Gear Rack Research Articles

A digital twin modeling and application for gear rack drilling rigs lifting system

A comprehensive digital transformation has been undergone by the oil and gas industry, wherein digital twins are leveraged to enable real-time data analysis, providing predictive and diagnostic engineering insights. The potential for developing intelligent oil and gas fields is substantial with the implementation of digital twins. A digital twin framework for gear rack drilling rigs is proposed, built upon an understanding of the digital twin composition and characteristics of the gear rack drilling rig lifting system. The framework encompasses descriptions of digital twin characteristics specific to drilling rigs, the application environment, and behavioral rules. The modeling approach integrates mechanism modeling, real-time performance response, instantaneous data transmission, and data visualization. To illustrate this framework, exemplary case studies involving the transmission unit and support unit of the lifting system are presented. Mechanism models are constructed to analyze dynamic gear performance and support unit response. Real-time data transmission is facilitated through sensor-based monitoring, enhancing the prediction speed and accuracy of dynamic performance through a synergy of mechanism modeling, machine learning, and real-time data analysis. The digital twin of the lifting system is visualized utilizing the Unity3D platform. Furthermore, functionalities on data acquisition, processing, and visualization across diverse application scenarios are encapsulated into modular components, streamlining the creation of high-fidelity digital twins. The frameworks and modeling methodologies presented herein can serve as a foundational and methodological guide for the exploration and implementation of digital twin technology within the oil and gas industry, ultimately fostering its advancement in this sector.

Design of Work Facility Improvements with a Macroergonomic Analysis and Design (MEAD) Approach in SMEs Andri Tofu

Small and Medium Enterprises Andri tofu is an industry engaged in food production which is located in Ngrampal District, Sragen. In the production process there is a non-optimal working system, where the process of setting up the mold tool takes more than 1 minute and the pressing process uses a load of more than 17 kg in the form of using a 20 liter bucket full of water. The purpose of this study is to identify the factors that influence the work system, measure complaints and posture, and design work facility improvement designs. The method used is in the form of Macroergonomic Analysis and Design to design work systems and facilities based on the location of the highest deviation. The results of the study found that there were dominant body complaints on the right hand by 5.18% and mild complaints on the thighs by 1.41%. Improvements to the design of the tool have an adjustable height of 140-170 cm, a width of 72 cm, a height of 57 cm for the feet of the tool, and the pressing uses a gear system with a rack gear of 70 cm and diameter a spin gear of 6 cm which is driven using a rotary press stirrer.

Effects and optimization of bionic texture parameters on the tribological behavior of line contacts under starved lubrication conditions

PurposeGears are prone to instantaneous failure when operating under extreme conditions, affecting the machinery’s service life. With numerous types of gear meshing and complex operating conditions, this study focuses on the gear–rack mechanism. This study aims to analyze the effects and optimization of biomimetic texture parameters on the line contact tribological behavior of gear–rack mechanisms under starvation lubrication conditions.Design/methodology/approachInspired by the microstructure of shark skin surface, a diamond-shaped biomimetic texture was designed to improve the tribological performance of gear–rack mechanism under starved lubrication conditions. The line contact meshing process of gear–rack mechanisms under lubrication-deficient conditions was simulated by using a block-on-ring test. Using the response surface method, this paper analyzed the effects of bionic texture parameters (width, depth and spacing) on the tribological performance (friction coefficient and wear amount) of tested samples under line contact and starved lubrication conditions.FindingsThe experimental results show an optimal proportional relationship between the texture parameters, which made the tribological performance of the tested samples the best. The texture parameters were optimized by using the main objective function method, and the preferred combination of parameters was a width of 69 µm, depth of 24 µm and spacing of 1,162 µm.Originality/valueThe research results have practical guiding significance for designing line contact motion pairs surface texture and provide a theoretical basis for optimizing line contact motion pairs tribological performance under extreme working conditions.

