Abstract
For the better design and monitoring of gearboxes operating under nonstationary conditions, the dynamic interaction behavior of an electric motor drive multistage gear set is investigated in this study. Initially, dynamic mathematical models of an asynchronous motor and a multistage gear set are established by using the equivalent circuit method and the lumped parameter method, respectively. An electromechanical model coupling the asynchronous motor and the gearbox is subsequently developed, which is suitable for nonstationary conditions. The system transient responses under an impact external load are analyzed, and the mechanical torsional-vibration and electric current response are compared. Finally, the dynamic load propagation mechanism and the interaction effect on different gears are examined. The results demonstrate that the vibration frequencies of the multistage gearbox in steady and transient states both can be captured in the current. Electric current can be applied to reflect the external load variation and the internal vibration status of the driven gearbox under stationary or nonstationary conditions. The mutual excitation effects between adjacent gear pairs change the respective dynamic characteristics of the gears, and gears with small nominal loads are susceptible.
Highlights
Multistage gear sets have advantages of high transmission power and strong bearing capacity; they are widely applied in heavy-load and high-power machinery applications, such as coal mining machines, wind turbines, and tunnel boring machines
The proposed model is implemented with MATLAB/Simulink simulation platform, and the dynamic response is solved with the 4-5 order Runge–Kutta numerical integration
The feature of the model was that the variation periods of tooth-mesh dynamic excitations, such as the mesh stiffness and the mesh error, were determined in real-time by operation conditions, making the model suitable for nonstationary conditions
Summary
Multistage gear sets have advantages of high transmission power and strong bearing capacity; they are widely applied in heavy-load and high-power machinery applications, such as coal mining machines, wind turbines, and tunnel boring machines. These applications often operate under nonstationary conditions, such as variable load or variable speed conditions, which endanger the stability and accelerate the failure of the gear sets. Wei et al [3] developed a dynamic modeling method for multistage planetary gears by applying an equivalent-shaft -element method and investigated the coupled vibration behavior of a two-stage planetary gear set. Gearboxes working as power transmission devices are frequently excited by the driving and driven machines operating in nonstationary conditions, for coal mining machines, tunnel boring machines, and other engineering applications
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