CN115203898A - A coupled dynamics modeling method for gearboxes excited by internal multi-source faults - Google Patents
A coupled dynamics modeling method for gearboxes excited by internal multi-source faults Download PDFInfo
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Abstract
本发明公开了一种受内部多源故障激励的齿轮箱耦合动力学建模方法,包括以下步骤:S1:齿轮啮合时变刚度、阻尼及动态摩擦力的计算:根据齿轮形貌以及局部剥落故障参数,计算得到齿轮啮合刚度随主动轮转角的函数关系;结合混合弹流润滑理论,通过输入动态的齿轮啮合力、表面粗糙度、卷吸速度参数在每个时刻计算得到当前齿轮啮合副的动态摩擦力以及啮合阻尼;S2:计算齿轮箱中每个轴承的内外圈作用力;S3:构建整个齿轮箱动力学模型的完整方程并求解。本发明,可以准确得到受啮合力、啮合摩擦、轴承内外圈动态作用力、弹流润滑、故障激励等多重因素影响下的齿轮箱的振动响应。
The invention discloses a coupling dynamics modeling method of a gearbox excited by an internal multi-source fault, comprising the following steps: S1: Calculation of variable stiffness, damping and dynamic friction force during gear meshing: according to gear topography and local spalling faults parameters, the function relationship between the gear mesh stiffness and the driving wheel rotation angle is calculated; combined with the hybrid elastohydrodynamic lubrication theory, the dynamic gear meshing force, surface roughness, and entrainment speed parameters are input at each moment to calculate the current gear meshing pair. Friction and mesh damping; S2: Calculate the inner and outer ring forces of each bearing in the gearbox; S3: Build and solve the complete equation of the entire gearbox dynamics model. The present invention can accurately obtain the vibration response of the gearbox under the influence of multiple factors such as meshing force, meshing friction, dynamic force of the inner and outer rings of the bearing, elastohydrodynamic lubrication, fault excitation and the like.
Description
技术领域technical field
本发明涉及机械设备健康状态评估及故障诊断技术领域,具体是一种受内部多源故障激励的齿轮箱耦合动力学建模方法。The invention relates to the technical field of health state assessment and fault diagnosis of mechanical equipment, in particular to a coupling dynamics modeling method of a gearbox excited by an internal multi-source fault.
背景技术Background technique
传动齿轮箱是机械系统的关键零部件之一,其状态直接影响到机械系统的运行状态,一旦齿轮箱出现故障,将很可能带来巨大的经济损失,甚至导致人员伤亡。机械故障特征提取等信号处理方法是齿轮箱故障诊断的有效途径,而这些故障诊断方法往往需要故障特征的先验知识作为理论基础。实验验证是获取故障特征先验知识的主要方法之一,但是具体齿轮箱的实验验证往往面临成本高昂、故障参数不明确、系统干扰大等难以克服的问题,因此通过动力学建模获取仿真信号来进行故障机理分析是十分重要的方法。齿轮箱内部受力情况相对复杂,且故障模式多变,传统的齿轮箱动力学模型往往通过简化其他部件(如轴承)来研究其中某一部件的故障特征。这种模型对于故障机理研究有一定参考性但是无法准确反映整个齿轮箱的实际行为与部件之间的耦合作用,存在较大的改进空间。The transmission gearbox is one of the key components of the mechanical system, and its state directly affects the operating state of the mechanical system. Once the gearbox fails, it is likely to bring huge economic losses and even lead to casualties. Signal processing methods such as mechanical fault feature extraction are effective ways of gearbox fault diagnosis, and these fault diagnosis methods often require prior knowledge of fault features as a theoretical basis. Experimental verification is one of the main methods to obtain prior knowledge of fault characteristics. However, the experimental verification of specific gearboxes often faces insurmountable problems such as high cost, unclear fault parameters, and large system interference. Therefore, simulation signals are obtained through dynamic modeling. It is a very important method to analyze the failure mechanism. The internal force of the gearbox is relatively complex, and the failure mode is changeable. The traditional dynamic model of the gearbox often studies the failure characteristics of one of the components by simplifying other components (such as bearings). This model has a certain reference for the study of the failure mechanism, but it cannot accurately reflect the actual behavior of the entire gearbox and the coupling between the components, and there is a large room for improvement.
发明内容SUMMARY OF THE INVENTION
本发明的目的在于提供一种受内部多源故障激励的齿轮箱耦合动力学建模方法,以解决现有技术中的问题。The purpose of the present invention is to provide a coupled dynamics modeling method of a gearbox excited by internal multi-source faults, so as to solve the problems in the prior art.
为实现上述目的,本发明提供如下技术方案:一种受内部多源故障激励的齿轮箱耦合动力学建模方法,包括以下步骤:In order to achieve the above object, the present invention provides the following technical solution: a method for modeling the coupling dynamics of a gearbox excited by an internal multi-source fault, comprising the following steps:
S1:齿轮啮合时变刚度、阻尼及动态摩擦力的计算:根据齿轮形貌以及局部剥落故障参数,计算得到齿轮啮合刚度随主动轮转角的函数关系;结合混合弹流润滑理论,通过输入动态的齿轮啮合力、表面粗糙度、卷吸速度参数在每个时刻计算得到当前齿轮啮合副的动态摩擦力以及啮合阻尼;S1: Calculation of time-varying stiffness, damping and dynamic friction force of gear meshing: According to the gear topography and local spalling failure parameters, the function relationship between gear meshing stiffness and driving wheel rotation angle is calculated; The parameters of gear meshing force, surface roughness and entrainment speed are calculated at each moment to obtain the dynamic friction force and meshing damping of the current gear meshing pair;
S2:计算齿轮箱中每个轴承的内外圈作用力:输入当前时刻的内外圈相对位移,通过准静态的滚动体公转与自转关系可以得到轴承内所有接触副的法向变形与切向速度;根据轴承结构参数与表面参数,结合混合弹流润滑理论与赫兹接触理论可以计算得到轴承内每个滚动体所受考虑阻尼的法向力;将这些法向力合成即可得到动态的轴承内外圈作用力;S2: Calculate the force on the inner and outer rings of each bearing in the gearbox: input the relative displacement of the inner and outer rings at the current moment, and obtain the normal deformation and tangential velocity of all contact pairs in the bearing through the quasi-static relationship between the revolution and rotation of the rolling elements; According to the bearing structural parameters and surface parameters, combined with the mixed elastohydrodynamic lubrication theory and the Hertzian contact theory, the normal force of each rolling element in the bearing considering the damping can be calculated; these normal forces can be synthesized to obtain the dynamic inner and outer rings of the bearing force;
S3:构建整个齿轮箱动力学模型的完整方程并求解:在前述步骤的基础上,引入齿轮啮合传动误差、驱动电机、制动器与齿轮箱外壳;通过牛顿第二定律建立完整的齿轮箱动力学微分方程组;使用数值求解方法对微分方程组进行求解,得到系统的动态响应;S3: Construct the complete equation of the entire gearbox dynamics model and solve it: On the basis of the previous steps, introduce the gear meshing transmission error, drive motor, brake and gearbox housing; establish a complete gearbox dynamics differential through Newton's second law Equation system; use numerical solution method to solve the differential equation system to obtain the dynamic response of the system;
S4:仿真信号故障特征分析:从齿轮箱系统的动力学数值解中选取最有研究意义的外壳加速度作为齿轮箱振动仿真信号,通过时域分析、功率谱与包络谱分析等基础手段对仿真信号进行分析,揭示齿轮箱在耦合故障条件下的振动行为。S4: Analysis of simulation signal failure characteristics: Select the most significant casing acceleration from the dynamic numerical solution of the gearbox system as the gearbox vibration simulation signal, and analyze the simulation through basic means such as time domain analysis, power spectrum and envelope spectrum analysis. The signals are analyzed to reveal the vibration behavior of the gearbox under coupled fault conditions.
