机电产品故障诊断和退化预测一体化便携式终端研究

An integrated portable terminal for fault diagnosis and degradation prediction of electromechanical products

  • 摘要: 针对航天器等复杂系统对机电产品健康监测多功能、便携式终端的迫切需求,研制了一套2.5 kg级软硬件一体化的故障诊断与退化预测装置。硬件端采用16通道、最高156 kHz采样率的数据采集箱,可统一接入振动、温度、流量、转速和力矩等多类型传感器;软件端嵌入BPNN、PSO-BPNN、GA-BPNN、FNN及构建的多神经网络融合(MNN)模型,并集成线性回归、高斯过程回归两种退化预测算法和振动分析模块,实现“采−存−诊−预”一站式作业。六折交叉验证表明:MNN模型相较于单一神经网络模型显著提升了故障分类精度与模型稳定性,针对航天器流体回路泵在36个样本和六折交叉验证下对测试集的诊断全部正确,均方误差仅0.010 3;装置准确识别了流体回路泵轴承滚道疲劳剥落故障、B7004C轴承内圈剥落和外圈剥落故障。该研究成果可为机电产品健康管理提供可靠的一站式模型算法与软硬件支撑。

     

    Abstract: To address the urgent need for a multifunctional portable terminal used in health monitoring of spacecraft electromechanical products, a 2.5 kg integrated hardware–software device for fault diagnosis and degradation prediction was developed. The hardware features a 16-channel data acquisition box with a maximum sampling rate of 156 kHz, capable of interfacing with multiple types of sensors, including vibration, temperature, flow rate, rotational speed, and torque. The embedded software integrates four individual neural network models–BPNN, PSO-BPNN, GA-BPNN, and FNN–along with a multi-neural-network fusion (MNN) model. It also incorporates two degradation prediction algorithms (linear regression and Gaussian process regression) and a vibration analysis module, enabling a comprehensive workflow encompassing data acquisition, storage, diagnosis, and prediction. Six-fold cross-validation results showed that the MNN model significantly improved fault classification accuracy and model stability compared with those of single neural network models. For a spacecraft fluid loop pump with 36 samples under six-fold cross-validation, all test set diagnoses were correct, yielding a mean squared error (MSE) of only 0.010 3. Fatigue spalling faults on the pump bearing raceway, along with inner- and outer-ring spalling faults of the B7004C bearing, were accurately identified by the device. This research provides reliable modeling algorithms and integrated software–hardware support for health management of electromechanical products.

     

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