大功率液力机械变速器状态监测与故障诊断系统

Condition Monitoring and Fault Diagnosis System for High-power Hydraulic Mechanical Transmission

摘要:

大功率液力机械器是重型特种车辆传动系统的关键核心部件，为满足整车高速、重载和高任务可靠性的使用要求，一方面需要提升液力机械变速器自身的强度和可靠性，另一方面要建立和完善大功率液力机械变速器的状态监测和故障诊断系统。基于专家系统和典型零部件的失效物理模型，针对液力机械变速箱系统和关键零部件的常见失效形式，建立了大功率液力机械变速器状态监测和故障诊断系统，分为变矩与闭锁功能监测及报警模块、换挡提示及报警模块、油位监测及报警模块、系统油压监测及报警模块和油温监测及报警模块共五大部分。通过实车测试证明，大功率液力机械变速器状态监测和故障诊断系统能够较为有效的识别系统的潜在失效和使用风险，或在出现严重故障前，通过简单的维护和保养，避免严重故障的发生，从而减少人力和零备件的需求，降低保障费用。

Abstract:

High-power hydraulic machinery is the key core component of the transmission system of heavy-duty special vehicles. In order to meet the requirements of high-speed, heavy-duty and high-reliability of the vehicle, on the one hand, it is necessary to improve the strength and reliability of the hydraulic mechanical transmission itself. On the other hand, it is necessary to establish and improve the condition monitoring and fault diagnosis system of the high-power hydraulic mechanical transmission. Based on the expert system and the failure physical model, the state monitoring and fault diagnosis system of the high-power hydraulic mechanical transmission is established for the common failure modes of the hydraulic mechanical transmission system and key components, which is divided into the torque conversion and blocking function monitoring and alarm modules , Shift prompt and alarm module, oil level monitoring and alarm module, system oil pressure monitoring and alarm module, and oil temperature monitoring and alarm module are five parts. The actual vehicle test proves that the high-power hydraulic mechanical transmission condition monitoring and fault diagnosis system can more effectively identify the potential failure and use risk of the system, or avoid the occurrence of serious faults through simple maintenance and maintenance before serious faults occur. Thereby reducing the demand for manpower and spare parts, and reducing guarantee costs.