阅读说明：本技术 蜗轮蜗杆磨损监测方法及系统 (Worm gear wear monitoring method and system ) 是由 刘红 方汉伟 张培勇 王兴 徐忠 于 2021-08-12 设计创作，主要内容包括：本发明公开了一种蜗轮蜗杆磨损监测方法及系统,电感式传感器的感测头获取蜗轮蜗杆之间的间距变化信号,并将间距变化信号转化为电感信号；电感信号经放大器进行放大后传输至信号处理器,处理器将电感信号进行处理和校准后传输至变送器,变送器将电感信号转化为电流信号,根据电流大小可得到蜗轮蜗杆的磨损程度。本发明提供的蜗轮蜗杆磨损监测方法及系统能及时监测到蜗轮蜗杆的磨损程度并及时更换蜗轮蜗杆,消除了飞机修理坞等设备存在的安全隐患。(The invention discloses a method and a system for monitoring wear of a worm gear, wherein a sensing head of an inductive sensor acquires a distance change signal between the worm gear and converts the distance change signal into an inductive signal; the inductance signal is amplified by the amplifier and then transmitted to the signal processor, the processor processes and calibrates the inductance signal and then transmits the inductance signal to the transmitter, the transmitter converts the inductance signal into a current signal, and the wear degree of the worm and the gear can be obtained according to the current. The worm and gear wear monitoring method and system provided by the invention can monitor the wear degree of the worm and gear in time and replace the worm and gear in time, thereby eliminating potential safety hazards of equipment such as airplane dock repair and the like.)

1. A worm and gear wear monitoring method is characterized by comprising the following steps:

s1: a sensing head of the inductive sensor acquires a distance change signal between the worm and the gear and converts the distance change signal into an inductive signal;

s2: the inductive signal is amplified by an amplifier;

s3: the signal processor processes and calibrates the inductance signal;

s4: the transmitter converts the inductive signal into a current signal.

2. The worm-gear wear monitoring method of claim 1, wherein the pitch change signal between the worm gears is derived by the inductive sensor from a change in amplitude of the sensing head.

3. The worm-gear wear monitoring method of claim 1, wherein the signal processor processes and calibrates the inductance signal according to a material of the worm gear.

4. The worm-gear wear monitoring method of claim 1, wherein the magnitude of the current indicates a degree of worm-gear wear.

5. The worm-gear wear monitoring method of claim 1, wherein the current value is between 4-20 mA.

6. A worm and gear wear monitoring system is characterized by comprising an inductive sensor, an amplifier, a processor and a transmitter, wherein a through hole matched with the inductive sensor is formed in the direction perpendicular to the diameter of a worm gear, the inductive sensor is installed on the worm and gear through the through hole, and the amplifier, the processor and the transmitter are integrated in the same shell and are electrically connected with the inductive sensor;

the inductive sensor is used for acquiring a distance change signal between the worm and the gear and converting the distance change signal into an inductive signal;

the amplifier is used for amplifying the inductive signal;

the processor is used for processing and calibrating the inductance signal;

the transmitter is used for converting the inductance signal into a current signal.

7. The worm-gear wear monitoring system of claim 6, wherein the inductive sensor is an eddy current sensor.

8. The worm-gear wear monitoring system of claim 6, wherein the inductive sensor has a tolerance ambient temperature of-10 ° to +60 °.

9. The worm and gear wear monitoring system of claim 6, further comprising a PLC power distribution cabinet electrically connected with the housing, the PLC power distribution cabinet being configured to supply power to the entire system and record and display the wear of the worm and gear.

10. The worm and gear wear monitoring system of claim 9, wherein the PLC distribution cabinet includes a power supply and a data recorder, the housing and the data recorder are electrically connected to the power supply, respectively, the power supply is used for supplying power to the entire system, and the data recorder is used for recording and displaying the wear condition of the worm and gear.

Technical Field

The invention relates to the technical field of worm gears, in particular to a worm gear wear monitoring method and system.

