CN115809595A - Digital twin model construction method reflecting rolling bearing defect expansion - Google Patents
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Abstract
Description
技术领域technical field
本发明涉及轴承健康管理和运行与维护领域,尤其涉及一种反映滚动轴承缺陷扩展的数字孪生模型构建方法。The invention relates to the fields of bearing health management and operation and maintenance, in particular to a method for constructing a digital twin model reflecting the expansion of rolling bearing defects.
背景技术Background technique
滚动轴承是旋转机械设备中最常用的零件之一,其工作可靠性直接影响旋转机械设备的安全性与运行稳定性,因此对滚动轴承的运行维护至关重要。许多学者通过建立局部故障动力学模型来模拟滚动轴承的动态响应,以对包含滚动轴承的大型机械设备进行运维。鉴于滚动轴承动力学模型的建立过程均存在不同程度的理想化,模型不能完全还原滚动轴承内部部件的运动行为,导致模型输出的仿真动态响应与滚动轴承真实的动态响应仍有差异。所以如何缩小滚动轴承的仿真动态响应与真实动态响应之间的差异,是提高滚动轴承故障检测精度的关键性问题。Rolling bearings are one of the most commonly used parts in rotating machinery equipment, and their working reliability directly affects the safety and operation stability of rotating machinery equipment, so it is very important for the operation and maintenance of rolling bearings. Many scholars have simulated the dynamic response of rolling bearings by establishing local fault dynamic models to operate and maintain large mechanical equipment containing rolling bearings. In view of the different degrees of idealization in the establishment process of the rolling bearing dynamic model, the model cannot completely restore the motion behavior of the internal components of the rolling bearing, resulting in differences between the simulated dynamic response output by the model and the real dynamic response of the rolling bearing. Therefore, how to reduce the difference between the simulated dynamic response and the real dynamic response of rolling bearings is a key issue to improve the accuracy of rolling bearing fault detection.
数字孪生技术可以充当仿真动态响应与真实动态响应之间的桥梁。大多数传统的数字孪生模型都是基于实时传感器数据,其建模过程往往需要一些仿真软件的帮助,如ICEM CFD、MATLAB、ANSYS等,或一些数学机械模型。它们根据实时传感器数据持续更新虚拟实体的参数,以模仿物理实体的运动并产生模拟的动态响应。目前,这项技术已经应用到了轴承的管理与运维之中。Farhat等人利用数字孪生技术给故障轴承分类的神经网络提供数据集,实验表明利用数字孪生技术生成的数据集仍可达到分类精度要求。Liu等人为了准确预测滚动轴承退化过程中的剩余使用寿命,基于轴承振动现象,建立了轴承数字孪生模型,并使用域对抗神经网络(DANN)来实现仿真数据和真实数据之间的域自适应。Qin等人基于动力学模型和轴承的历史测量数据提出了一种数据与模型联合驱动的数字孪生模型构建方法,该模型生成的仿真振动信号经过循环生成对抗网络(CycleGAN)修正后与测量振动信号高度一致。然而,传感器提供的信息是有限的,某些参量是无法通过传感器直接获得的,如滚动轴承的局部缺陷尺寸,这导致传统的数字孪生模型无法展示这些物理量。Digital twin technology can act as a bridge between the simulated dynamic response and the real dynamic response. Most traditional digital twin models are based on real-time sensor data, and their modeling process often requires the help of some simulation software, such as ICEM CFD, MATLAB, ANSYS, etc., or some mathematical mechanical models. They continuously update the parameters of virtual entities based on real-time sensor data to mimic the motion of physical entities and generate simulated dynamic responses. At present, this technology has been applied to the management and operation and maintenance of bearings. Farhat et al. used digital twin technology to provide data sets for the neural network of faulty bearing classification. Experiments show that the data sets generated by digital twin technology can still meet the classification accuracy requirements. In order to accurately predict the remaining service life of rolling bearings during the degradation process, Liu et al. established a digital twin model of bearings based on bearing vibration phenomena, and used Domain Adversarial Neural Network (DANN) to achieve domain adaptation between simulation data and real data. Based on the dynamic model and the historical measurement data of the bearing, Qin et al. proposed a digital twin model construction method driven by the joint data and model. The simulated vibration signal generated by the model was corrected with the measured vibration signal after being corrected by CycleGAN. highly consistent. However, the information provided by the sensor is limited, and some parameters cannot be directly obtained by the sensor, such as the local defect size of the rolling bearing, which makes the traditional digital twin model unable to display these physical quantities.
发明内容Contents of the invention
本发明所要解决的技术问题在于针对传统数字孪生模型的不足,提供一种反映滚动轴承缺陷扩展的数字孪生模型构建方法,基于信号降噪方法、数学机理模型、动态更新方法和深度学习技术,实现滚动轴承的时变局部缺陷尺寸的实时预测,并产生于测量振动信号高度一致的仿真振动信号。The technical problem to be solved by the present invention is to provide a digital twin model construction method that reflects the expansion of rolling bearing defects based on the shortcomings of traditional digital twin models, based on signal noise reduction methods, mathematical mechanism models, dynamic update methods and deep learning technology. Real-time prediction of time-varying local defect sizes and generation of simulated vibration signals that are highly consistent with measured vibration signals.