优选的,所述S1的具体步骤包括:Preferably, the specific steps of the S1 include:
S11:通过几何参数的变化引入齿轮局部故障。本发明通过表面剥落的形式在齿轮中引入局部故障;表面剥落形貌描述为椭圆形,具有一定的深度hs,宽度wmax与长度lmax;这种表面剥落会影响齿轮啮合时的有效接触长度Ls与刚度计算时的截面属性;S11: Introduce local faults of gears through changes in geometric parameters. The present invention introduces local faults in the gear in the form of surface spalling; the surface spalling morphology is described as an ellipse with a certain depth h s , a width w max and a length l max ; such surface spalling will affect the effective contact when the gear meshes Section properties when calculating length L s and stiffness;
其中xs_center表示剥落椭圆的中心坐标位置,xs_start表示剥落椭圆的起始坐标位置,xs_end表示剥落椭圆的结束坐标位置;θs表示剥落椭圆的倾斜角;这部分受故障影响的数值会影响啮合刚度的计算,并通过啮合刚度,影响整个动力学系统,达到引入齿轮故障的目的;Where x s_center represents the center coordinate position of the spalling ellipse, x s_start represents the starting coordinate position of the spalling ellipse, x s_end represents the end coordinate position of the spalling ellipse; θ s represents the inclination angle of the spalling ellipse; the value affected by the fault will affect Calculation of meshing stiffness, and through meshing stiffness, affects the entire dynamic system to achieve the purpose of introducing gear faults;
S12:计算啮合齿轮的时变刚度。将轮齿看作变截面悬臂梁,通过能量法推导得到某一轮齿的赫兹接触刚度kh,、弯曲刚度kb、剪切刚度ks、轴向抗压刚度ka与角基础刚度kf;得到两轮齿在啮合状态下的综合串联刚度:S12: Calculate the time-varying stiffness of meshing gears. Considering the gear teeth as a cantilever beam with variable section, the Hertzian contact stiffness k h , bending stiffness k b , shear stiffness k s , axial compressive stiffness ka and angular foundation stiffness k of a gear tooth are derived by energy method f ; Obtain the comprehensive series stiffness of the two gear teeth in the meshing state:
由于齿轮啮合过程中不止一对轮齿接触,存在两对轮齿同时接触的情况,需要将两对轮齿的串联刚度并联,最终得到关于主动轮转角的啮合刚度函数:Since there are more than one pair of gear teeth in contact during the gear meshing process, and there are two pairs of gear teeth in contact at the same time, it is necessary to connect the series stiffness of the two pairs of gear teeth in parallel, and finally obtain the meshing stiffness function of the driving wheel angle:
S13:计算齿轮啮合的弹流润滑阻尼与摩擦系数;首先根据润滑条件与物理参数,计算啮合副当前的润滑油膜厚度hc:S13: Calculate the elastohydrodynamic lubrication damping and friction coefficient of the gear meshing; first, according to the lubrication conditions and physical parameters, calculate the current lubricating oil film thickness h c of the meshing pair:
其中,KHc是表面微峰形貌参数,设置为1;W是无量纲负载参数;U是无量纲速度参数;G是无量纲材料参数;R是等效接触曲率半径;是无量纲表面粗糙度,V是无量纲硬度参数;Among them, K Hc is the surface micro-peak topography parameter, which is set to 1; W is the dimensionless load parameter; U is the dimensionless velocity parameter; G is the dimensionless material parameter; R is the equivalent contact radius of curvature; is the dimensionless surface roughness, V is the dimensionless hardness parameter;
根据油膜厚度、润滑剂粘度以及接触面积可以近似计算得到齿轮接触副的接触阻尼cfilm:According to the oil film thickness, lubricant viscosity and contact area, the contact damping c film of the gear contact pair can be calculated approximately:
据齿轮啮合中的混合弹流润滑条件下的摩擦理论,动态摩擦系数可由下式计算:According to the friction theory under the condition of mixed elastohydrodynamic lubrication in gear meshing, the dynamic friction coefficient can be calculated by the following formula:
其中的中间参数可由下式得到:The intermediate parameters can be obtained by the following formula:
其中upi和ugi分别是每一对齿轮接触副中主动轮和从动轮的表面速度;S是均方根表面粗糙度;Ph是赫兹接触压力,b1至b9是定值系数:where u pi and u gi are the surface speeds of the driving wheel and the driven wheel in each pair of gear contact pairs, respectively; S is the root-mean-square surface roughness; P h is the Hertzian contact pressure, and b 1 to b 9 are constant value coefficients:
b1-9=-8.92,1.03,1.04,-0.35,2.81,-0.10,0.75,-0.39,0.62b 1-9 = -8.92, 1.03, 1.04, -0.35, 2.81, -0.10, 0.75, -0.39, 0.62
由于齿轮啮合过程可能存在两对齿啮合,因此需要在每一对啮合的轮齿上分别计算摩擦力后再合成;首先根据负载分配系数Sri计算每一对齿上的负载:Since there may be two pairs of teeth meshing in the gear meshing process, it is necessary to calculate the friction force on each pair of meshing gear teeth separately and then synthesize it; first, calculate the load on each pair of teeth according to the load distribution coefficient S ri :
然后即可得到摩擦力与摩擦力矩的计算公式:Then the calculation formula of friction force and friction torque can be obtained:
其中下标p表示作用于主动轮,下标g表示作用于从动轮;The subscript p means acting on the driving wheel, and the subscript g means acting on the driven wheel;
总的来说,步骤1提供了了齿轮啮合部分产生的作用力的计算方式,这部分计算充分描述了齿轮啮合的动态行为,构成了整体模型中齿轮啮合的部分。In general,
优选的,所述S2的具体步骤包括:Preferably, the specific steps of S2 include:
S21:计算轴承滚动体的等效刚度与阻尼;将轴承每个滚动体的内外接触副串联,等效为一个弹簧阻尼系统;因此需要首先求出每个接触副下的刚度与阻尼;轴承的赫兹接触刚度可由公式得到:S21: Calculate the equivalent stiffness and damping of the bearing rolling elements; connect the inner and outer contact pairs of each rolling element of the bearing in series, which is equivalent to a spring damping system; therefore, it is necessary to first obtain the stiffness and damping under each contact pair; The Hertzian contact stiffness can be obtained from the formula:
其中Eb,νb和Σρ分别是杨氏模量、泊松比和滚道曲率和;δ*无量纲变形系数;根据弹流润滑相关研究,滚动体的弹流润滑阻尼由润滑油膜的入口区产生,入口区润滑阻尼可由以下公式计算得到:where E b , ν b and Σρ are Young's modulus, Poisson's ratio and the sum of the raceway curvature, respectively; δ * dimensionless deformation coefficient; zone is generated, and the lubrication damping in the inlet zone can be calculated by the following formula:
其中η0是润滑粘度;Rx是卷吸方向的有效曲率;a是接触椭圆的长半轴长度;点接触润滑油膜厚度hc可由下式计算:where η 0 is the lubricating viscosity; R x is the effective curvature of the entrainment direction; a is the length of the major semi-axis of the contact ellipse; the point contact lubricating oil film thickness h c can be calculated from the following formula:
hc=2.69U0.67G0.53Q-0.067(1-0.61e-0.73κ)Rx (13)h c =2.69U 0.67 G 0.53 Q -0.067 (1-0.61e -0.73κ )R x (13)
由于轴承滚道接触副并非完全弹性润滑,考虑表面状况对于油膜厚度的影响,因此在膜厚计算上引入了修正系数如下:Since the contact pair of the bearing raceway is not completely elastically lubricated, considering the influence of the surface condition on the thickness of the oil film, the correction coefficient is introduced in the calculation of the film thickness as follows:
其中C和r分别是取值为0.87和1.5的定值系数;hcT即为修正后的膜厚;Among them, C and r are fixed value coefficients with values of 0.87 and 1.5 respectively; h cT is the corrected film thickness;
得到每一接触副的刚度与阻尼后,可通过复刚度串联公式得到滚动体等效的串联刚度阻尼:After obtaining the stiffness and damping of each contact pair, the equivalent series stiffness damping of the rolling elements can be obtained through the complex stiffness series formula:
其中in
式中线性刚度k1,2=kbδ0.5,线性阻尼c=ce;ω接触副自由振动的固有频率;where linear stiffness k 1,2 = k b δ 0.5 , linear damping c = c e ; natural frequency of free vibration of ω contact pair;
S22:根据接触几何与局部故障计算轴承内外圈接触力;使用半正弦轮廓的位移激励来描述轴承滚道中的局部故障,位移激励方程如下:S22: Calculate the contact force of the inner and outer rings of the bearing according to the contact geometry and local faults; use the displacement excitation of the half-sine profile to describe the local faults in the bearing raceway. The displacement excitation equation is as follows:
其中Rr是滚动体半径;Ldefect是局部故障长度;φl是故障长度对应的角度范围;是第j个滚动体相对于故障位置的角度,可由下式计算:where R r is the rolling element radius; L defect is the local fault length; φ l is the angle range corresponding to the fault length; is the angle of the jth rolling element relative to the fault position, which can be calculated by the following formula:
其中φd是故障的起始位置角度;轴承内外圈间作用力可由下式计算得到:Where φ d is the starting position angle of the fault; the force between the inner and outer rings of the bearing can be calculated by the following formula:
其中λ(δ)为控制函数,当δ为正值,此函数输出为1,其他情况下输出为0,保证只有内外圈处于接触状态时才产生接触力;滚动体位置角ψj=2π(j-1)/Nb+ψc;并且ψc=0.5(1-D/Dm)θi,其中θi表示内圈转角,这是由轴承的几何关系得到的;δj表示第j个滚动体位置的变形量,可由下式计算得到:Among them, λ(δ) is the control function. When δ is a positive value, the output of this function is 1. In other cases, the output is 0, which ensures that the contact force is generated only when the inner and outer rings are in contact; the rolling element position angle ψ j = 2π( j-1)/N b +ψ c ; and ψ c =0.5(1-D/D m )θ i , where θ i represents the inner ring rotation angle, which is obtained from the bearing geometry; δ j represents the jth The deformation of each rolling element position can be calculated by the following formula:
此式中c0表示径向游隙。In this formula, c 0 represents the radial clearance.