Investigating tooth surface reconstruction principle of a gear rack and pinion system with variable transmission ratio pinion

Rack-and-pinion gear sets with variable transmission ratios have gradually become a standard core component in steering systems, as the harmony between portability and sensitivity in vehicle steering can be achieved with such applications. When the conventional meshing theory is adopted to calculate point clouds of variable-ratio tooth surfaces, drawbacks will occur with respect to unevenness in point cloud density, inaccessible tooth surface boundaries, and point cloud fusion at the interface between the working tooth surface and fillet. Thus, the generated point cloud of variable ratio tooth surfaces is inapplicable for computer-aided engineering (CAE) and plastic forming. In this study, the point cloud reconstruction of pinion tooth surfaces with variable transmission ratio was investigated. Meanwhile, based on the analysis of transient length in contact lines that occur during gear meshing, various criteria were proposed to determine the validity of the variable-ratio rack-and-pinion design in terms of whether continuous and reverse driving can be achieved. By adopting the proposed methods, the designed variable-ratio pinion tooth surfaces demonstrate point clouds with equidistant distributions and clear boundaries. CAE analysis results also indicate a good quality in gear meshing. The real-time gear meshing status of variable-ratio rack-and-pinion sets is characterized by the transient length of contact lines. The measured variation curves for the transmission ratios of a prototype demonstrate significant consistency with the theoretical curves, indicated by attaining transmission ratio errors within a reasonable range. The validity of the design methods proposed in this study has been verified by the aforementioned results.

Active vibration control for reduction of interior noise caused by R-MDPS

This paper presents an active vibration control (AVC) to reduce the vibration of motor driven power steering (MDPS). The MDPS used in the experiment was R-MDPS, an MDPS connected to Rack Gear. When the R-MDPS generates vibration in the operating state, the vibration is transmitted through the subframe. The vibration transmitted through the subframe generates indoor noise and reduces the driving quality of the driver. To reduce vibration, the AVC was used by inserting an actuator between R-MDPS and subframe. The actuator used Piezo material is called a Piezo actuator. To select the location of the actuator, Transfer path analysis (TPA) was performed. the effect was confirmed by setting the main path to error point. The experiment was conducted for feasibility by connecting R-MDPS and subframe to a test bench manufactured in the laboratory. The algorithm used for vibration control used the Filtered-X Least Mean Square (FxLMS) algorithm and the control result was reduced from 4 to 5 dB. It is shown that proposed method is an effective vibration reduction effect of R-MDPS.

Increasing the Effectiveness of Electricity-Generating Floors Through the Mechanical Energy of DC Generators

The increasing electricity consumption of the Indonesian population requires renewable energy as an alternative to electricity generation supplies. Renewable energy can be formed through mechanical energy in its simplest form, namely in the form of a footrest. Generally, energy-harvesting floors that utilise human footsteps are designed with piezoelectric sensors. This sensor is responsible for converting mechanical energy into electrical energy. However, the power generated from piezoelectrics is only around 0.041 μW to 240.59 μW. So, in this study, an alternative design for a footstep floor is proposed capable of harvesting electrical energy using a DC generator. The proposed platform consists of a platform design that utilises the translational motion of the gears on the gear rack and is assisted by four springs surrounding the sides of the iron plate. Apart from that, the platform has a power management and storage system. Unlike controllers in general, solar charger controllers are used for charging (voltage and current in the accumulator) and flowing current to the load (lights). The subjects used in this floor test ranged from 20-100 kg. Compared to floors that use piezoelectrics, the results are that floors with DC generators experience an increase in power of around 0.62%. Hence, DC generators are more effective in harvesting electrical energy.

