Gearbox Components Research Articles

Pengaruh Variasi Waktu Operasi Mesin Terhadap Perubahan Nilai Viskositas Dan Total Acid Number Untuk Pelumas Gearbox

Lubricating is one of the methods to prevent temperature rise and wear due to friction among gearbox components. The lubricant quality is an essential factor in ensuring lubricant functions optimally. Long-term use of the machine changes lubricant quality, which can be measured by viscosity parameters and Total Acid Number (TAN). This research aims to determine the effect of machine operating time on viscosity and TAN lubricant changes of milling machine gearbox heads (Headstock) used for educational purposes. The study used a quantitative research method in which data was collected using statistical data analysis tools and selecting a random sampling. Forty samples of Shell Tellus 46 lubricant were taken every 5 hours for 200 operation hours with an operating temperature of 27.5-44.4°C and 300 rpm speed. Viscosity testing uses Visgage and Fluidscan to check TAN. Data analysis using a simple linear regression analysis method with the statistical software Minitab 21.3. The results showed that operating time had a significant effect on: 1) a 95% change in viscosity value with 3.67 cSt (7.39%) decline or 0.018776 cSt per operation hour; 2) 99.34% change in TAN value with 0.27 mg KOH/g (16.56%) increase or 0.001297 mg KOH/g per operation hour.

Research on time-varying reliability of wind power gearbox with failure correlation

1. An Z.W., Liu B., Xu J., 2013, Dynamic reliability analysis of wind power gearbox component, Proceedings of 2013 International Conference on Quality, Reliability, Risk, Maintenance and Safety Engineering, 215-219. CrossRef Google Scholar

Effect of input shaft torque control during gear shifting processes in automatic stepped transmissions

Introduction (problem statement and relevance).Designing gear shifting algorithms is one of the major problems in development of control systems for automatic gearboxes. Structure and parameters of these algorithms govern such characteristics of shifting processes as torque transients and energy dissipation due to clutch slippage; these, in turn, affect vehicle comfort and lifespan of the gearbox components. In particular, one of the factors defining the said characteristics is engine torque control provided during gear shifts. The functionality of the torque control extends when using the gearbox as a part of a hybrid powertrain with a traction electric machine connected to the gearbox input shaft. Studying gear shifting processes in this aspect is a relevant task aimed at improving control systems of automatic transmissions.The purpose of the studyis to compare different methods of controlling torque at the gearbox input shaft regarding their effect on gear shifting dynamics, clutch energy dissipation, and vehicle comfort.Methodology and research methods.The study was conducted by means of simulations using a mathematical model describing dynamics of a vehicle equipped with an automatic gearbox with an option of having an electric machine installed at the input shaft. Considering straight-line accelerated motion of the vehicle, both upshifts and downshifts were simulated with a correcting torque introduced in inertia phases of the shifts. Analysis of the simulation results allowed calculating key parameters of vehicle dynamics and clutch energy dissipation.Scientific novelty and results.The simulation results show a significant decrease (aver. 40%) of jerks when using an electric machine to correct the input shaft torque in inertia phases of both upshifts and downshifts. It is also shown that correction of the shaft torque allows reducing energy dissipation due to clutch slippage by 16–24% in the case of engine torque control and by 28–34% in the case of torque correction by an electric machine. However, using torque correction by means of an electric machine during downshifts raises the clutch energy dissipation 1.4–2.4 times.The practical significance.The results of the study can be used in designing control systems for automatic gearboxes intended for both conventional and electrified vehicles.

Fault diagnosis of planetary gears based on intrinsic feature extraction and deep transfer learning

The planetary gearbox is a key transmission apparatus used to change speed and torque. The planetary gear is one of the most failure-prone components in a planetary gearbox. Due to the complexity of working environments, collected vibration signals contain a lot of noise and interference; fault characteristic frequencies are usually submerged or even lost. Thus, feature extraction from the vibration signal is beneficial to subsequent fault diagnosis. As a fault identification approach that has been increasingly popular in the field of fault diagnosis, deep learning requires a large number of samples to train the model. Insufficient samples lead to low diagnostic accuracy for deep learning models. This paper proposes a novel fault diagnosis approach for planetary gears based on intrinsic feature extraction and deep transfer learning. The original vibration signals are decomposed into a series of band-limited intrinsic mode functions (BLIMFs) by variational mode decomposition. BLIMF with the most apparent fault characteristics is selected to generate two-dimensional time-frequency maps by continuous wavelet transform. The preprocessed time-frequency maps are adopted as the input of the pretrained VGG16 model. The bottom layers are frozen, and the top layers are fine-tuned to achieve fault diagnosis for planetary gears. Applications to planetary gear datasets verify the superiority of the proposed method.