优选的,所述S3具体包括:Preferably, the S3 specifically includes:
建立完备的齿轮箱动力学模型;由于工业齿轮箱包含深沟球轴承与直齿轮,所以齿轮箱的振动主要由径向激励引起;因此齿轮箱所有轴向的自由度被忽略,由于齿轮箱的轴长相对较短,所以转轴的弯曲以及轴的摇摆运动也没有被考虑;每个轴有X与Y两个方向的运动自由度以及转动自由度;齿轮箱壳体与所有轴承外圈固连,有两个方向的平动自由度;轴承内圈与转轴固连,随转轴旋转;齿轮箱共包含四个轴承,两个位于主动轴,两个位于从动轴;至此可以将齿轮箱构建为一个九自由度的动力学模型,系统方程如下:A complete dynamic model of the gearbox is established; since the industrial gearbox contains deep groove ball bearings and spur gears, the vibration of the gearbox is mainly caused by radial excitation; therefore, all axial degrees of freedom of the gearbox are ignored, due to the The shaft length is relatively short, so the bending of the shaft and the rocking motion of the shaft are not considered; each shaft has two degrees of freedom of movement in the X and Y directions and rotational degrees of freedom; the gearbox housing is fixed to all bearing outer rings , there are translation degrees of freedom in two directions; the inner ring of the bearing is fixedly connected with the shaft and rotates with the shaft; the gearbox contains a total of four bearings, two on the driving shaft and two on the driven shaft; so far, the gearbox can be constructed For a nine-degree-of-freedom dynamic model, the system equations are as follows:
其中θL、θp和θg分别是负载、主动轮和从动轮的动态转角;mp、mg和mf依次表示主动轮、从动轮和齿轮箱外壳的质量;IL、Ip和Ig依次表示负载、主动轮和从动轮的转动惯量;TLoad是施加在负载上的力矩,是电机的转速。Fpg是动态啮合力,可由下式计算得到:where θ L , θ p and θ g are the dynamic rotation angles of the load, the driving wheel and the driven wheel, respectively; m p , m g and m f represent the masses of the driving wheel, the driven wheel and the gearbox casing in turn; IL , I p and I g represents the moment of inertia of the load, the driving wheel and the driven wheel in turn; T Load is the torque applied to the load, is the speed of the motor. F pg is the dynamic meshing force, which can be calculated from the following equation:
其中km和cm是在S1中计算得到的时变啮合刚度和阻尼;ζ和ξ分别是齿面剥落引起的几何偏差和齿轮传递误差;where k m and cm are the time-varying mesh stiffness and damping calculated in S1; ζ and ξ are the geometric deviation and gear transmission error caused by tooth surface spalling, respectively;
总的来说,步骤2给出了轴承内外圈之间的作用力;此作用力充分体现了轴承的动态特性,可以准确的描述齿轮箱系统中的轴承的动态作用。In general,
优选的,所述S3具体包括:Preferably, the S3 specifically includes:
仿真信号故障特征分析;根据微分方程得到的数值结果,可以得到齿轮箱系统在一段时间内的振动响应;通过响应的时域分析,可以知道齿轮箱内物理变量在整个过程中的变化特征;同时可以分析得到不通故障模式下齿轮箱振动在时域上的特点;使用傅里叶变换将时域加速度信号转变为频域信号,得到仿真信号的功率谱,通过功率谱可以得到不同模式下齿轮箱的频域响应;分析不同故障模式在齿轮箱频域响应上的体现,总结得到功率谱上不同故障模式的特征;通过希尔伯特变换得到原始仿真信号的包络线,再对包络线作傅里叶变换得到仿真信号的包络谱;通过包络谱可以更加清晰的得到齿轮箱振动的特征频率成分,明确不同故障模式的包络谱频率特征。Analysis of the fault characteristics of the simulated signal; according to the numerical results obtained by the differential equation, the vibration response of the gearbox system in a period of time can be obtained; through the time domain analysis of the response, the change characteristics of the physical variables in the gearbox during the whole process can be known; at the same time The characteristics of the gearbox vibration in the time domain under the failure mode can be analyzed and obtained; the Fourier transform is used to convert the acceleration signal in the time domain into a signal in the frequency domain, and the power spectrum of the simulated signal can be obtained. Through the power spectrum, the gearbox in different modes can be obtained. The frequency domain response of different fault modes is analyzed; the characteristics of different fault modes on the power spectrum are summarized by analyzing the reflection of different failure modes in the frequency domain response of the gearbox; the envelope of the original simulation signal is obtained by Hilbert transform, and then the envelope The envelope spectrum of the simulated signal can be obtained by Fourier transform; the characteristic frequency components of the gearbox vibration can be obtained more clearly through the envelope spectrum, and the frequency characteristics of the envelope spectrum of different failure modes can be defined.
一种计算机设备,包括存储器、处理器及存储在存储器上并可在处理器上运行的计算机程序,所述处理器执行所述程序时实现任一项所述方法的步骤。A computer device includes a memory, a processor, and a computer program stored on the memory and executable on the processor, the processor implementing the steps of any one of the methods when the processor executes the program.
一种计算机可读存储介质,其上存储有计算机程序,该程序被处理器执行时实现任一项所述方法的步骤。A computer-readable storage medium having a computer program stored thereon, the program implementing the steps of any one of the methods when executed by a processor.
一种处理器,所述处理器用于运行程序,其中,所述程序运行时执行任一项所述的方法。A processor for running a program, wherein the program executes any one of the methods when the program is running.
与现有技术相比,本发明的有益效果是:Compared with the prior art, the beneficial effects of the present invention are:
1、该发明首先建立了充分考虑齿轮啮合、轴承作用、齿轮箱外壳的齿轮箱动力学模型;对于齿轮箱内部轴承局部故障、齿轮啮合几何特征、齿轮局部故障有准确的数学描述,可以准确得到受啮合力、啮合摩擦、轴承内外圈动态作用力、弹流润滑、故障激励等多重因素影响下的齿轮箱的振动响应;1. The invention firstly establishes a gearbox dynamics model that fully considers gear meshing, bearing action, and gearbox housing; there is an accurate mathematical description for local bearing failures, gear meshing geometric features, and gear local failures in the gearbox, which can be accurately obtained. The vibration response of the gearbox under the influence of multiple factors such as meshing force, meshing friction, dynamic force of the inner and outer rings of the bearing, elastohydrodynamic lubrication, and fault excitation;
2、该发明相比传统动力学模型建模方法,充分考虑了轴承与齿轮局部故障的数学描述方法;通过分析不同局部故障模式下的齿轮箱振动,结合传统的傅里叶变换和包络谱分析方法,可以得到受到内部多源激励下的齿轮箱外壳振动的频域特征;相比传统模型,本发明提供的方法可以为轴承、齿轮等不同位置缺陷激励下的响应提供横向比对的方法,为齿轮箱故障诊断提供更加深刻的机理分析。2. Compared with the traditional dynamic model modeling method, the invention fully considers the mathematical description method of local faults of bearings and gears; by analyzing the vibration of the gearbox under different local fault modes, combined with the traditional Fourier transform and envelope spectrum The analysis method can obtain the frequency domain characteristics of the vibration of the gearbox casing under the internal multi-source excitation; compared with the traditional model, the method provided by the present invention can provide a lateral comparison method for the responses of bearings, gears and other positions under the excitation of defects , to provide a more profound mechanism analysis for gearbox fault diagnosis.
附图说明Description of drawings
附图用来提供对本发明的进一步理解,并且构成说明书的一部分,与本发明的实施例一起用于解释本发明,并不构成对本发明的限制。在附图中:The accompanying drawings are used to provide a further understanding of the present invention, and constitute a part of the specification, and are used to explain the present invention together with the embodiments of the present invention, and do not constitute a limitation to the present invention. In the attached image:
图1为本发明齿轮箱动力学模型的内部部分;Fig. 1 is the internal part of the gearbox dynamics model of the present invention;
图2为本发明齿轮箱动力学模型的外部部分;Fig. 2 is the external part of the gearbox dynamics model of the present invention;
图3为本发明内部多源耦合故障激励的齿轮箱动力学建模方法流程图;Fig. 3 is the flow chart of the gearbox dynamics modeling method of the internal multi-source coupling fault excitation of the present invention;
图4为本发明从动轮局部故障与轴承外圈故障下齿轮箱外壳的振动响应;Fig. 4 is the vibration response of the gearbox casing under the partial failure of the driven wheel and the failure of the bearing outer ring according to the present invention;
图5为本发明从动轮局部故障与轴承内圈故障下齿轮箱外壳的振动响应;Fig. 5 is the vibration response of the gearbox casing under the partial failure of the driven wheel and the failure of the bearing inner ring according to the present invention;
图6为本发明高速轴轴承内圈故障与从动轮故障实验验证;Fig. 6 is the experimental verification of the fault of the inner ring of the high-speed shaft bearing of the present invention and the fault of the driven wheel;
图7为本发明高速轴轴承外圈故障与从动轮故障实验验证;Fig. 7 is the experimental verification of the fault of the outer ring of the high-speed shaft bearing of the present invention and the fault of the driven wheel;
图8为本发明的齿轮参数表;Fig. 8 is the gear parameter table of the present invention;
图9为本发明的轴承参数表;Fig. 9 is the bearing parameter table of the present invention;
图10为本发明的齿轮箱结构参数表;Fig. 10 is the gear box structure parameter table of the present invention;
图11为本发明的齿轮箱动力学模型振动特征频率表。FIG. 11 is a vibration characteristic frequency table of the gearbox dynamics model of the present invention.
