CN102636346B - Stress analysis system of self-powered wireless gear - Google Patents

Stress analysis system of self-powered wireless gear Download PDF

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Publication number
CN102636346B
CN102636346B CN201210100567.7A CN201210100567A CN102636346B CN 102636346 B CN102636346 B CN 102636346B CN 201210100567 A CN201210100567 A CN 201210100567A CN 102636346 B CN102636346 B CN 102636346B
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gear
analysis system
stress
wireless
stress analysis
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CN102636346A (en
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谢小平
周长江
白云志
罗云峰
郝立峰
张敏
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Hunan University
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Hunan University
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Abstract

The invention discloses a stress analysis system of a self-powered wireless gear, and the system comprises a gear transmission test system, a generating set, an AC/DC converter, a rechargeable battery, a power supply system formed by a protection circuit of the rechargeable battery, a stress collecting system and a stress collecting and analyzing system composed of a wireless receiving and sending device and a stress analysis system. The rechargeable battery and the protection circuit of the rechargeable battery are fixed on the gear to rotate with the gear, the alternating current generated by the rotation of the rotor of the generating set driven by the rotating gear shaft is supplied to the stress collecting system and a wireless sending device through the AC/DC converter and charges the battery at the same time; and a data collecting system transmits signals in a wireless manner, and the analysis system calculates and analyzes stress signals so as to provide data reference for dynamically analyzing and calculating the service life of the gear. The stress analysis system of the self-powered wireless gear has an energy-saving effect and strong anti-interference capability during a signal collecting process.