Penentuan Interval Waktu Penggantian dan Perbaikan Komponen Kritis Mesin Bubut Type SS-850 di PT. Hamdan Jaya Makmur Dengan Metode Age Replacement

PT. Hamdan Jaya Makmur is a company that runs in the field of Machining, Engineering, Fabrication, Stamping, and Trading Company, which produces products for small, medium and modern industries. Less than optimal maintenance system with corrective maintenance causes PT. Hamdan Jaya Makmur often experiences machine failure. Based on historical data, it can be seen that the lathe machine type SS-850 experienced very high downtime. Therefore, it is necessary to plan optimal and preventive maintenance of the machine in order to produce according to the target and increase the reliability of the machine. The purpose of this research is to determine the time interval and cost of preventive replacement on components of the lathe machine type SS-850 at PT. Hamdan Jaya Makmur. The method used in this research is the Age Replacement method, namely by determining critical components, determining the distribution pattern of damage, determining distribution parameters, and calculating MTTF and MTTR, where the results obtained are preventive replacement time intervals, and calculating preventive replacement costs. The results obtained from this research are that there are four critical components on the lathe machine type SS-850, namely electric components with a preventive replacement time interval of 11 days and a preventive replacement cost of Rp.3,080,679,253, bearing components have a preventive replacement time interval of 14 days and a preventive replacement cost of Rp.4,931,989,307, the gearbox component has a preventive replacement time interval of 33 days and a preventive replacement cost of Rp.11,621,532,829, and bolt and nut components have a preventive replacement time interval of 11 days and a preventive replacement cost of Rp.1,615,296,412.

Application of Geometric Product Specifications on gearbox component drawings

Technical documentation of individual gearbox components is an important part of the production process. For the development and production of these components, an improved engineering tool is used to specify and verify the geometry of the workpiece - Geometrical Product Specifications (GPS) system. This system is intended only for checking geometry and is based on computational mathematics and correct, consistent logic using general sets of rules. This paper is devoted to the application of geometric tolerances used in drawings to components of gearboxes, such as gearbox bodies, shafts, covers, and gears.

Experimental study on vibration control of spur geared rotor system with active magnetic bearings

The gearbox vibrations and noise caused by variation of contact forces often causes failure in the components of gearbox, which are then transmitted to the surrounding structures. The concept of active control of gearbox vibrations with piezoelectric actuators at the mounting points has been analysed earlier in several studies, then with certain limitations. There has been little research on how Active Magnetic Bearings (AMBs) might mitigate gear vibrations. AMBs are used in this study to investigate active internal shaft vibration control caused by rotor unbalance, gear runout, transmission error, which usually resides within the gearbox. Hence, minimizing the effect of vibrational amplitude at gear mesh frequency and its harmonics to have quieter gear operation. A mathematical model is developed for the torsional-lateral dynamic analysis of a spur geared rotor-AMB system. Responses are computed numerically with different gear-rotor faults. Based on the mathematical model, setted up an experimental test rig in the laboratory, and the effectiveness of the proposed model is compared with and without the application of AMBs. The approach is based on active control of the shaft transverse vibration with an electromagnetic actuator. The control forces are applied to the rotor shafts supported on conventional rolling element bearings by an eight-pole radial AMB, as an auxiliary component and a closed-loop linear output feedback control is employed for stable, reliable, and robust operation. A linear PID controller working on differential mode is used to generate the appropriate control signals and the experimental results are presented. It was found that there is a considerable amount of reduction in the geared rotor vibration levels and correspondingly in overall measured gear noise levels.