具体实施方式Detailed ways
为使本发明实施方式的目的、技术方案和优点更加清楚,下面将结合本发明实施方式中的附图,对本发明实施方式中的技术方案进行清楚、完整地描述,显然,所描述的实施方式是本发明一部分实施方式,而不是全部的实施方式。基于本发明中的实施方式,本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施方式,都属于本发明保护的范围。因此,以下对在附图中提供的本发明的实施方式的详细描述并非旨在限制要求保护的本发明的范围,而是仅仅表示本发明的选定实施方式。基于本发明中的实施方式,本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施方式,都属于本发明保护的范围。In order to make the purposes, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments These are some embodiments of the present invention, but not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention. Thus, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the invention as claimed, but is merely representative of selected embodiments of the invention. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.
请参阅图1-11,本发明实施例中,一种受内部多源故障激励的齿轮箱耦合动力学建模方法,包括以下步骤:Referring to FIGS. 1-11 , in an embodiment of the present invention, a method for modeling coupled dynamics of a gearbox excited by an internal multi-source fault includes the following steps:
S1:齿轮啮合时变刚度、阻尼及动态摩擦力的计算:根据齿轮形貌以及局部剥落故障参数,计算得到齿轮啮合刚度随主动轮转角的函数关系;结合混合弹流润滑理论,通过输入动态的齿轮啮合力、表面粗糙度、卷吸速度参数在每个时刻计算得到当前齿轮啮合副的动态摩擦力以及啮合阻尼;S1: Calculation of time-varying stiffness, damping and dynamic friction force of gear meshing: According to the gear topography and local spalling failure parameters, the function relationship between gear meshing stiffness and driving wheel rotation angle is calculated; The parameters of gear meshing force, surface roughness and entrainment speed are calculated at each moment to obtain the dynamic friction force and meshing damping of the current gear meshing pair;
S2:计算齿轮箱中每个轴承的内外圈作用力:输入当前时刻的内外圈相对位移,通过准静态的滚动体公转与自转关系可以得到轴承内所有接触副的法向变形与切向速度;根据轴承结构参数与表面参数,结合混合弹流润滑理论与赫兹接触理论可以计算得到轴承内每个滚动体所受考虑阻尼的法向力;将这些法向力合成即可得到动态的轴承内外圈作用力;S2: Calculate the force on the inner and outer rings of each bearing in the gearbox: input the relative displacement of the inner and outer rings at the current moment, and obtain the normal deformation and tangential velocity of all contact pairs in the bearing through the quasi-static relationship between the revolution and rotation of the rolling elements; According to the bearing structural parameters and surface parameters, combined with the mixed elastohydrodynamic lubrication theory and the Hertzian contact theory, the normal force of each rolling element in the bearing considering the damping can be calculated; these normal forces can be synthesized to obtain the dynamic inner and outer rings of the bearing force;
S3:构建整个齿轮箱动力学模型的完整方程并求解:在前述步骤的基础上,引入齿轮啮合传动误差、驱动电机、制动器与齿轮箱外壳;通过牛顿第二定律建立完整的齿轮箱动力学微分方程组;使用数值求解方法对微分方程组进行求解,得到系统的动态响应;S3: Construct the complete equation of the entire gearbox dynamics model and solve it: On the basis of the previous steps, introduce the gear meshing transmission error, drive motor, brake and gearbox housing; establish a complete gearbox dynamics differential through Newton's second law Equation system; use numerical solution method to solve the differential equation system to obtain the dynamic response of the system;
S4:仿真信号故障特征分析:从齿轮箱系统的动力学数值解中选取最有研究意义的外壳加速度作为齿轮箱振动仿真信号,通过时域分析、功率谱与包络谱分析等基础手段对仿真信号进行分析,揭示齿轮箱在耦合故障条件下的振动行为。S4: Analysis of simulation signal failure characteristics: Select the most significant casing acceleration from the dynamic numerical solution of the gearbox system as the gearbox vibration simulation signal, and analyze the simulation through basic means such as time domain analysis, power spectrum and envelope spectrum analysis. The signals are analyzed to reveal the vibration behavior of the gearbox under coupled fault conditions.
优选的,所述S1的具体步骤包括:Preferably, the specific steps of the S1 include:
S11:通过几何参数的变化引入齿轮局部故障。本发明通过表面剥落的形式在齿轮中引入局部故障;表面剥落形貌描述为椭圆形,具有一定的深度hs,宽度wmax与长度lmax;这种表面剥落会影响齿轮啮合时的有效接触长度Ls与刚度计算时的截面属性;S11: Introduce local faults of gears through changes in geometric parameters. The present invention introduces local faults in the gear in the form of surface spalling; the surface spalling morphology is described as an ellipse with a certain depth h s , a width w max and a length l max ; such surface spalling will affect the effective contact when the gear meshes Section properties when calculating length L s and stiffness;
其中xs_center表示剥落椭圆的中心坐标位置,xs_start表示剥落椭圆的起始坐标位置,xs_end表示剥落椭圆的结束坐标位置;θs表示剥落椭圆的倾斜角;这部分受故障影响的数值会影响啮合刚度的计算,并通过啮合刚度,影响整个动力学系统,达到引入齿轮故障的目的;Where x s_center represents the center coordinate position of the spalling ellipse, x s_start represents the starting coordinate position of the spalling ellipse, x s_end represents the end coordinate position of the spalling ellipse; θ s represents the inclination angle of the spalling ellipse; the value affected by the fault will affect Calculation of meshing stiffness, and through meshing stiffness, affects the entire dynamic system to achieve the purpose of introducing gear faults;
S12:计算啮合齿轮的时变刚度。将轮齿看作变截面悬臂梁,通过能量法推导得到某一轮齿的赫兹接触刚度kh,、弯曲刚度kb、剪切刚度ks、轴向抗压刚度ka与角基础刚度kf;得到两轮齿在啮合状态下的综合串联刚度:S12: Calculate the time-varying stiffness of meshing gears. Considering the gear teeth as a cantilever beam with variable section, the Hertzian contact stiffness k h , bending stiffness k b , shear stiffness k s , axial compressive stiffness ka and angular foundation stiffness k of a gear tooth are derived by energy method f ; Obtain the comprehensive series stiffness of the two gear teeth in the meshing state:
由于齿轮啮合过程中不止一对轮齿接触,存在两对轮齿同时接触的情况,需要将两对轮齿的串联刚度并联,最终得到关于主动轮转角的啮合刚度函数:Since there are more than one pair of gear teeth in contact during the gear meshing process, and there are two pairs of gear teeth in contact at the same time, it is necessary to connect the series stiffness of the two pairs of gear teeth in parallel, and finally obtain the meshing stiffness function of the driving wheel angle:
S13:计算齿轮啮合的弹流润滑阻尼与摩擦系数;首先根据润滑条件与物理参数,计算啮合副当前的润滑油膜厚度hc:S13: Calculate the elastohydrodynamic lubrication damping and friction coefficient of the gear meshing; first, according to the lubrication conditions and physical parameters, calculate the current lubricating oil film thickness h c of the meshing pair:
其中,KHc是表面微峰形貌参数,设置为1;W是无量纲负载参数;U是无量纲速度参数;G是无量纲材料参数;R是等效接触曲率半径;是无量纲表面粗糙度,V是无量纲硬度参数;Among them, K Hc is the surface micro-peak topography parameter, which is set to 1; W is the dimensionless load parameter; U is the dimensionless velocity parameter; G is the dimensionless material parameter; R is the equivalent contact radius of curvature; is the dimensionless surface roughness, V is the dimensionless hardness parameter;
根据油膜厚度、润滑剂粘度以及接触面积可以近似计算得到齿轮接触副的接触阻尼cfilm:According to the oil film thickness, lubricant viscosity and contact area, the contact damping c film of the gear contact pair can be calculated approximately:
据齿轮啮合中的混合弹流润滑条件下的摩擦理论,动态摩擦系数可由下式计算:According to the friction theory under the condition of mixed elastohydrodynamic lubrication in gear meshing, the dynamic friction coefficient can be calculated by the following formula:
其中的中间参数可由下式得到:The intermediate parameters can be obtained by the following formula:
其中upi和ugi分别是每一对齿轮接触副中主动轮和从动轮的表面速度;S是均方根表面粗糙度;Ph是赫兹接触压力,b1至b9是定值系数:where u pi and u gi are the surface speeds of the driving wheel and the driven wheel in each pair of gear contact pairs, respectively; S is the root-mean-square surface roughness; P h is the Hertzian contact pressure, and b 1 to b 9 are constant value coefficients:
b1-9=-8.92,1.03,1.04,-0.35,2.81,-0.10,0.75,-0.39,0.62b 1-9 = -8.92, 1.03, 1.04, -0.35, 2.81, -0.10, 0.75, -0.39, 0.62
由于齿轮啮合过程可能存在两对齿啮合,因此需要在每一对啮合的轮齿上分别计算摩擦力后再合成;首先根据负载分配系数Sri计算每一对齿上的负载:Since there may be two pairs of teeth meshing in the gear meshing process, it is necessary to calculate the friction force on each pair of meshing gear teeth separately and then synthesize it; first, calculate the load on each pair of teeth according to the load distribution coefficient S ri :
然后即可得到摩擦力与摩擦力矩的计算公式:Then the calculation formula of friction force and friction torque can be obtained:
其中下标p表示作用于主动轮,下标g表示作用于从动轮。The subscript p means acting on the driving wheel, and the subscript g means acting on the driven wheel.