Description

Self-power wireless gear stress analysis system
Technical field
The present invention relates to a kind of self-power wireless gear stress analysis system.
Background technology
Gear drive is a topmost class gearing in mechanical drive, extensive in various application in machine equipments, because spiral gear is in the time transmitting motion and power, have that load-bearing capacity is high, transmission is more steady, shock and vibration and noise are compared with the advantage such as little and be widely used in various plant equipment and instrument and meter.
The quality of transmission properties directly affects the quality of transmission system performance, along with machinery to efficiently, at a high speed, accurate, multifunctional direction development, function to gear train and the requirement of performance are also more and more higher, and the serviceability, serviceable life, energy resource consumption, vibration noise of machinery etc. depends on the performance of kinematic train to a great extent.Although designer just notes improving at links the mechanical transfer performance of complete machine in the time of design, the mechanical transmission performance of designing through theory is often subject to the restriction of safety coefficient, and it can only be served as with reference to value.Along with the progress of the reach of science, technology, the kind of drive of machine driven system, method, load-bearing capacity have had development rapidly, people have proposed higher stricter requirement to properties of product and product quality, for the performance to machine driven system, life-span test and analyze, the strain of gear train assembly is carried out to real-time monitoring and just seem very necessary.
Self-power wireless gear stress analysis system in contrast to former method following 4 advantages: the signal transmission of (1) original gear Strain Analysis System generally adopts mercury slip ring, its rotating speed is the highest at 2000-3000r/min, and rotating speed improves port number minimizing later, on market, generally only have 2 passages when common mercury slip ring 2000r/min, and high-speed slip rings port number is more but price is very expensive.Wireless signal transmission can adapt to exceed the high speed conditions of 10000r/min, and as long as channel bandwidth is enough, can realize compared with multi-channel synchronous image data.The WLS-9237 wireless strain harvester adopting now can be realized the synchronous strain signal collection of 4 passage 50k/s; (2) disturb and the current/voltage interference causing that suddenlys change because slip ring inside has electromagnetism to mix, be only suitable for forceful electric power and transmit, be not suitable for the particularly transmission of strain signal of feeble signal.Adopt wireless transmission to overcome above disadvantage, signal quality has had significantly lifting.(3) mercury slip ring or high-speed slip rings are rotated together with system with one end that system connects, and the other end is that signal output part does not rotate and will additionally fix in outside.One end and the system synchronization of rotation are very good, and stiff end and system must be in complete matching states, otherwise easily cause when High Rotation Speed and slide and displacement, cause slip ring to be damaged.
Summary of the invention
Technical matters to be solved by this invention is to provide a kind of self-power wireless gear stress analysis system, and this self-power wireless gear stress analysis system has energy-saving effect, and collection signal is strong interference immunity.
The technical solution of invention is as follows:
A kind of self-power wireless gear stress analysis system, is characterized in that, comprises gear train assembly, power-supply system and strain acquirement and stress analysis system;
Gear train assembly comprises motor, gear case, input speed torque sensor, output speed torque sensor and magnetic powder brake; Motor is connected with input torque speed probe by shaft coupling, input torque speed probe is again through shaft coupling drive gear casing, gear case is connected to output torque rotary speed sensor through shaft coupling, and output torque rotary speed sensor is connected with magnetic powder brake by shaft coupling again; Input torque speed probe and output torque rotary speed sensor are measured respectively torque and the rotating speed of input shaft and output shaft.In the time that motor driven gear kinematic train is rotated, when the gear in gear case engages, the stress of tooth root portion is determined by gear bulk material structure, lubricating condition, rotating speed and load.The material of gear and structure and lubricating condition are known conditions parameter, and torque and rotational speed need to measure by high precision torque rotary speed sensor.Input and output rotating speed is same numerical value substantially, and what when gear engagement, suffered load was output torque and input torque is poor; ]
Power-supply system comprises Blast Furnace Top Gas Recovery Turbine Unit (TRT), AC/DC transducer and lithium ion battery; The AC sending and receiving electric installation of AC/DC transducer, the direct current side joint lithium battery of AC/DC transducer; Described Blast Furnace Top Gas Recovery Turbine Unit (TRT) comprises stator supporter, stator and rotor, and rotor is with the gear shaft rotation in gear case;
Strain acquirement and stress analysis system comprise strainometer, data acquisition and wireless base station apparatus, radio receiver and stress analysis system; Strainometer sticks on the gear grooved root of gear case, and in the time that motor driven gear kinematic train is rotated by setting speed, deflection when strainometer engages gear is converted into analog electrical signal; The output termination data acquisition system (DAS) of strainometer, [simulating signal is converted into digital signal outwards transmitting by data acquisition and wireless base station apparatus]; The power end power-supply system of data acquisition and wireless base station apparatus; Radio receiver receives by the strain signal of wireless launcher and passes to stress analysis system and connects.
Stress analysis system is according to stress and strain relation, stress diagrams while obtaining gear rotation, it is compared with the stress result obtaining that carries out CAE numerical simulation according to the concrete material of gear and structure, lubricating condition, rotating speed and load, further revise realistic model.
Magnetic powder brake is controlled by loading control.
