeth 2 gone out uniform configuration and the processor of each gear teeth 2 that processor the is known alerting signal that fractures shows after step 3.
Fig. 4 is the circuit connection diagram of the present invention with the Hall element 3 of magnetic part 4, and wherein signal Vout is the electric signal that Hall element 3 exports to processor, Fig. 5 shows the characteristic electron schematic diagram of Hall element of the present invention, under the effect of outside magnetic field, when magnetic induction density reaches positive transition point, Hall element 3 exports high level, if when the magnetic induction density of externally-applied magnetic field is reduced to negative trip point, Hall element 3 output low level, when gap between the gear teeth 2 of gear 1 is in the certain limit apart from described Hall element 3, the magnetic line of force is disperseed, the magnetic induction density of external magnetic field is lowered, when the gear teeth 2 of gear 1 are in the certain limit apart from described Hall element 3, the magnetic line of force becomes concentrated, the magnetic induction density of external magnetic field strengthens, here certain limit can be 1 ~ 5mm.Hall element 3 can be arranged on the gear teeth 2 side, magnetic part 4 and the gear teeth 2 are separately positioned on the two sides of Hall element 3, Hall element 3 is arranged in pairs or groups magnetic part 4, and make the accuracy of detection of Hall element 3 by the impact of temperature, humidity and light intensity, accuracy of detection is higher, when gear 1 rotates, Hall element 3 intermittently senses the gear teeth 2 and exports corresponding low and high level signal, particularly, when the described gear teeth 2 are near described Hall element 3, described Hall element 3 exports high level, when the described gear teeth 2 leave described Hall element 3, there is not as Fig. 6 shows gear 1 of the present invention the signal schematic representation that the gear teeth 2 thickness reduces or in the situation that fractures, Hall element 3 exports in described Hall element 3 output low level, described processor is according to the time of each gear teeth 2 of the low and high level signal acquisition received through described Hall element 3, and then know the uniform configuration of the described gear teeth 2, the high level signal wherein exported or the duration of low level signal can be different because the state of the gear teeth 2 is different, when the thickness of a certain gear teeth 2 reduces, the duration of the high level signal of its correspondence then shortens, the signal schematic representation that Hall element 3 exports in the gear teeth 2 thickness reduction situation is there is as Fig. 7 shows gear 1 of the present invention, and then according to the speed that the gear teeth 2 thickness reduces, the serviceable life of gear 1 can be predicted, the described processor output device signal out of service when the uniform configuration of the arbitrary gear teeth 2 known is reduced to predeterminable level, this equipment is the equipment comprising described gear 1, and, once occur that a certain gear teeth 2 are fractureing, then Hall element 3 cannot sense this gear teeth 2, the high level signal disappearance that Hall element 3 can be made to export, then correspondingly, the duration of the low level signal that Hall element 3 exports can be elongated, there are the gear teeth 2 to fracture the signal schematic representation that Hall element 3 exports in situation as Fig. 8 shows gear 1 of the present invention, by described processor, the duration of each low level signal that described Hall element 3 exports and the second preset durations are compared, when the duration of arbitrary low level signal higher than the second preset durations time, described processor exports the gear teeth 2 and to fracture alerting signal, and then the equipment applying this gear 1 performs corresponding safeguard measure, accident is avoided to occur, described first preset durations and the second preset durations are preset in advance, when different gears 1 operates under different rotating speeds, the first corresponding preset durations and the second preset durations are different, first should carry out information acquisition to the intact gear 1 of a certain concrete plant equipment, obtain the duration of high level signal and the duration of low level signal of Hall element 3 output under this gear 1 different rotating speeds, and then determine the first preset durations and the second preset durations, usual first preset durations value is that intact gear 1 when operating under same rotating speed, Hall element 3 export high level signal duration 2/3, second preset durations value is that intact gear 1 when operating under same rotating speed, 2 times of duration of the low level signal that Hall element 3 exports.
Frequency, the detecting distance of Hall element Information Monitoring of the present invention and induced field change should meet accuracy requirement, the memory span of the single-chip microcomputer selected and computing velocity should meet actual needs, and display should be able to demonstrate change and the gear teeth 2 crack conditions of the gear teeth 2 thickness intuitively; The present invention be a kind of can detection of gear lost efficacy intelligent device, can be arranged in the gear case of the machines such as automobile, steamer, coalcutter, can realize the duty monitoring gear, the unusual condition in Timeliness coverage working gear is also warned, to avoid unnecessary loss; In the application places of some bad environments, manual detection is very difficult, employing the present invention can when not taking gear case apart, the machinery and equipment worked under rugged surroundings is detected, convenient and swift, save recruitment cost, and then according to gear practical working situation, machine maintenance equipment, avoids the further destruction causing gear case because of broken teeth, prevents the burst accident caused because of gear failure.The present invention can also show the situation of change of the gear teeth intuitively, is convenient to the duty of user's understanding gear accurately and timely, and protection plant equipment, avoids accident to occur.