为实现上述目的,本发明提供如下技术方案:To achieve the above object, the present invention provides the following technical solutions:
一种反映滚动轴承缺陷扩展的数字孪生模型构建方法,包括以下步骤:A digital twin model construction method reflecting the expansion of rolling bearing defects, including the following steps:
S1:获取滚动轴承的全生命周期振动信号,利用奇异值分解(SVD)技术对采集的振动信号进行降噪预处理;S1: Obtain the full life cycle vibration signal of the rolling bearing, and use the singular value decomposition (SVD) technology to perform noise reduction preprocessing on the collected vibration signal;
S2:基于赫兹接触理论构建描述滚动轴承局部缺陷扩展行为的动力学模型;S2: Construct a dynamic model describing the propagation behavior of local defects in rolling bearings based on the Hertzian contact theory;
S3:根据信号逼近法,以实际测量数据更新动力学模型参数并估计滚动轴承的时变缺陷尺寸;S3: According to the signal approximation method, update the dynamic model parameters and estimate the time-varying defect size of the rolling bearing with the actual measurement data;
S4:利用长短时记忆网络(LSTM)建立实际测量振动信号和时变缺陷的关系,建立数字孪生模型,实现物理实体至虚拟实体的实时映射;S4: Use the long short-term memory network (LSTM) to establish the relationship between the actual measured vibration signal and the time-varying defect, establish a digital twin model, and realize the real-time mapping from the physical entity to the virtual entity;
S5:根据局部缺陷扩展的程度监测滚动轴承的运行状态和健康情况,估计当前滚动轴承在全生命周期中的运行阶段,在轴承失效前及时做出决策和反馈。S5: Monitor the operating status and health of rolling bearings according to the extent of local defect expansion, estimate the current operating stages of rolling bearings in their entire life cycle, and make timely decisions and feedback before bearing failure.
所述利用奇异值分解对采集的振动信号进行降噪预处理,具体为:基于相空间重构理论,构造r×s阶的Hankel矩阵,设定传感器采集的振动信号为Y=[y1 y2…yn],则Hankel矩阵如式(1)所示:The noise reduction preprocessing of the vibration signal collected by using singular value decomposition is specifically: based on the phase space reconstruction theory, constructing a Hankel matrix of r×s order, and setting the vibration signal collected by the sensor as Y=[y 1 y 2 …y n ], then the Hankel matrix is shown in formula (1):
其中,H为r×s矩阵,n为信号的总长度,n=r+s-1,且r≤s,H可拆分为H=D+W;D为光滑信号在重构空间的矩阵,W为噪声干扰信号的矩阵,所述H、D、W均为r×s阶矩阵,对H进行奇异值分解,可得到:Among them, H is an r×s matrix, n is the total length of the signal, n=r+s-1, and r≤s, H can be split into H=D+W; D is the matrix of the smooth signal in the reconstruction space , W is the matrix of the noise interference signal, and the H, D, and W are all r×s order matrices, and the singular value decomposition of H can be obtained:
H=USVT (2)H = USV T (2)
其中,U和VT分别为r×r和s×s阶的矩阵,S为r×s阶的对角矩阵,主对角线为λi(i=1,2,…,m),其中m=min(r,s),即:Among them, U and V T are matrices of order r×r and s×s respectively, S is a diagonal matrix of order r×s, and the main diagonal is λ i (i=1,2,…,m), where m=min(r,s), that is:
S=diag(λ1,λ2,…,λm) (3)S=diag(λ 1 ,λ 2 ,…,λ m ) (3)
其中,λ1,λ2,…,λm即为H的奇异值,且λ1≥λ2≥…≥λm,U和VT表示为H的左右奇异矩阵;经过奇异值分解的逆运算,得到重构的矩阵Hn,将Hn重新展开为新的振动信号Yn,得到降噪后的振动信号;Among them, λ 1 , λ 2 ,...,λ m are the singular values of H, and λ 1 ≥ λ 2 ≥... ≥ λ m , U and V T are expressed as the left and right singular matrices of H; after the inverse operation of singular value decomposition , get the reconstructed matrix H n , re-expand H n into a new vibration signal Y n , and get the noise-reduced vibration signal;
将奇异值差分值定义为bi=λi-λi+1(i=1,2,…,m-1),差分后形成奇异值差分序列B=(b1+b2+…+bm-1)。The singular value difference value is defined as b i =λ i -λ i+1 (i=1,2,…,m-1), and the singular value difference sequence B=(b 1 +b 2 +…+b m-1 ).
所述基于赫兹接触理论构建描述滚动轴承局部缺陷扩展行为的动力学模型,具体为:The dynamic model describing the expansion behavior of local defects in rolling bearings is constructed based on the Hertzian contact theory, specifically:
S2.1:将滚动轴承局部缺陷设定为深度为H、长度为L及宽度等于轴承外滚道的宽度的长方体缺陷,根据滚动体与外滚道接触情况分析故障阶段;S2.1: Set the local defect of the rolling bearing as a cuboid defect with a depth of H, a length of L and a width equal to the width of the outer raceway of the bearing, and analyze the fault stage according to the contact between the rolling body and the outer raceway;
S2.2:采用分段函数作为位移激励,建立二自由度动力学模型。S2.2: Using a piecewise function as the displacement excitation, establish a two-degree-of-freedom dynamic model.
