轴承的智能免维护.docx

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1、轴承的智能免维护 xuliyuan 导语：PCI电感式角定位系统因其本身特点，目前是回转轴承最有效和最优雅的旋转接头传感器解决方案。 Summary The PCI inductive angular positioning system currently represents the most efficient and most elegant sensor solution for rotary joints and slewing bearings due to its outstanding characteristics. No existing alt rnatives are

2、 capable of combining such essential characteristics in a single system. The non-contact system operates free of wear, does not require any additional mechanisms and produces valid absolute values without slipping, immediately after switching on. The sensor system is insusceptible to the adhesion of

3、 metal abrasion, not affected by bearing grease and insensitive to a variety of adverse ambient conditions, including heat, sand and dust on solar power plants in the desert, the aggressive saltwater environment of off-shore wind farms, o dirt, oil and grease on cranes, loading units o special vehic

4、les. These properties form a solid foundation for many years of reliable operation and help reduce maintenance costs. PCI电感式角定位系统因其本身特点，目前是回转轴承最有效和最优雅的旋转接头传感器解决方案。目前还没有一个独立系统可结合与其同等的基本特征和能力。非接触式的系统保证了无磨损运作，不需要任何额外的机械装置便可输出有效的绝对位置值，信号输出无延迟。该传感器系统不会因金属磨损而出错，不受轴承油脂影响结果，适用于多样的极端环境，包括热，沙子和沙漠中太阳能发电厂遭受的灰尘，

5、海上风厂的盐水环境，装载部件或特种车辆以及起重机上的污垢和油腻。这些特性构成了其多年可靠运行的坚实基础，并有助于降低维修成本。 Inductive angular positioning system designed for heavy machine construction专为重型机械制造设计的电感式角定位系统 Inductive sensor systems are characterized by their exceptional robustness and resistance to dirt, oil, grease and humidity under difficult

6、ambient conditions. The fact that even large solar and wind power plants as well as marine engineering and port systems technology can benefit from these advantages provides an interesting insight into how the inductive measuring system has developed. The system was designed for measuring angular po

7、sitions on rotary joints and slewing bearings with diameters ranging from half a meter to approximately four meters. 电感式传感器系统的特点是其出色的坚固性与抵抗污垢，油，油脂和湿度以及恶劣的工作环境。事实上，只要大型的太阳能和风力发电厂以及海洋工程和港口系统技术才能能够受益于它的这些优势，进而令电感式测量系统怎样开发成了一个有趣的话题。该系统是专为测量旋转接头和轴承的角位置，直径范围从0.5米到4米不等。 The Position Coding System (PCI) is

8、an inductive angular positioning system from Pepperl+Fuchs that is a further development of the PMI series manufactured by the same company. Numerous coil/oscillating circuit systems positioned closely beside one another use an intelligent microcontroller control interface to measure the position of

9、 metal target elements (Fig. 2) with a high degree of precision and form the basis of both series. Current systems are only capable of detecting one metal target object that moves along a linear o circular trajectory depending on the sensor type. When this method of measured value acquisition is emp

10、loyed, the size of the measurement range o the shaft diameter is restricted to the physical expansion of the sensor because the measurement target must always be located above the inductively sensitive coil/oscillating circuit. The inductive linear measuring systems that incorporate PMI technology c

11、urrently achieve a maximum measurement range of 1000 mm, while the inductive PMI angular positioning system is suitable for maximum shaft diameters of 40 millimeters. 位置编码系统PCI是由德国倍加福由PMI系列基础上研发出的电感式角定位系统。多个线圈/振荡电路系统的定严密排放，通过智能微控制器对金属目的物进行高精度测量图2。目前的系统根据传感器类型只能探测沿直线或圆形轨迹移动的金属目的物。当采取这两种测量值的综合方法时，测量范围

12、或轴的直径仅限于传感器的物理扩张，由于测量的目的，必须始终位于敏感的电感线圈/振荡电路的上方。电感式线性测量系统采用了PMI技术，目前最大的测量范围到达1000毫米，而电感式PMI的角度定位系统为轴直径40毫米最为适宜。 Clever coding pushes the limits智能编码应用更为广泛 The new PCI system is not affected by this restriction and is therefore suitable for application areas involving much larger spatial dimensions. Th

13、e sensor now doubles up as a reading head which measures the position of a moving code rail that allows a sensor head with multiple lengths. A row of steel pins serving is secured to the backing material on the code rail as targets. The pins are arranged on the code rail in pairs so that the reading

14、 head detects a minimum of one pair of targets at all times. In addition, each pair is characterized by a gap with a specific distance that appears only once along the entire code rail, e.g. 80 mm. The code rail and reading head are adapted perfectly to one another and the absolute position of each