The Design, Analysis, and Optimization of a New Pitch Mechanism for Small Wind Turbines

This article proposes and designs a novel variable pitch adjustment device for small wind turbines. The generator spindle is designed to be hollow so that the drive rod passes through it and connects the pitch drive mechanism to the pitch actuator. The article introduces the basic structure and working principle of the pitch mechanism and verifies the feasibility of the pitch device by using 3D printing technology to produce a small-scale model. The stress analysis of the wind turbine was carried out using the unidirectional fluid–structure coupling method. The results show that the maximum equivalent stress of the pitch mechanism is 27.42 MPa, the maximum tooth surface contact stress of the gear is 38.40 MPa, and the maximum tooth root bending stress is 18.13 MPa. The rack synchronous disk, blade handle, and gear rack mechanism were designed with light weight using various optimization schemes. The results of the optimization showed that the overall mass of the pitch mechanism was reduced by 33.2%, improving the applicability of the new pitch mechanism.

RE-DESIGN TANGGA PESAWAT UNTUK LOADING DAN UNLOADING KURSI PADA PESAWAT AIRBUS 320 NEO DI PT BAT

PT. Batam Aero Technic which is a subsidiary of Lion Air airline that focuses on Maintenance, Repair and Overhaul (MRO) or maintenance of aircraft. One of the maintenance in the BAT hangar is the maintenance of the aircraft cabin section which is commonly called the Cabin Base Maintenance (CBM) Division. The CBM Division is responsible for the interior of the aircraft, starting from small to large scale repairs. In the initial observation, there was the biggest complaint of work posture of 66.67%, pain in the upper neck when lifting airplane seats manually and using stairs that did not fit properly. So it is important to design a tool to reduce musculoskeletal complaints. The aim of the research is to design ergonomic stairs using the EFD method to determine design specifications and meet user needs and anthropometric measurements with NBM. Then, a survey by distributing questionnaires to obtain the design parameters of the transportation equipment developed with the results of the unloading size with Dimension Platform 4,14 m x 404 m, Height Min 1 m | Max 4,5 m, Structure Materials Body and Frame : Structure Steel with Coating, Electrical Control Panel Specification Remote Control / Wireless, Control panel box, Motor 1.5 HP 380 volt 3 phase, Flow Rate 3.2 LPM/210 bar. Others Specification Included, Hydraulic Jack Mounting, Tire Wheel c/w steering towing, Aluminum platform layer Railing, Rubber Bumper, Manual Box, Safety Locking Devices, 2 sets of Rack Gear with Electric Solenoid Release. The design developed is valid according to user needs and according to the 5% significance level and is better than the prefix design due to a more ergonomic ladder position and faster loading/unloading seats.

Study the muti-bolt fastening under different load positions in gear rack drilling rig.

During the operation of drilling rigs, bolts are subjected to significant loads, rendering bolt groups vulnerable to failure due to uneven load distribution. This study investigates the multi-bolt load distribution characteristics of eight-gear and four-gear symmetric transmission mechanisms in drilling rigs. The spring stiffness method is utilized to analyze multi-bolt load distribution. A finite element model of the bolted connection is developed by integrating the structural shape and transmission mechanism. The model's accuracy is validated through a rack strain test under various loads. Based on the finite element analysis results, this study proposes an evaluation method for bolted connections using relative deformation difference. The impacts of bolt pitch, end distance, preload, and thickness of the derrick connection plate under different load positions on the connection are examined. This paper presents a methodology and conclusions that can inform the design of bolted connections for heavy-duty drive systems.

Design and Analysis of Internal–External Composite Meshing Hy-Vo Chain

The internal–external composite meshing mechanism should be the best way to improve the transmission performance of a silent chain drive, but there is no internal–external composite meshing Hy-Vo chain under the classical design approach. In this research, by building the Hy-Vo chain meshing system, the difference between the meshing of the chain–sprocket and the meshing of the rack–gear is deeply analyzed. By rigidifying the external meshing Hy-Vo chain as a rack, the fluctuation range of the pitch line of the external meshing Hy-Vo chain is analyzed. Based on the relations between the actual chain pitch line and the rigid chain pitch line, the design method for the internal meshing profile of the internal–external composite meshing Hy-Vo chain is deduced, the necessary conditions are obtained, and the meshing characteristics are analyzed. By conducting comparative multi-body dynamics experiments, the results prove that the design method of the internal–external composite meshing Hy-Vo chain proposed in this study is effective and feasible. The results also show that the description of the internal–external composite meshing in the classical meshing theory is not completely correct. In fact, the internal–external composite meshing mechanism cannot reduce the meshing impact of the Hy-Vo chain system and can only improve the system polygon action, the meshing performance, and the transmission stability.