所述根据滚动体与外滚道接触情况分析故障阶段包括:The stage of analyzing the fault according to the contact condition between the rolling element and the outer raceway includes:
根据几何关系,计算滚动体与局部缺陷两边缘同时接触时的径向位移最大值Hd,如式(4)所示:According to the geometric relationship, calculate the maximum radial displacement H d when the rolling element is in contact with the two edges of the local defect at the same time, as shown in formula (4):
其中,r为滚动体半径;Among them, r is the radius of the rolling element;
若Hd<H,则滚动体仅与缺陷边缘接触,此时为故障前期;If H d < H, the rolling element is only in contact with the edge of the defect, which is the early stage of failure;
若Hd>H,则滚动体即与缺陷边缘接触,又与缺陷底部接触,此时为故障后期。If H d >H, the rolling element is in contact with the edge of the defect and the bottom of the defect, which is the late stage of the fault.
所述采用分段函数作为位移激励,建立二自由度动力学模型,具体包括:The use of piecewise functions as displacement excitations to establish a two-degree-of-freedom dynamics model specifically includes:
引入分段位移激励函数:Introduce a piecewise displacement activation function:
对于故障前期,位移激励函数,如式(5)所示:For the early stage of failure, the displacement excitation function is shown in formula (5):
对于故障后期,位移激励函数,如式(6)所示:For the later stage of the fault, the displacement excitation function is shown in formula (6):
其中,R为外圈滚道半径,β0为局部缺陷相对于X轴正方向的初始角位置,β为局部缺陷范围角,θi为第i个滚动体在t时刻相对X轴正方向的角,βq为滚动体与局部缺陷底边接触时的弧度长,Hmax为滚动体经过局部缺陷时,滚动体的实际径向位移最大值,如式(7)所示:Among them, R is the radius of the raceway of the outer ring, β0 is the initial angular position of the local defect relative to the positive direction of the X-axis, β is the range angle of the local defect, and θi is the angle of the i-th rolling element relative to the positive direction of the X-axis at time t β q is the arc length when the rolling body contacts the bottom edge of the local defect, and H max is the actual maximum radial displacement of the rolling body when the rolling body passes through the local defect, as shown in formula (7):
滚动体与轴承内、外圈滚道之间的接触刚度满足Hertz接触理论,其载荷-变形关系,如式(8)所示:The contact stiffness between the rolling elements and the raceways of the inner and outer rings of the bearing satisfies the Hertz contact theory, and its load-deformation relationship is shown in formula (8):
F=Kδn (8)F= Kδn (8)
其中,K为滚动体与内、外圈的总接触刚度,F为赫兹接触力,δ为接触变形,n为载荷-变形指数,球轴承n=1.5,Ki和Ko分别为滚动体与内、外圈的接触刚度,将轴承系统作为集中弹簧-质量模型,建立二自由度动力学方程,如式(9)所示:Among them, K is the total contact stiffness between the rolling element and the inner and outer rings, F is the Hertzian contact force, δ is the contact deformation, n is the load-deformation index, n=1.5 for the ball bearing, K i and K o are the rolling element and K o respectively For the contact stiffness of the inner and outer rings, the bearing system is regarded as a concentrated spring-mass model, and a two-degree-of-freedom dynamic equation is established, as shown in formula (9):
其中,M为内圈与轴的质量和,C为系统的阻尼,K为滚动体与内外圈滚道的接触刚度,分别为内圈在X和Y方向的振动加速度,分别为内圈在X和Y方向的振动速度,Fx、Fy分别为水平和竖直方向的载荷分量,δi为第i个滚动体与滚道之间的接触变形,如式(10)所示:Among them, M is the mass sum of the inner ring and the shaft, C is the damping of the system, K is the contact stiffness between the rolling body and the inner and outer ring raceways, are the vibration accelerations of the inner ring in the X and Y directions, respectively, are the vibration velocities of the inner ring in the X and Y directions, F x and F y are the load components in the horizontal and vertical directions, respectively, and δ i is the contact deformation between the i-th rolling element and the raceway, as shown in formula (10 ) as shown:
δi=xcosθi+ysinθi-c-H′ (10)δ i =xcosθ i +ysinθ i -cH′ (10)
其中,x、y分别为内圈在X和Y方向的振动位移,c为滚动轴承的径向游,H′为位移激励函数,当Hd<H时,H′=H1,当Hd>H时,H′=H2,λ表示第i个滚动体的有效接触面积参数,如式(11)所示:Among them, x and y are the vibration displacement of the inner ring in the X and Y directions respectively, c is the radial travel of the rolling bearing, H' is the displacement excitation function, when H d <H, H'=H 1 , when H d > When H, H'=H 2 , λ represents the effective contact area parameter of the i-th rolling element, as shown in formula (11):
所述根据信号逼近法,以实际测量数据更新动力学模型参数并估计滚动轴承的时变缺陷尺寸,具体包括以下步骤:According to the signal approximation method, updating dynamic model parameters with actual measurement data and estimating the time-varying defect size of the rolling bearing specifically includes the following steps:
S3.1:计算每组目标信号的峰值pkm(i),i=1,2,…,n,其中,n为最后一组目标信号的序号;所述目标信号为全生命周期降噪信号;S3.1: Calculate the peak value pkm(i) of each group of target signals, i=1, 2,...,n, wherein, n is the serial number of the last group of target signals; the target signal is a full life cycle noise reduction signal;
S3.2:设定初始缺陷长度L',步长Δ和停止逼近的误差δ,利用龙格库塔数值积分法求解动力学方程,获得当前缺陷长度对应的振动信号峰值pks,若pks<pkm,L'=L'+Δ则令再次比较pks和pkm,直到pks≥pkm;S3.2: Set the initial defect length L', the step size Δ and the error δ of the stop approach, use the Runge-Kutta numerical integration method to solve the dynamic equation, and obtain the peak value pks of the vibration signal corresponding to the current defect length, if pks<pkm , L'=L'+Δ then compare pks and pkm again until pks≥pkm;
S3.3:令L'=L'+Δ/100,获得当前缺陷长度对应的pks,若pks≥pkm,则继续L'=L'+Δ/100,直到pks-pkm≤δ;S3.3: Set L'=L'+Δ/100 to obtain the pks corresponding to the current defect length, if pks≥pkm, continue to L'=L'+Δ/100 until pks-pkm≤δ;
S3.4:将S3.1-S3.3应用到每一组目标信号,得到全生命周期虚拟实体的缺陷长度L(i)和其对应的振动信号峰值pks(i);S3.4: Apply S3.1-S3.3 to each group of target signals to obtain the defect length L(i) of the virtual entity in the full life cycle and its corresponding vibration signal peak value pks(i);
S3.5:将获得的虚拟实体的缺陷长度L(i)反代入式中,获得全生命周期的仿真振动信号。S3.5: Substitute the obtained defect length L(i) of the virtual entity into the formula to obtain the simulated vibration signal of the whole life cycle.
