Method and apparatus for detecting metal wipe damages of plane bearing
This is a continuation of application Ser. No. 195,106, filed Oct. 8, 1980 now abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates to a method and apparatus for detecting metal wipe damages of plane bearings which are used in rotary machines. 
     Burn-out of bearing metal leads to serious problems especially in large-sized steam turbine generators rotating at high speed. Therefore, it is highly desirable to detect, in plane bearings metal wipe damages caused by, for example axial vibration, rubbing when the generators are in operation. 
     In, for example, &#34;Instrumentation Technology&#34;, September, 1977, pp 59-60, a popular detection method is proposed wherein a temperature of bearings is monitored; however, a disadvantage of this proposed method resides in the fact that the detection is effected only after an enlargement of the metal wipe. Accordingly, it is very difficult to detect the metal wipe damages in an initial stage before the rubbing occurs. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is an object of this invention to provide a method and apparatus for detecting a occurrence of the metal wipe. 
     Another object of this invention is to provide a method and apparatus for detecting an enlarged state of the metal wipe damages. 
     The metal wipe which leads to the rubbing, etc. generates ultrasonic signal (as acoustic emission signal) when it occurs. The ultrasonic signal is characterized in that the appearance is almost periodical, and that the amplitude is nearly equal to each another. As described above, the ultrasonic signal generated by both in a metal wipe has certain characteristics in the generation period and signal amplitude. Accordingly, the metal wipe damages can be detected by monitoring such a ultrasonic signal. 
     In accordance with the above-mentioned objects of the invention, method and apparatus are disclosed for detecting the metal wipe of plane bearings, wherein the method includes the steps of receiving ultrasonic signal by a transducer fixed in the neighborhood of the plane bearings, and deciding whether the ultrasonic signal is generated periodically or not, and wherein the apparatus includes means fixed in the neighborhood of the plane bearings for receiving ultrasonic signal generated by the metal wipe, means for converting the received ultrasonic signal into a pulse signal, means for storing every pulse signal received within a predetermined period of time, and means for computing the ratio of the pulse signal stored within the previous period of time to that stored within the current period of time provided an output signal indicative of a metal wipe. 
     According to the present invention, an impending failure in the plane bearings of the rotary machine can be detected in an initial stage before the rubbing or the axial vibration occurs. 
     Other objects and advantages of the invention will become apparent from the following detailed description taken in connection with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a graph showing the count of ultrasonic signal, the Babbit metal temperatures and the oil purging temperatures. 
     FIG. 2 is a diagram showing an arrangement of the detectors for receiving the ultrasonic signal, the Babbit metal temperature and the oil purging temperatures, and a circuit for processing the received ultrasonic signal. 
     FIG. 3 is a wave form diagram depicting output ultrasonic signal generated by the metal wipe. 
     FIG. 4 is a block diagram of an illustrative embodiment of the present invention. 
     FIG. 5 is a block diagram of the periodic decision circuit shown in FIG. 4. 
     FIG. 6 is a wave form diagram depicting various signals developed at several points in FIG. 5, 
     FIG. 7 is a block diagram of another embodiment of the present invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     With reference to FIG. 1, Babbit metal temperatures are represented by a curve designated A, oil purging temperatures by a curve designated, B and ultrasonic are represented by a curve C, with the data in the graphical representation being obtained from experiments conducted to determine the metal wipe damages. 
     Referring to FIG. 2, the Babbit metal temperatures A and the oil purging temperatures B, respectively, are measured by thermocouples 13a and 13b which are provided in Babbit metal 11 and housing 12, respectively. The ultrasonic signal is received by using a transducer 14 fixed to the Babbit metal 11. The received ultrasonic signal is amplified by a preamplifier 15 and a main amplifier 16, and is counted by a counter 17. 
     As shown in FIG. 1, the Babbit metal temperatures A and the oil purging temperatures B increase slowly before and after the occurrence of metal wipe (time T). However, the number of the ultrasonic signals increases significantly after a metal wipe has occurred. 