Active vibration control for reduction of interior noise caused by R-MDPS of electric power steering in electric vehicle

This paper presents a novel active vibration control (AVC) system for a motor driven power steering (MDPS) system to reduce interior noise in an electric vehicle. The novel control algorithm used for the AVC system is developed based on selection of two reference signals. One is the frequency modulation signal using the rotation speed of motor shaft of MDPS the other one is the band passed signal of acceleration measured on the major path structure identified by the blocked transfer path (BF-TPA). In addition, the piezo stack actuator is used for generation of control force of the AVC system in the frequency over 400 Hz. An MDPS system uses electronic power steering. An MDPS system attached to the rack gear of power steering system is called an R-MDPS. The vibration generated by the R-MDPS is transmitted to the car body through mounts attached onto the car subframe. Panel vibrations of car body are sources of vibroacoustic noise generated inside the car cabin. This vibracoustic noise is a structure-borne noise and causes passenger annoyance. The frequencies of the structure-borne noise measured inside the car cabin are 460 Hz and 920 Hz, which are the rotating frequency of the R-MDPS motor shaft and the second-order harmonic of the rotating speed of the motor shaft. To directly reduce the interior noise inside the car cabin, active noise control (ANC) has been used for the active cancellation of noises with frequencies less than 400 Hz. However, because the frequency of interior noise generated by the operation of the R-MDPS is higher than 400 Hz, AVC was employed in this study for the active cancellation of vibrations transmitted to the car body through the subframe mounts of the car. For application of AVC to the test car, the control force should be known. Therefore, the actuator for generating the control force should be inserted in the mount between the subframe and R-MDPS system. Installing the actuator in the test car is challenging because of the geometry limit of commercial cars. Hence, a test jig composed of an R-MDPS system and the subframe of the test car was developed and set up in the laboratory to study the applicability of AVC to R-MDPS. All investigations of AVC were performed using the test jig in the laboratory. The proposed method was successfully applied to the active cancellation of vibration at a target point on the subframe.

Meshing impact analysis of the gear and rack of the pumping machine based on the SPH–FEM coupling method

This paper explores the feasibility of using the coupled smooth particle hydrodynamics–finite element method (SPH–FEM) to study the gear rack and meshing impact problem. Firstly, a numerical model containing both SPH and FEM units is established, and its accuracy is verified. Then, the principle of gear rack meshing impact is analyzed from the perspective of impact dynamics theory, and the formula of maximum meshing impact force is derived. Finally, the meshing impact process of the rack and pinion is simulated using the coupled SPH–FEM method, and experiments are designed to verify it. The analysis results show that the SPH–FEM coupling method can simulate the meshing impact behavior of the gear mechanism more accurately. On the other hand, the severity of the impact in each operating section was obtained. It is also found that the impact stress has reached the material's tensile limit, revealing the mechanism of tooth surface wear caused by the impact. The results of the study provide a choice of research methods for gear mechanism meshing impact and also provide some reference for gear rack tooth shape optimization.

