带式输送机托辊轴承健康状态识别方法

Health state identification method for belt conveyor idler bearings

  • 摘要: 针对带式输送机托辊轴承健康状态智能识别过程中,单一模态对退化表征不足、多模态间关系互补性和一致性差、健康状态类别与连续退化关联特征提取困难等问题,提出了一种基于声振融合健康指标构建与多粒度有序对比学习的轴承健康状态识别方法。对振动与声音原始信号进行预处理后提取其时频域特征,依据相关性、单调性和鲁棒性筛选退化敏感特征;提出基于Mamba−双向交叉注意力的声振融合健康指标构建方法,通过双分支Mamba编码器捕获声振信号特征在轴承全寿命周期过程中的长时序关联,引入双向交叉注意力实现2种模态特征交互增强,结合物理约束实现健康、良好、一般、退化和故障5类状态健康指标构建;提出融合离散状态监督和连续退化约束的多粒度有序对比学习方法,使特征表示同时保持类间可分性、状态等级有序性和类内退化连续性,通过K近邻分类实现健康状态识别。实验结果表明,该方法在XJTU公开数据集G1,G2,G4上的识别准确率分别为0.972,0.918,0.965,推理延时仅为6.183 ms;在基于带式输送机模拟实验台构建数据集上的识别准确率达0.947,优于XGBoost,MLP,MSCCNN等对比模型。

     

    Abstract: Intelligent health state identification of belt conveyor idler bearings faces challenges including insufficient degradation characterization by a single modality, poor complementarity and consistency between modalities, and difficulty extracting features that link health state classes to continuous degradation. To address these challenges, a bearing health state identification method based on acoustic–vibration fusion for Health Indicator (HI) construction and Multi-Granularity Ordinal Contrastive Learning (MGOCL) was proposed. Time- and frequency-domain features were extracted from preprocessed vibration and acoustic signals, and degradation-sensitive features were selected based on correlation, monotonicity, and robustness. An acoustic–vibration fusion method for HI construction based on Mamba-Bidirectional Cross Attention (Mamba-BiCA) was developed. Dual-branch Mamba encoders captured long-term temporal dependencies in acoustic and vibration features throughout bearing degradation. Bidirectional cross attention enhanced interactions between the two modalities, and physical constraints were incorporated to construct HIs for five health states: healthy, good, fair, degraded, and failed. MGOCL combined discrete state supervision with continuous degradation constraints to preserve interclass separability, the ordering of health states, and intraclass degradation continuity in the learned representations. Health states were identified using k-nearest neighbor classification. Experimental results showed that the method achieved identification accuracies of 0.972, 0.918, and 0.965 on subsets G1, G2, and G4 of the XJTU public dataset, respectively, with an inference latency of only 6.183 ms. On a self-built dataset collected using a belt conveyor simulation test rig, the identification accuracy reached 0.947, outperforming comparison models including XGBoost, MLP, and MSCCNN.

     

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