In the time that gear remains static or just started rotation and powered to data acquisition and wireless base station apparatus by lithium battery while not reaching power requirement, in the time that normally rotating, gear powered to data acquisition and wireless base station apparatus by Blast Furnace Top Gas Recovery Turbine Unit (TRT), and to lithium battery power supply.Adopt the gear train assembly of rotation to data acquisition and wireless base station apparatus power supply, saved externally fed device, reduced electric energy loss.
Wireless base station apparatus and radio receiver communicate to connect based on 802.11 wireless communication protocols.
Described motor is connected [by Frequency Converter Control rotating speed] with frequency converter.
Beneficial effect:
Self-power wireless gear stress analysis system of the present invention mainly comprises strain acquirement and the analytic system of power-supply system, strain acquisition system, wireless transmitter and the Strain Analysis System composition of gear drive pilot system, Blast Furnace Top Gas Recovery Turbine Unit (TRT), AC/DC transducer and rechargeable battery and holding circuit composition thereof.Rechargeable battery and holding circuit thereof are to be fixed on gear to rotate together with gear, the alternating current that drives Blast Furnace Top Gas Recovery Turbine Unit (TRT) rotor (coil) rotation to produce in the time that gear shaft rotates, convert to strain acquisition system and wireless base station apparatus and use by AC/DC, charge the battery simultaneously; Battery is to strain acquisition system and wireless base station apparatus power supply when system has just started and Blast Furnace Top Gas Recovery Turbine Unit (TRT) generated energy is not enough; Data acquisition system (DAS) collects strain signal, wireless base station apparatus sends the digital signal of strain, radio receiver is accepted wireless strain signal and sends into Strain Analysis System according to 802.11 wireless communication protocols, analytic system is carried out computational analysis to strain signal, and analyzing the Frotteurism of gear and weigh gear life for subsequent dynamic provides data foundation.
Self-power wireless gear stress analysis system of the present invention in contrast to former method following 4 advantages:
(1) signal transmission of original gear Strain Analysis System generally adopts mercury slip ring, its rotating speed is the highest at 2000-3000r/min, and rotating speed improves port number minimizing later, on market, generally only have 2 passages when common mercury slip ring 2000r/min, and high-speed slip rings port number is more but price is very expensive.Wireless signal transmission can adapt to exceed the high speed conditions of 10000r/min, and as long as channel bandwidth is enough, can realize compared with multi-channel synchronous image data.The WLS-9237 wireless strain harvester adopting now can be realized the synchronous strain signal collection of 4 passage 50k/s;
(2) disturb and the current/voltage interference causing that suddenlys change because mercury slip ring inside has electromagnetism to mix, be only suitable for forceful electric power and transmit, be not suitable for the particularly transmission of strain signal of feeble signal.Adopt wireless transmission to overcome above disadvantage, signal quality has had significantly lifting.
(3) mercury slip ring or high-speed slip rings are rotated together with system with one end that system connects, and the other end is that signal output part does not rotate and will additionally fix in outside.One end and the system synchronization of rotation are very good, and stiff end and system must be in complete matching states, otherwise easily cause when High Rotation Speed and slide and displacement, cause slip ring to be damaged, and the present invention have avoided this situation to occur.
(4) adopt self-powered method can save slip ring to wireless strain harvester power supply and supply transmitting device as external electric energy, cost.The feature of simultaneously utilizing rotating object self to generate electricity, reaches energy-conservation object.
In addition, gear drive (test) system is for the gear drive situation of simulating actual conditions, for mechanical output open type testing table, simple in structure, manufacture, easy for installation, flexible configuration;
Brief description of the drawings
Fig. 1 is self-power wireless gear stress analysis system schematic diagram;
Fig. 2 is the structural representation of gear drive pilot system;
Fig. 3 is Blast Furnace Top Gas Recovery Turbine Unit (TRT) schematic diagram; (figure a left view, figure b is front view)
Fig. 4 measures the stress comparison diagram recording with emulation; (figure a is for measuring stress diagram, and figure b is simulated stress figure)
Label declaration: 1 frequency control motor 2 shaft coupling 3 input torque speed probe 4 tests are exported torque rotary speed sensor 6 magnetic powder brake 7 loading control 8 frequency converter 9 computing machines, 11-stator, 12-rotor, 13-stator supporter, 14-gear shaft with gear case 5.
Embodiment
Below with reference to the drawings and specific embodiments, the present invention is described in further details:
Embodiment 1:
As shown in Figure 1, self-power wireless gear stress analysis system comprises the power-supply system, strain acquisition system of gear train assembly, electricity generation system, AC/DC transducer and rechargeable battery and holding circuit thereof composition, strain acquirement and the analytic system being made up of wireless transmitter and Strain Analysis System.Rechargeable battery and holding circuit thereof are to be fixed on gear to rotate together with gear, Blast Furnace Top Gas Recovery Turbine Unit (TRT) rotor (coil) charges to strain acquisition system power supply and battery after AC/DC transducer along with the rotation of gear shaft produces alternating current, and strain acquisition system gathers strain signal with NI-9237 data collecting card; NI-9237 has 24 bit resolutions, be furnished with RJ50 connector ± 25mV analog input, analog input is synchronously adopted on 4 roads; The highest sampling rate reaches 50kS/s, the complete programming of half-bridge and full-bridge, and internal motivation can reach 10V, compatible intelligent sensor (TEDS).The strain signal collecting sends strain digital signal through WLS-9237 wireless base station apparatus, radio receiver is accepted wireless signal and is sent into Strain Analysis System according to 802.11 communication protocols, strain signal is carried out to computational analysis, realize the dynamic monitoring to gear train assembly.Strain signal is converted into stress curve, and when stress curve has reflected gear drive, the mutual collision of tooth produces distortion and stressing conditions, and it is relevant to the composite factor such as gear structure, material, rotational speed, lubricating condition, temperature.