总的来说,S1提供了了齿轮啮合部分产生的作用力的计算方式,这部分计算充分描述了齿轮啮合的动态行为,构成了整体模型中齿轮啮合的部分。In general, S1 provides the calculation method of the force generated by the gear meshing part. This part of the calculation fully describes the dynamic behavior of the gear meshing and constitutes the gear meshing part of the overall model.
优选的,所述S2的具体步骤包括:Preferably, the specific steps of S2 include:
S21:计算轴承滚动体的等效刚度与阻尼;将轴承每个滚动体的内外接触副串联,等效为一个弹簧阻尼系统;因此需要首先求出每个接触副下的刚度与阻尼;轴承的赫兹接触刚度可由公式得到:S21: Calculate the equivalent stiffness and damping of the bearing rolling elements; connect the inner and outer contact pairs of each rolling element of the bearing in series, which is equivalent to a spring damping system; therefore, it is necessary to first obtain the stiffness and damping under each contact pair; The Hertzian contact stiffness can be obtained from the formula:
其中Eb,νb和Σρ分别是杨氏模量、泊松比和滚道曲率和;δ*无量纲变形系数;根据弹流润滑相关研究,滚动体的弹流润滑阻尼由润滑油膜的入口区产生,入口区润滑阻尼可由以下公式计算得到:where E b , ν b and Σρ are Young's modulus, Poisson's ratio and the sum of the raceway curvature, respectively; δ * dimensionless deformation coefficient; zone is generated, and the lubrication damping in the inlet zone can be calculated by the following formula:
其中η0是润滑粘度;Rx是卷吸方向的有效曲率;a是接触椭圆的长半轴长度;点接触润滑油膜厚度hc可由下式计算:where η 0 is the lubricating viscosity; R x is the effective curvature of the entrainment direction; a is the length of the major semi-axis of the contact ellipse; the point contact lubricating oil film thickness h c can be calculated from the following formula:
hc=2.69U0.67G0.53Q-0.067(1-0.61e-0.73κ)Rx (13)h c =2.69U 0.67 G 0.53 Q -0.067 (1-0.61e -0.73κ )R x (13)
由于轴承滚道接触副并非完全弹性润滑,考虑表面状况对于油膜厚度的影响,因此在膜厚计算上引入了修正系数如下:Since the contact pair of the bearing raceway is not completely elastically lubricated, considering the influence of the surface condition on the thickness of the oil film, the correction coefficient is introduced in the calculation of the film thickness as follows:
其中C和r分别是取值为0.87和1.5的定值系数;hcT即为修正后的膜厚;Among them, C and r are fixed value coefficients with values of 0.87 and 1.5 respectively; h cT is the corrected film thickness;
得到每一接触副的刚度与阻尼后,可通过复刚度串联公式得到滚动体等效的串联刚度阻尼:After obtaining the stiffness and damping of each contact pair, the equivalent series stiffness damping of the rolling elements can be obtained through the complex stiffness series formula:
其中in
式中线性刚度k1,2=kbδ0.5,线性阻尼c=ce;ω接触副自由振动的固有频率;where linear stiffness k 1,2 = k b δ 0.5 , linear damping c = c e ; natural frequency of free vibration of ω contact pair;
S22:根据接触几何与局部故障计算轴承内外圈接触力;使用半正弦轮廓的位移激励来描述轴承滚道中的局部故障,位移激励方程如下:S22: Calculate the contact force of the inner and outer rings of the bearing according to the contact geometry and local faults; use the displacement excitation of the half-sine profile to describe the local faults in the bearing raceway. The displacement excitation equation is as follows:
其中Rr是滚动体半径;Ldefect是局部故障长度;φl是故障长度对应的角度范围;是第j个滚动体相对于故障位置的角度,可由下式计算:where R r is the rolling element radius; L defect is the local fault length; φ l is the angle range corresponding to the fault length; is the angle of the jth rolling element relative to the fault position, which can be calculated by the following formula:
其中φd是故障的起始位置角度;轴承内外圈间作用力可由下式计算得到:Where φ d is the starting position angle of the fault; the force between the inner and outer rings of the bearing can be calculated by the following formula:
其中λ(δ)为控制函数,当δ为正值,此函数输出为1,其他情况下输出为0,保证只有内外圈处于接触状态时才产生接触力;滚动体位置角ψj=2π(j-1)/Nb+ψc;并且ψc=0.5(1-D/Dm)θi,其中θi表示内圈转角,这是由轴承的几何关系得到的;δj表示第j个滚动体位置的变形量,可由下式计算得到:Among them, λ(δ) is the control function. When δ is a positive value, the output of this function is 1. In other cases, the output is 0, which ensures that the contact force is generated only when the inner and outer rings are in contact; the rolling element position angle ψ j = 2π( j-1)/N b +ψ c ; and ψ c =0.5(1-D/D m )θ i , where θ i represents the inner ring rotation angle, which is obtained from the bearing geometry; δ j represents the jth The deformation of each rolling element position can be calculated by the following formula:
此式中c0表示径向游隙。In this formula, c 0 represents the radial clearance.
总的来说,S2给出了轴承内外圈之间的作用力。此作用力充分体现了轴承的动态特性,可以准确的描述齿轮箱系统中的轴承的动态作用。In general, S2 gives the force between the inner and outer rings of the bearing. This force fully reflects the dynamic characteristics of the bearing, which can accurately describe the dynamic action of the bearing in the gearbox system.
优选的,所述S3具体包括:Preferably, the S3 specifically includes:
建立完备的齿轮箱动力学模型;由于工业齿轮箱包含深沟球轴承与直齿轮,所以齿轮箱的振动主要由径向激励引起;因此齿轮箱所有轴向的自由度被忽略,由于齿轮箱的轴长相对较短,所以转轴的弯曲以及轴的摇摆运动也没有被考虑;每个轴有X与Y两个方向的运动自由度以及转动自由度;齿轮箱壳体与所有轴承外圈固连,有两个方向的平动自由度;轴承内圈与转轴固连,随转轴旋转;齿轮箱共包含四个轴承,两个位于主动轴,两个位于从动轴;至此可以将齿轮箱构建为一个九自由度的动力学模型,系统方程如下:A complete dynamic model of the gearbox is established; since the industrial gearbox contains deep groove ball bearings and spur gears, the vibration of the gearbox is mainly caused by radial excitation; therefore, all axial degrees of freedom of the gearbox are ignored, due to the The shaft length is relatively short, so the bending of the shaft and the rocking motion of the shaft are not considered; each shaft has two degrees of freedom of movement in the X and Y directions and rotational degrees of freedom; the gearbox housing is fixed to all bearing outer rings , there are translation degrees of freedom in two directions; the inner ring of the bearing is fixedly connected with the shaft and rotates with the shaft; the gearbox contains a total of four bearings, two on the driving shaft and two on the driven shaft; so far, the gearbox can be constructed For a nine-degree-of-freedom dynamic model, the system equations are as follows:
其中θL、θp和θg分别是负载、主动轮和从动轮的动态转角;mp、mg和mf依次表示主动轮、从动轮和齿轮箱外壳的质量;IL、Ip和Ig依次表示负载、主动轮和从动轮的转动惯量;TLoad是施加在负载上的力矩,是电机的转速。Fpg是动态啮合力,可由下式计算得到:where θ L , θ p and θ g are the dynamic rotation angles of the load, the driving wheel and the driven wheel, respectively; m p , m g and m f represent the masses of the driving wheel, the driven wheel and the gearbox casing in turn; IL , I p and I g represents the moment of inertia of the load, the driving wheel and the driven wheel in turn; T Load is the torque applied to the load, is the speed of the motor. F pg is the dynamic meshing force, which can be calculated from the following equation:
其中km和cm是在S1中计算得到的时变啮合刚度和阻尼;ζ和ξ分别是齿面剥落引起的几何偏差和齿轮传递误差。where k m and cm are the time-varying mesh stiffness and damping calculated in S1; ζ and ξ are the geometric deviation and gear transmission error caused by tooth flank spalling, respectively.