所述利用长短时记忆网络(LSTM)建立实际测量振动信号和时变缺陷的关系,实现物理实体至虚拟实体的实时映射,包括以下步骤:The use of the long-short-term memory network (LSTM) to establish the relationship between the actual measurement vibration signal and the time-varying defect, to realize the real-time mapping from the physical entity to the virtual entity, comprises the following steps:
S4.1:计算实测振动信号的均方根值rms(i),将rms(i)作为LSTM的输入,将虚拟实体的缺陷长度L(i)作为输出,构造样本;S4.1: Calculate the root mean square value rms(i) of the measured vibration signal, use rms(i) as the input of LSTM, and use the defect length L(i) of the virtual entity as the output to construct a sample;
S4.2:将样本按比例划分为训练集和验证集,用以训练LSTM神经网络;S4.2: Divide the sample into a training set and a verification set in proportion to train the LSTM neural network;
S4.3:将传感器采集的振动信号输入至训练好的LSTM神经网络,获得估计的时变缺陷尺寸。S4.3: Input the vibration signal collected by the sensor into the trained LSTM neural network to obtain the estimated time-varying defect size.
有益技术效果Beneficial technical effect
1、本发明采用的技术方案与传统的数字孪生模型相比,不仅充分利用了历史测量数据和动力学模型,而且还根据故障机理和滚动轴承的动态响应之间的关系,利用提出的动态更新方法来动态地更新虚拟实体,使得本发明不仅可以生成与测量振动信号一致的模拟振动信号,还可以直接估计滚动轴承的局部缺陷尺寸,探索了连续服役条件下滚动轴承局部缺陷的扩展行为,为滚动轴承的运维和健康监测提供了一种新手段。1. Compared with the traditional digital twin model, the technical solution adopted by the present invention not only makes full use of the historical measurement data and dynamic model, but also uses the proposed dynamic update method according to the relationship between the fault mechanism and the dynamic response of the rolling bearing Dynamically update the virtual entity, so that the present invention can not only generate the simulated vibration signal consistent with the measured vibration signal, but also directly estimate the size of the local defect of the rolling bearing, and explore the expansion behavior of the local defect of the rolling bearing under the condition of continuous service. Peacekeeping health monitoring offers a new tool.
2、本发明利用滚动轴承的振动信号桥接物理空间与虚拟空间,采用信号逼近法实现虚拟实体的动态更新,而无需测量轴承的实际缺陷尺寸,解决了轴承运行状态下难以获取其时变缺陷大小的难题。利用LSTM建立实测振动信号均方根值与虚拟空间局部缺陷长度的关系,将物理空间信号映射至虚拟空间,模型经过历史数据的训练后在同工况下可根据采集的振动信号直接预测出实际轴承的局部缺陷尺寸,帮助快速更新虚拟实体。2. The present invention uses the vibration signal of the rolling bearing to bridge the physical space and the virtual space, and uses the signal approximation method to realize the dynamic update of the virtual entity without measuring the actual defect size of the bearing, which solves the problem that it is difficult to obtain the time-varying defect size in the running state of the bearing. problem. Use LSTM to establish the relationship between the root mean square value of the measured vibration signal and the length of the local defect in the virtual space, and map the physical space signal to the virtual space. The local defect size of the bearing, which helps to update the virtual entity quickly.
附图说明Description of drawings
图1为本发明实施例提出的一种反映滚动轴承缺陷扩展的数字孪生模型构建方法流程图;Fig. 1 is a flow chart of a digital twin model construction method reflecting the expansion of rolling bearing defects proposed by the embodiment of the present invention;
图2为本发明实施例提出的数字孪生模型构建方法的技术路线图;Fig. 2 is the technical roadmap of the digital twin model construction method that the embodiment of the present invention proposes;
图3为本发明实施例提出的滚动轴承的局部缺陷扩展情况示意图;Fig. 3 is a schematic diagram of the expansion of local defects of the rolling bearing proposed by the embodiment of the present invention;
图4为本发明实施例提出的滚动轴承位移激励函数几何关系示意图;Fig. 4 is a schematic diagram of the geometric relationship of the rolling bearing displacement excitation function proposed by the embodiment of the present invention;
图5为本发明实施例提出的信号逼近法流程图。FIG. 5 is a flowchart of a signal approximation method proposed by an embodiment of the present invention.
