Model Of Gearbox Research Articles

COMPUTER MODELING OF TRANSIENT ELECTROMECHANICAL PROCESSES IN A WIND POWER PLANT WITH A MAGNETIC GEARBOX

In this work, a computer Simulink model of a wind power plant has been developed, which uses a magnetic gearbox instead of a mechanical gearbox and also contains a synchronous permanent magnet generator. A separate Simulink model of a magnetic gearbox built on the basis of a modulated magnetic field in the air gap was developed, which al-lows to study the stability of its operation both in steady-state and transient modes. Calculations of various dynamic modes of the wind power plant’s operation were carried out, based on the developed model, such as the starting mode, an instantaneous increase in the wind speed acting on the wind turbine, and an increase in the load of the electric gen-erator. According to the results of the calculations, it is shown that in transient modes, when short-term overloads oc-cur, both rotors of the magnetic gearbox can fall out of synchronous motion for a certain period of time and then, de-pending on the parameters of the gearbox (as well as its other elements), the electromechanical system either reaches a certain operating steady-state mode or loses the ability to transfer mechanical power from the wind turbine to the gen-erator. It has been shown that the use of a more powerful magnetic gearbox, with an increased value of the maximum magnetic torque, allows of a more overload-resistant operation of both: a gearbox and the wind plant as a whole. Ref-erences 9, figures 10.

3D DESIGN OF A AUTOMOTIVE 5 SPEED SYNCHROMESH GEARBOX IN AUTODESK INVENTOR

The gearbox is a rotary assembly that provides speed and torque conversions from one rotary power supply (crankshaft) to another device (drive wheels) due to internal combustion engine limitations and also facilitates the shaft steering output.Autodesk Inventor is a computer aided design (CAD) application for creating 3D digital prototypes used in mechanical design, visualization, tooling creation and product simulation. It allows the user to create prototype products that accurately simulate the weight, stress, friction, driving loads, and many more properties of the products and their components in a simulated 3D environment.This paper contains all the graphic knowledge and operations required to create a 3D model of a manual gearbox by using the Autodesk Inventor software, and step by step, procedure for generating a 3D model of an synchromesh gearbox, starting from the initial calculus in Mathconnex.

Interactive Application as a Teaching Aid in Mechanical Engineering

This paper examines the integration of interactive 3D applications into the teaching process in mechanical engineering education. An innovative interactive 3D application has been developed as a teaching aid for engineering students. The main advantage is its easy availability through a web browser on mobile devices or desktop computers. It includes four explorable 3D gearbox models with assembly animations, linked technical information, and immersive virtual and augmented reality (AR) experiences. The benefits of using this application in the teaching process were monitored on a group of students at the end of the semester. Assessments conducted before and after the use of the interactive 3D application measured learning outcomes. Qualitative feedback from students was also collected. The results demonstrated significant improvements in engagement, spatial awareness, and understanding of gearbox principles compared to traditional methods. The versatility and accessibility of the application also facilitated self-directed learning, reducing the need for external resources. These findings indicate that interactive 3D tools have the potential to enhance student learning and engagement and to promote sustainable practices in engineering education. Future research could explore the scalability and applicability of these tools across different engineering disciplines and educational contexts.

Investigation on the fusion reliability and cluster consistency of multivariable entropy method

Recent researches have shown that the multivariable entropy based feature extraction method can obtain better diagnosis results for fault diagnosis of planetary gearbox. However, the nature properties of multivariable entropy have still not been deeply explored: the reliability of multi-source information fusion and cluster consistency for the same fault signal. These two properties will affect the accuracy of fault diagnosis based on multivariate entropy. This paper aims to reveal the nature properties of multivariate entropy. Firstly, a rigid-flexible coupling dynamic model of a planetary gearbox is conducted to establish a pure test environment. Then the generated vibration signals are used to evaluate the fusion reliability and cluster consistency of multivariable entropy. Additionally, a new multivariable entropy feature extraction method called variational embedding refined composite multiscale diversity entropy (veRCMDE) is proposed. Finally, the simulation and experiment results show that high fusion reliability and high cluster consistency enable multivariate entropy to extract more valuable features, and the proposed veRCMDE performs the best in all experiments.