Laser: a proven tool with a lot more potential

AbstractLasers reliably cut and weld body panels and gearbox components in the automobile industry. They repair turbine blades in the aircraft industry with laser deposition welding and generate customized and lightened components for the space industry using the laser powder bed fusion process. Short pulse lasers are contributing greatly in the electronics industry to the miniaturization of new devices through their drilling, cutting or structuring capabilities. In summary: the laser is an all‐round tool that has established itself in the most varied of industries.

Investigation of a converter fault for a DFIG wind turbine and analysis of the resulting gearbox component loads

Abstract Doubly fed induction generators are widely used in wind turbines in the field. The main advantage is the significantly lower cost of the partial scale power converter compared to the full scale power converter. Converter faults in wind turbines lead to significant generator torque excitations that lead to dynamic loads in the drivetrain. Dynamic loads and changing rotational speeds can lead to gearbox damages. The generator torque excitations have the highest influence on the high speed shaft torque due to the coupling to the generator. Gearbox damages occur mainly on the components of the high speed shaft. Thus, in this paper the influence of a converter fault in a wind turbine with doubly fed induction generator on the high speed shaft component damages is investigated. It is shown that the converter fault can induce dynamic torque excitations with a maximum increase to around 2.5 times rated torque. Due to the resulting dynamic gearbox loading the safety against scuffing in the high speed gear stage decreases by maximum 19 percent. The smearing risk in the high speed shaft bearings increases to around 2 times the value during rated power production.

Development of a Generalized Model to Predict Efficiency of Electrified Power Transmission Considering Optimal Driving Efficiency

<div class="section abstract"><div class="htmlview paragraph">Over the last decade the electrified powertrain has been expanded due to strict fuel efficiency regulations, which leads to the development of various powertrain systems. It is recent trend to improve the overall system efficiency in which various power sources such as ICE and motor are combined with a simple gearbox. Accordingly, it is becoming indispensable to analyze the efficiency of the entire system from the initial stage of system development. In this study, a generalized numerical model is developed to predict the loss of gearbox under various power sources and power flows. This numerical model newly applied generalized equations for additional various power transmissions, including the previously verified power loss equation of gearbox components. In addition, for a reasonable and objective efficiency comparison between gearboxes, the optimal operating points are calculated in consideration of the overall powertrain system efficiency covering the total vehicle load. The average efficiency at the optimal operating points is introduced as the efficiency index of the gearbox. The developed model is employed to predict the efficiency of a HEV system and a EV system. The results are discussed from various perspectives.</div></div>

ANALISIS INTERVAL PEMELIHARAAN KOMPONEN KRITIS UNIT FUEL CONVEYOR DENGAN PENDEKATAN RELIABILITY CENTERED MAINTENANCE (RCM

The scheduling of the machine maintenance system is a system that can assist companies in preventing machine damage which results in disrupted production processes. Corrective treatment methods have not been able to guarantee a smooth production process. This research will plan preventive maintenance activities to increase the reliability of production machines using the Reliability Centered Maintenance (RCM) approach. The result shows the highest downtime was boiler station with a percentage of 22.25%. The machine that works at the boiler station which has the highest level of damage was the fuel conveyor 2 with a percentage of 35.10%. The critical components which are the root causes of the highest damage problems in the fuel conveyor 2 machine were electromotor, chain coupling, and gearbox. In the electromotor, chain coupling, and gearbox components, preventive maintenance scheduling based on the results of each simulation were when t = 158, t = 190, and t = 67, respectively. The results of critical component maintenance scheduling indicated the achievement of the reliability value from before. After doing preventive maintenance, the reliability value of each component increased by 12%, 32%, and 8%, respectively. The frequency of periodic inspection every month on electromotor, chain coupling, and gearbox components were at least 4 times, 3 times, and 10 times, respectively. Keywords: downtime, maintenance, preventive maintenance. reliability, scheduling

Vibration fault detection of vehicle transmission gearbox based on time-frequency analysis of non-stationary signals

The traditional vibration fault detection method of vehicle transmission gearbox cannot realise feature extraction of non-stationary fault signal, which leads to large error of detection result and low fault detection rate. Therefore, this paper proposes a new method of vehicle transmission gearbox vibration fault detection based on non-stationary signal time-frequency analysis. The components of transmission gearbox are analysed, and the transmission path of vibration fault signal of transmission gearbox is obtained according to its structural characteristics. The time-frequency characteristics of non-stationary signals are extracted by empirical mode method to complete the vibration fault detection of vehicle transmission gearbox. Experimental results show that the proposed method has high detection accuracy and high detection rate under the premise of amplitude and phase modulation of fault signal.

