Transmission Gearbox Research Articles

Stochastic Optimization-Based Comparative Study of New Energy Vehicles’ Noise Characteristics

The gearbox gearbox transmission system, which is the foundation of a new energy vehicle, is responsible for the crucial duty of power transmission. In reality, the reducer gearbox system is the primary source of noise inside cars because of the design of the system, mistakes made during manufacturing and assembly, and gear engagement impulses. The research target is the second-stage retarder gearbox system of a new energy vehicle. A three-dimensional model of the retarder gearbox system is created using the Romax software.Static and dynamic analyses were carried out in Romax software based on the five typical conditions of start, acceleration, equal speed, deceleration, and stop in order to derive performance data such as maximum contact and bending stresses of the gears, single-position length load distribution, gearbox error, etc. In the NVH analysis, the system’s vibration acceleration was ascertained using the findings of the gearbox error analysis. In order to provide comparative data for vibration and noise reduction of gear modification, the comparative study analyses the data output results under various working conditions and analyses the relationship between gear engagement force and gear vibration.

Structural design and dynamic characteristics analysis of braided composite two-stage gear transmission system

In order to realize the lightweight design of the transmission system, the braided composite material is applied to the two-stage gear transmission system. According to the structural characteristics of the two-stage gear reducer box, the whole box is designed to be assembled with the braided base and the box wall. Woven composite materials are applied to the web parts of mixed metal composite gears to realize the design goal of lightweight gears. Then, under the assumption of ignoring the influence of friction, bearings and other factors on the system, the dynamic model of the two-stage gear transmission system considering the box is established. By normalizing and dimensionless processing of the equations, the dimensionless differential equations of motion are obtained. The fourth-order Runge–Kutta method is used to analyze the relationship between the connection parameters and the dynamic characteristics of the system under the two working conditions of rigid and flexible connection between the composite base and the box wall.Through the analytical analysis of vibration displacement of two-stage gear reducer and box, the theoretical basis is found for the numerical analysis results. Finally, the dynamic characteristics of the transmission system are studied by vibration resonance analysis through high and low frequency interference. It is found that in a certain frequency range, with the decrease of the mass and moment of inertia of the transmission parts corresponding to the mixed metal composite gear, the amplitude-frequency characteristic Q of the lightweight gear and gearbox transmission system is slightly lower than that of the common gear and gearbox system, and the stability of the system is increased, and the dynamic characteristics of the system are improved.

Dynamics model and vibrational response analysis of helical gear-rotor-bearing transmission system

As a core component of wind turbines, wind power gear speed increasers often work in harsh environments, so it is necessary to study the vibration characteristics of gear transmission systems. Taking a wind turbine gearbox high-speed stage helical gear transmission system as the research object, the dynamics model of multi-degree-of-freedom helical gear-rotor-bearing transmission system is established by the lumped parameter method and solved by Runge-Kutta method, taking into account the tooth side clearance of the gear, transmission error, eccentricity and support force of the nonlinear bearing. The effects of input torque, transmission error and tooth side clearance on the vibration characteristic response of the helical gear train were analyzed. The relationship between the trend of amplitude change in each direction of the gear and the trend of change in the major frequency components was analyzed under the conditions of changing internal and external excitation. The results show that torsional vibration dominates in the system. As the input torque increases, the vibration amplitude of the driving and driven gears decreases, and the frequency amplitude decreases significantly at multiple locations. Gear transmission errors and changes in tooth side clearance have significant effects on gear vibration amplitudes, but are sensitive only to the meshing frequency. The trend of gear vibration amplitude caused by the change of external excitation of the gear set is synchronized with the trend of main frequency amplitude in the corresponding direction, while the change of vibration amplitude caused by internal excitation is consistent with the trend of mesh frequency amplitude in the corresponding direction. The results of this paper can pave a certain foundation for the design and fault diagnosis of wind power gearbox transmission system.