Optimization of gearbox housing shape for agricultural UTV using structural–acoustic coupled analysis

In this study, gearbox radiated noise was successfully reduced through housing shape optimization. First, dynamic and structural–acoustic coupled analysis models of an agricultural UTV gearbox were developed. Then, the test equipment was configured to match that of the simulation model, and a test was conducted. The analysis and test results showed errors within 0.1 dB for vibration and 0.2 dB(A) for noise, indicating that the models were reliable. The housing design was then optimized using topology optimization based on the developed structural–acoustic coupling analysis model. The sound pressure level around the housing was used as an objective function for topology optimization. The optimal distribution of materials for the housing was also derived to reduce the radiated noise. Lastly, the housing rib was designed based on the optimization result, and an improvement in the radiated noise by approximately 2.43 dB(A) was confirmed in the operation area.

Investigation of mesh force features under different planet tooth faults in planetary gearboxes

The mesh force of planetary gearboxes is the major excitation source of vibration. Thus, comprehending how gear faults impact the mesh force is essential in identifying specific fault information from the vibration response for accurate fault diagnosis. In this paper, the internal mesh force and mesh stiffness models of the planetary gearbox are established to depict the influence mechanism of planet tooth faults on the internal mesh force. Further, the theoretical internal mesh force features are validated via the ring tooth root strain, where the strain simulation and measurement are carried out, and a strain separation method is developed to obtain the actual mesh force features. The experimental and theoretical results both demonstrate that different planet tooth faults exhibit specific phase and trend features in the internal mesh force, which provides a foundation for tooth fault classification in planetary gearboxes.

Study on the dynamic characteristics of planetary gear transmission mechanism of metal cold rolling mill

Using the parametric modelling feature in Solidworks software, a three-dimensional solid model of a planetary gearbox with linear reciprocating motion of the output shaft was constructed. By conducting theoretical calculations related to the kinematics of the transmission system and combining Adams virtual prototyping simulation technology, a dynamic simulation model of the planetary gear transmission mechanism was established to analyse the motion laws and dynamic characteristics. The simulation results were compared and analysed against the theoretical calculation results, and they showed good agreement and consistency. The study also investigated the impact of counterweights on the inertia forces and moments of the output shaft in the transmission mechanism. The results indicated that adding counterweights effectively reduced the inertia impact caused by inertia forces at the start and end positions of the stroke, as well as the inertia torque caused by changes in angular acceleration during the startup and stopping phases, thereby enhancing the smooth operation of the mechanism. Additionally, different thicknesses of counterweights had varying effects on balancing the inertia forces and moments of the output shaft. The study aimed to find the optimal thickness of counterweights to achieve the best balance effect. Furthermore, the study examined the influence of different speeds of the driving gear on the inertia forces of the output shaft. The results showed that at a driving gear speed of 1500 rpm, the horizontal thrust generated by the output shaft was 63566 N, which could provide the required thrust for the rolling mill operation, and the inertia forces of the output shaft tended to stabilize.

Multi-time scale thermal tribological dynamics coupling model of the helicopter intermediate reducer under severe loss of lubrication

There is no lubrication in the contact area, which leads to a significant influence of the thermal characteristics on the friction dynamics and life of the helicopter intermediate reducer because the helicopter experiences severe loss of lubrication. In this study, for evaluating the non-linear friction dynamics and transient thermal network models of the intermediate gearbox, a multi-time scale coupling method was proposed to establish a proportional allocation method between the oil film region and the rough peak contact region of the tooth surface by considering the effect of temperature and to study the adsorption film under the condition of severe lubrication loss. The coupled thermal and kinetic characteristics of the severe lubrication loss condition were obtained by calculating the friction coefficients in the lubricated and dry-friction regions. The results showed that the friction coefficient of the bevel gear tooth surface fluctuated between 0.1 and 0.6, and the degree of the gear axis trajectory shift was more evident owing to the increase in the friction force excitation caused by the increase in the friction coefficient.