具体实施方式Detailed ways
下面结合附图和实施例,对本发明的具体实施方式作进一步详细描述。The specific implementation manners of the present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments.
本发明提出了一种反映滚动轴承缺陷扩展的数字孪生模型构建方法,大多数传统的数字孪生模型根据实时传感器数据持续更新虚拟实体的参数,以模仿物理实体的运动并产生模拟的动态响应,然而,传感器提供的信息是有限的,某些参量是无法通过传感器直接获得的,如滚动轴承的局部缺陷尺寸,这导致传统的数字孪生模型无法展示这些物理量,为解决滚动轴承工作时局部缺陷尺寸难以在线监测的问题,本方法基于数字孪生五维模型理论,包含信号处理、动力学建模及深度学习等技术,估计了滚动轴承局部缺陷尺寸的大小,并利用信号逼近法实现数字孪生模型的动态更新,以模拟缺陷扩展的全过程,最后利用LSTM建立滚动轴承实测振动信号与估计的时变缺陷尺寸之间的关系,实现实时映射,该模型的优势是模型的建立过程无需测量滚动轴承实际的局部缺陷尺寸大小,以虚拟实体的变化即可表征物理实体的变化;一种动态更新和实时映射滚动轴承局部缺陷扩展行为的数字孪生模型构建方法,如图1所示,包括以下步骤:The present invention proposes a digital twin model construction method that reflects the expansion of rolling bearing defects. Most traditional digital twin models continuously update the parameters of virtual entities based on real-time sensor data to imitate the movement of physical entities and generate simulated dynamic responses. However, The information provided by the sensor is limited, and some parameters cannot be directly obtained by the sensor, such as the local defect size of the rolling bearing, which makes the traditional digital twin model unable to display these physical quantities. Problem, this method is based on the digital twin five-dimensional model theory, including signal processing, dynamic modeling and deep learning technology, estimates the size of the local defect size of the rolling bearing, and uses the signal approximation method to realize the dynamic update of the digital twin model to simulate In the whole process of defect expansion, LSTM is finally used to establish the relationship between the measured vibration signal of the rolling bearing and the estimated time-varying defect size to realize real-time mapping. The change of the virtual entity can represent the change of the physical entity; a digital twin model construction method for dynamically updating and real-time mapping of the local defect expansion behavior of rolling bearings, as shown in Figure 1, includes the following steps:
为实现上述目的,本发明提供如下技术方案:To achieve the above object, the present invention provides the following technical solutions:
一种动态更新和实时映射滚动轴承局部缺陷扩展行为的数字孪生模型构建方法,如图1所示,包括以下步骤:A digital twin model construction method for dynamically updating and real-time mapping of the local defect expansion behavior of rolling bearings, as shown in Figure 1, includes the following steps:
S1:获取滚动轴承的全生命周期振动信号,利用奇异值分解(SVD)技术对采集的振动信号进行降噪预处理;S1: Obtain the full life cycle vibration signal of the rolling bearing, and use the singular value decomposition (SVD) technology to perform noise reduction preprocessing on the collected vibration signal;
所述利用奇异值分解对采集的振动信号进行降噪预处理,具体为:基于相空间重构理论,构造r×s阶的Hankel矩阵,设定传感器采集的振动信号为Y=[y1 y2…yn],则Hankel矩阵如式(1)所示:The noise reduction preprocessing of the vibration signal collected by using singular value decomposition is specifically: based on the phase space reconstruction theory, constructing a Hankel matrix of r×s order, and setting the vibration signal collected by the sensor as Y=[y 1 y 2 …y n ], then the Hankel matrix is shown in formula (1):
其中,H为r×s矩阵,n为信号的总长度,n=r+s-1,且r≤s,H可拆分为H=D+W;D为光滑信号在重构空间的矩阵,W为噪声干扰信号的矩阵,所述H、D、W均为r×s阶矩阵,对H进行奇异值分解,可得到:Among them, H is an r×s matrix, n is the total length of the signal, n=r+s-1, and r≤s, H can be split into H=D+W; D is the matrix of the smooth signal in the reconstruction space , W is the matrix of the noise interference signal, and the H, D, and W are all r×s order matrices, and the singular value decomposition of H can be obtained:
H=USVT (2)H = USV T (2)
其中,U和VT分别为r×r和s×s阶的矩阵,S为r×s阶的对角矩阵,主对角线为λi(i=1,2,…,m),其中m=min(r,s),即:Among them, U and V T are matrices of order r×r and s×s respectively, S is a diagonal matrix of order r×s, and the main diagonal is λ i (i=1,2,…,m), where m=min(r,s), that is:
S=diag(λ1,λ2,…,λm) (3)S=diag(λ 1 ,λ 2 ,…,λ m ) (3)
其中,λ1,λ2,…,λm即为H的奇异值,且λ1≥λ2≥…≥λm,U和VT表示为H的左右奇异矩阵;经过奇异值分解的逆运算,得到重构的矩阵Hn,将Hn重新展开为新的振动信号Yn,得到降噪后的振动信号;Among them, λ 1 , λ 2 ,...,λ m are the singular values of H, and λ 1 ≥ λ 2 ≥... ≥ λ m , U and V T are expressed as the left and right singular matrices of H; after the inverse operation of singular value decomposition , get the reconstructed matrix H n , re-expand H n into a new vibration signal Y n , and get the noise-reduced vibration signal;
使用奇异值差分谱法确定了SVD重构分量,差分值能反映两个奇异值的相差程度,差分值越大代表奇异值相差越大,而这些大的差分值的出现就是因为有效信号和噪声信号的不相关性较大导致的,奇异值差分谱序列可以描述奇异值序列的变化情况和变化趋势,The SVD reconstruction component is determined using the singular value difference spectrum method. The difference value can reflect the degree of difference between two singular values. The larger the difference value is, the larger the difference between the singular values is. The appearance of these large difference values is due to the effective signal and noise. Due to the large irrelevance of the signal, the singular value difference spectrum sequence can describe the change and trend of the singular value sequence.