     FIG. 3 illustrates a waveform of the ultrasonic signal generated by the metal wipe. In FIG. 3, the abscissa indicates time, in which T designates a time point of occurrence of the metal wipe. The ultrasonic signal occurs during about the same period, with an amplitude of the signal being about the same magnitude. 
     As described above, the ultrasonic signal generated by the metal wipe has certain characteristics both in a period of generation and the amplitude of the signal. Accordingly, the metal wipe can be detected by monitoring the ultrasonic signal. 
     As shown in FIG. 4, a plane bearing arrangement is provided including a journal, 20 a plane bearing, 21 and a transducer 22 formed as a piezoelectric ceramic element. The transducer 22 is fixed by pressure welding or bonding at position where it can receive ultrasonic signal generated by the metal wipe damages on the surface of the plane bearing 21. The ultrasonic signal received by the transducer 22 is supplied to a rotation decision circuit 23 (the rotation operation is the preliminary operation of machine speed of about 2 rpm). A signal of a rotation frequency is also supplied to the circuit 23. The rotation decision circuit decides whether the machine is in the turning operation or in a normal operation, to supply an output signal of the transducer 22 to a preamplifier 24 only when the machine is in a rotation operation. If it is obvious that the machine is in a rotation operation, the output signal of the transducer 22 can be applied directly to the preamplifier 24. The preamplified signal is supplied through a noise filter 25 to a main amplifier 26. The amplified signal is supplied through a detector 27 to a comparator 28. The comparator 28 converts the ultrasonic signal into pulse signal. The pulse signal is supplied to a periodic decision circuit 29, in which the periodic nature of the pulse signal is detected. The output signal of the eriodic decision circuit 29 is applied to a counter 30 when the periodic nature is detected, that is, the output signal, hereinafter referred to as a metal wipe signal, of the circuit 29 indicates the occurrence of the metal wipe. The count of the output signal is displayed on a display 31. 
     FIG. 5 shows the periodic decision circuit shown in FIG. 4, with FIG. 6 illustrating waveforms of various signals developed at several points in FIG. 5. 
     Referring to FIG. 5 and FIG. 6, the output signal of the comparator 28 is applied to a gate circuit 40, which includes a timer 41. A gate (A) 42a and a gate (B) 42b are operated alternately by the timer 41 so as to pass the output signal to digital memory circuits 43a and 43b, respectively. The digital memory circuits are constructed such that the stored signal is cleared upon an input of a next signal. 
     As described above the ultrasonic signal is generated periodically after the metal wipe occurred. Therefore, the occurrence of the metal wipe can be detected by computing in the following manner. 
     The signals stored in the digital memory circuits 43a and 43b are applied to a divider 44 every read-in time t 1 , t 2 , t 3 , - - - . The ratio of the output signal A of the circuit 43a to the output signal B of the circuit 43b, that is, A 1  /B 1 , A 1  /B 2 , A 2  /B 2 , etc. is computed by the divider 44. The divider 44 outputs a direct voltage signal as 5 volts when the signal A nearly equals to the signal B. Finally, an AND gate 45 performs an AND logical operation in response to the application of the output signal of the comparator 28 and that of the divider 44. 
     The foregoing operation is clearly illustrated by the waveforms of FIG. 6, wherein a heavy lines designates computation time. The divider 44 reads in the signals A 2  and B 2  within a period of time t 3 , and computes A 2  /B 2  within the next period of time t 4  to output the direct voltage signal which acts as a gate signal of the AND gate 45. 
     FIG. 7 shows another embodiment of the present invention, wherein a microcomputer 59 and a CRT display 60 are provided. In this embodiment, the microcomputer 59 is employed instead of the periodic decision circuit 29 and the counter 30 shown in FIG. 4 however, the apparatus functions in a similar manner to the apparatus of FIG. 4.