CN110764027A - Electric connector intermittent fault diagnosis method based on frequency spectrum characteristic change - Google Patents
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Abstract
Translated fromChineseDescription
Translated fromChinese技术领域technical field
本发明涉及故障诊断技术领域，尤其涉及一种基于频谱特征变化的电连接器发生间歇故障诊断方法。The invention relates to the technical field of fault diagnosis, in particular to a method for diagnosing intermittent faults of electrical connectors based on changes in spectral characteristics.
背景技术Background technique
复杂装备系统中普遍存在间歇故障问题，进而带来严重的费用负担和安全风险。间歇故障是一种可反复出现，未经处理可自行消失的非永久故障，具有随机性、间歇性和反复性。在电子设备尤其是大规模集成电路中，由于制造工艺不佳和不规范使用等导致的元器件虚焊、芯片管脚和连线松动等均会导致电路间歇故障的发生。间歇故障发生频率是永久故障的10～30倍，是造成系统失效的主要原因。其中电连接器间歇故障是间歇故障的主要来源，其存在难复现、难测试、难诊断。统计表明，各种系统失效的70％是由元器件的失效引起，而这其中又有40％是电连接器的失效引起。如汽车中30～60％的电子故障由电连接器退化引起，在对某舰船的现场故障数据统计分析发现，连接型故障占所有故障的26.89％，而这还未包含整体封装零件中的连接型故障。可以肯定的是，连接型故障占所有故障的比重高于30％。Intermittent failures are common in complex equipment systems, resulting in serious cost burdens and safety risks. Intermittent failure is a kind of non-permanent failure that can appear repeatedly and disappear by itself without treatment. It is random, intermittent and repetitive. In electronic equipment, especially in large-scale integrated circuits, due to poor manufacturing process and irregular use, component soldering, chip pins and loose connections will all lead to intermittent circuit failures. The frequency of intermittent faults is 10 to 30 times that of permanent faults, which is the main reason for system failure. Among them, intermittent faults of electrical connectors are the main source of intermittent faults, which are difficult to reproduce, test and diagnose. Statistics show that 70% of the failures of various systems are caused by the failure of components, and 40% of them are caused by the failure of electrical connectors. For example, 30-60% of the electronic failures in automobiles are caused by the degradation of electrical connectors. In the statistical analysis of the field failure data of a certain ship, it is found that connection-type failures account for 26.89% of all failures, and this does not include the overall package parts. Connection type failure. To be sure, connection failures account for more than 30% of all failures.
目前，提取故障特征的方法有很多，如快速傅里叶变换、小波变换、小波包变换、倒谱和Wigner分布等，但间歇故障由于其存在随机性和间断性，难以对其故障特征进行提取。美国Universal Synaptic研制的间歇故障检测和隔离系统(Intermittent FaultDetection and Isolation System，IFDIS)，能够检测传输线路的缺陷和故障，但非间歇故障，其产品IDF-2000连接设备线路后发出信号并检测回波信号，通过检测待测单元电阻的瞬时变化来判断是否故障；Zanardelli、Zaidi等针对交流永磁电机间歇电阻增加和相线圈短路两种间歇故障，分别利用短时傅里叶变换、非抽样离散小波变换、Wigner-Ville分布、Choi-Williams分布从原始采集信号提取故障特征，采用线性分类器和k-mean分类器，实现对故障模式的判别；Banerjee提出聚类DFD(Distribution fault diagnosis)策略，用以诊断传感器节点的间歇故障；Alamuti针对中等电压输电系统中馈线的电弧间歇故障，基于线路固有参数，推导出故障特征，通过在单端测量电压和电流，对间歇故障予以识别定位，但该方法依赖建模的精度；Cui Tao针对电力传输系统接地瞬时故障和间歇故障，采用希尔伯特变换辨识瞬时功率方向，并基于该信号特征提出了故障诊断的算法，综上，目前并无合适方法判断电连接器发生间歇故障概率和程度。