本发明使用龙格库塔算法对动力学微分方程组求解,时间步长设置为10μs,方程初值设置如下:xp=-3.5×10-6m,yp=-8.4×10-6m,xg=3.5×10-6m和yg=8.4×10-6m;转速设置为1000RPM,负载力矩设置为16Nm。The present invention uses the Runge-Kutta algorithm to solve the dynamic differential equation system, the time step is set to 10μs, and the initial value of the equation is set as follows: x p = -3.5×10 -6 m, y p = -8.4×10 -6 m , x g =3.5×10 −6 m and y g =8.4×10 −6 m; the rotational speed is set to 1000RPM, and the load torque is set to 16Nm.
优选的,所述S3具体包括:Preferably, the S3 specifically includes:
仿真信号故障特征分析;根据微分方程得到的数值结果,可以得到齿轮箱系统在一段时间内的振动响应;通过响应的时域分析,可以知道齿轮箱内物理变量在整个过程中的变化特征;同时可以分析得到不通故障模式下齿轮箱振动在时域上的特点;使用傅里叶变换将时域加速度信号转变为频域信号,得到仿真信号的功率谱,通过功率谱可以得到不同模式下齿轮箱的频域响应;分析不同故障模式在齿轮箱频域响应上的体现,总结得到功率谱上不同故障模式的特征;通过希尔伯特变换得到原始仿真信号的包络线,再对包络线作傅里叶变换得到仿真信号的包络谱;通过包络谱可以更加清晰的得到齿轮箱振动的特征频率成分,明确不同故障模式的包络谱频率特征。Analysis of the fault characteristics of the simulated signal; according to the numerical results obtained by the differential equation, the vibration response of the gearbox system in a period of time can be obtained; through the time domain analysis of the response, the change characteristics of the physical variables in the gearbox during the whole process can be known; at the same time The characteristics of the gearbox vibration in the time domain under the failure mode can be analyzed and obtained; the Fourier transform is used to convert the acceleration signal in the time domain into a signal in the frequency domain, and the power spectrum of the simulated signal can be obtained. Through the power spectrum, the gearbox in different modes can be obtained. The frequency domain response of different fault modes is analyzed; the characteristics of different fault modes on the power spectrum are summarized by analyzing the reflection of different failure modes in the frequency domain response of the gearbox; the envelope of the original simulation signal is obtained by Hilbert transform, and then the envelope The envelope spectrum of the simulated signal can be obtained by Fourier transform; the characteristic frequency components of the gearbox vibration can be obtained more clearly through the envelope spectrum, and the frequency characteristics of the envelope spectrum of different failure modes can be defined.
经过数值求解与分析,轴承外圈故障与齿轮从动轮故障的耦合振动响应如图4所示。其中轴承故障包含了两种情况,分别为高速轴轴承故障和低速轴轴承故障。每种故障情况都是用时域信号、功率谱、包络谱三种手段进行分析。从时域信号中可以看到轴承外圈故障与从动轮故障会在齿轮箱外壳上产生明显的冲击。可以通过时域信号中的冲击性判断齿轮箱内部的故障情况,但是仅从时域中无法得知具体故障模式。功率谱中占主要的频率成分是啮合频率及其谐频,其中最大的频率为4gmf,这是受齿轮箱外壳固有频率调制引起的,固有频率由齿轮箱参数决定。轴承外圈故障在功率谱中激起了明显的以外圈特征频率为间隔的边频带,高速轴与低速轴轴承由于转速不同,边频带间隔也不同。这些边频带主要分布在4gmf附近,这说明轴承特征频率与啮合频率一样,受到了齿轮箱外壳固有频率的幅值调制。同样的,从动轮故障激起的以从动轮转速为间隔的边频带在功率谱中拥有同样的分布特征,说明这些频率也受到固有频率调制。由于齿轮故障激起的边频带间隔较密、幅值较低,又和轴承故障边频带拥有同样的分布,所以容易被轴承边频带覆盖而不易发现。这些易被覆盖的频带在图中被用红色虚线标识。在包络谱中,特征频率主要以基频和低阶谐频的形式出现。轴承外圈特征频率此时超过啮合频率成为主要频率成分,但啮合频率在包络谱中依然可见。齿轮故障导致的转频分量由于频率较低、幅值较小,主要集中在包络谱的低频区,被用红色虚线标识出来。包络谱和功率谱中的轴承故障特征频率、齿轮故障特征频率呈现叠加的状态,没有发现明显的互相调制现象。After numerical solution and analysis, the coupled vibration response of the bearing outer ring fault and the gear driven wheel fault is shown in Figure 4. The bearing faults include two cases, namely high-speed shaft bearing faults and low-speed shaft bearing faults. Each fault condition is analyzed by three means: time domain signal, power spectrum, and envelope spectrum. From the time domain signal, it can be seen that the bearing outer ring failure and the driven wheel failure will produce obvious shocks on the gearbox casing. The fault condition inside the gearbox can be judged by the shock in the time domain signal, but the specific fault mode cannot be known only from the time domain. The main frequency components in the power spectrum are the meshing frequency and its harmonic frequency, of which the maximum frequency is 4gmf, which is caused by the modulation of the natural frequency of the gearbox casing, and the natural frequency is determined by the gearbox parameters. The fault of the outer ring of the bearing arouses obvious sidebands separated by the characteristic frequency of the outer ring in the power spectrum. The high-speed shaft and low-speed shaft bearings have different sideband intervals due to different rotational speeds. These sidebands are mainly distributed around 4gmf, which indicates that the bearing characteristic frequency, like the meshing frequency, is modulated by the amplitude of the natural frequency of the gearbox housing. Similarly, the sidebands separated by the rotational speed of the driven wheel caused by the fault of the driven wheel have the same distribution characteristics in the power spectrum, indicating that these frequencies are also modulated by the natural frequency. Since the sidebands caused by gear faults are densely spaced and have low amplitudes, and have the same distribution as the bearing fault sidebands, they are easily covered by the bearing sidebands and are not easy to find. These easily covered frequency bands are marked with red dashed lines in the figure. In the envelope spectrum, the eigenfrequencies appear mainly in the form of fundamental and lower harmonics. At this time, the characteristic frequency of the outer ring of the bearing exceeds the meshing frequency and becomes the main frequency component, but the meshing frequency is still visible in the envelope spectrum. The rotational frequency component caused by the gear fault is mainly concentrated in the low frequency region of the envelope spectrum due to its low frequency and small amplitude, and is marked by a red dotted line. The characteristic frequencies of bearing faults and gear faults in the envelope spectrum and power spectrum are superimposed, and no obvious mutual modulation is found.
轴承内圈故障与从动轮故障的情况见图5。与外圈故障一致,内圈故障也从高速轴轴承与低速轴轴承两种情况考虑。内圈故障下,故障位置随内圈旋转,故障位置受力会在最大值与零之间波动,所以轴承时域冲击会小于外圈的情况,但轴承故障引起的冲击依然可以被找到。齿轮故障引起的冲击与外圈时一致。内圈故障与从动轮故障的频域响应同样被展示在图5中。齿轮故障引起的边频带用红色虚线标识,这些边频带与轴承外圈故障的情况下相同,这表明轴承故障的模式不会影响齿轮故障对于齿轮箱外壳振动的频域响应。轴内圈故障引起的特征频率更加复杂,除了以内圈特征频率为间隔的边频带外,在功率谱与包络谱中的特征频率还受到轴承转频的调制现象。这与从单一轴承的动力学模型中得到的结论是一致的,这也证明了该发明建立的模型的正确性。与外圈故障时一致,轴承内圈故障的特征频率同样没有与齿轮故障特征频率发生调制现象,互相呈叠加状态。The situation of bearing inner ring failure and driven wheel failure is shown in Figure 5. Consistent with the fault of the outer ring, the fault of the inner ring is also considered from the two situations of the high-speed shaft bearing and the low-speed shaft bearing. Under the inner ring fault, the fault position rotates with the inner ring, and the force at the fault position will fluctuate between the maximum value and zero, so the time-domain impact of the bearing will be smaller than that of the outer ring, but the impact caused by the bearing fault can still be found. The shock caused by the gear failure is the same as that of the outer ring. The frequency domain responses for inner ring fault and driven wheel fault are also shown in Figure 5. The sidebands caused by the gear fault are marked with red dashed lines, and these sidebands are the same as in the case of the bearing outer ring fault, indicating that the mode of the bearing fault does not affect the frequency domain response of the gear fault to the vibration of the gearbox housing. The eigenfrequencies caused by the faults of the inner ring of the shaft are more complicated. In addition to the sidebands spaced by the eigenfrequencies of the inner ring, the eigenfrequencies in the power spectrum and the envelope spectrum are also modulated by the rotational frequency of the bearing. This is consistent with the conclusion obtained from the dynamic model of a single bearing, which also proves the correctness of the model established by this invention. Consistent with the fault of the outer ring, the characteristic frequency of the fault of the inner ring of the bearing is also not modulated with the characteristic frequency of the gear fault, and they are superimposed on each other.
