齿轮缺陷调谐共振检测机理及关键技术

Rapid detection of the defects of finished gear, such as burr, scratches, knocking , micro cracks and so on, is an urgent technical issue to resolve. Especially the fast detection of micro cracks, is lack of a more effective solution with mature technical support. Gear resonance is a large risk in the state of work which should be avoided. Therefore, this project creatively introduces gear resonance into gear defect detecting technology, and proposes a fast in-line detecting method for gear defect based on structurally tuned resonance. When the tested gear and standard gear are detected under the single flank rolling test, tuned tuning resonance detection for measuring system is realized through changing the measurement system structural feature. Detect gear defect using the resonance amplification effect on frequency spectrum characteristics of gear. This project will study the principle of structurally tuned vibration and the vibration characteristics of gear defect in the condition of resonance. And then explore the mechanism of structurally tuned vibration checking for all kinds of gear, develop a rapid detection system of gear defects and carry our experimental research. This method not only can detect the gear geometry defects, but also can detect micro cracks. Those faults are avoided, which is used in the current gear production field testing through gear double flank meshing rolling method. Because rich information, high detecting speed and low environmental requirements and so on, etc., this method is especially suitable for defect inspection for large quantities of finished product gear manufacturing. A new way has been opened up for rapidly detecting of mechanical parts on site in a new way.

大批量成品齿轮的毛刺、划痕、磕碰伤和微裂纹等缺陷的现场快速检测是急需解决的技术难题，尤其是微裂纹的快速检测，更缺乏有效的解决办法和成熟技术。齿轮共振是齿轮工作中必须避免的状态，而本项目创造性地将齿轮共振引入齿轮缺陷检测中，提出齿轮缺陷调谐共振的快速检测方法。被检齿轮与标准齿轮作单面啮合检测，通过改变检测系统的结构特征，实现检测系统的调谐共振，利用共振对齿轮振动频谱特性的放大效应去检测齿轮缺陷。项目将研究结构调谐共振原理和共振状态下齿轮缺陷的振动特性，探索各类齿轮缺陷调谐共振检测机理，研制齿轮缺陷快速检测系统，并在此基础上开展实验研究。本方法不仅能检测齿轮几何缺陷，还能检测微裂纹，避免了目前齿轮生产现场检测中常采用的齿轮双面啮合检测方法的缺点，具有检测信息丰富、快速、环境要求低等特点，特别适合生产现场大批量成品齿轮的缺陷检测，为机械零部件生产现场的快速检测开辟了新途径。

装配前对齿轮的毛刺、划痕、磕碰伤和微裂纹的检测一直以来都是齿轮缺陷检测的难题，尤其是微小裂纹的检测，目前缺乏有效的解决办法和成熟的技术。齿轮检测现场环境复杂，快速、准确、大批量的检测微小缺陷是高端齿轮发展的迫切需求。齿轮缺陷的形式多样，在不同工况下缺陷振动信号差异明显，在复杂噪声干扰下,准确、可靠的分离、提取微弱的振动信号是齿轮缺陷检测的关键。本项目创新性研究共振条件下齿轮缺陷的振动特性，将共振对齿轮振动频谱特性的放大效应运用于齿轮微小缺陷的快速检测中，提出齿轮缺陷调谐共振的快速检测方法。.主要研究内容和结果如下：.1、基于共振对齿轮振动频谱峰值的放大效应，研究影响齿轮共振的因素，通过调谐使系统产生的某阶频率与外界齿轮啮合频率是同频率或者是啮合频率的倍频，响应将会得到一定程度的放大；.2、分析了微弱的缺陷信号在调谐共振下的规律和表现形式，研究准确分离、提取齿轮振动信号的处理算法，提出了一种基于相关性的EMD与形态奇异值分解相结合的方法。该方法解决了由模态混叠现象导致的去噪后信号有用成分丢失和缺陷特征不易识别的问题，突出了原始振动信号的缺陷特征，具有很强的自适应性，提高了齿轮缺陷信息提取的可靠性和准确性；.3、对齿轮缺陷检测系统进行研究，完成了检测系统的机械结构设计、开发、调试及精度分析，研制的检测系统可用于生产现场齿轮缺陷的快速检测。.4、采用模态分析技术对研制的齿轮缺陷检测系统进行动态特性分析研究，提出了一种齿轮微小裂纹缺陷检测系统的结构调谐共振方法，设计结构调谐装置和加载装置达到共振条件。.5、在齿轮缺陷检测系统上开展试验研究，采用结构调谐装置对系统的模态频率进行调节，并对采集到的齿轮信号进行分析和处理，试验表明，信号频谱中啮合频率周围的边频带频率更明显，能探测到过去以精度检测为主的检测手段所不能发现的齿轮微小裂纹缺陷，为齿轮微小裂纹检测提供了一种新方法。