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摘要: 利用某新型3 499.5 kW齿轮箱试验台搭建了用于齿轮箱地面试车磨损状态监控的滑油静电监测系统, 完成了齿轮箱滑油系统全流量磨粒静电监测试验, 通过连续加载试验和加速寿命试验采集了原始静电信号, 提取时域信号的均方根值作为特征参数, 表征滑油中颗粒荷电情况, 在2个试验阶段分别分析了静电信号的变化趋势, 并与MetalSCAN在线监测数据和油样光谱离线分析结果进行对比验证。分析结果表明: 在连续加载试验阶段, 滑油静电信号随着转速变化细微波动; 加速寿命试验阶段, 齿轮箱单个循环试验的静电信号均与扭矩同步变化; 在加速寿命试验第8次循环的极限载荷试验阶段监测到2号齿轮箱异常磨损, 而1号齿轮箱正常运行, 与MetalSCAN和光谱分析结果相符; 齿轮箱拆机故障检测发现了2号齿轮箱联轴器膜片疲劳裂纹和高速输出轴齿轮齿根点蚀现象。这证明了静电监测方法用于齿轮箱磨损状态监测的可行性和有效性, 为进一步实现齿轮箱寿命预测和实际风场装机在线监测奠定了基础。Abstract: The lubricating oil electrostatic monitoring system that was built by a new type 3 499.5 kW gearbox test rig for the wear condition monitoring of gearbox in ground test, was used to complete the full flow abrasive particle electrostatic monitoring test for the lubricating oil systems of gearboxes.The original electrostatic signals were obtained from continuous loading test and accelerated life test.The root-mean-square values of time-domain signals were extracted as the characteristic parameters to represent the particle charging situation in the lubricating oil.The variation tendency of electrostatic signals were analyzed at two test stages respectively and compared with MetalSCAN online monitoring data and the offline result of oil sample spectrum analysis for validation.Analysis result shows that at the continuous loading test stage, the lubricating oil electrostatic signal fluctuates slightly with the change of rotational speed.At accelerated life test stage, the electrostatic signals of gearboxes synchronously change with the torque in a single cycle test.The abnormal wear of gearbox 2 is detected at the ultimate load test stage of the eighth cycle in accelerated life test, while gearbox 1operates normally, which is in accord with the results of MetalSCAN monitoring and the spectrum analysis.The fatigue crack of coupling diaphragm and the gear tooth root pitting of high-speed output shaft in gearbox 2arefound in disassemble gearbox fault detection.This proves electrostatic monitoring method is feasible and effective in wear condition monitoring of the gearbox and establishes the foundation for further implement of gearbox life prediction and installed online monitoring of the actual wind field.
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图 5 油路静电传感器等效测量电路
Figure 5. Equivalent measurement circuit of oil-line electrostatic sensor
图 7 正常运行情况下原始静电信号
Figure 7. Original electrostatic signal under normal operation circumstances
图 8 有带电颗粒经过时原始静电信号
Figure 8. Original electrostatic signal when charged particles are passing
图 12 不同转速下1号齿轮箱静电监测RMS值
Figure 12. Electrostatic monitoring RMS values of gearbox 1 at different rotational speeds
图 14 加速寿命试验单个循环中1号齿轮箱静电监测RMS值
Figure 14. Electrostatic monitoring RMS values of gearbox 1 in a single cycle of accelerated life test
图 15 加速寿命试验单个循环中2号齿轮箱静电监测RMS值
Figure 15. Electrostatic monitoring RMS values of gearbox 2 in a single cycle of accelerated life test
图 16 极限载荷试验中2号齿轮箱静电监测RMS值
Figure 16. Electrostatic monitoring RMS values of gearbox 2 in limit load test
图 17 第1~9次试车循环中1号齿轮箱静电RMS变化趋势
Figure 17. Electrostatic RMS variation tendency of gearbox 1 in 1-9 test cycles
图 18 第1~9次试车循环中2号齿轮箱静电RMS变化趋势
Figure 18. Electrostatic RMS variation tendency of gearbox 2 in 1-9 test cycles
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