为进一步验证该发明的正确性,使用单级直齿齿轮传动齿轮箱通过交流电机驱动。负载通过安装在输出轴末端的磁粉制动器施加。振动信号通过安装在齿轮箱箱体上的传感器获取。齿轮局部故障被设置在从动轮上,轴承局部故障被设置在高速轴轴承中。为了消除实验信号的噪声干扰,实验信号均进行了去噪处理。选取了[9216Hz,10240Hz]的频带对仿真信号与实验信号进行滤波。图6展示了内圈轴承故障和从动轮故障的实验与仿真结果对比。图7展示了外圈轴承故障和从动轮故障下的实验与仿真结果对比。图中绿色点标识了齿轮故障特征频率,即从动轮转频,红色点标识了轴承故障特征频率与啮合频率。从实验对比图中可以得知,尽管频率幅值存在部分误差,但是频率特征基本一致,这可以说明该实验可以证明该发明所提供的内部多源耦合故障激励的工业齿轮箱动力学建模方法的准确性。To further verify the correctness of the invention, a single-stage spur gear transmission gearbox is used to drive it through an AC motor. The load is applied by a magnetic powder brake mounted at the end of the output shaft. The vibration signal is acquired by sensors mounted on the gearbox casing. The partial failure of the gear is set on the driven wheel, and the partial fault of the bearing is set in the high-speed shaft bearing. In order to eliminate the noise interference of the experimental signals, the experimental signals were all denoised. The frequency band of [9216Hz, 10240Hz] is selected to filter the simulated and experimental signals. Figure 6 shows the comparison of experimental and simulation results for inner ring bearing failure and driven wheel failure. Figure 7 shows the comparison between the experimental and simulation results under the outer ring bearing fault and the driven wheel fault. The green point in the figure identifies the gear fault characteristic frequency, that is, the rotational frequency of the driven wheel, and the red point marks the bearing fault characteristic frequency and meshing frequency. It can be seen from the experimental comparison diagram that although there are some errors in the frequency amplitude, the frequency characteristics are basically the same, which shows that the experiment can prove the industrial gearbox dynamics modeling method provided by the invention for the internal multi-source coupling fault excitation. accuracy.
为了解决传统动力学模型不完备,无法为受内部多源故障机理的齿轮箱振动提供理论基础的问题,本发明从传统齿轮啮合模型出发,充分考虑了轴承动态作用力、齿轮箱外壳、弹流润滑和局部故障描述等方面,构建了全新的受内部多源耦合故障激励的工业齿轮箱动力学建模方法。并且从该动力学模型出发,研究了齿轮箱外壳在内部多源耦合故障机理下的振动响应。利用经典的傅里叶变换和包络谱分析方法分析了了不同故障模式下的齿轮箱振动特征,揭示了轴承与齿轮局部故障在齿轮箱外壳上的叠加作用机理,为故障特征提取等信号处理方法提供了理论依据。最后,通过将齿轮箱试验台测得的实验信号与该发明中得到的仿真信号相比对,证明了该发明的内部多源耦合故障激励的工业齿轮箱动力学建模方法具有一定的有效性。In order to solve the problem that the traditional dynamic model is incomplete and cannot provide a theoretical basis for the vibration of the gearbox subject to the internal multi-source fault mechanism, the present invention starts from the traditional gear meshing model, and fully considers the dynamic force of the bearing, the casing of the gearbox, the elasto-hydrodynamic force In terms of lubrication and local fault description, a new dynamic modeling method for industrial gearboxes excited by internal multi-source coupled faults is constructed. And based on the dynamic model, the vibration response of the gearbox casing under the internal multi-source coupling fault mechanism is studied. Using the classical Fourier transform and envelope spectrum analysis methods, the vibration characteristics of the gearbox under different failure modes are analyzed, and the superposition mechanism of the partial faults of bearings and gears on the gearbox casing is revealed, which is used for signal processing such as fault feature extraction. The method provides a theoretical basis. Finally, by comparing the experimental signal measured by the gearbox test bench with the simulation signal obtained in the invention, it is proved that the industrial gearbox dynamics modeling method of the internal multi-source coupling fault excitation of the invention has certain validity .
下面结合仿真信号分析与实验验证对该发明进行详细说明。The invention will be described in detail below in combination with simulation signal analysis and experimental verification.
齿轮箱动力学模型的示意图如下图1与图2所示,内部外部模型通过轴承作用力互相影响,构成完整齿轮箱。本发明使用的齿轮箱参数图8-10所示:The schematic diagram of the gearbox dynamic model is shown in Figure 1 and Figure 2 below. The internal and external models interact with each other through the bearing force to form a complete gearbox. The parameters of the gearbox used in the present invention are shown in Figures 8-10:
所述S4包括:The S4 includes:
仿真信号故障特征分析;根据微分方程得到的数值结果,可以得到齿轮箱系统在一段时间内的振动响应;通过响应的时域分析,可以知道齿轮箱内物理变量在整个过程中的变化特征;同时可以分析得到不通故障模式下齿轮箱振动在时域上的特点;使用傅里叶变换将时域加速度信号转变为频域信号,得到仿真信号的功率谱,通过功率谱可以得到不同模式下齿轮箱的频域响应;分析不同故障模式在齿轮箱频域响应上的体现,总结得到功率谱上不同故障模式的特征;通过希尔伯特变换得到原始仿真信号的包络线,再对包络线作傅里叶变换得到仿真信号的包络谱;通过包络谱可以更加清晰的得到齿轮箱振动的特征频率成分,明确不同故障模式的包络谱频率特征;Analysis of the fault characteristics of the simulated signal; according to the numerical results obtained by the differential equation, the vibration response of the gearbox system in a period of time can be obtained; through the time domain analysis of the response, the change characteristics of the physical variables in the gearbox during the whole process can be known; at the same time The characteristics of the gearbox vibration in the time domain under the failure mode can be analyzed and obtained; the Fourier transform is used to convert the acceleration signal in the time domain into a signal in the frequency domain, and the power spectrum of the simulated signal can be obtained. Through the power spectrum, the gearbox in different modes can be obtained. The frequency domain response of different fault modes is analyzed; the characteristics of different fault modes on the power spectrum are summarized by analyzing the reflection of different failure modes in the frequency domain response of the gearbox; the envelope of the original simulation signal is obtained by Hilbert transform, and then the envelope The envelope spectrum of the simulated signal can be obtained by Fourier transform; the characteristic frequency components of the gearbox vibration can be obtained more clearly through the envelope spectrum, and the frequency characteristics of the envelope spectrum of different failure modes can be defined;
经过数值求解与分析,轴承外圈故障与齿轮从动轮故障的耦合振动响应如图4所示;其中轴承故障包含了两种情况,分别为高速轴轴承故障和低速轴轴承故障;每种故障情况都是用时域信号、功率谱、包络谱三种手段进行分析;从时域信号中可以看到轴承外圈故障与从动轮故障会在齿轮箱外壳上产生明显的冲击;可以通过时域信号中的冲击性判断齿轮箱内部的故障情况,但是仅从时域中无法得知具体故障模式;功率谱中占主要的频率成分是啮合频率及其谐频,其中最大的频率为4gmf,这是受齿轮箱外壳固有频率调制引起的,固有频率由齿轮箱参数决定;轴承外圈故障在功率谱中激起了明显的以外圈特征频率为间隔的边频带,高速轴与低速轴轴承由于转速不同,边频带间隔也不同;这些边频带主要分布在4gmf附近,这说明轴承特征频率与啮合频率一样,受到了齿轮箱外壳固有频率的幅值调制;同样的,从动轮故障激起的以从动轮转速为间隔的边频带在功率谱中拥有同样的分布特征,说明这些频率也受到固有频率调制;由于齿轮故障激起的边频带间隔较密、幅值较低,又和轴承故障边频带拥有同样的分布,所以容易被轴承边频带覆盖而不易发现;这些易被覆盖的频带在图中被用红色虚线标识;在包络谱中,特征频率主要以基频和低阶谐频的形式出现;轴承外圈特征频率此时超过啮合频率成为主要频率成分,但啮合频率在包络谱中依然可见;齿轮故障导致的转频分量由于频率较低、幅值较小,主要集中在包络谱的低频区,被用红色虚线标识出来;包络谱和功率谱中的轴承故障特征频率、齿轮故障特征频率呈现叠加的状态,没有发现明显的互相调制现象;After numerical solution and analysis, the coupled vibration response of bearing outer ring fault and gear driven wheel fault is shown in Figure 4; the bearing fault includes two cases, namely high-speed shaft bearing fault and low-speed shaft bearing fault; each fault condition They are all analyzed by three means of time domain signal, power spectrum and envelope spectrum; from the time domain signal, it can be seen that the fault of the outer ring of the bearing and the fault of the driven wheel will produce obvious impact on the gearbox casing; the time domain signal can be used for analysis. The impact in the gear box is used to judge the fault situation inside the gearbox, but the specific fault mode cannot be known only from the time domain; the main frequency components in the power spectrum are the meshing frequency and its harmonic frequency, of which the maximum frequency is 4gmf, which is It is caused by the modulation of the natural frequency of the gearbox shell, and the natural frequency is determined by the parameters of the gearbox; the fault of the outer ring of the bearing arouses obvious sidebands separated by the characteristic frequency of the outer ring in the power spectrum. , the sideband intervals are also different; these sidebands are mainly distributed around 4gmf, which indicates that the bearing characteristic frequency, like the meshing frequency, is modulated by the amplitude of the natural