Multi-obective performance analysis of a wind power plant equipped with a PAT system

In conventional wind power plants, the wind turbine drives an electrical generator equipped with an AC/DC converter for battery charging purposes and with an inverter inverter to supply power to the grid / AC load. This approach exhibits some drawbacks like the energy losses associated to the power electronics and the cost and the waste management of the battery storage systems.To overcome such drawbacks, this work proposes a new plant scheme, where the battery system has been removed (or strongly reduced) and the storage task is accomplished by a pumping system equipped with a reversible hydraulic machinery which can operate both as centrifugal pump and a hydraulic turbine (called Pump as Turbine). In this scenario, when the wind velocity is quite high, the reversible hydraulic machinery, working as centrifugal pump, will store energy in the form of potential energy pumping fluid to an elevated water reservoir. On the contrary, in low wind conditions, the Pump as Turbine will operate as a hydraulic turbine, helping the wind turbine to overcome the external mechanical load. This solution results in a number of advantages: lower plant costs, longer Pump as Turbine life with lesser maintenance and reduced waste costs.The present work focuses on a multi-objective performance analysis of the proposed wind system power scheme. Specifically, this multi-objective sensitivity analysis will be addressed to the net potential energy stored by the reversible hydraulic machinery, the extracted wind energy and the torque supplied by the Pump as Turbine in hydraulic turbine mode. Such an analysis will considered as design variables the Pump as Turbine (centrifugal pump mode) specific speed (pump geometry), the gear box transmission ratio between the centrifugal pump and the wind turbine and the pump head. The aim of this analysis is to evaluate the design variables range which could lead to determine the set of the multi-objective wind systems optimal design.

Design, Simulation and Multi-Objective Optimization of a Micro-Scale Gearbox for a Novel Rotary Peristaltic Pump.

Peristaltic pumps are widely used in biomedical applications to ensure the safe flow of sterile or medical fluids. They are commonly employed for drug injections, IV fluids, and blood separation (apheresis). These pumps operate through a progressive contraction or expansion along a flexible tube, enabling fluid flow. They are also utilized in industrial applications for sanitary fluid transport, corrosive fluid handling, and novel pharmacological delivery systems. This research provides valuable insights into the selection and optimal design of the powertrain stages for peristaltic pumps implemented in drug delivery systems. The focus of this paper lies in the simulation and optimization of the performance of a power transmission gearbox by examining the energy consumption, sound levels, reliability, and volume as output metrics. The components of the powertrain consist of a helical gear pair for the first stage, a bevel gear pair for the second one, and finally a planetary transmission. Through extensive simulations, the model exhibits promising results, achieving an efficiency of up to 90%. Furthermore, alternative configurations were investigated to optimize the overall performance of the powertrain. This process has been simulated by employing the KISSsoft/KISSsys software package. The findings of this investigation contribute to advancements in the field of biomedical engineering and hold significant potential for improving the efficiency, reliability, and performance of drug delivery mechanisms.

Design of organic fertilizer pellet machine with a capacity of 170.90 Kg/Hour using verein deutcher ingenieure 2222 method

Due to population expansion and heavy consumption, there has been an increase in household garbage in recent years. One of the waste processing techniques that is kind to the environment is turning organic waste into organic fertilizer. Pellets created from organic fertilizer will be more convenient to use and effective. This study aims to construct an organic fertilizer pellet printing machine using the VDI 2222 method to turn organic fertilizer into pellets. this design approach is used to make sure the finished product or system satisfies defined technical requirements and customer needs. A variation of the design for an organic fertilizer pellet machine has been created based on the research, and the design evaluation is based on a survey. The third machine variation was picked as the best machine variant based on the design's outcomes. This machine is made of materials that are generally accessible on the market, has a solid construction, and a simpler manufacturing procedure. The organic fertilizer pellet mill can produce 8 mm x 22 mm pellets at a rate of 170.90 kilograms per hour. An electric motor and coupler acting as a gearbox transmission link power this machine. UNP Steel was used to construct the framework to increase strength and lessen vibration

Weighted block ℓ1 norm induced 2D off-grid compressive beamforming for acoustic source localization: Methodology and applications

Identifying acoustic sources with high spatial resolution and precision is significant for machinery noise control. Off-grid compressive beamforming is an effective method for creating acoustic maps with a high spatial resolution. In this study, a two-dimensional off-grid compressive beamforming method via weighted block ℓ1 norm regularization (WBS-OCSBF) is proposed. The weighted ℓ1 norm offers a more uniform sparsity penalty compared to the ℓ1 norm. This method can enhance the performance of off-grid compressive beamforming. Additionally, it is easily implemented on mature linear programming solvers and converges with only a few iterations. Numerical simulations are conducted to analyze the effects of several major parameters on the performance of the proposed method. The simulation results demonstrate the superiority of the proposed method over some traditional methods. The proposed method is then validated using a loudspeaker noises localization experiment. A gearbox transmission system and a transformer are used as two specific objects to explore the industrial application value. The proposed method can effectively localize the gear meshing noise and transformer discharge faults with a high spatial resolution.