ANALYSIS OF RESEARCH ON PLANETARY GEARBOXES OF ARMORED VEHICLES (REVIEW ARTICLE)

The work is devoted to the review of modern trends in the research and use of planetary gearboxes of armored vehicles. An analysis of the areas of application of mechanical transmissions was carried out. The advantages and disadvantages of using gear gearboxes as part of mechanical transmissions are described. The design features of the use of gears in transmissions are considered. The requirements for gear gearboxes as part of transmissions are defined. The advantages and disadvantages of using planetary gearboxes and their areas of use are analyzed. The classification of mechanical adjustable gears according to general features, as well as individual ones, is considered. An overview of the fulfillment of the conditions for increasing reliability was carried out, taking into account the design features of stepped gearboxes, which are divided into three groups: simple gearboxes (with fixed shaft axes); planetary gearboxes (with movable shaft axes); combined (combination of a simple and planetary gearbox in one unit). A brief review of modern approaches to planetary gear box modeling, taking into account inertial, elastic, dissipative, transformer and frictional properties, taking into account other characteristic features of the planetary series, is carried out. An analysis of known ways of solving problems of such modeling was carried out. Modern methods of calculating the strength of planetary gearboxes, including those with partial destruction, and corresponding software complexes are analyzed. The need for the development of more advanced mathematical models that adequately describe the stress-strain state in gear engagements has been identified. Keywords: design, planetary gearboxes, mechanical transmission, influence of operating factors, diagnostic parameters, synthesis of kinematic schemes

Research on Splash Lubrication Characteristics of a Spiral Bevel Gearbox Based on the MPS Method

In order to accurately and efficiently analyze the distribution law and motion status of lubricating oil in the spiral bevel gearbox of the electric multiple unit (EMU), a high-fidelity 3D CFD model of the spiral bevel gearbox of the EMU was established for the first time. The moving particle semi-implicit method was used to visualize the lubricating-oil flow field distribution characteristics of the gearbox. The distribution characteristics of lubricating oil in the gearbox with varying gear rotation speeds, initial lubricating-oil volume levels and oil temperatures were analyzed. It was found that the initial lubricating-oil volume is the factor with the largest influence, while the influences of gear rotation speed and oil temperature are relatively small. By analyzing the churning loss under various simulation conditions, it was found that the churning loss is positively correlated with the gear rotation speed and initial oil volume, and is more affected by the initial oil volume. The churning loss is negatively correlated with the oil temperature, and both are nonlinear relationships. The proportion of churning loss related to the driven gear is higher compared to that of the driving gear. These results can provide a theoretical basis for the subsequent optimization of the gearbox.

Wind Turbine Gearbox Condition Monitoring Using Hybrid Attentions and Spatio-Temporal BiConvLSTM Network

Gearbox fault deterioration can significantly impact the safety, reliability, and efficiency of wind turbines, resulting in substantial economic losses for wind farms. However, current condition monitoring methods face challenges in effectively mining the hidden spatio-temporal features within SCADA data and establishing reasonable weight allocations for model input variables. To tackle these issues, we proposed a novel condition monitoring method for wind turbine gearboxes called HBCE, which integrated a feature-time hybrid attention mechanism (HA), the bidirectional convolutional long short-term memory networks (BiConvLSTM), and an improved exponentially weighted moving-average (iEWMA). Specifically, utilizing historical health SCADA data acquired through the modified Thompson tau data-cleaning algorithm, a normal behavior model (HA-BiConvLSTM) of gearbox was constructed to effectively extract the spatio-temporal features and learn normal behavior patterns. An iEWMA-based outlier detection approach was employed to set dynamic adaptive thresholds, and real-time monitor the prediction residuals of HA-BiConvLSTM to identify the early faults of gearbox. The proposed HBCE method was validated through actual gearbox faults and compared with conventional spatio-temporal models (i.e., CNN-LSTM and CNN&LSTM). The results illustrated that the constructed HA-BiConvLSTM model achieved superior prediction precision in terms of RMSE, MAE, MAPE, and R2, and the proposed method HBCE can effectively and reliably identify early anomalies of a wind turbine gearbox in advance.

