现代制造工程 ›› 2025, Vol. 540 ›› Issue (9): 146-156.doi: 10.16731/j.cnki.1671-3133.2025.09.019

• 设备设计/诊断维修/再制造 • 上一篇    

伺服电机内置编码器IAS信号增强方法及其在齿轮故障诊断中的应用研究

徐晓强1,2, 宋霹1, 何知义1,2, 胡宏伟1,2   

  1. 1 长沙理工大学汽车与机械工程系,长沙 410114;
    2 长沙理工大学工程装备智能检测与控制技术湖南省高校重点实验室,长沙 410114
  • 收稿日期:2024-12-24 出版日期:2025-09-18 发布日期:2025-09-23
  • 通讯作者: 徐晓强,博士,副教授,主要研究方向为无损检测、机械动态信号处理。E-mail:xiaoqiangXu@csust.cn。
  • 作者简介:宋霹,硕士研究生,主要研究方向为齿轮故障诊断。何知义,博士,讲师,主要研究方向为机器学习与智能诊断、健康管理与智能运维。胡宏伟,博士,教授,主要研究方向为智能检测与信号处理。E-mail:321698884@qq.com。
  • 基金资助:
    国家重点研发计划项目(2023YFB3406101);国家自然科学基金项目(52005052,52305091)

Enhanced IAS signal processing for servo motor built-in encoders and its application in gear fault diagnosis

XU Xiaoqiang1,2, SONG Pi1, HE Zhiyi1,2, HU Hongwei1,2   

  1. 1 College of Automotive and Mechanical Engineering,Changsha University of Science and Technology,Changsha 410114,China;
    2 Hunan Provincial University Key Laboratory of Intelligent Detection and Control Technology for Engineering Equipment,Changsha University of Science and Technology,Changsha 410114,China
  • Received:2024-12-24 Online:2025-09-18 Published:2025-09-23

摘要: 内置旋转编码器在电机位置和转速反馈控制中扮演关键角色,其测量的瞬时角速度(Instantaneous Angular Speed,IAS)信号能反映传动系统的扭振状态,能够被用来揭示传动系统中存在的机械缺陷,支撑构建具有自感知自诊断能力的伺服控制系统。针对低精度的内置编码器利用传统信号处理方法从IAS信号中精准提取故障特征困难的问题,提出了一种IAS信号增强方法。该方法首先通过EtherCAT总线伺服驱动系统获取伺服电机的瞬时角位置信号,随后采用时间戳提取和局部多项式拟合微分技术获取IAS信号,最后通过角域同步平均技术处理获取的IAS信号,实现了对传动系统局部故障的定量诊断。仿真和齿轮故障试验验证了该方法的有效性,证明了其在低成本传动系统健康监测中的潜力。

关键词: 伺服电机, 内置编码器, 故障诊断, 信号增强, 瞬时角速度

Abstract: The built-in rotary encoder is pivotal for motor positioning and speed feedback,providing Instantaneous Angular Speed (IAS) signals that reflect the torsional vibration of the transmission system,thereby revealing mechanical faults and enabling the development of self-aware and self-diagnostic servo control systems. To address the challenge of extracting fault characteristics accurately from IAS signals of low-precision encoders using conventional signal processing methods,an IAS signal enhancement method was proposed. It commenced with acquiring the servo motor′s instantaneous angular position signals via an EtherCAT bus servo drive system,the IAS signals were subsequently obtained using timestamp extraction and local polynomial fitting differentiation techniques. Finally the acquired IAS signals were processed by the angular domain synchronized averaging technique. Validation through simulations and gear fault experiments confirmed the method′s efficacy,highlighting its potential in cost-effective health monitoring for drive systems.

Key words: servo motor, built-in encoder, fault diagnosis, signal enhancement, Instantaneous Angular Speed (IAS)

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