将奇异值差分值定义为bi=λi-λi+1(i=1,2,…,m-1),差分后形成奇异值差分序列B=(b1+b2+…+bm-1);The singular value difference value is defined as b i =λ i -λ i+1 (i=1,2,…,m-1), and the singular value difference sequence B=(b 1 +b 2 +…+b m-1 );
本实施例中,对测量振动信号进行降噪预处理的目的在于降低白噪声对振动信号的幅值的影响,从而使后续的动态更新步骤更加精准,估计出的滚动轴承局部缺陷尺寸更加准确;In this embodiment, the purpose of performing noise reduction preprocessing on the measured vibration signal is to reduce the influence of white noise on the amplitude of the vibration signal, so that the subsequent dynamic update steps are more accurate, and the estimated size of the local defect of the rolling bearing is more accurate;
S2:基于赫兹接触理论构建描述滚动轴承局部缺陷扩展行为的动力学模型;S2: Construct a dynamic model describing the propagation behavior of local defects in rolling bearings based on the Hertzian contact theory;
如图2所示,一种动态更新和实时映射滚动轴承局部缺陷扩展行为的数字孪生模型构建方法基于数字孪生五维模型理论,集物理空间、虚拟空间、孪生空间、服务和数据连接于一体;模型的物理空间主要包括物理平台搭建、传感器的布置和数据上传等;虚拟空间主要包括几何模型、物理模型、行为模型和规则模型;几何模型是对物理实体的几何参数描述,如形状、尺寸等;物理模型则描述物理实体的物理属性、受力情况和约束条件;行为模型在此框架中主要表现为滚动轴承局部缺陷随时间而扩展的过程;规则模型包括基于历史关联数据的规律规则和基于隐性知识总结的经验,在此框架中对应为利用LSTM建立实测振动信号和虚拟实体的关系;As shown in Figure 2, a digital twin model construction method for dynamically updating and real-time mapping of the local defect expansion behavior of rolling bearings is based on the digital twin five-dimensional model theory, which integrates physical space, virtual space, twin space, service and data connection; the model The physical space mainly includes physical platform construction, sensor arrangement, and data uploading; the virtual space mainly includes geometric models, physical models, behavior models, and rule models; the geometric model is a description of the geometric parameters of physical entities, such as shape and size; The physical model describes the physical properties, stress conditions and constraints of physical entities; the behavior model in this framework mainly represents the process of the local defects of rolling bearings expanding over time; the rule model includes regular rules based on historical associated data and implicit The experience of knowledge summary corresponds to using LSTM to establish the relationship between the measured vibration signal and the virtual entity in this framework;
目的在于用数学机理模型模拟滚动轴承的内部运动逻辑,从机理和数学的角度呈现了滚动轴承的局部缺陷扩展对其动态响应的影响;如图3所示,进而产生与实际测量数据相似的仿真数据,包括以下步骤:The purpose is to use the mathematical mechanism model to simulate the internal motion logic of the rolling bearing, and present the influence of the local defect expansion of the rolling bearing on its dynamic response from the perspective of mechanism and mathematics; as shown in Figure 3, and then generate simulation data similar to the actual measurement data, Include the following steps:
S2.1:将滚动轴承局部缺陷设定为深度为H、长度为L及宽度等于轴承外滚道的宽度的长方体缺陷,根据滚动体与外滚道接触情况分析故障阶段;S2.1: Set the local defect of the rolling bearing as a cuboid defect with a depth of H, a length of L and a width equal to the width of the outer raceway of the bearing, and analyze the fault stage according to the contact between the rolling body and the outer raceway;
所述根据滚动体与外滚道接触情况分析故障阶段包括:The stage of analyzing the fault according to the contact condition between the rolling element and the outer raceway includes:
根据几何关系,计算滚动体与局部缺陷两边缘同时接触时的径向位移最大值Hd,如式(4)所示:According to the geometric relationship, calculate the maximum radial displacement H d when the rolling element is in contact with the two edges of the local defect at the same time, as shown in formula (4):
其中,r为滚动体半径;Among them, r is the radius of the rolling element;
若Hd<H,则滚动体仅与缺陷边缘接触,此时为故障前期;If H d < H, the rolling element is only in contact with the edge of the defect, which is the early stage of failure;
若Hd>H,则滚动体即与缺陷边缘接触,又与缺陷底部接触,此时为故障后期;If H d > H, the rolling element is in contact with the edge of the defect and the bottom of the defect, which is the late stage of the fault;
S2.2:采用分段函数作为位移激励,建立二自由度动力学模型;S2.2: Using a piecewise function as the displacement excitation, establish a two-degree-of-freedom dynamic model;
所述采用分段函数作为位移激励,建立二自由度动力学模型,具体包括:The use of piecewise functions as displacement excitations to establish a two-degree-of-freedom dynamics model specifically includes:
如图4所示,引入分段位移激励函数:As shown in Figure 4, the segmented displacement excitation function is introduced:
对于故障前期,位移激励函数,如式(5)所示:For the early stage of failure, the displacement excitation function is shown in formula (5):