An Improved Coupled Dynamic Modeling for Exploring Gearbox Vibrations Considering Local Defects

Gearbox is a key part in machinery, in which gear, shaft and bearing operate together to transmit motion and power. The wide usage and high failure rate of gearbox make it attract much attention on its health monitoring and fault diagnosis. Dynamic modeling can study the mechanism under different faults and provide theoretical foundation for fault detection. However, current commonly used gear dynamic model usually neglects the influence of bearing and shaft, resulting in incomplete understanding on gearbox fault diagnosis especially under the effect of local defects on gear and shaft. To address this problem, an improved gear-shaft-bearing-housing dynamic model is proposed to reveal the vibration mechanism and responses considering shaft whirling and gear local defects. Firstly, an eighteen degree-of-freedom gearbox dynamic model is proposed, taking into account the interaction among gear, bearing and shaft. Secondly, the dynamic model is iteratively solved. Then, vibration responses are expounded and analyzed considering gear spalling and shaft crack. Numerical results show that the gear mesh frequency and its harmonics have higher amplitude through the spectrum. Vibration RMS and the shaft rotating frequency increase with the spalling size and shaft crack angle in general. An experiment is designed to verify the rationality of the proposed gearbox model. Lastly, comprehensive analysis under different spalling size and shaft crack angle are analyzed. Results show that when spalling size and crack angle is lager, RMS and the amplitude of shaft rotating frequency will not increase linearly. The dynamic model can accurately simulate the vibration of gear transmission system, which is helpful to gearbox fault diagnosis.

Variable stiffness-based vibration prediction for full coupling model of gearbox

Vibration is a problem worthy of attention in gearbox design. In the case of high speed and heavy load, vibration may be more significant, so some methods are needed to predict the vibration of the gearbox. At present, most vibration prediction methods have the problems of few research parameters, low fidelity and a large amount of calculation. In this paper, a fully coupled finite method model of variable stiffness gearbox based on lumped parameter method (LPM) is proposed, and the vibration prediction of gearbox housing is carried out considering time-varying meshing stiffness (TVMS), transmission error and other factors. Firstly, a new stiffness calculation method was proposed based on finite element theory and potential energy method, which can accurately solve the TVMS of fault gear. At the same time, the comprehensive meshing error of gear was solved. At then, the TVMS and comprehensive meshing error of the healthy gear and fault gear were brought into the dynamic equation of two-stage spur gear to obtain meshing force. After that, the meshing force was used as an excitation to solve the vibration of the gearbox housing. Finally, the vibration regularity of the health gearbox and fault gearbox was compared. The sensitivity of each gear shaft to the vibration caused by fault and the vibration regularity of different bearing seats of the same gear shaft was explored. The effectiveness of the simulation results was verified by experiments.

Mathematical modeling of a hybrid magnetic gear for an autonomous low-power wind turbine

In traditional wind turbines, a mechanical gearbox is used to transmit the torque. This device converts the low rotation speed of the wind turbine blades into the high rotation speed of the generator shaft. Mechanical gearboxes are characterized by low reliability. They consist of rotating gears, all the torque between which is transmitted through the contact of the teeth at one point, which is accompanied by friction. Magnetic multipliers are more efficient than gear reducers. They contain no wearing parts and have a relatively high torque density. The modulator transforms the magnetic field between the inner and outer rotor, due to which the speed of rotation changes. This device has a number of advantages over a mechanical gearbox - the interaction between rotating elements (torque transmission) occurs over their entire area, while the gears of mechanical gearboxes perceive all the transmitted force at one point of contact between them. Research of autonomous wind turbines built on the basis of magnetic gearboxes is a relevant direction. This will reduce operating costs, increase the efficiency of converting wind energy into electricity, and increase the reliability of the wind turbine as a whole. The purpose of the work is the development of a two-dimensional field mathematical model of a hybrid magnetic gearbox for the evaluation of its parameters and characteristics and the optimization of its geometric dimensions. A generator with a built-in magnetic multiplier is the object of this study. The magnetic multiplier during operation creates a rotating magnetic field that can be used to induce emf in the generator winding. Such a generator is more compact than a gear drive, so this option was chosen as a prototype in this study. Geometrical models of a hybrid generator with a magnetic gearbox were developed and numerical field mathematical models were developed for the analysis of its parameters and characteristics. An analysis of the electromagnetic field and characteristics of the basic generator was carried out in the COMSOL Multiphysics software complex, on the basis of which optimization of its geometric dimensions was carried out to optimize mass and dimensional indicators

Research on gearbox temperature field image fault diagnosis method based on transfer learning and deep belief network

This paper applies thermal imaging technology to gearbox fault diagnosis. The temperature field calculation model is established to obtain the temperature field images of various faults. A deep learning network model combining transfer learning of convolutional neural network with supervised training and unsupervised training of deep belief network is proposed. The model requires one-fifth of the training time of the convolutional neural network model. The data set used for training the deep learning network model is expanded by using the temperature field simulation image of the gearbox. The results show that the network model has over 97% accuracy for the diagnosis of simulation faults. The finite element model of gearbox can be modified with experimental data to obtain more accurate thermal images, and this method can be better used in practice.