Background

Worm gears are commonly used to transfer motion and power between two interleaved shafts. The worm wheel and the worm are equivalent to a gear and a rack in the middle plane, and the worm is similar to a screw in shape. The worm wheel and worm mechanism is often used in the occasions of two-shaft staggering, large transmission ratio, low transmission power or intermittent work.

In real life, the worm gear and the worm are widely applied to lifting equipment such as airplane dock repairing and the like, the operation is more than 0.9 times of full-load operation, and the abrasion of the worm gear and the worm is serious along with the increase of the service life. The wear degree of the worm wheel and the worm cannot be checked in time in daily use, and great potential safety hazards exist, so that the problem that how to monitor the wear degree of the worm wheel and the worm in real time and timely replace the worm wheel and the worm with new wear degrees becomes urgent to be solved in the field.

Disclosure of Invention

Therefore, the embodiment of the invention provides a method and a system for monitoring wear of a worm and gear, which aim to solve the problems that the wear degree of the worm and gear cannot be known in time and the worm and gear can be replaced in time according to the wear degree in the prior art.

In order to achieve the above object, the embodiments of the present invention provide the following technical solutions:

in a first aspect, a worm and gear wear monitoring method includes the steps of:

s1: a sensing head of the inductive sensor acquires a distance change signal between the worm and the gear and converts the distance change signal into an inductive signal;

s2: the inductive signal is amplified by an amplifier;

s3: the signal processor processes and calibrates the inductance signal;

s4: the transmitter converts the inductive signal into a current signal.

Further, the distance change signal between the worm and the gear is obtained by the inductive sensor through the amplitude change of the sensing head.

Further, the signal processor processes and calibrates the inductance signal according to the material of the worm gear.

Further, the current magnitude shows the wear degree of the worm and the gear.

Further, the current value is 4-20 mA.

In a second aspect, a worm and gear wear monitoring system comprises an inductive sensor, an amplifier, a processor and a transmitter, wherein a through hole matched with the inductive sensor is formed in the direction perpendicular to the diameter of a worm wheel, the inductive sensor is installed on the worm and gear through the through hole, and the amplifier, the processor and the transmitter are integrated in the same shell and electrically connected with the inductive sensor;

the inductive sensor is used for acquiring a distance change signal between the worm and the gear and converting the distance change signal into an inductive signal;

the amplifier is used for amplifying the inductive signal;

the processor is used for processing and calibrating the inductance signal;

the transmitter is used for converting the inductance signal into a current signal.

Further, the inductive sensor is an eddy current sensor.

Further, the inductive sensor has a tolerance ambient temperature of-10 ° to +60 °.

Further, still include the PLC switch board, the PLC switch board with the casing electricity is connected, the PLC switch board is used for supplying power and record and demonstration worm gear wearing and tearing condition for entire system.

Further, the PLC switch board includes power supply and data record appearance, the casing with data record appearance respectively with the power supply electricity is connected, power supply is used for supplying power for entire system, data record appearance is used for the record and shows the worm gear wearing and tearing condition.

The invention has at least the following beneficial effects: the invention provides a method and a system for monitoring wear of a worm gear, wherein a sensing head of an inductive sensor acquires a distance change signal between the worm gear and converts the distance change signal into an inductive signal; the inductance signal is amplified by the amplifier and then transmitted to the signal processor, the processor processes and calibrates the inductance signal and then transmits the inductance signal to the transmitter, the transmitter converts the inductance signal into a current signal, and the wear degree of the worm and the gear can be obtained according to the current. The worm and gear wear monitoring method and system provided by the invention can monitor the wear degree of the worm and gear in time and replace the worm and gear in time, thereby eliminating potential safety hazards existing in common doors, large heavy doors and the like.

Drawings

In order to more clearly illustrate the prior art and the present invention, the drawings which are needed to be used in the description of the prior art and the embodiments of the present invention will be briefly described. It should be apparent that the drawings in the following description are merely exemplary, and that other drawings may be derived from the provided drawings by those of ordinary skill in the art without inventive effort.