15、gap is stored in the software in the reading head. 新型PCI系统不受限制，合适大空间尺度的应用。该传感器现有两部分组成，一个移动编码带、一个测量编码位置的读取头，进而能进行多种长度的测量。一排铁条分布在码带上冲当被测的目的物。这些铁条成对安置在码带上，使代码的读取头在任何时候都能检测出至少一对目的物。此外，每一对铁条之间保证特定的距离，在整个编码带上只出现一次，例如，相差80毫米。编码带与读取头相互配合得天衣无缝，每个空隙的绝对位置存储于读取头的软件中。 The sensor is therefore capable of calculati

16、ng the current position of the code rail accurately at any time via a two-stage evaluation process. Initially the sensor detects the target pair gap above the reading head for purposes of general positioning, e.g. the gap L5 with distance of 80 mm, so that the system knows that the position of the t

17、arget nearest to the reference is located at an absolute position of 680 mm, for example. Fine positioning is performed in a second step, wh reby the remaining distance between the target nearest to the o iginal position and the reference point on the reading head are added together. (Fig. 2: if the

18、 residual distance were 30 mm, the end result would be 680 mm + 30 mm = 710 mm.) 因而，通过两个阶段的评估，该传感器可随时准确计算码带的准确位置。起初，传感器检测目的物成对间距的目的是为了定位，例如：L5空隙的距离是80毫米，系统因而知最接近参考点的目的物的实际位置是在680毫米的绝对位置上。精细定位在第二个步骤的执行中，加上剩余的距离，即读取头的参考点和距离参考点近期的目的物之间的距离图2：假如剩余的距离为30毫米，最终的结果将是680毫米+ 30毫米= 710毫米。 Absolute measuring, no

19、n-contact and wear-free绝对测量，非接触，无磨损 The Position Coding System is suitable for slewing bearings with diameters of 0.5.4 meters and allows direct, slip-free angle detection on large rotary joints. The absolute measuring principle make the current position available immediately after the coding system

20、 is restarted o switched on. Reference runs are not necessary after maintenance, faults o failure of the power supply. The measurement range extends from 1,500 to 12,000 millimeters, depending on the sensor version and the specified bearing diameters. With an absolute direction resolution of 1 mm al

21、ong the circumference, the system can achieve angle resolutions between 0.24 and 0.03. Angle speeds of 3/sec to 12/sec are achieved at a signal refresh rate of 36 ms, depending on the bearing diameter and required measurement accuracy. The sensor is ideal for outdoor application due to the robust me

22、chanical design and integral temperature compensation feature. 位置编码系统合适0.5 . 4米直径的轴承，允许直接、自由滑移、大型旋转节点的角度检测。绝对位置测量的原理令编码系统重启或开启后的当前位置立即可得。维修、故障或电力供给中断后无需参考运行。根据传感器的版本和指定的轴承直径，测量范围从1500到12000毫米。该系统沿绝对圆周方向精度 1毫米，能够到达0.24 和0.03的角分辨率精度。根据轴承的直径和测量精度要求，3 /秒至12 /秒的速度角下能够实现每36毫秒一次的信号刷新率。该传感器具有坚固的机械设计和整体温度补偿功

23、能，是户外应用的理想选择。 The code rail can be mounted either directly on the bearing o on the bearing flange. The maximum read distance of 5mm gives the measuring system a high guide tolerance. Compared to magnetic systems that operate with air gap sizes of only 0.1.1.5 millimeters, this read distance can be c

24、onsidered more than adequate. Problems arising from abrasive effects caused by dirt and sand o even metallic friction between targets and the reading head can therefore be prevented depending on the system. The system can easily compensate for corresponding changes in distance caused by mechanical i

25、mbalances during operation (Fig. 3). 该编码带能够直接安装在轴承或轴承法兰上。读取的最大距离为5mm令测量系统具备了较高的容错性。与气隙距离仅0.1 .1.5毫米的磁性系统相比，这个读取距离已经绰绰有余。由于目的物和读取头之间的灰尘、沙子或金属摩擦磨损引起的问题，能够通过系统设置而有效防止。该系统能够轻松地弥补操作经过中的机械不平衡图3引起的距离变化。 Ideal properties for harsh outdoor applications恶劣户外应用的理想特性 The inductive sensor system is suitable for a

26、pplications in the renewable energy, marine engineering and port system equipment and commercial o special vehicle construction industries. In solar power plants, solar trackers enable the cell panels to follow the path of the sun. The described measuring system for controlling the azimuth angle in

27、solar tracker applications has already been used with great success. In solar thermal power plants with a concentration of direct solar radiation, countless parabolic mirror systems must be continuously moved to direct the sunlight accurately towards the central absorber. Nowadays, solar thermal pla