Experimental investigation for fault diagnosis of a single stage worm gearbox using response surface methodology

Gearbox transmission system is a fundamental factor in the industrial applications. If gearbox stop working due to different faults, it may break normal machine operation and cause a production loss. This research paper focused on fault analysis of combination of worm wheel and bearing by using root mean square (RMS) and response surface method (RSM). Faults considered on outer race and inner race of worm wheel bearing, on worm wheel tooth. These faults and load were considered as an important independent factor to understand their effects on RMS response of worm gearbox. Worm gearbox experimental setup is for laboratory experimentation and RSM for analysis. Twenty-seven experimental trial conducted for three level of parameters based on design of experiment (DOE). Vibration based response measured in frequency domain and root mean square parameter extracted for the fault analysis. Box behnken design RSM is implemented to investigate independent parameters effect on output parameter i.e. RMS. The result shows that effect of faulty inner race bearing is more on worm wheel as compared to faulty outer race bearing and fault parameter influence RMS than load parameter.

A robust intelligent fault diagnosis method for rotating machinery under noisy labels

Despite achieving considerable success, the fault diagnosis methods will still be disturbed by noisy labels, this causes the model’s degradation and reduced diagnostic precision. Focused on solving the above issues, a robust intelligent fault diagnosis approach for rotating machinery under noisy labels is proposed. Firstly, we maintain two deep neural networks (DNNs) and alternatively execute parameters updating and models optimization by referring to the Co-teaching strategy, which can maximize filtering different error types and implement pre-training of DNNs. Secondly, adopting a two-component Gaussian mixture model (GMM) to fit training dataset’s cross-entropy (CE) loss and realize the clean and noisy labels division according to the threshold. Then, a data augmentation method called Mixup operation is employed in semi-supervised learning (SSL) to increase noise robustness and avoid error accumulation, subsequently, performing fine-tuning and correction for clean and noisy samples. Challenging experiments on a transmission gearbox dataset under different noisy labels levels show that the proposed method has robustness to noise and significantly surpasses other approaches, which provides an important reference value for accurate fault diagnosis for rotating equipment parts with noisy labels.

Virtual Prototyping Modeling and Fault Diagnosis Technology for Mechanical and Electrical Equipment

<p>In order to study common faults in motors and motor transmission systems, this article uses a 5kW motor system as an experimental platform to establish a virtual prototype model. The prototype model includes the following five parts: motor unit, 6-degree of freedom loading mechanism, transmission gearbox, loading spindle, and AC excitation converter. Then, the BP neural network is used to identify typical faults in the virtual prototype. The final recognition time for vibration changes, temperature changes, and current disturbances does not exceed 45 seconds, with an average accuracy rate of over 99%. Overall, the algorithm can accurately diagnose typical faults in a relatively short time.</p> <p> </p>

Influences of Base Motions on Additional Excitations of Floating Wind Turbine Gearbox Transmission System

Influences of Base Motions on Additional Excitations of Floating Wind Turbine Gearbox Transmission System

Modelling and analysis of electric two-wheeler with novel planetary gear box transmission

With the world moving towards new sustainable sources of power for automobiles, electric powertrain systems are considered to be suitable. The study focuses on modelling and analysis of electric two-wheelers and designing and analysis of planetary gear box. Based on the analysis and market survey, recommendations for primary components are given. The electric vehicle is analysed using the drive cycle data and modelled using vehicle dynamics equations (Transportation Secure Data Centre). The result of this analysis is the current profile requirement to be fulfilled by the battery pack. The battery modelling and analysis is done based on the equivalent circuit modelling (Jackey et al., 2013; Jackey et al., 2009). The current profiles and battery testing data are used as input to the battery model (Jackey et al., 2009; Hu et al., 2014; Decibels Labs Pvt. Ltd.). SOC and voltage variations were determined from this modelling. The transmission gear ratio and geometry was determined (TM4 Electrodynamics). The dynamic analysis and life cycle estimation of the gear box was done in Ricardo SABR (Ricardo Software, 2020).