Investigation of Dynamic Loads in Wind Turbine Drive Trains Due to Grid and Power Converter Faults

Electrical faults can lead to transient and dynamic excitations of the electromagnetic generator torque in wind turbines. The fast changes in the generator torque lead to load oscillations and rapid changes in the speed of rotation. The combination of dynamic load reversals and changing rotational speeds can be detrimental to gearbox components. This paper shows, via simulation, that the smearing risk increases due to the electrical faults for cylindrical roller bearings on the high speed shaft of a wind turbine research nacelle. A grid fault was examined for the research nacelle with a doubly fed induction generator concept. Furthermore, a converter fault was analyzed for the full size converter concept. Both wind turbine grid connection concepts used the same mechanical drive train. Thus, the mechanical component loading was comparable. During the grid fault, the risk of smearing increased momentarily by a maximum of around 1.8 times. During the converter fault, the risk of smearing increased by around 4.9 times. Subsequently, electrical faults increased the risk of damage to the wind turbine gearbox bearings, especially on the high speed stage.

Calculating component temperatures in gearboxes for transient operation conditions

The knowledge of component temperatures during transient operation conditions is essential for an optimal design of a gearbox. This is because critical peak temperatures limit the transferable power as well as the load capacity. Moreover, understanding the thermal behavior of the gearbox is key to improving its efficiency. Therefore, the Thermal Network Method (TNM) of the calculation program WTplus was extended to calculate component temperatures in gearboxes for transient operation conditions. Specifically, the TNM considers the component masses and specific heat capacities of each node modelling the gearbox structure. This enables the algorithm to compute a corresponding system of differential equations and thus determine the temperature change over time. Therefore, WTplus can be used to identify critical gearbox component temperatures during load cycles. The applied method was validated with measurements collected at the FZG gear efficiency test rig.

Coupling fault diagnosis of wind turbine gearbox based on multitask parallel convolutional neural networks with overall information

With the development of smart grid, capacity of wind power that connects to the grid increases gradually, which makes the continuous and stable operation of wind turbine (WT) critically important. Therefore, by considering gearbox structure and operating condition, a diagnosis approach for coupling faults of WT gearbox is proposed based on multitask parallel convolutional neural network with reinforced input (RI-MPCNN). The overall information array of gearbox that fuses wavelet packet transform of vibration signals, domain knowledge of gearbox components and operating condition s used as RI-MPCNN input. Then, RI-MPCNN that has parallel sub-convolutional neural networks (sub-CNNs) and multiple classifiers realizes the diagnosis of coupling faults of multiple components simultaneously. Meanwhile, a reinforced input is added to each sub-CNN to improve the diagnosis accuracy of each component. It is notable that the proposed approach not only fuses the overall gearbox information at system level, but also realizes fault diagnosis at component level. In the approach evaluation based on two case studies, the proposed approach can improve diagnosis accuracies by about 3 and 20% compared with the existing methods, respectively.

Hoist Tulangan Machine Maintenance Design Using Lean Maintenance Method (Case Studi Of Pt. Xyz)

PT. XYZ is a company engaged in manufacturing concrete. There are many machines that used in this company, one of them is the Reinforcement Hoist machine. The Reinforcement Hoist machine is the engine with the highest downtime on line 8 during 2019 with 90 hours. The maintenance system that applied in this company is corrective maintenance. To implement a preventive maintenance system, researcher has used the Lean Maintenance method to find the MTTF value for each component and analyzing maintenance activities by Maintenance Value Stream Mapping (MVSM).The purpose of this research was to determine the critical components of the Reinforcement Hoist machine using FMEA, determine the reliability value of machine using RBD, determine preventive scheduling using selected distributions, and calculate maintenance efficiency using the Lean Maintenance method. From the results of the FMEA critical components are the Gearbox and End Carriage components. The Reliability Value of the Reinforcement Hoist engine is 85.69% with MTTF Gearbox component every 3 days and the End Carriage component every 6 days. The results of the Maintenance Efficiency of the Gearbox component are 49.59% and the End Carriage component is 61.35%.

