Research On Rotating Machinnery Fault Synchronization Vibration Model And Wireless Vibration Sensor System

Machine fault diagnosis plays an important part in reducing mechanical equipment failure frequency and control ling maintenance cost. As the demand of monitoring production equipment working condition is getting higher, it comes up with the demand of critically and sustainable monitoring a single part’s working status of the production equipment. Tradit ional fault diagnosis method would place the sensors on the external surface of the equipment or on the components which are fixed on the equipment. Machine’s working condition can only be measured by analyzing vibration signals through various analysis methods and the analysis can be complicated. The thesis comes up with the model of rotating machine fault synchronization vibration, and develop a small wireless vibration sensor system which can be placed on the rotating axis inside the equipment which gets more close to the so urce of trouble, improving the signal’s SNR(Signal to Noise Ratio), making it more convenient for equipment diagnosis.According to the design and application requirements, the thesis places the wireless vibration sensor on the shaft. Aiming at gear tooth crack fault and wear of tooth surface in the gear box, the paper analyzes amplitude modulation and frequency modulation of the signal collected by the sensor under the combined action of rotating measurement and gear fault vibration. The article derivation the formula of the collected fault signal vibration condition while putting the sensor on the shaft and acquires a new failure frequency, as well as bringing forward an A-B shaft measurement method for the gear fault feature while analyzing the gear problem. At the same time, the paper analyzes the pitting corrosion failure of antifriction bearing inner and outer race. Comparing to the traditional measurement mode, the advantages and disadvantages of shaft rotating measure mode is analyzed. According to th e requirement of the shaft rotation measurement, the wireless vibration sensor is designed. It includes sensors, ADC, CPU and other modular hardware structure of wireless vibration sensor, as well as finishing the design and proofing of PCB, and manufactur e of the prototype. At last, the paper writes the bottom-driven and operating control programs of wireless vibration sensor system based on the Arduino platform.Finally, the wireless vibration sensor system’s performance is tested, and installed on the shaft to test gear tooth crack fault, varying degrees fatigue wear on the surface of gear and bearing inner race fault. We also make a comparison of testing results between wireless vibration sensor system and traditional external piezoelectric sensor. The results shows the correctness of synchronization vibration model and the performance of wireless vibration sensor system can meet the requirements of the inside the rotating machinery fault diagnosis.