28、nts are becoming larger and larger and are focusing more and more on maximizing energy yield and efficiency. Reliable sensor systems are making an important contribution to the overall cost-effectiveness of these plants. 电感传感器系统适用于可再生能源，海洋工程和港口系统设备和商业建筑等行业或特殊车辆的应用。在太阳能电站，太阳能跟踪让太阳能板时时追踪太阳途径。我们的测量系统成功

29、应用在控制太阳的方位角跟踪系统。在太阳热能厂，太阳光能的辐射需要集中，无数镜面系统就必须不断转移、准确地吸收阳光，直接集中到中央吸收器。如今，太阳能热电厂的规模正在变得越来越大，以能源产量的最大化和效率为重点。可靠的传感器系统正为工厂的整体成本效益做出重要奉献。 The PCI inductive angular positioning system can also be used for several different applications in wind power plants. First of all, for measuring the current angular p

30、osition on the large rotary joint that supports the entire turbine and can reach diameters of up to four meters. The system can also be used on the rotor blades, whose pitch angle can also be modified. Modifications to the pitch angle can influence the incident flow in the required way when the roto

31、r starts o during active braking sequences. The bearings on the rotor blades can still reach diameters of about one meter. PCI电感式角定位系统可以用于风力发电厂的几个不同的应用。首先，测量支持整个风机的大型旋转部件的当前角度位置，能够到达4米直径的角度位置。该系统可以用于风机的叶片，控制倾斜角度。在引擎启动或制动经过中，倾角的修改能够按需求影响气流。转子的轴承仍然能够到达约一米直径。 Other important application areas include t

32、he commercial vehicle, special vehicle, marine engineering and port systems technology sectors. Various load and slewing cranes, lifting and working platforms, loading units, rotary fire service ladders etc. form the backbone of operational logistics processes as well as other activities. The plants

33、 are permanently exposed to moisture, dirt, dust, oil and grease and failures cost the operating company a great deal of money. 其他重要的应用领域包括商用车辆，特种车辆，海洋工程和港口系统科技行业，不同的负载和起重机，升降机和工作平台，装载部件，旋转的消防云梯等构成了物流操作经过以及其他活动的中流砥柱。这些工厂常年累月地暴露在潮湿，污垢，灰尘，油脂和故障的环境中，给公司运营造成了大量的资金损失。 Inductive measuring principle fears

34、no comparison电感应式测量原理的优越性 With angle speeds of up to 12/sec, the dynamics of the sensor system are adapted to the target application areas of industrial and heavy machine construction. An RS232 interface is fitted as standard to transfer the measured values, although the standards used in the releva

35、nt applications and major projects depend heavily on the respective industry and the technical control environment. The modular structure of the angular positioning system enables both mechanical adaptation to the specific customer application as well as modification of the interface to match the co

36、rresponding control technology. 随着高达12 /秒的角速度，传感器系统的动力学适用于工业和重型机械建设的目的应用领域。固然有关的标准和重大项目的应用很大程度上取决于各自的行业和技术的控制环境，一个RS232接口合适传输标准装备的测量值。该角定位系统的模块化构造，允许根据特定客户的应用进行机械调整和界面的修改，以配合相应的控制技术。 From a cost perspective, the inductive sensor system is comparable to a magnetic system, only without disadvantages s

37、uch as the small, sensitive air gap, residual magnetism that changes with the temperature and sensitivity to magnetic interference fields and metallic abrasion. The new sensor offers cost advantages over rotary encoder solutions because the absolute rotary encoder and the cost-intensive installation

38、 of the mechanical encoder coupling using components such as transmission gears o a friction wheel are no longer required. Friction wheels are also a potential source of failure due to their susceptibility to wear. 从成本的角度来看，电感式传感器系统相当于电磁系统，但是不具有气隙高灵敏度，剩磁随温度变化，对电磁干扰和金属磨损敏感等这些不利因素。新型传感器较旋转编码器提供了更具成本优势

39、的解决方案，由于绝对值旋转编码器和编码器机械耦合所需的昂贵配件，如传动齿轮或摩擦轮组件，都不再需要。摩擦轮同时也是系统磨损的潜在来源。 Fig. 1: The PCI Position Coding System facilitates the non-contact detection of rotation angles on slewing bearings used in renewable energy systems, marine engineering and port systems technology as well as commercial and special v

40、ehicle construction. Fig. 2: Functional principle The system of coils does not require permanent magnets to measure the absolute rotation angle. The distance traveled is measured with reference to the positions of the steel pins along a code rail, which are stored in the sensor. Fig. 3: The large reading distance of 5 mm safeguards against failures caused by dirt and guarantees sufficient tolerance to imbalances o concentricity errors. 0