At present, there are many methods for extracting fault features, such as fast Fourier transform, wavelet transform, wavelet packet transform, cepstrum and Wigner distribution, etc. However, due to the randomness and discontinuity of intermittent faults, it is difficult to extract their fault features. . The Intermittent Fault Detection and Isolation System (IFDIS) developed by Universal Synaptic in the United States can detect the defects and faults of the transmission line, but it is not intermittent. Its product IDF-2000 sends out signals and detects echoes after connecting the equipment lines. The fault is judged by detecting the instantaneous change of the resistance of the unit under test; Zanardelli, Zaidi, etc. used short-time Fourier transform, non-sampling discrete wavelet for two intermittent faults of AC permanent magnet motor intermittent resistance increase and phase coil short circuit respectively. Transform, Wigner-Ville distribution, Choi-Williams distribution to extract fault features from the original acquisition signal, and use linear classifier and k-mean classifier to distinguish the fault mode; Banerjee proposed a clustering DFD (Distribution fault diagnosis) strategy, using In order to diagnose the intermittent fault of sensor nodes; Alamuti, for the arc intermittent fault of the feeder in the medium voltage transmission system, deduces the fault characteristics based on the inherent parameters of the line, and identifies and locates the intermittent fault by measuring the voltage and current at the single end, but this method Depends on the accuracy of modeling; Cui Tao uses Hilbert transform to identify the instantaneous power direction for grounding transient faults and intermittent faults in power transmission systems, and proposes a fault diagnosis algorithm based on the signal characteristics. To sum up, there is currently no suitable method. Determine the probability and degree of intermittent failure of electrical connectors.
发明内容SUMMARY OF THE INVENTION
本发明所解决的技术问题在于提供一种基于频谱特征变化的电连接器发生间歇故障诊断方法，以解决上述背景技术中的问题。The technical problem solved by the present invention is to provide a method for diagnosing intermittent faults of an electrical connector based on changes in spectral characteristics, so as to solve the above-mentioned problems in the background art.
本发明所解决的技术问题采用以下技术方案来实现：The technical problem solved by the present invention adopts the following technical solutions to realize:
基于频谱特征变化的电连接器发生间歇故障诊断方法，具体步骤如下：A method for diagnosing intermittent faults of electrical connectors based on changes in spectral characteristics, the specific steps are as follows:
1)选择电连接器的一路待测试连线，根据其连接线长短设定脉冲宽度值τ、作用时间T及判定两频谱不一致能量比阈值λmax；1) select a line to be tested of the electrical connector, set the pulse width value τ, the action time T and judge the inconsistency energy ratio threshold λmax of the two spectrums according to the length of the connection line;
2)通过单片机产生幅值为5V、宽度为τ的脉冲信号，经信号处理电路放大后输出至电连接器的待测试连线，电连接器另一端连接实际设备，并将实际设备置于模拟工作环境中；2) A pulse signal with an amplitude of 5V and a width of τ is generated by the single-chip microcomputer. After being amplified by the signal processing circuit, it is output to the connection to be tested of the electrical connector. The other end of the electrical connector is connected to the actual device, and the actual device is placed in the simulation. in the working environment;