Active Vibration Control of Motor Driven Power Steering for Reduction of Interior Noise

This study presents a novel active vibration control (AVC) system on motor driven power steering (MDPS) to reduce interior noise reduction caused by operating the MDPS in an electric vehicle. MDPS is electronic power steering (EPS). The MDPS attached to the rack gear of power steering system is called R-MDPS. Operating of the R-MDPS generates a structural vibration of R-MDPS, and the vibration is transmitted to car body through mounts of car subframe. The vibrating body of car becomes a monopole and dipole sources of vibroacoustic noise generated inside car. This vibracoustic noise is a structure borne noise and makes passenger annoyance. To reduce interior noise inside a car directly, active noise control (ANC) has been used as active method and is a useful method for active cancellation of the low frequency noises less than 400Hz. However, in this study, because the frequency range of interior noise due to operation of R-MDPS is higher than 400Hz, the AVC system is employed and is applied to active cancellation of the vibration transmitted to car body through the subframe mounts. For application of AVC to test car, the control force is required and the actuator for generation of control force should be install on the mounts. For application of AVC to test car, the control force is required and the actuator for generation of control force should be inserted in the mount between subframe and R-MDPS. It requires an extra rework of test car. In this study to study the feasibility for the application of AVC system to R-MDPS, the test jig, which composes of R-MDPS and subframe of test car, is made and is set up in the laboratory. All study on AVC is performed in the laboratory. The proposed method is successfully applied to the active cancellation of vibration at target point of subframe. The developed method is going to be applied to the AVC of real test vehicle.

Особенности силового нагружения и самоторможения реечных и инверсных реечных передач

Rack gears are related to the three-link cylindrical spur gears and could be considered as the limiting case in external gearing with the negative gear ratio, where the number of teeth of one wheel becomes infinitely high. The paper presents results of studies on the synthesis of a new type of rack and pinion gears using helical or chevron out-of-pole gearing in order to achieve the self-braking effect. Geometric parameters and power loading of such gears are described, conditions for self-braking of pre-pole and post-pole gears are determined. Rack and pinion gears of the inverse gearing are described, where the output link moves in the opposite direction to that in structures with conventional gearing. The article is devoted to design and development of a new variety of rack and pinion inverse gears to increase their operational capabilities based on the self-braking effect, which makes it possible to create simple and compact machine drives for various fields of technology.

The Profiling of Hob Mill Used for Generating a Cycloidal Reducer’s Disk

This paper presents the profiling of the hob mill designed to generate the active surface of the cam of a cycloidal reducer. The algorithm allows determining the active surface of the generating rack gear, which is reciprocally enveloping with the active surface of the cycloidal disk. The novelty of the algorithm, based on the determination of the intermediate surface, consists in the fact that an innovative method of determining this surface is used, called the “virtual pole” method. The method allows determining the enwrapping curve of an ordered curl of surfaces, generated in the rolling movement of two conjugated centrodes. Using the “virtual pole” method, the calculation time for tool profiling is significantly reduced and the disadvantage of the resulting error, small enough to be neglected from a technical point of view, is fully compensated by this reduction in calculation time.

Experiments and finite element analysis on a hybrid polymer gear rack

This article presents the results of experiments and finite element analysis on a hybrid polymer gear concept. The study aimed to investigate the effectiveness of the hybrid gear concept by using a rack tooth geometry.The results of the experiments have shown that the hybrid gear concept improves the heat evacuation from the flank and root regions, potentially increasing the load-carrying capacity. Additionally, the results of the experiments were compared with those obtained from the finite element analysis to validate the numerical model. The results showed that the hybrid polymer gear rack exhibited good thermal performance, and the finite element analysis accurately predicted the behaviour of the gear rack specimens. The study also analyses the influence of the interference fit on the contact pressure and thermal contact conductance in a hybrid polymer gear concept, taking into account surface roughness and temperature. It provides insights for optimizing the press fit to ensure efficient heat dissipation in practical applications.Overall, the study provides valuable insights into the potential use of hybrid polymer–metal materials in gear applications and supports the validity of the hybrid gear concept.