The structures, proportions, sizes, and other dimensions shown in the specification are for illustrative purposes only and are not intended to limit the scope of the present invention, which is defined by the claims, and it is to be understood that all such modifications, changes in proportions, or alterations in size which do not affect the efficacy or objectives of the invention are not to be seen as within the scope of the present invention.

FIG. 1 is a block diagram of a worm and gear wear monitoring method and system provided by an embodiment of the invention;

FIG. 2 is a schematic diagram of an inductive sensor ranging provided in an embodiment of the present invention;

FIG. 3 provides a calibration schematic of a processor according to an embodiment of the present invention;

FIG. 4 is a schematic circuit diagram of a system according to an embodiment of the present invention;

FIG. 5 is a schematic view of an inductive sensor installation provided by an embodiment of the present invention; wherein, fig. a is a front view of the mounting point, fig. b is an enlarged view of the front view of the mounting point, fig. c is a top view of the mounting point, fig. d is a side view of the mounting point, and fig. e is an enlarged view of the side view of the mounting point.

Description of reference numerals:

1-an eddy current sensor; 2-an amplifier; 3-a processor; 4-a transmitter; 5-a power supply; 6-detecting by a PLC system; 7-a data recorder; 11-a sensing head; 12-eddy current; 8-a worm gear; 9-through hole.

Detailed Description

In order to make the objects, technical solutions and advantages of the present application more apparent, the present application is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present application and are not intended to limit the present application.

In the description of the present invention, "a plurality" means two or more unless otherwise specified. The terms "first," "second," "third," "fourth," and the like in the description and claims of the present invention and in the above-described drawings (if any) are intended to distinguish between referenced items. For a scheme with a time sequence flow, the term expression does not need to be understood as describing a specific sequence or a sequence order, and for a scheme of a device structure, the term expression does not have distinction of importance degree, position relation and the like.

Furthermore, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, or apparatus that comprises a list of steps or elements is not necessarily limited to those steps or elements specifically listed, but may include other steps or elements not expressly listed that are inherent to such process, method, article, or apparatus or that are added to a further optimization scheme based on the present inventive concept.

Referring to fig. 1, a method for monitoring wear of a worm gear includes the following steps:

s1: a sensing head 11 of the inductive sensor 1 acquires a distance change signal between the worm wheel 8 and the worm and converts the distance change signal into an inductive signal;

referring to fig. 2, specifically, the inductive sensor 1 measures a high-frequency magnetic field formed by passing a high-frequency current through a sensing head coil, and when a metal object is in the magnetic field, an eddy current 12 perpendicular to a magnetic flux direction is formed on a surface of the metal object due to electromagnetic induction, so that the resistance of the sensing head coil changes; as the subject matter approaches the sensing head 11, the amplitude decreases and the phase shift relative to the reference waveform increases. By detecting the change in amplitude and phase, the inductive sensor 1 can obtain the distance between the sensing head 11 and the subject matter and a value proportional to the change in the spacing.

S2: the inductive signal is amplified by an amplifier 2;

s3: the signal processor 3 processes and calibrates the inductance signal;

referring to fig. 3, the EX-500 series sensor can measure all types of nonferrous metal objects such as copper and aluminum by using a method of recognizing amplitude and phase shift, but it cannot be determined whether the cause of the change is a difference in material or a difference in distance between the sensing head 11 and the object only by the detected amplitude change, so that the inductive sensor 1 can detect the change in material by using a phase shift detection method, and then digital processing and correction are performed on the value by using a high-precision linearizer.

S4: the transducer 4 converts the inductive signal into a current signal.

