軋機產線齒輪箱斷齒失效之狀態監控與振動分析

Condition Monitoring and Vibration Analysis of Gearbox Broken Tooth Failure in a Rolling Mill Production Line

林譽峰(Yu-Feng Lin) ； 林益煌(Yih-Hwang Lin) ； 吳崇勇(Chung-Yung Wu) ； 楊筑鈞(Jwu-Jiun Yang) ； 何秋誼(Chiou-Yi Hor) ； 李增賢(Tseng-Hsien Li) ； 吳邦齊(Ban-Chi Wu) ； 劉熙銘(Hsi-Ming Liu)

《應用聲學與振動學刊》 14卷1&2期 (2022/12) Pp. 13-18

https://doi.org/10.6282/JASV.202212_14(1_2).0002

摘要

設備因長時運轉逐漸損耗、老化，而提高運維成本，需提高設備可靠性和可用性，研究顯示齒輪箱為故障高風險之組件，齒輪與軸承之損傷為典型之故障模式，為停機主要成因之一。為降低維護成本並提高可靠性與安全性，可透過振動訊號的量測，以監控齒輪箱組件的操作狀況，並進行故障診斷。齒輪箱由於機械元件組成複雜，因此在量測時會包含不同轉軸上各齒輪、軸承之振動訊號。齒輪劣化時可藉由對應之特有故障特徵頻率進行監控，以瞭解其於不同劣化狀態下之差異，有效監控齒輪箱操作狀態。本研究基於軋機產線齒輪箱之實際振動量測數據，探討斷齒失效狀況下之適宜監控策略。本研究顯示傳統指標root mean square（RMS）與原始振動時序難以做為有效監控參考，有賴敏感健康指標之建立，邊頻帶功率因素之趨勢指標具參考價值，而斷齒軸轉速振幅趨勢可提供有效之監控參考，本案例之警戒值可設定為0.2 g以供早期預警，避免不預期之產線停機，而造成巨大之成本損失。

關鍵字

狀態監控 ； 故障診斷 ； 斷齒失效

並列摘要

The equipment can gradually wear out and age due to long-term operation, which increases the operation and maintenance cost. It is necessary to improve the reliability and availability of the equipment. Research shows that the gearbox is a component with high failure risk, and the damage of gears and bearings is a typical failure mode, which is one of the main causes of downtime. To reduce maintenance costs and improve reliability and safety, the measurement of vibration signals can be used to monitor the operation condition of gearbox components and subsequently perform fault diagnosis. Due to the complex mechanical components of the gearbox, the vibration signal will include the contributions from each gear and bearing on different rotating shafts in the measurement. When the gear is deteriorating, it can be effectively monitored by the corresponding unique fault characteristic frequency to differentiate the difference under various deterioration conditions. Based on the actual vibration measurement data of the gearbox of the rolling mill production line, this study explores the appropriate monitoring strategy under the condition of broken tooth failure. This study shows that the traditional index, root mean square (RMS), and the original vibration time series are difficult to be applied for effective condition monitoring. The establishment of a sensitive health index is essential. The fault trend of the sideband power factor (SBPF) appears to be valuable, and the speed amplitude trend of the shaft with broken-tooth failure proves to be effective for condition monitoring. The associated warning threshold of the present case can be set to 0.2 g for early warning to avoid unexpected production line downtime, which causes huge capital losses.

並列關鍵字

Condition Monitoring ； Fault Diagnosis ； Broken Tooth Failure