Structural design and mechanics research of a bionic pelican floating object fishing device

In order to meet the needs of surface floating objects fishing operations in small areas such as lakes and rivers, a fishing device is developed that can be used for high-intensity operations and is highly adaptable to the environment. In this paper, a water and land type bionic pelican surface floating object fishing device is developed based on the MeArm robotic arm combined with a three-degree-of-freedom linkage robotic arm using bionic principles. In order to meet the needs of the fishing function, the overall structure of the surface floating object fishing device was bionically designed by combining the large beak and flexible neck of the pelican, The innovative design of the mouth lower beak opening and closing mechanism, the lower beak gear rack lever slide mechanism, the mouth throat pouch bottom release mechanism and the neck structure are mainly carried out.The structural strength of the device under the most dangerous operating conditions was simulated using finite element analysis software for statics and dynamics simulation. The research results show that the structure of this design is reliable, and the experimental test of the prototype model verifies the validity and reliability of this design scheme, which provides the theoretical and experimental basis for the further development of the subsequent products.

Research form of rack teeth for movement mechanism engine

Assumptions and limitations have been adopted for studying the shape of the teeth of the gear rack and pinion of the object. The parameters of the gear line are determined under the condition of minimizing friction forces. Variants of the profile of the propeller rail teeth are offered. The criteria for choosing the best profile of the rack teeth are given. The best forms of the profile of the rack teeth for the heavily loaded driving conditions have been determined.

Research on obstacle performance and tipping stability of a novel wheel–leg deformation mechanism

Abstract. A new type of wheel–leg deformation mechanism, based on an electromagnetic clutch and gear rack transmission mechanism, is designed. This mechanism has a compact structure and simple operation, which can roll on wheels and surmount obstacles with a support leg. Firstly, the walking model is established to study the kinematics characteristics of the mechanism. The alternation of the support legs does not affect smooth obstacle crossing, but will cause the step change of the angular velocity of the centroid of the main body. Secondly, the obstacle-surmounting performance of roll-over mode and obstacle-crossing mode using support legs is analyzed. For roll-over mode, the maximum climbing height is 87.36 mm. For obstacle-crossing mode using support legs, the maximum climbing height is the maximum extension length of the support leg. According to the climbing height, the switching criteria of different climbing modes are obtained. In addition, the rolling angle of the main body has a greater impact on the support force and driving torque, while the contact angle between the legs and the ground has a small impact. Finally, the tipping stability and anti-interference ability of the wheel–leg deformation mechanism is evaluated using the stability cone method.

ANALYSIS OF THE INFLUENCE OF THE DISPLACEMENT OF THE GEAR RACK PROFILE OF THE PAIR EVOLUTION GEARING ON THE QUALITY INDICATORS OF THE TRANSMISSION

The article is devoted to the study of the influence of the modification of the paired evolute gearing with convex-concave contact on the quality indicators of transmission, namely, the contact pressure and the speed of slippage in the engagement. Previous studies of evolute gears showed the presence of characteristic zones on the side surface of the tooth, which have worse values of quality indicators than in similar involute gear. One of the ways to remove these zones or to reduce their impact on the load capacity of the transmission is to modify the tooth profile, which will be implemented by shifting the profile of the processing gear rack. A displacement factor is added to the equation of the rail profile curve, which has the same value for the gear and wheel teeth, but the opposite sign. On the basis of the developed equation, the side profiles of the teeth of the gear and the wheel were constructed. Several values of the rack displacement coefficient with a positive and negative sign for the gear teeth are considered. The results of the research allow us to evaluate the influence of the amount and direction of the rail displacement on the curvature of the tooth profiles, the contact pressure in engagement along the height of the tooth, and the relative and absolute speed of sliding. The modifications of the profile of the processing toothed rack proposed in this work will expand the existence of paired evolute gears with a different set of quality indicators. This will make it possible to design gears with rational values of contact pressures and slip speeds when they are used in heavily loaded transmissions created for specific operating conditions. Gears with relatively high slip speeds can be used in road and construction equipment transmissions, which are characterized by low shaft rotation frequency, in which the speed of slip between the teeth does not have a significant effect on the life or efficiency of the transmission. Otherwise, gears with relatively low slip speeds are very relevant when they are implemented in the transmission of modern and promising vehicles with a hybrid or fully electric power unit, especially in the case of passenger cars with high-speed electric motors.