基于机器视觉转速提取的定滑轮组故障诊断方法
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1.电子科技大学机械与电气工程学院成都611731; 2.中国石油集团川庆钻探工程有限公司 安全环保质量监督检测研究院德阳618300

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TH165.3

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国家重点研发计划(2024YFB3409303)、四川省科技计划(2024JDHJ0057)项目资助


Fault diagnosis of fixed sheave blocks based on the machine vision-based rotational speed extraction method
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1.School of Mechanical Electrical Engineering, University of Electronic Science and Technology of China, Chengdu 611731, China; 2.Safety Environment Quality Supervision and Testing Research Inspection, CNPC, CCDC, Deyang 618300, China

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    摘要:

    针对钻机提升系统定滑轮组在线监测中存在的安装空间受限、倍率耦合导致故障定位困难以及速度波动易掩盖微弱磨损特征等问题,提出了一种基于机器视觉转速提取的钻机提升系统定滑轮组故障诊断方法。该方法通过在滑轮轮缘预置恒密度条纹,利用面阵相机采集滑轮旋转过程中的动态条纹图像序列,将滑轮的机械旋转运动映射为图像灰度变化信号;随后结合互相关分析与时频分析技术,提取互相关系数的时频脊线,进而实现多目标滑轮瞬时转速的同步提取。进一步针对变转速工况下整体速度波动对诊断特征的干扰,构建转速比相对偏差矩阵作为故障诊断特征,通过转速比相对偏差矩阵有效抵消全局扰动,突显绳槽磨损引起的滑轮转速异常偏离特征,从而实现磨损滑轮的识别与定位。为验证方法有效性,基于钻机提升系统故障模拟实验台开展对比实验。结果表明,该方法在电机恒定转速(最高设置为2 800 rpm)、电机时变转速(1 600-2 800-1 600 rpm)以及不同负载(40、80 kg)等多种工况下,平均准确率达到了86.11%±2.90%,平均F1-Score为86.05%±2.90%,表明该方法具有较好的鲁棒性与泛化能力,可为钻机提升系统滑轮磨损识别提供一种非接触式、在线、不依赖模型训练、对转速工况不敏感且适用于多目标滑轮同步监测的工程技术方案,为后续状态评估与故障维护决策提供数据支撑。

    Abstract:

    The online monitoring of fixed sheave block in a drilling rig hoisting system suffers from the limited installation space, coupled reeving ratios that make fault localization difficult and speed fluctuations that can hide weak wear features. Correspondingly this study proposes a machine-vision speed extraction based fault diagnosis method. The constant-density stripes are preset on the sheave rim and an area-scan camera captures an image sequence of stripes during rotation, which converts the sheave rotation into a grayscale-variation signal. The cross-correlation analysis and time-frequency analysis are then used to extract the time-frequency ridges of the cross-correlation coefficient, which enables the synchronous extraction of multiple sheaves’ instantaneous speed. In order to mitigate the effect of overall speed fluctuations under the variable-speed operation, a relative deviation matrix of speed ratios is used as the diagnostic feature. This matrix cancels global disturbances and highlights abnormal speed deviations caused by the rope-groove wear, so the worn sheave can be identified and located. Comparative experiments are carried out on a fault-simulation test bench for the drilling rig hoisting system. Results show that under the constant motor speed (up to 2 800 rpm), time-varying motor speed (1 600-2 800-1 600 rpm), and different loads (40 kg and 80 kg), the method achieves an average accuracy of 86.11%±2.90% and an average F1-score of 86.05%±2.90%. These results show the stable performance under different tests. Overall the online method provides a non-contact, non-sensitive to speed changes solution without relying on the model training, which supports the synchronous monitoring of multiple sheaves for wear identification and provides data support for the later condition assessment and maintenance decisions.

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陈鑫,廖飞龙,杨磊磊,周咏琳,刘志亮.基于机器视觉转速提取的定滑轮组故障诊断方法[J].仪器仪表学报,2026,47(8):116-127

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  • 在线发布日期: 2026-10-29
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