Modelling and analysis of electric two-wheeler with novel planetary gear box transmission

Modelling and analysis of electric two-wheeler with novel planetary gear box transmission

ТОРОИДАЛЬНЫЙ ВАРИАТОР С ФУНКЦИЕЙ АКТИВНОГО ИЗМЕНЕНИЯ ПРИЖИМНОГО УСИЛИЯ

The paper describes the results of the analysis of automatic transmission gearboxes (ATG) used in automotive industry, proposes an alternative variant of automatic transmission gearbox based on the toroidal type variator, gives advantages as well as a proposal to improve this type of automatic transmission in order to increase the level of its resource and carrying capacity by changing the clamping force of the working elements in critical modes. The proposed design of toroidal variator will allow to solve the problems with reliability of variators, to expand the possibility of using variators with more powerful engines while reducing maintenance costs, which will allow to use this design in serial automobiles.

Virthuman Application: Is an Autonomous Vehicle with Non-standard Seating Safe in a Side Crash?

Highly Automated Vehicles (HAVs) will be more comfortable for their occupants than common cars from different aspects. For instance, their occupants can access extra spaces to adjust their seats as there will be no steering wheel and gearbox transmission handle in the interior. Among a wide range of seating configuration possibilities, the majority of passengers prefer to be in the Face-to-Face or the Living room configurations that are known as non-standard seating configurations. The present survey investigated how safe are these non-standard seating configurations in a side crash in comparison with the standard one in which all seats are facing the front windshield. Four identical 50th percentile Virthuman models were integrated into a schematic of automated vehicle's interior. Standard three-point seatbelts fastened bodies to up-right seats made from Polyurethane foam. A 30 km/h crash acceleration pulse was applied to the model for simulating side crash with a virtual sledge test in the Virtual Performance Solution (VPS) environment, PAMCRASH module. Results revealed that the Living room configuration was safer for the Rear Left occupant in comparison with the Standard one. Also, the Front Left occupant did not experience safer occasions in non-standard configurations from a Head & Neck injury point of view.

Theoretical transmission analysis to optimize Gearbox for a 2.6 kW automatic pepper transplanter

A gearbox is an essential component of an automatic transplanter to transmit engine power to the transplanter components. It is necessary to find the appropriate gearbox dimensions and materials for the pepper transplanter to minimize transmission losses. Therefore, the objectives of this research were to simulate the power transmission efficiency of the gearbox, and to determine a suitable number of stages, and materials and the dimensions of the spur gears. A 2.6 kW gasoline engine was considered as the prime source to power the entire transplanter. The available maximum length between the engine and transplanter subsystem was 422 mm. By considering design issues, a simulation model was created to determine the efficiency of the pepper transplanter gearbox, including various types of mechanical losses in the gearing system. Three different modules (1, 2, and 3 mm) and two materials were used to evaluate the effects on transmission. The analysis results indicated that the gearbox transmission efficiency levels of seven to twelve stages were in the range of 93.0–98.7%, whereas the eight-stage gearbox yielded the maximum efficiency of 98.7%, greater than our target efficiency of 98.0%. Therefore, an eight-stage gearbox was selected for power transmission to the components. The power transmission simulation results showed that the overall efficiency from engine to transplanting mechanism shaft varied in range of 95.2–95.9% owing to contact of the gear meshes. The analysis results also indicated that the 25CrMo4 carbon steel material with a 2-mm module gear was appropriate for the pepper transplanter. The analysis in this paper can be used as reference in the design of pepper transplanter gears and gearboxes with suitable material properties to provide the desired efficiency.