3)脉冲信号通过电连接器端口将产生反射信号，若连接的实际设备也产生有负载效应，最后形成实际的返回信号，经信号处理电路处理，返回至单片机控制的ADC口进行模拟信号采样，ADC口所采集的数据包括该待测试连线线路存在的正常状态、间歇故障状态和永久故障状态信息；3) The pulse signal will generate a reflected signal through the electrical connector port. If the actual equipment connected also has a load effect, the actual return signal will finally be formed. After being processed by the signal processing circuit, it will be returned to the ADC port controlled by the single-chip microcomputer for analog signal sampling. The data collected by the ADC port includes the normal state, intermittent fault state and permanent fault state information of the connection line to be tested;
4)单片机对步骤3)中ADC口所采集的数据进行FFT变换，形成频谱特征并保存起来，构成1组频谱特征数据；4) The single-chip microcomputer performs FFT transformation on the data collected by the ADC port in step 3) to form a spectrum feature and save it to form a group of spectrum feature data;
5)保持脉冲宽度和作用时间不变情况下，重复步骤1)～步骤4)N次，以得到N组频谱特征数据；5) Under the condition of keeping the pulse width and the action time unchanged, repeat steps 1) to 4) N times to obtain N groups of spectral characteristic data;
6)单片机比较步骤5)中所得N组频谱特征数据中任意第i、j两组的能量频谱差异程度λij，若能量频谱差异程度λij小于能量比阈值λmax，判断其属于同一种系统工作状态；在N组频谱特征数据中，能量频谱分布一致的数据组数目最多的判定为正常工作状态或永久故障工作状态，数目少(也可能为0)判定为存在间歇故障状态；6) The single-chip computer compares the energy spectrum difference degree λij of any i and j groups in the N groups of spectrum characteristic data obtained in step 5). If the energy spectrum difference degree λij is less than the energy ratio threshold λmax , it is judged that it belongs to the same system Working state; in the N groups of spectral characteristic data, the data group with the largest number of data groups with consistent energy spectrum distribution is judged as normal working state or permanent fault working state, and a small number (may be 0) is judged as intermittent fault state;
7)计算步骤6)中间歇故障状态的所占比例数，作为间歇故障发生概率，从而得到该电连接器待测试连线上发生间歇故障的概率；7) Calculate the proportion of the intermittent fault state in step 6) as the probability of intermittent fault occurrence, so as to obtain the probability of intermittent fault occurrence on the connection line to be tested of the electrical connector;
8)再选择电连接器上其他未测试的连线，重复步骤1)～步骤7)，当该电连接器所有插针或插孔的连线都测试过后，统计分析出结果，得到该电连接器发生间歇故障概率。8) Then select other untested connections on the electrical connector, and repeat steps 1) to 7). When the connections of all pins or jacks of the electrical connector are tested, statistically analyze the results to obtain the electrical connector. Intermittent failure probability of connectors.
在本发明中，步骤1)中，脉冲宽度值τ设置10纳秒～10微秒。In the present invention, in step 1), the pulse width value τ is set to 10 nanoseconds to 10 microseconds.
在本发明中，步骤2)中，脉冲信号作用时间T不超过5秒。In the present invention, in step 2), the pulse signal action time T does not exceed 5 seconds.
在本发明中，步骤6)中，所述能量频谱差异程度λij的计算公式为：In the present invention, in step 6), the calculation formula of the energy spectrum difference degree λij is:
式(1)中，a、b为所关注频段范围，Ec是所关注特征频段内的能量，Eci表示第i次所关注频段的能量，Aki表示第i次第k个频率分量的幅值，当λij大于0.2时，判定其差异非常明显。In formula (1), a and b are the frequency range of interest, Ec is the energy in the characteristic frequency band of interest, Eci represents the energy of the i-th frequency band of interest, and Aki represents the amplitude of the k-th frequency component of the i-th time. value, when λij is greater than 0.2, it is judged that the difference is very obvious.
在本发明中，步骤6)中，能量比阈值λmax取0.2。In the present invention, in step 6), the energy ratio threshold λmax is taken as 0.2.