As shown in Figure 2, gear train assembly mainly comprises frequency control motor, hereinafter to be referred as motor, shaft coupling, input torque speed probe, gear case, output torque rotary speed sensor, magnetic powder brake, loading control, frequency converter, computing machine for test.Its principle of work is as follows: motor is connected with input torque speed probe by shaft coupling, drive test gear case through shaft coupling again, be connected to output torque rotary speed sensor with gear case through shaft coupling from test, be connected with magnetic powder brake by shaft coupling again, loading control control magnetic powder brake produces load, motor by computer-controlled transducer drive, and input and output torque rotary speed sensor is measured the torque rotary speed of input and output shaft.This system is various gear drive operating modes in simulating actual conditions effectively.In the time that motor driven gear kinematic train is rotated, when the gear in gear case engages, the stress of tooth root portion is determined by the concrete material of gear and structure, lubricating condition, rotating speed and load.The material of gear and structure and lubricating condition are known conditions parameter, and torque and rotational speed need to measure by high precision torque rotary speed sensor.Input and output rotating speed is a numerical value substantially, and what when gear engagement, suffered load was output torque and input torque is poor.
As shown in Figure 3, a notable feature of the present invention is exactly to realize the self-powered of system, and Blast Furnace Top Gas Recovery Turbine Unit (TRT) is very special, extracted current from rotor (coil).The stator (electromagnet) of Blast Furnace Top Gas Recovery Turbine Unit (TRT) is arranged near the gear shaft both sides between torque and speed sensors and the gear case of input shaft, rotor (coil) is arranged along the gear shaft near between torque and speed sensors and the gear case of input shaft, gear shaft rotarily drives rotor (coil) circumgyration incision magnetic line of force generation current and draws from rotor the AC/DC transducer of flowing through and convert to a part and be fixed on gear the charging of the battery on axle, and a part is used to strain acquisition system and wireless base station apparatus.Power supply adopts in the past and is applicable to forceful electric power transmission mercury slip ring or battery, and too short with battery life, both are not ideal to the power supply of strain harvester, have realized the self-powered of system by this cover system, and the power supply of system improves and saves energy.
The power-supply system of AC/DC transducer and lithium battery and holding circuit composition system thereof, AC/DC has the conversion of voltage AC-DC, and regulated output voltage can be protected to system power supply in short-term after system starts time in the time that battery electric quantity is not enough; Battery adopt lithium ion battery, holding circuit adopt S8254, prevent battery overvoltage, under-voltage, overcharge, overdischarge.Rechargeable battery is to be fixed on gear to rotate together with gear, the alternating current that drives engine rotation to produce in the time that gear rotates, being transformed into direct current by AC/DC uses to strain acquisition system and wireless base station apparatus, charge the battery simultaneously, battery be system while just having started and when generated energy is not enough to strain acquisition system and wireless base station apparatus power supply.Power supply adopts in the past and is applicable to forceful electric power transmission mercury slip ring or battery, and too short with battery life, both are not ideal to the power supply of strain harvester.Therefore, improve by this covering device powerup issue.
The collection transmission of gear strain signal adopts wireless transmission, and NI-9237 data acquisition system (DAS) gathers strain signal, and wireless base station apparatus WLS-9237 sends strain digital signal, and radio receiver is accepted wireless strain signal according to 802.11 communication protocols.Strain Analysis System is analyzed strain signal, obtains the Frotteurism of gear.The mercury slip ring that before ining contrast to, signal transmission is used has following 2 advantages: (1) mercury slip ring rotating speed is the highest at 2000-3000r/min, and after rotating speed raising, port number reduces, and generally only supports 2 passages when common mercury slip ring reaches 2000r/min on market; And high-speed slip rings port number is more but expensive; (2) disturb and the current/voltage interference causing that suddenlys change because slip ring inside has electromagnetism to mix, be only suitable for forceful electric power and transmit, be not suitable for the particularly transmission of strain signal of feeble signal.Adopt wireless transmission to overcome above disadvantage, signal quality has had significantly lifting.
The comparative analysis of gear stress measurement and simulation result
When being obtained the strain of gear by wireless strain acquisition system and being transferred to after computing machine, according to the relation of stress σ and strain stress strain is converted into stress, the elastic modulus that wherein E is material.Then the stress obtaining with upper stress and emulation measuring is analyzed.Because elastic modulus E is generally constant, so stress and strain curve is identical.
Be 343.24 revs/min at rotating speed, when torque is 33.71 Ns of rice, measures the strain recording with emulation and contrast as shown in Figure 4.Wherein the current gear teeth are to the stress measurement figure of tooth root portion as shown in Fig. 4 (a), and the quasi-static analysis of carrying out implicit expression in the situation that of same load in CAE software Ansys records the stress of tooth root portion and sees Fig. 4 (b).Be analyzed known to two figure:
1. the strain of tooth root portion is roughly the same, and emulation is more bigger than the measured maximum strain of test.
2. the variation tendency of strain curve is more identical, has clearly engaging-in and nibbles out impact.And Fig. 4 (b) compares Fig. 4 (a) and has more the significantly variation in Gear Contact region, main cause is in test because the synergistic effect of front and back two gear teeth is obvious, and in emulation due to calculated amount be related to computing time shorter do not embody before and after the synergistic effect in Liang Chishuannie district.
3. the maximum strain recording in test is converted into stress according to stress-strain relation and elastic modulus E=2.09 × 1011 (every square metre of ox), as shown in table 1 with simulation result contrast.Only have 9.22% with respect to test error, the accuracy of visible test and simulation result.
Table 1 is tested, the root stress maximal value of emulation
Test Emulation
Bending stress 14.42MP 15.75MP
Error 922%