Production technology research – Building blocks for competitiveness and solution for future challenges in aerospace component manufacturing

Production technology research is a vital building block for enabling efficient and cost-effective aerospace component manufacturing. This paper describes, from an industrial perspective, examples of key technologies being developed and successfully implemented in modern production of aerospace components. A technical focus is set on advanced cutting and production technology for Nickel alloys using high performance machining principles and high speed CBN turning operations. Case studies presented include alternative machining solutions for gear machining of Power Gearbox components, and hybrid process solutions for Ceramic Matrix composites (CMC) machining. These examples, underpinned by digital tools, demonstrate the range of topics covered by production technology research, in order to enable state of the art aerospace component production.

Development and validation of a dynamic model for a two-stage speed-reducer

This paper presents the development and validation of a six degree of freedom (DOF) dynamic model of a two-stage parallel shaft gearbox, without flaws, which is able to determine the reaction of gearbox components to varying torque inputs and loads. The model utilises flexible shafts and gears rather than using a rigid assumption, to further understand the effect of varying mesh stiffness. The paper replicates the results presented by Diehl and Tang, and improves the number of frequencies that can be analysed. The gear meshing frequencies were expected to dominate the result, however due to the use of a sinusoidal approximation of the varying tooth mesh frequency, the presented model shows the additional gear generated frequencies are present and analysable in the data.

Optimization of planetary gear of onboard gear-box using the method of differential evolution

Problem. Further modernization of combat vehicles, associated with the installation of additional equipment, requires the use of more powerful engines, which leads to increased loads on parts and components of the onboard gearbox. In modern conditions, the onboard gearbox of the T-64 tank works at the limit of its technical capabilities. To maintain the existing advantages and eliminate these short-comings, the design of the onboard planetary gear-box needs to be upgraded. Goal. The goal is to increase the load capacity and as a consequence to increase the service life of the elements of the onboard gearbox by carrying out optimization of the onboard planetary gearbox. Methodology. Methods for calculating planetary mechanisms and methods for analyzing the strength of gears were used to build a mathematical model. When constructing the optimal design algorithm, the method of differential evolution was used. Results. The literature review of the existing methods of multicriteria optimization of planetary gears has been made. According to the developed method of optimization of the onboard gearbox, a study of the parameters of planetary gear for optimality according to the criteria of maximum load capacity and minimum dimensions has been made. Originality. An algorithm for optimal design using the method of differential evolution for optimization of planetary gearboxes has been developed. Practical value. The use of the received design of a planetary gear reduce loading on elements of a transmission of the T-64 tank, thus the overall dimensions and design features of an onboard gearbox remain. The proposed approach to optimization of planetary gears can be used in the design of modern models of planetary gearboxes.

Fault Diagnosis Method for Bearing of High-Speed Train Based on Multitask Deep Learning

High-speed trains often pass through tunnel, turnout, ramp, bridge, and other line features in the process of running. At the same time, the length of the operation time, weather conditions, changes in train running conditions, and other conditions will lead to the loss of the train. In view of the complexity of a high-speed train structure and operation environment, in order to effectively evaluate the health of the train in the operation process, this paper proposes a diagnosis method of bearing temperature anomaly of a high-speed train based on condition identification and multitask deep learning. In this paper, the important components of bogie axle box, gearbox, and traction motor are taken as the research object. Firstly, the operating condition parameters of the high-speed train are analyzed and identified, and the K-means algorithm is used to classify and identify the operating condition of the high-speed train. Then, based on the operating condition identification and multitask deep learning, the bearing temperature prediction model is constructed. In addition, according to statistical quality control theory, the difference between the value predicted by the model and the real value is used to diagnose the anomaly of the bearing temperature of the high-speed train. Finally, the accuracy and availability of the model are verified by an example. The model can judge whether the running train bearing temperature is in the normal range in real time and predict and alarm the abnormal bearing temperature.