对于故障后期,位移激励函数,如式(6)所示:For the later stage of the fault, the displacement excitation function is shown in formula (6):
其中,R为外圈滚道半径,β0为局部缺陷相对于X轴正方向的初始角位置,β为局部缺陷范围角,θi为第i个滚动体在t时刻相对X轴正方向的角,βq为滚动体与局部缺陷底边接触时的弧度长,Hmax为滚动体经过局部缺陷时,滚动体的实际径向位移最大值,如式(7)所示:Among them, R is the radius of the raceway of the outer ring, β0 is the initial angular position of the local defect relative to the positive direction of the X-axis, β is the range angle of the local defect, and θi is the angle of the i-th rolling element relative to the positive direction of the X-axis at time t β q is the arc length when the rolling body contacts the bottom edge of the local defect, and H max is the actual maximum radial displacement of the rolling body when the rolling body passes through the local defect, as shown in formula (7):
滚动体与轴承内、外圈滚道之间的接触刚度满足Hertz接触理论,其载荷-变形关系,如式(8)所示:The contact stiffness between the rolling elements and the raceways of the inner and outer rings of the bearing satisfies the Hertz contact theory, and its load-deformation relationship is shown in formula (8):
F=Kδn (8)F= Kδn (8)
其中,K为滚动体与内、外圈的总接触刚度,F为赫兹接触力,δ为接触变形,n为载荷-变形指数,球轴承n=1.5,Ki和Ko分别为滚动体与内、外圈的接触刚度,将轴承系统作为集中弹簧-质量模型,建立二自由度动力学方程,如式(9)所示:Among them, K is the total contact stiffness between the rolling element and the inner and outer rings, F is the Hertzian contact force, δ is the contact deformation, n is the load-deformation index, n=1.5 for ball bearings, K i and K o are the rolling elements and For the contact stiffness of the inner and outer rings, the bearing system is regarded as a concentrated spring-mass model, and a two-degree-of-freedom dynamic equation is established, as shown in formula (9):
其中,M为内圈与轴的质量和,C为系统的阻尼,K为滚动体与内外圈滚道的接触刚度,分别为内圈在X和Y方向的振动加速度,分别为内圈在X和Y方向的振动速度,Fx、Fy分别为水平和竖直方向的载荷分量,δi为第i个滚动体与滚道之间的接触变形,如式(10)所示:Among them, M is the mass sum of the inner ring and the shaft, C is the damping of the system, K is the contact stiffness between the rolling body and the inner and outer ring raceways, are the vibration accelerations of the inner ring in the X and Y directions, respectively, are the vibration velocities of the inner ring in the X and Y directions, F x and F y are the load components in the horizontal and vertical directions, respectively, and δ i is the contact deformation between the i-th rolling element and the raceway, as shown in formula (10 ) as shown:
δi=xcosθi+ysinθi-c-H′ (10)δ i =xcosθ i +ysinθ i -cH′ (10)
其中,x、y分别为内圈在X和Y方向的振动位移,c为滚动轴承的径向游,H′为位移激励函数,当Hd<H时,H′=H1,当Hd>H时,H′=H2,λ表示第i个滚动体的有效接触面积参数,如式(11)所示:Among them, x and y are the vibration displacement of the inner ring in the X and Y directions respectively, c is the radial travel of the rolling bearing, H' is the displacement excitation function, when H d <H, H'=H 1 , when H d > When H, H'=H 2 , λ represents the effective contact area parameter of the i-th rolling element, as shown in formula (11):
S3:根据信号逼近法,以实际测量数据更新动力学模型参数并估计滚动轴承的时变缺陷尺寸;如图5所示,建立虚拟空间仿真信号与物理空间实测信号的关系将虚拟空间产生的仿真数据最大程度逼近物理空间实测数据,使虚拟实体参数根据物理空间数据不断更新,并使用虚拟实体数据来表征物理空间物理实体缺陷扩展的过程,实现数字孪生,S3: According to the signal approximation method, the dynamic model parameters are updated with the actual measurement data and the time-varying defect size of the rolling bearing is estimated; Approximate the measured data in the physical space to the greatest extent, so that the parameters of the virtual entity are continuously updated according to the data in the physical space, and use the data of the virtual entity to represent the process of the defect expansion of the physical entity in the physical space, so as to realize the digital twin,
本实施例中,如图5所示,由于无法在滚动轴承运行中测量其时变缺陷的尺寸,只能通过传感器采集的振动信号对轴承的缺陷扩展情况进行分析,因此提出一种信号逼近法,来建立虚拟空间仿真信号与物理空间实测信号的关系;信号逼近法的目的是将虚拟空间产生的仿真数据最大程度逼近物理空间实测数据,使虚拟实体参数根据物理空间数据不断更新,并使用虚拟实体数据来表征物理空间物理实体缺陷扩展的过程,实现数字孪生;由于信号逼近的目标信号是经过SVD降噪预处理后的实测信号,其幅值变化平滑、冲击特征较为明显,所以选择逼近算法较为简单的峰值作为评价逼近效果的指标,具体包括以下步骤:In this embodiment, as shown in Figure 5, since the size of the time-varying defect cannot be measured during the operation of the rolling bearing, the expansion of the defect of the bearing can only be analyzed through the vibration signal collected by the sensor, so a signal approximation method is proposed, To establish the relationship between the virtual space simulation signal and the physical space measured