有益效果：Beneficial effects:
1)本发明无需研究电连接器复杂的动态特性，通过单端测试以判定电连接器每根连线存在间歇故障的概率，简单实用可靠；只需要针对电连接器每路连接线加载N次可重复的脉冲作用信号，获取足够多的采样数据进行频谱特征分析，统计分析其频谱特征的一致性，当不一致时，判定发生间歇故障，综合电连接器所有连线的测试结果判断该电连接器发生间歇故障的概率；1) The present invention does not need to study the complex dynamic characteristics of the electrical connector. The single-ended test is used to determine the probability of intermittent failure of each connection line of the electrical connector, which is simple, practical and reliable; it only needs to load N times for each connection line of the electrical connector. Repeatable pulse action signal, obtain enough sampling data to analyze the spectral characteristics, and analyze the consistency of the spectral characteristics. probability of intermittent failure of the device;
2)本发明通过能量频谱差异程度公式，结合傅里叶变换获得采样信号的频谱特征，进而比较各频段的能量频谱特征的一致性，若超出所设噪声能量比的阈值，则认为其发生间歇故障，出现越多这种状态，在实际工作过程中，发生间歇故障的可能性越高，与其他方法相比，这种方法简单可靠，并估计出发生间歇故障的概率。2) The present invention obtains the spectral characteristics of the sampled signal through the energy spectrum difference degree formula in combination with Fourier transform, and then compares the consistency of the energy spectrum characteristics of each frequency band. The more faults occur, the higher the probability of intermittent faults in the actual working process. Compared with other methods, this method is simple and reliable, and estimates the probability of intermittent faults.
附图说明Description of drawings
图1为本发明的较佳实施例中的电连接器连接示意图。FIG. 1 is a schematic diagram of the connection of an electrical connector in a preferred embodiment of the present invention.
图2为本发明的较佳实施例中的发生间歇故障诊断流程图。FIG. 2 is a flowchart of intermittent fault diagnosis in a preferred embodiment of the present invention.
具体实施方式Detailed ways
为了使本发明实现的技术手段、创作特征、达成目的与功效易于明白了解，下面结合具体图示，进一步阐述本发明。In order to make it easy to understand the technical means, creation features, achieved goals and effects of the present invention, the present invention will be further described below with reference to the specific figures.
参见图1～2的基于频谱特征变化的电连接器发生间歇故障诊断方法，具体步骤如下：Referring to the method for diagnosing intermittent faults in electrical connectors based on changes in spectral characteristics, the specific steps are as follows:
1)选择电连接器的一路待测试连线，根据其连接线长短设定脉冲宽度值τ(设置10纳秒～10微秒)、作用时间T(脉冲宽度的10000倍)及判定两频谱不一致能量比阈值λmax；1) Select one line of the electrical connector to be tested, and set the pulse width value τ (set 10 nanoseconds to 10 microseconds), the action time T (10,000 times the pulse width) according to the length of the connecting line, and determine that the two spectrums are inconsistent energy ratio threshold λmax ;
2)通过单片机(或FPGA)产生幅值为5V、宽度为τ的脉冲信号，经信号处理电路放大后输出至电连接器的待测试连线，电连接器另一端连接实际设备，并将实际设备置于模拟工作环境中(如振动、温度条件)，脉冲信号作用时间T不超过5秒；2) A pulse signal with an amplitude of 5V and a width of τ is generated by a single-chip microcomputer (or FPGA), which is amplified by the signal processing circuit and then output to the connection to be tested of the electrical connector. The other end of the electrical connector is connected to the actual device, and the actual The equipment is placed in a simulated working environment (such as vibration, temperature conditions), and the pulse signal action time T does not exceed 5 seconds;
