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Research on modeling, testing, and state monitoring of racks in the Three Gorges ship lift
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摘要:
三峡升船机采用齿轮齿条爬升式垂直升船机型式，其中齿条作为升船机船厢升降运行的传动设备，其设备安全可靠性对升船机的稳定运行至关重要，为其设置智能状态监测系统十分必要。通过小比例试验台，对齿轮有可能出现的缺陷与不良工况进行模拟试验，并采用基于同步压缩小波变换时频谱切片的分析方法及门控循环神经网络的故障诊断方法，进行齿条不良润滑、齿面点蚀与齿根裂纹故障信号的采集与识别。以试验结果为依据，提出了三峡升船机齿条状态监测和故障诊断方案，为三峡升船机齿条状态监测和故障诊断方案的现场实施奠定了良好基础。
Abstract:The Three Gorges ship lift employs a vertical ship lift model using gears and racks, with the racks serving as the transmission component for the driving equipment of the ship lift during lifting operations. The safety and reliability of the equipment are crucial for the overall safety of the ship lift operation. Therefore, it is essential to establish an intelligent online state monitoring system for this purpose. This study constructs a small-scale test bench to simulate various defect conditions and utilizes the frequency spectrum slice analysis method based on synchronous compression wavelet transform and the fault diagnosis method of gated cyclic neural network to detect and identify issues such as poor lubrication, tooth surface pitting, and tooth root cracks in the racks. The experiments demonstrate the effectiveness of this diagnostic approach. Building upon these findings, an online condition monitoring scheme for the pinions and racks used in the Three Gorges ship lift is proposed, aiming to provide technical support for the intelligent management and maintenance of the lift.
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图 2 三峡升船机齿轮齿条小比例模型试验平台
Figure 2. Experimental platform for gear/rack of the Three Gorges ship lift
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图 4 各工况同步压缩小波变换切片
Figure 4. Section of synchronous compression wavelet transform for each condition
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图 7 状态监测方案实施步骤
Figure 7. The implementation steps of the online status monitoring scheme
表 1 各工况同步压缩小波变换特征值
Table 1 Characteristic value of synchronous compression wavelet transform for each condition
单位：10−4 m/s2 工况 均值 峰峰值 均方根 2倍频 3倍频 2倍频 3倍频 2倍频 3倍频 良好润滑 0.198 0 0.211 6 1.448 3 1.545 1 0.283 6 0.315 5 不良润滑 0.197 4 0.336 9 1.421 2 2.396 3 0.271 9 0.498 9 良好润滑+点蚀 0.172 8 0.275 6 1.406 3 3.017 6 0.251 7 0.443 8 良好润滑+点蚀+裂纹 0.202 6 0.228 2 1.621 7 1.998 0 0.296 3 0.345 7 
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表 2 提取统计特征参数
Table 2 Extracted characteristic parameters
特征值 计算式 特征值 计算式 平均值 $ {{x}_{\mathrm{m}}={\displaystyle\sum\limits_{n=1}^{N}x\left(n\right)}/{N}} $ 峭度因子 $ {{x}_{\mathrm{k}\mathrm{u}}=\dfrac{\displaystyle\sum\limits _{n=1}^{N}{\left(x\left(n\right)-{x}_{\mathrm{m}}\right)}^{4}}{\left(N-1\right){x}_{\mathrm{s}\mathrm{t}\mathrm{d}}^{4}}} $ 均方根值 $ {{x}_{\mathrm{r}\mathrm{m}\mathrm{s}}=\sqrt[\uproot{18}{\scriptstyle{2}}]{{\displaystyle\sum\limits _{n=1}^{N}{\left(x\left(n\right)\right)}^{2}}/{N}}} $ 偏度因子 $ {{x}_{\mathrm{s}\mathrm{k}}=\dfrac{\displaystyle\sum\limits _{n=1}^{N}{\left(x\left(n\right)-{x}_{\mathrm{m}}\right)}^{3}}{\left(N-1\right){x}_{\mathrm{s}\mathrm{t}\mathrm{d}}^{3}}} $ 峰峰值 $ {{x}_{\mathrm{p}}=\mathrm{max}\left(x\left(n\right)\right)-\mathrm{min}\left(x\left(n\right)\right)} $ 裕度因子 $ {{x}_{\mathrm{p}\mathrm{f}}=\dfrac{\mathrm{max}\left(x\left(n\right)\right)}{{\left(\dfrac{1}{N}\displaystyle\sum\limits _{n=1}^{N}\sqrt{\left|x\left(n\right)\right|}\right)}^{2}}} $ 标准差 $ {{x}_{\mathrm{s}\mathrm{t}\mathrm{d}}=\sqrt[\uproot{18}{\scriptstyle{2}}]{{\displaystyle\sum\limits _{n=1}^{N}{\left(x\left(n\right)-{x}_{\mathrm{m}}\right)}^{2}}/{(N-1)}}} $ 变异系数 $ {{x}_{\mathrm{c}\mathrm{v}}={{x}_{\mathrm{s}\mathrm{t}\mathrm{d}}}/{{x}_{\mathrm{m}}}} $ 脉冲因子 $ {{x}_{\mathrm{c}\mathrm{f}}={\mathrm{max}\left(x\left(n\right)\right)}/{{x}_{\mathrm{a}\mathrm{m}}}} $ 注：xam为信号整流平均值，即信号绝对值的平均值。
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