基于数字孪生的谐波减速器状态监测与故障预测方法
Condition Monitoring and Fault Prediction Method for Harmonic Reducer Based on Digital Twin
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摘要: 针对谐波减速器早期故障特征微弱、剩余使用寿命(Remaining Useful Life,RUL)预测精度不足的工程痛点,提出一种基于数字孪生的谐波减速器状态监测与故障预测方法。首先,构建包含物理实体、虚拟模型、数据孪生、服务数据、连接交互的5维数字孪生框架,实现多物理场传感数据与高保真数字孪生模型的实时映射与协同演化;其次,结合多源数据,将注意力机制(Attention Mechanism)引入长短期记忆网络(Long Short-term Memory,LSTM),构建LSTM-Attention故障预测模型,提升退化趋势及早期故障预测精度;最后,利用加速寿命试验验证该方法的有效性。结果表明,相较标准LSTM,该方法的均方根误差(Root Mean Square Error,RMSE)下降18.7%,平均绝对误差(Mean Absolute Error,MAE)下降22.3%,并提前150个工作循环识别出柔轮疲劳裂纹,为谐波减速器预测性维护提供有效技术路径。Abstract: To address the engineering challenges of weak early failure characteristics and insufficient prediction accuracy of remaining useful life(RUL)for harmonic reducer,a condition monitoring and fault prediction method for harmonic reducer based on digital twin is proposed.Firstly,a 5-dimensional digital twin framework including physical entities,virtual models,data twins,service data,and connection interactions is constructed to achieve real-time mapping and collaborative evolution of multi-physical field sensing data and high-fidelity digital twin models.Secondly,by combining multiple sources of data,the attention mechanism is introduced into the long short-term memory network(LSTM),and an LSTM-Attention fault prediction model is constructed to improve the accuracy of degradation trends and early fault predictions.Finally,the effectiveness of the method is verified through accelerated life tests.The results show that compared with the standard LSTM,the root mean square error(RMSE)of the method decreases by 18.7%,the mean absolute error(MAE)decreases by 22.3%,and the fatigue cracks of the flexible wheel are identified 150 working cycles earlier,providing an effective technical path for predictive maintenance of harmonic reducer.
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