3)脉冲信号通过电连接器端口将产生反射信号，若连接的实际设备也产生有负载效应，最后形成实际的返回信号，经信号处理电路处理，返回至单片机(或FPGA)控制的ADC口进行模拟信号采样，ADC口所采集的数据包括该待测试连线线路存在的正常状态、间歇故障状态和永久故障状态信息，由于脉冲信号宽度τ有限，作用时间T短，可认为其只处于一种状态；3) The pulse signal will generate a reflected signal through the electrical connector port. If the actual device connected also has a load effect, the actual return signal will finally be formed, which will be processed by the signal processing circuit and returned to the ADC port controlled by the microcontroller (or FPGA) for processing. Analog signal sampling, the data collected by the ADC port includes the normal state, intermittent fault state and permanent fault state information of the connection line to be tested. Because the pulse signal width τ is limited and the action time T is short, it can be considered that it is only in one state;
4)单片机(或FPGA)对步骤3)中采集的数据进行FFT变换，形成频谱特征并保存起来，构成1组频谱特征数据；4) The single-chip microcomputer (or FPGA) performs FFT transformation on the data collected in step 3) to form spectral features and save them to form a group of spectral feature data;
5)保持脉冲宽度和作用时间不变情况下，对步骤1)～步骤4)重复N次，以得到N组频谱特征数据，注意所模拟的振动、温度等工作环境条件，应该反映在这N次测试中；5) Under the condition of keeping the pulse width and action time unchanged, repeat steps 1) to 4) N times to obtain N groups of spectral characteristic data. Pay attention to the simulated vibration, temperature and other working environment conditions, which should be reflected in this N in the test;
6)单片机(或FPGA)比较步骤5)中所得N组频谱特征数据中任意第i、j两组的能量频谱差异程度λij，若能量频谱差异程度λij小于能量比阈值λmax，判断其属于同一种系统工作状态；在N组频谱特征数据中，能量频谱分布一致的数据组数目最多的应该属于正常工作状态或永久故障工作状态，数目少(也可能为0)的判定为存在间歇故障状态；6) The single chip (or FPGA) compares the energy spectrum difference degree λij of any i and j groups in the N groups of spectrum characteristic data obtained in step 5), if the energy spectrum difference degree λij is less than the energy ratio threshold λmax , judge its It belongs to the same system working state; in the N groups of spectral characteristic data, the data group with the largest number of data groups with consistent energy spectrum distribution should belong to the normal working state or permanent fault working state. state;
所述能量频谱差异程度λij的计算公式为：The calculation formula of the energy spectrum difference degree λij is:
式(1)中，a、b为所关注频段范围，Ec是所关注特征频段内的能量，Eci表示第i次所关注频段的能量，Aki表示第i次第k个频率分量的幅值，当λij大于0.2时，判定其差异非常明显，λmax一般取0.2；In formula (1), a and b are the frequency range of interest, Ec is the energy in the characteristic frequency band of interest, Eci represents the energy of the i-th frequency band of interest, and Aki represents the amplitude of the k-th frequency component of the i-th time. When λij is greater than 0.2, it is judged that the difference is very obvious, and λmax is generally taken as 0.2;
因间歇故障发生时，不一定是全频段频谱能量都发生显著不一致，仅仅是某个频段具有显著变化，在实际比较中，是将整个频段平分为M段(一般不小于20)，求得每一频段的λij，最后选择M个频段中最大值λijM作为其第i，j两组数据能量频谱差异程度；When an intermittent fault occurs, it is not necessarily that the spectrum energy of the entire frequency band is significantly inconsistent, but only a certain frequency band has a significant change. λij of a frequency band, and finally select the maximum value λijM in the M frequency bands as the difference degree of the i-th and j two groups of data energy spectrums;
7)计算步骤6)中间歇故障状态的所占比例数，作为间歇故障发生概率，从而得到该电连接器待测试连线上发生间歇故障的概率；7) Calculate the proportion of the intermittent fault state in step 6) as the probability of intermittent fault occurrence, so as to obtain the probability of intermittent fault occurrence on the connection line to be tested of the electrical connector;
8)再选择电连接器上其他未测试的连线，重复步骤1)～步骤7)，当该电连接器所有插针或插孔的连线都测试过后，统计分析出结果，得到该电连接器发生间歇故障的情况。8) Then select other untested connections on the electrical connector, and repeat steps 1) to 7). When the connections of all pins or jacks of the electrical connector are tested, statistically analyze the results to obtain the electrical connector. A condition of intermittent failure of the connector.
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