The above; be only the present invention's preferably embodiment; but protection scope of the present invention is not limited thereto; anyly be familiar with those skilled in the art in the technical scope that the present invention discloses; be equal to according to technical scheme of the present invention and inventive concept thereof and replace or change, all should be encompassed within protection scope of the present invention.
Claims (10)
1. an intelligent gear failure pick-up unit, is characterized in that described device comprises: the magnetic part outside the gear teeth being arranged on gear or inside the gear teeth, the processor being arranged on the gear teeth of gear and the Hall element between described magnetic part and being connected with described Hall element output terminal; When described pinion rotation, the gear teeth that this gear has are one by one through described Hall element, described Hall element senses the changes of magnetic field that described gear teeth process is brought and exports electric signal to described processor, described processor obtains each gear teeth through the time of described Hall element according to the low and high level change of the electric signal received, and then knows the uniform configuration of the described gear teeth.
2. intelligent gear failure pick-up unit according to claim 1, it is characterized in that when having the gear teeth through out-of-date in the certain limit apart from described Hall element, described Hall element exports high level, when not having the gear teeth through out-of-date in the certain limit apart from described Hall element, described Hall element output low level.
3. intelligent gear failure pick-up unit according to claim 2, it is characterized in that described processor compared the duration of each high level signal that described Hall element exports and the first preset durations, when the duration of arbitrary high level signal is less than the first preset durations, described processor output device signal out of service, this equipment is the equipment comprising described gear.
4. intelligent gear failure pick-up unit according to claim 2, it is characterized in that described processor compared the duration of each low level signal that described Hall element exports and the second preset durations, when the duration of arbitrary low level signal higher than the second preset durations time, described processor exports break of gear tooth alerting signal.
5. intelligent gear failure pick-up unit according to claim 4, it is characterized in that described device also comprises the display be connected with described processor, this display is used for the uniform configuration of each gear teeth that processor is known and shows the break of gear tooth alerting signal that processor exports; Described magnetic part is magnet steel; Described Hall element is Hall element; Described processor is single-chip microcomputer.
6. an intelligent gear failure detection method, is characterized in that described detection method comprises the steps:
Step 1: configuration magnetic part is outside the gear teeth of gear or inside the gear teeth, and configuration Hall element is between the gear teeth and described magnetic part of gear; Described Hall element is connected with processor;
Step 2: when described pinion rotation, the gear teeth that this gear has are one by one through described Hall element, and described Hall element senses the changes of magnetic field that described gear teeth process is brought and exports electric signal to described processor;
Step 3: described processor obtains each gear teeth through the time of described Hall element according to the low and high level change of the electric signal received, and then knows the uniform configuration of the described gear teeth.
7. intelligent gear failure detection method according to claim 6, it is characterized in that when having the gear teeth through out-of-date in the certain limit apart from described Hall element, described Hall element exports high level, when not having the gear teeth through out-of-date in the certain limit apart from described Hall element, described Hall element output low level.
8. intelligent gear failure detection method according to claim 7, is characterized in that also comprising the steps: after step 3
Described processor compared the duration of each high level signal that described Hall element exports and the first preset durations, when the duration of arbitrary high level signal is less than the first preset durations, described processor output device signal out of service, this equipment is the equipment comprising described gear.
9. intelligent gear failure detection method according to claim 7, is characterized in that also comprising the steps: after step 3
Described processor compared the duration of each low level signal that described Hall element exports and the second preset durations, when the duration of arbitrary low level signal higher than the second preset durations time, described processor exports break of gear tooth alerting signal.
10. intelligent gear failure detection method according to claim 9, is characterized in that,
Described magnetic part is magnet steel; Described Hall element is Hall element; Described processor is single-chip microcomputer;
Also comprise the steps: after step 3
The break of gear tooth alerting signal that uniform configuration and the processor of each gear teeth that processor is known go out is shown.
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| CN201510884005.XA CN105510025A (en) | 2015-12-03 | 2015-12-03 | Intelligent gear failure detection device and its detection method |
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| CN201510884005.XA CN105510025A (en) | 2015-12-03 | 2015-12-03 | Intelligent gear failure detection device and its detection method |
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Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN107290145A (en) * | 2017-06-30 | 2017-10-24 | 太仓宝达齿条有限公司 | A kind of gear accelerates analyzer |
| CN108844463A (en) * | 2018-06-12 | 2018-11-20 | 南京理工大学 | Underground piping dimensional orientation measuring system and method based on laser spot position |
| CN111435104A (en) * | 2019-01-11 | 2020-07-21 | 加特可株式会社 | Inspection apparatus |
| CN111502658A (en) * | 2020-04-03 | 2020-08-07 | 黑龙江科技大学 | Intelligent monitoring shearer pick state device based on linear Hall multi-probe |
| CN116124447A (en) * | 2022-12-08 | 2023-05-16 | 中车永济电机有限公司 | Detection Systems |
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| CN116124447A (en) * | 2022-12-08 | 2023-05-16 | 中车永济电机有限公司 | Detection Systems |
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