Chaos and Impact Characteristics Analysis of a Multistage Planetary Gear System Based on the Energy Method

A dynamic modeling method for Multistage Planetary Gear Transmission (MPGT) is proposed based on the concept of integral planetary gearbox modeling. The integrated interaction of multiple nonlinear parameters is considered in the dynamic model. The time-varying mesh stiffness of each gear pair is calculated by the energy method. The effects of input torque, gear backlash, and meshing damping on the chaos and impact characteristics of the system are analyzed in detail. The results show that the dynamic behavior of the system is closely related to the Dynamic Meshing Force (DMF). When the system is in the states of chaos, bifurcation, and jumping, the DMF fluctuates violently, and the stability and reliability of the system are seriously affected. With the increase of input torque and meshing damping, the system exits chaos through the inverse period-doubling bifurcation path, which indicates that increasing the input torque and meshing damping can suppress the chaotic motion and enhance the stability of the system. The backlash has a significant effect on the nonlinear behavior and meshing impact characteristics of the system. When the backlash is small, the system is in bilateral impact, and the meshing impact tends to be stable as the backlash increases. In order to improve the vibration characteristics of the system, a slightly larger backlash is necessary. The results can be used to guide the dynamic characteristics design and vibration control of the MPGT.

A Health Assessment Technique Based on WPD and Multiple Linear Regression Analysis

A health assessment technique based on WPD and multiple linear regression analysis is studied in this paper. Firstly, the Temperature-Vibration function model is established by analyzing the mechanism of vibration and temperature of the gearbox. Secondly, the vibration and temperature signals and ambient temperature of the quayside crane lifting gearbox were decomposed by wavelet packet, and the total energy after wavelet packet reconstruction was calculated respectively. Thirdly, multiple linear regression analysis is carried out to obtain the multiple linear regression model of the lifting gearbox based on the established function model. Finally, the absolute error between the total energy of the wavelet packet of the actual and the calculated temperature is calculated to judge the health status of the gearbox during 2009-2015 according to the model. The results show that the judged health state of the quayside crane lifting gearbox is consistent with the actual situation, indicating that the technique can be effectively applied to the health assessment of the gearbox.

Manual assembly of products with interactive support of operations

The feature of workplaces automation in production is considered. The application of the Active Assist software package as an interactive support environment for manual assembly of a product is shown. A simplified model of a planetary gearbox and its stage-by-stage assembly with interactive support of the technological process are described. The advantages of interactive support using for the stages of the product manual assembly applied for automation the workplace are determined. Keywords automation of production processes, automated workplace, interactive support, industrial production, manual assembly, technological process, computer vision system, subassembly, digital transformation

Multi-resolution dynamic mode decomposition for damage detection in wind turbine gearboxes

Abstract We introduce an approach for damage detection in gearboxes based on the analysis of sensor data with the multi-resolution dynamic mode decomposition (mrDMD). The application focus is the condition monitoring of wind turbine gearboxes under varying load conditions, in particular irregular and stochastic wind fluctuations. We analyze data stemming from a simulated vibration response of a simple nonlinear gearbox model in a healthy and damaged scenario and under different wind conditions. With mrDMD applied on time-delay snapshots of the sensor data, we can extract components in these vibration signals that highlight features related to damage and enable its identification. A comparison with Fourier analysis, time synchronous averaging, and empirical mode decomposition shows the advantages of the proposed mrDMD-based data analysis approach for damage detection.

DESIGN OF A TRAINING WORKPLACE WITH A COLLABORATIVE AND INDUSTRIAL ROBOT

The article deals with the design of a training workplace equipped with two robots, one of which is industrial and the other collaborative. The assemblyof a gearbox model equipped with three different shafts is carried out at the training robotic workplace. The entire assembly process requires the mutual cooperation of an industrial, collaborative robot and a human operator. Use the assembly parts to create a large number of combinations, so that a number of individual tasks can be created at the workplace. The safety of workers at the workplace is solved by the use of safety laser scanners, so that there is no danger to people