Abstract
Expert insights into the time-domain dynamic behavior of heavy-duty gearboxes form the foundations of design evaluation and improvement. However, in the existing lateral–torsional coupling (LTC) modeling method for gearboxes that is normally used for frequency-domain dynamic behavior, the meshing forces are modeled as spring dampers with fixed acting points on the meshing gears to simulate only the transient LTC effect, and thus the steady state characteristic in the time domain cannot be obtained due to the unrealistic distortion of positions and orientations as the gear angles increase. In this paper, a novel and generally applicable LTC modeling method for heavy-duty gearboxes, mainly planetary gear sets with floating components, is proposed by using space-fixed spring dampers with floating acting points on the meshing gears to study the time-domain dynamic response and to support the dynamic design of heavy-duty gearboxes. Based on the proposed method, a LTC model of a 2 megawatt (MW) wind turbine gearbox with floating components considering the time-varying meshing stiffness, bearing stiffness, torsional stiffness, and floating effect was established. The simulated results of representative components were in accordance with experimental results on a test rig, and dynamic behavior was calculated.
Highlights
Gear systems are the most significant and extensively adopted mechanical transmission devices in modern applications such as automobile, locomotive, mining, metallurgy, electric power, petroleum and chemical industries
A novel and generally applicable lateral–torsional coupling (LTC) modeling approach for calculating the dynamic behavior of heavy-duty gearboxes in the time domain with consideration of the floating effect, time-varying meshing stiffness, bearing stiffness, torsional stiffness, etc., is proposed
Based on the proposed method, a LTC model of a full test rig was built, which was used to test a 2 MW wind turbine gearbox (WTG) consisting of two planetary gear sets and a parallel-shaft helical gear set
Summary
Gear systems are the most significant and extensively adopted mechanical transmission devices in modern applications such as automobile, locomotive, mining, metallurgy, electric power, petroleum and chemical industries. Since most WTGs contain planetary gear sets with floating components because of the advantages of compact structure, high power density, and coaxial arrangement of transmission shafts [2], the varying mesh stiffness, meshing incentive, impact of floating components, and composition error generate the internal excitations [3,4]. An appropriate and generally applicable modeling approach of heavy-duty gearboxes, mainly the planetary gear set, is proposed to investigate dynamic behavior in the time domain, and a LTC model of a 2 MW WTG was built in which the time-varying meshing stiffness, bearing stiffness, torsional stiffness, and floating factor were considered. The model was verified by experiments on a test rig, and dynamic characteristics of the WTG were revealed on the verified model
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