Specifically, it should be noted that the subject matter of the present invention is the worm wheel 8 and the worm, because the worm wheel 8 and the worm are equivalent to a gear and a rack in a middle plane thereof, when the worm wheel 8 and the worm are in transmission, threads on the worm wheel 8 and the worm collide with each other to cause mutual abrasion, and because of the abrasion, a distance between the worm wheel 8 and the worm is increasingly large, so that the abrasion degree between the worm wheel 8 and the worm can be displayed by measuring the distance between the worm wheel 8 and the worm and then converting a distance signal into a current signal, the current value is 4-20mA, the corresponding abrasion degree between the worm wheel 8 and the worm is 0-5mm, and when the abrasion degree exceeds 5mm, the new worm wheel 8 and the worm need to be replaced.

Referring to fig. 4, the inductive sensor 1 transmits an inductive signal to the amplifier 2 for pre-amplification, the inductive signal is transmitted to the analog-to-digital converter for conversion after amplification, the inductive signal is transmitted to the processor 3 for processing and calibration after being converted by the analog-to-digital converter, the inductive signal is then output after being amplified by the post-amplifier after being converted by the digital-to-analog converter, the communication system receives the output data signal and records and displays the data signal, and a worker can visually see the current and the corresponding wear degree of the worm and gear.

A worm and gear wear monitoring system comprises an inductive sensor 1, an amplifier 2, a processor 3 and a transmitter 4, wherein a through hole 9 matched with the inductive sensor 1 is formed in a direction perpendicular to the diameter of a worm wheel 8, the inductive sensor 1 is installed on the worm wheel 8 through the through hole 9, and the amplifier 2, the processor 3 and the transmitter 4 are integrated in the same shell and are electrically connected with the inductive sensor 1;

the inductive sensor 1 is used for changing a distance signal between the worm wheel 8 and the worm and converting the distance signal into an inductive signal;

the amplifier 2 is used for amplifying the inductive signal;

the processor 3 is used for processing and calibrating the inductance signal;

the transducer 4 is used to convert the inductive signal into a current signal.

In particular, the inductive sensor 1 is an eddy current sensor, which is resistant to ambient temperatures of-10 ° to +60 °, which means that the measurement is generally not affected when droplets adhere to the surface of the sensor, and therefore, the sensor can be used in harsh environments, such as air that is saturated with water vapor and oil gas; the resolution ratio is high, the precision is high, and the quick response can be realized; the inductive sensor 1 has a plurality of types of sensing heads 11, including small or thin type, and can be flexibly selected according to specific application requirements and available installation space; still include the PLC switch board, the PLC switch board is connected with the casing electricity, and the PLC switch board is used for supplying power and record and demonstration worm wheel 8 and the worm wearing and tearing condition for entire system.

The PLC switch board includes power supply 5 and data record appearance 7, and power supply 5 is used for the entire system power supply, and casing and data record appearance 7 are connected with power supply 5 electricity respectively, and data record appearance 7 is used for the record and shows worm wheel 8 and the worm wearing and tearing condition, and general data record appearance 7 is communication electronic products such as computer.

Table 1 shows the main parameters of the device in the worm and gear wear monitoring system provided by the present invention:

in conclusion, the wear monitoring method and system for the worm gear can directly display the service condition and service life of the worm gear through the wear degree of the worm gear, and workers can judge the residual use amount according to the wear degree of the worm gear, so that the method and system provide very reliable data support for complete equipment, enable the service life of the worm gear to be visual and digital, can quickly sense the service condition of the equipment at any time, make safe maintenance work on the equipment in advance, and eliminate potential safety hazards of equipment such as airplane repair dock and the like.

All the technical features of the above embodiments can be arbitrarily combined (as long as there is no contradiction between the combinations of the technical features), and for brevity of description, all the possible combinations of the technical features in the above embodiments are not described; these examples, which are not explicitly described, should be considered to be within the scope of the present description.

The present invention has been described in considerable detail by the general description and the specific examples given above. It should be noted that it is obvious that several variations and modifications can be made to these specific embodiments without departing from the inventive concept, which falls within the scope of protection of the present application. Therefore, the protection scope of the present patent shall be subject to the appended claims.