signal; the purpose of the signal approximation method is to approximate the simulated data generated in the virtual space to the measured data in the physical space to the greatest extent, so that the virtual entity parameters are continuously updated according to the physical space data, and use the virtual entity The data is used to represent the process of the expansion of physical entity defects in the physical space to realize the digital twin; since the target signal of the signal approximation is the measured signal after SVD noise reduction preprocessing, its amplitude changes smoothly and the impact characteristics are more obvious, so the selection of the approximation algorithm is more The simple peak is used as an indicator to evaluate the approximation effect, which specifically includes the following steps:
S3.1:计算每组目标信号的峰值pkm(i),i=1,2,…,n,其中,n为最后一组目标信号的序号;所述目标信号为全生命周期降噪信号;S3.1: Calculate the peak value pkm(i) of each group of target signals, i=1, 2,...,n, wherein, n is the serial number of the last group of target signals; the target signal is a full life cycle noise reduction signal;
S3.2:设定初始缺陷长度L',步长Δ和停止逼近的误差δ,利用龙格库塔数值积分法求解动力学方程,获得当前缺陷长度对应的振动信号峰值pks,若pks<pkm,L'=L'+Δ则令再次比较pks和pkm,直到pks≥pkm;S3.2: Set the initial defect length L', the step size Δ and the error δ of the stop approach, use the Runge-Kutta numerical integration method to solve the dynamic equation, and obtain the peak value pks of the vibration signal corresponding to the current defect length, if pks<pkm , L'=L'+Δ then compare pks and pkm again until pks≥pkm;
S3.3:令L'=L'+Δ/100,获得当前缺陷长度对应的pks,若pks≥pkm,则继续L'=L'+Δ/100,直到pks-pkm≤δ;S3.3: Set L'=L'+Δ/100 to obtain the pks corresponding to the current defect length, if pks≥pkm, continue to L'=L'+Δ/100 until pks-pkm≤δ;
S3.4:将S3.1-S3.3应用到每一组目标信号,得到全生命周期虚拟实体的缺陷长度L(i)和其对应的振动信号峰值pks(i);S3.4: Apply S3.1-S3.3 to each group of target signals to obtain the defect length L(i) of the virtual entity in the full life cycle and its corresponding vibration signal peak value pks(i);
S3.5:将获得的虚拟实体的缺陷长度L(i)反代入式中,获得全生命周期的仿真振动信号;S3.5: Substitute the obtained defect length L(i) of the virtual entity into the formula to obtain the simulated vibration signal of the whole life cycle;
S4:利用长短时记忆网络(LSTM)建立实际测量振动信号和时变缺陷的关系,建立数字孪生模型,实现物理实体至虚拟实体的实时映射;S4: Use the long short-term memory network (LSTM) to establish the relationship between the actual measured vibration signal and the time-varying defect, establish a digital twin model, and realize the real-time mapping from the physical entity to the virtual entity;
所述LSTM神经网络,建立物理空间实测信号和虚拟实体之间的关系,具体步骤如下:The LSTM neural network establishes the relationship between the physical space measured signal and the virtual entity, and the specific steps are as follows:
S4.1:计算实测振动信号的均方根值rms(i),将rms(i)作为LSTM的输入,将虚拟实体的缺陷长度L(i)作为输出,构造样本;S4.1: Calculate the root mean square value rms(i) of the measured vibration signal, use rms(i) as the input of LSTM, and use the defect length L(i) of the virtual entity as the output to construct a sample;
S4.2:将样本按比例划分为训练集和验证集,用以训练LSTM神经网络;本实施例中,70%作为训练集,30%作为验证集;S4.2: Divide the sample into a training set and a verification set in proportion to train the LSTM neural network; in this embodiment, 70% is used as a training set and 30% is used as a verification set;
S4.3:将传感器采集的振动信号输入至训练好的LSTM神经网络,获得估计的时变缺陷尺寸;S4.3: Input the vibration signal collected by the sensor into the trained LSTM neural network to obtain the estimated time-varying defect size;
如图5所示,降噪信号的幅值整体上比含噪信号小,经过降噪处理后,信号的幅值更加平滑,这种降噪后的信号更加适合作为信号逼近的目标函数,为下一阶段利用信号逼近法更新虚拟实体打下基础;As shown in Figure 5, the amplitude of the noise-reduced signal is generally smaller than that of the noise-containing signal. After de-noising, the amplitude of the signal is smoother. This de-noised signal is more suitable as the target function for signal approximation. In the next stage, use the signal approximation method to update the virtual entity to lay the foundation;
S5:根据局部缺陷扩展的程度监测滚动轴承的运行状态和健康情况,估计当前滚动轴承在全生命周期中的运行阶段,在轴承失效前及时做出决策和反馈。S5: Monitor the operating status and health of rolling bearings according to the extent of local defect expansion, estimate the current operating stages of rolling bearings in their entire life cycle, and make timely decisions and feedback before bearing failure.
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