Claims (2)

1. a self-power wireless gear stress analysis system, is characterized in that, comprises gear train assembly, power-supply system and strain acquirement and stress analysis system;
Gear train assembly comprises motor, gear case, input speed torque sensor, output speed torque sensor and magnetic powder brake; Motor is connected with input torque speed probe by shaft coupling, input torque speed probe is again through shaft coupling drive gear casing, gear case is connected to output torque rotary speed sensor through shaft coupling, and output torque rotary speed sensor is connected with magnetic powder brake by shaft coupling again;
Power-supply system comprises Blast Furnace Top Gas Recovery Turbine Unit (TRT), AC/DC transducer and lithium ion battery; The AC sending and receiving electric installation of AC/DC transducer, the direct current side joint lithium battery of AC/DC transducer; Described Blast Furnace Top Gas Recovery Turbine Unit (TRT) comprises stator supporter, stator and rotor, and rotor is with the gear shaft rotation in gear case;
Strain acquirement and stress analysis system comprise strainometer, data acquisition and wireless base station apparatus, radio receiver and stress analysis system; Strainometer sticks on the gear grooved root of gear case, and in the time that motor driven gear kinematic train is rotated by setting speed, deflection when strainometer engages gear is converted into analog electrical signal; The output termination data acquisition system (DAS) of strainometer; The power end power-supply system of data acquisition and wireless base station apparatus; Radio receiver receives by the strain signal of wireless launcher and passes to stress analysis system and connects;
Magnetic powder brake is controlled by loading control;
Wireless base station apparatus and radio receiver communicate to connect based on 802.11 wireless communication protocols.
2. self-power wireless gear stress analysis system according to claim 1, is characterized in that, described motor is connected with frequency converter.
CN201210100567.7A 2012-04-09 2012-04-09 Stress analysis system of self-powered wireless gear Active CN102636346B (en)

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CN103728919A (en) * 2012-10-10 2014-04-16 财团法人精密机械研究发展中心 Self-power-generation sensing device, monitoring system and operation method of machining equipment
CN105628378B (en) * 2016-01-18 2018-06-05 中国航空动力机械研究所 Gear dynamic stress rest equipment
CN110441057B (en) * 2019-09-10 2024-03-08 北鲲睿航科技(上海)有限公司 Marine propulsion shaft remote sensing type strain measurement system and measurement device and measurement method thereof

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