Online anomaly detection and remaining useful life prediction of rotating machinery based on cumulative summation features

The bearing is the core component of the gearbox transmission system. Once it is damaged during operation, it will cause the shutdown of the mechanical equipment for maintenance. It has important application significance to carry out fault detection and remaining useful life (RUL) prediction. Whereas, some bottlenecks, such as the noise interference of state characteristics, the excessive dependence of supervised learning on prior samples, and the practical RUL online calculation, restrict the industrial application of RUL prediction for rotating machinery equipment. To overcome the above problems, this paper introduces the discrete wavelet transform (DWT) to decrease the noise of the vibration acceleration signal obtained, and then uses the sliding average method to weaken the transient excitation. To make the state characteristics of the monitored bearing trendy, linear, and monotonic, this paper proposes a new set of state interpret indicators: energy and cumulative summation feature (CSF) to reflect the bearing health status. Based on the available bearing health information, the fault boundary threshold is established through the 3[Formula: see text] criteria, which serves as the basis for first predicting time (FPT) detection. Once the FPT point is determined, this paper applies CSF to replace the original vibration acceleration amplitude as the degradation indicator, which has better linearity and monotonicity than amplitude-based indicators, and which is conducive to the implementation of simple structure curve fitting to carry out the overall RUL prediction. Comparing with existing methods, such as relevance vector machine (RVM), deep belief network (DBN), and particle filtering (PF)-based methods, the experimental results demonstrate that the proposed method has the best RUL prediction efficiency and the fastest convergence.

Increasing the wind power generation by modifying the windmill mechanism

The population-consuming resources are expanding by the day; the resources are mostly used in a limited fashion. As a result, a technique for connecting natural resources with growing populations is necessary. Wind turbine technology produces the highest power of any currently available renewable energy source, but it only converts energy into electricity in one direction of wind flow. Power creation is constrained since the current technique is intended to produce energy by receiving input from just one direction. This initiative aims to address this problem. This project's mechanism uses wind energy in both clockwise and counter-clockwise directions as input. Under perfect conditions, this system creates a lot more electricity than the existing traditional windmill system. This output is attained by changing the windmill's gearbox transmission system from a planetary gear system to a simple gear train system along with intermediate gear. As a consequence, if the wind blades allowed the two directional effects, then using this system the wind turbine blade's rotational position is reversed. Therefore, it can obtain an increase in power production by the recommended designed mechanism. These effects are analyzed by ANSYS Fluent software and the results are used to prove this increased output energy than the existing domestic windmills. In terms of electricity and energy conservation, this project shows a successful output.

COMPARISON OF GENETIC ALGORITHM AND NEURAL NETWORK APPROACHES FOR THE PROGNOSIS OF MECHANICAL IDLE RUNNING LOSSES IN AGRICULTURE TRACTOR TRANSMISSION

An experimental investigation of mechanical idle running losses in an agriculture tractor transmission was used to collect a wide range of data. The influence of the engine rotation speed, the number of switched-on gears, and the oil level in the transmission gearbox on the idle running losses was determined. Adequate regression models in cases of switched-on and switched-off PTO were received. A genetic algorithm was used to optimize mathematical models obtained using regression analysis. A feed-forward artificial neural network was also developed to estimate the same experimental data for mechanical idle running losses in transmission. A back-propagation algorithm was used when training and testing the network. A comparison of the correlation coefficient, reduced chi-square, mean bias error, and root mean square error between the experimental data and fit values of the obtained models was made. It was concluded that the neural network represented the mechanical idle running losses in tractor transmission more accurately than other models.

Aerodynamic Analyses of an Integrated Low-Pressure Compression System for Adaptive-Cycle Micro Turbofan Type Jet Engine

Unmanned Aerial Vehicles (UAVs) are commonly propeller-driven and low-speed. The concept of cost-efficient, much higher speed and longer range applications of micro jet engines was previously addressed such that an existing basic turbojet engine was converted into a single spool turbofan without using additional components of booster and low pressure turbine. Normally, this situation emerges matching problems since two spools are required to adjust the fan speed independently. A simple solution was to use a Continuously Variable Transmission (CVT) gearbox to adjust optimal speed for the fan. As a result, missing of the positive functionality of the booster would lump into the fan root to form a unified low pressure compression system (unified-LPC). Such a unified-LPC demands unique characteristics of having an extreme twist, very high pressure ratio and mass flux at the root section than at the tip section, despite the exact opposite is being enforced due to the wheel speed rise with radius. In light of these challenges, this work aims to investigate detailed aerodynamics of an existing design previously made and reported by the authors. It is shown that, despite the aerodynamic loading contrast throughout the span, the unified-LPC can still have a wide operating range and acceptable off-design aerodynamics. Complementing the previous design-oriented work, this paper aims to provide guidelines for such unified compression systems.