frequency of the gearbox casing; similarly, the driven wheel failure is caused by the driven wheel. The sidebands with the interval of rotation speed have the same distribution characteristics in the power spectrum, indicating that these frequencies are also modulated by the natural frequency; the sidebands caused by the gear fault are densely spaced and have lower amplitudes, and they have the same characteristics as the bearing fault sidebands. Therefore, it is easy to be covered by the bearing sidebands and not easy to find; these easily covered frequency bands are marked with red dotted lines in the figure; in the envelope spectrum, the characteristic frequencies mainly appear in the form of fundamental frequency and low-order harmonics; At this time, the characteristic frequency of the outer ring of the bearing exceeds the meshing frequency and becomes the main frequency component, but the meshing frequency is still visible in the envelope spectrum; the rotational frequency component caused by the gear fault is mainly concentrated in the envelope spectrum due to its low frequency and small amplitude. The low-frequency area is marked by a red dotted line; the characteristic frequencies of bearing faults and gear faults in the envelope spectrum and power spectrum are superimposed, and no obvious mutual modulation phenomenon is found;
轴承内圈故障与从动轮故障的情况见图5;与外圈故障一致,内圈故障也从高速轴轴承与低速轴轴承两种情况考虑;内圈故障下,故障位置随内圈旋转,故障位置受力会在最大值与零之间波动,所以轴承时域冲击会小于外圈的情况,但轴承故障引起的冲击依然可以被找到;齿轮故障引起的冲击与外圈时一致;内圈故障与从动轮故障的频域响应同样被展示在图5中;齿轮故障引起的边频带用红色虚线标识,这些边频带与轴承外圈故障的情况下相同,这表明轴承故障的模式不会影响齿轮故障对于齿轮箱外壳振动的频域响应;轴内圈故障引起的特征频率更加复杂,除了以内圈特征频率为间隔的边频带外,在功率谱与包络谱中的特征频率还受到轴承转频的调制现象;这与从单一轴承的动力学模型中得到的结论是一致的,这也证明了该发明建立的模型的正确性;与外圈故障时一致,轴承内圈故障的特征频率同样没有与齿轮故障特征频率发生调制现象,互相呈叠加状态;The faults of the inner ring of the bearing and the fault of the driven wheel are shown in Figure 5; the same as the fault of the outer ring, the fault of the inner ring is also considered from the two situations of the high-speed shaft bearing and the low-speed shaft bearing; under the fault of the inner ring, the fault position rotates with the inner ring, and the fault occurs. The position force will fluctuate between the maximum value and zero, so the impact of the bearing in the time domain will be smaller than that of the outer ring, but the impact caused by the bearing failure can still be found; the impact caused by the gear failure is the same as that of the outer ring; the inner ring failure The frequency domain response with the driven wheel failure is also shown in Figure 5; the sidebands caused by the gear failure are marked with red dashed lines, and these sidebands are the same as in the case of the bearing outer ring failure, indicating that the mode of the bearing failure does not affect the gears The frequency domain response of the fault to the vibration of the gearbox casing; the eigenfrequencies caused by the fault of the inner ring of the shaft are more complicated. In addition to the sidebands spaced by the eigenfrequencies of the inner ring, the eigenfrequencies in the power spectrum and the envelope spectrum are also affected by the bearing rotation frequency. The modulation phenomenon; this is consistent with the conclusion obtained from the dynamic model of a single bearing, which also proves the correctness of the model established by the invention; consistent with the outer ring fault, the characteristic frequency of the bearing inner ring fault is also not There is a modulation phenomenon with the gear fault characteristic frequency, which is superimposed on each other;
为进一步验证该发明的正确性,使用了齿轮箱试验台进行实验验证;此单级直齿齿轮传动齿轮箱通过交流电机驱动;负载通过安装在输出轴末端的磁粉制动器施加;振动信号通过安装在齿轮箱箱体上的传感器获取;齿轮局部故障被设置在从动轮上,轴承局部故障被设置在高速轴轴承中;为了消除实验信号的噪声干扰,实验信号均进行了去噪处理;选取了[9216Hz,10240Hz]的频带对仿真信号与实验信号进行滤波;图6展示了内圈轴承故障和从动轮故障的实验与仿真结果对比;图7展示了外圈轴承故障和从动轮故障下的实验与仿真结果对比;图中绿色点标识了齿轮故障特征频率,即从动轮转频,红色点标识了轴承故障特征频率与啮合频率;从实验对比图中可以得知,尽管频率幅值存在部分误差,但是频率特征基本一致,这可以说明该实验可以证明该发明所提供的内部多源耦合故障激励的工业齿轮箱动力学建模方法的准确性;In order to further verify the correctness of the invention, a gearbox test bench is used for experimental verification; the single-stage spur gear transmission gearbox is driven by an AC motor; the load is applied by the magnetic powder brake installed at the end of the output shaft; the vibration signal is installed at the end of the output shaft. The sensor on the gearbox box is acquired; the partial fault of the gear is set on the driven wheel, and the partial fault of the bearing is set in the high-speed shaft bearing; in order to eliminate the noise interference of the experimental signal, the experimental signals are all denoised; selected [ The frequency band of 9216Hz, 10240Hz] filters the simulated signal and the experimental signal; Figure 6 shows the comparison between the experimental and simulation results of the inner ring bearing fault and the driven wheel fault; Figure 7 shows the experimental and simulated results under the outer ring bearing fault and the driven wheel fault. Comparison of simulation results; the green point in the figure identifies the gear fault characteristic frequency, that is, the rotational frequency of the driven wheel, and the red point marks the bearing fault characteristic frequency and meshing frequency; it can be seen from the experimental comparison diagram that although there are some errors in the frequency amplitude, But the frequency characteristics are basically the same, which shows that the experiment can prove the accuracy of the industrial gearbox dynamics modeling method provided by the invention for the internal multi-source coupling fault excitation;
为了解决传统动力学模型不完备,无法为受内部多源故障机理的齿轮箱振动提供理论基础的问题,本发明从传统齿轮啮合模型出发,充分考虑了轴承动态作用力、齿轮箱外壳、弹流润滑和局部故障描述等方面,构建了全新的受内部多源耦合故障激励的工业齿轮箱动力学建模方法;并且从该动力学模型出发,研究了齿轮箱外壳在内部多源耦合故障机理下的振动响应;利用经典的傅里叶变换和包络谱分析方法分析了了不同故障模式下的齿轮箱振动特征,揭示了轴承与齿轮局部故障在齿轮箱外壳上的叠加作用机理,为故障特征提取等信号处理方法提供了理论依据;最后,通过将齿轮箱试验台测得的实验信号与该发明中得到的仿真信号相比对,证明了该发明的内部多源耦合故障激励的工业齿轮箱动力学建模方法具有一定的有效性。In order to solve the problem that the traditional dynamic model is incomplete and cannot provide a theoretical basis for the vibration of the gearbox subject to the internal multi-source fault mechanism, the present invention starts from the traditional gear meshing model, and fully considers the dynamic force of the bearing, the casing of the gearbox, the elasto-hydrodynamic force In terms of lubrication and local fault description, a new dynamic modeling method for industrial gearboxes excited by internal multi-source coupled faults is constructed; and based on the dynamic model, the mechanism of gearbox casing under internal multi-source coupled faults The vibration response of the gearbox was analyzed by using the classical Fourier transform and envelope spectrum analysis methods, and the vibration characteristics of the gearbox under different failure modes were analyzed, and the superposition mechanism of the partial faults of the bearing and gear on the gearbox casing was revealed, which is the fault characteristic. Extraction and other signal processing methods provide a theoretical basis; finally, by comparing the experimental signal measured by the gearbox test bench with the simulated signal obtained in the invention, it is proved that the invention has an industrial gearbox excited by internal multi-source coupling faults The dynamic modeling method has certain validity.
最后应说明的是:以上所述仅为本发明的优选实施例而已,并不用于限制本发明,尽管参照前述实施例对本发明进行了详细的说明,对于本领域的技术人员来说,其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换。凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。Finally, it should be noted that the above descriptions are only preferred embodiments of the present invention, and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, for those skilled in the art, the The technical solutions described in the foregoing embodiments may be modified, or some technical features thereof may be equivalently replaced. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.
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