The inconvenient loading and unloading of a long and heavy drill pipe gives rise to the difficulty in measuring the contour parameters of its threads at both ends. To solve this problem, in this paper we take the SCK230 drill pipe thread-repairing machine tool as a carrier to design and achieve a fast and on-machine measuring system based on a laser probe. This system drives a laser displacement sensor to acquire the contour data of a certain axial section of the thread by using the servo function of a CNC machine tool. To correct the sensor’s measurement errors caused by the measuring point inclination angle, an inclination error model is built to compensate data in real time. To better suppress random error interference and ensure real contour information, a new wavelet threshold function is proposed to process data through the wavelet threshold denoising. Discrete data after denoising is segmented according to the geometrical characteristics of the drill pipe thread, and the regression model of the contour data in each section is fitted by using the method of weighted total least squares (WTLS). Then, the thread parameters are calculated in real time to judge the processing quality. Inclination error experiments show that the proposed compensation model is accurate and effective, and it can improve the data acquisition accuracy of a sensor. Simulation results indicate that the improved threshold function is of better continuity and self-adaptability, which makes sure that denoising effects are guaranteed, and, meanwhile, the complete elimination of real data distorted in random errors is avoided. Additionally, NC50 thread-testing experiments show that the proposed on-machine measuring system can complete the measurement of a 25 mm thread in 7.8 s, with a measurement accuracy of ±8 μm and repeatability limit ≤ 4 μm (high repeatability), and hence the accuracy and efficiency of measurement are both improved.

This study proposes a high-efficiency method using a co-prime circular microphone array (CPCMA) for the bearing fault diagnosis, and discusses the acoustic characteristics of three fault-type signals at different rotation speeds. Due to the close positions of various bearing components, radiation sounds are seriously mixed, and it is challenging to separate the fault features. Direction-of-arrival (DOA) estimation can be used to suppress noise and directionally enhance sound sources of interest; however, classical array configurations usually require a large number of microphones to achieve high accuracy. To address this, a CPCMA is introduced to raise the array’s degrees of freedom in order to reduce the dependence on the microphone numbers and computation complexity. The estimation of signal parameters via rotational invariance techniques (ESPRIT) applied to a CPCMA can quickly figure out the DOA estimation without any prior knowledge. By using the techniques above, a sound source motion-tracking diagnosis method is proposed according to the movement characteristics of impact sound sources for each fault type. Additionally, more precise frequency spectra are obtained, which are used in combination to determine the fault types and locations.

The early fault impulses of rolling bearing are often submerged by harmonic interferences and background noise. In this paper, a fault diagnosis scheme called probabilistic principal component analysis assisted optimal scale average of erosion and dilation hat filter (OSAEDH-PPCA) is presented for the fault detection of rolling bearing. Based on morphological erosion operator and morphological dilation operator, a new morphological top-hat operator, namely average of erosion and dilation hat (AEDH) operator is firstly proposed to extract the fault impulses in the vibration signal. Simulation analysis shows the filter characteristics of proposed AEDH operator. Comparative analyses demonstrate that the feature extraction property of the AEDH operator is superior to existing top-hat operators. Then, the probabilistic principal component analysis is introduced to enhance the filter property of AEDH for highlighting the fault feature information of rolling bearing further. Experimental signals collected from the test rig and the engineering are employed to validate the availability of proposed method. Experimental results show that the OSAEDH-PPCA can effectively extract the early fault impulses from vibration signal of rolling bearing. Comparison results verify that the OSAEDH-PPCA has advantage in early fault detection of rolling bearing than other morphological filters in existence.

Aiming at the difficulty of early fault vibration signal extraction of rolling bearing, a method of fault weak signal extraction based on variational mode decomposition (VMD) and quantum particle swarm optimization adaptive stochastic resonance (QPSO-SR) for denoising is proposed. Firstly, stochastic resonance parameters are optimized adaptively by using quantum particle swarm optimization algorithm according to the characteristics of the original fault vibration signal. The best stochastic resonance system parameters are output when the signal to noise ratio reaches the maximum value. Secondly, the original signal is processed by optimal stochastic resonance system for denoising. The influence of the noise interference and the impact component on the results is weakened. The amplitude of the fault signal is enhanced. Then the VMD method is used to decompose the denoised signal to realize the extraction of fault weak signals. The proposed method was applied in simulated fault signals and actual fault signals. The results show that the proposed method can reduce the effect of noise and improve the computational accuracy of VMD in noise background. It makes VMD more effective in the field of fault diagnosis. The proposed method is helpful to realize the accurate diagnosis of rolling bearing early fault.