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Gear fault diagnosis using gear meshing stiffness identified by gearbox housing vibration signals

《机械工程前沿（英文）》 2022年 第17卷 第4期 doi: 10.1007/s11465-022-0713-3

摘要： Gearbox fault diagnosis based on vibration sensing has drawn much attention for a long time. For highly integrated complicated mechanical systems, the intercoupling of structure transfer paths results in a great reduction or even change of signal characteristics during the process of original vibration transmission. Therefore, using gearbox housing vibration signal to identify gear meshing excitation signal is of great significance to eliminate the influence of structure transfer paths, but accompanied by huge scientific challenges. This paper establishes an analytical mathematical description of the whole transfer process from gear meshing excitation to housing vibration. The gear meshing stiffness (GMS) identification approach is proposed by using housing vibration signals for two stages of inversion based on the mathematical description. Specifically, the linear system equations of transfer path analysis are first inverted to identify the bearing dynamic forces. Then the dynamic differential equations are inverted to identify the GMS. Numerical simulation and experimental results demonstrate the proposed method can realize gear fault diagnosis better than the original housing vibration signal and has the potential to be generalized to other speeds and loads. Some interesting properties are discovered in the identified GMS spectra, and the results also validate the rationality of using meshing stiffness to describe the actual gear meshing process. The identified GMS has a clear physical meaning and is thus very useful for fault diagnosis of the complicated equipment.

关键词： gearbox fault diagnosis     meshing stiffness     identification     transfer path     signal processing    

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Numerical analysis and experimental investigation of modal properties for the gearbox in wind turbine

Pengxing YI,Peng HUANG,Tielin SHI

《机械工程前沿（英文）》 2016年 第11卷 第4期   页码 388-402 doi: 10.1007/s11465-016-0404-z

摘要：

Wind turbine gearbox (WTG), which functions as an accelerator, ensures the performance and service life of wind turbine systems. This paper examines the distinctive modal properties of WTGs through finite element (FE) and experimental modal analyses. The study is performed in two parts. First, a whole system model is developed to investigate the first 10 modal frequencies and mode shapes of WTG using flexible multi-body modeling techniques. Given the complex structure and operating conditions of WTG, this study applies spring elements to the model and quantifies how the bearings and gear pair interactions affect the dynamic characteristics of WTGs. Second, the FE modal results are validated through experimental modal analyses of a 1.5 WM WTG using the frequency response function method of single point excitation and multi-point response. The natural frequencies from the FE and experimental modal analyses show favorable agreement and reveal that the characteristic frequency of the studied gearbox avoids its eigen-frequency very well.

关键词： wind turbine gearbox     modal analysis     finite element analysis     modal frequency     bearing equivalence    

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Digital twin-assisted gearbox dynamic model updating toward fault diagnosis

《机械工程前沿（英文）》 2023年 第18卷 第2期 doi: 10.1007/s11465-023-0748-0

摘要： One of the core challenges of intelligent fault diagnosis is that the diagnosis model requires numerous labeled training datasets to achieve satisfactory performance. Generating training data using a virtual model is a potential solution for addressing such a problem, and the construction of a high-fidelity virtual model is fundamental and critical for data generation. In this study, a digital twin-assisted dynamic model updating method for fault diagnosis is thus proposed to improve the fidelity and reliability of a virtual model, which can enhance the generated data quality. First, a virtual model is established to mirror the vibration response of a physical entity using a dynamic modeling method. Second, the modeling method is validated through a frequency analysis of the generated signal. Then, based on the signal similarity indicator, a physical–virtual signal interaction method is proposed to dynamically update the virtual model in which parameter sensitivity analysis, surrogate technique, and optimization algorithm are applied to increase the efficiency during the model updating. Finally, the proposed method is successfully applied to the dynamic model updating of a single-stage helical gearbox; the virtual data generated by this model can be used for gear fault diagnosis.

关键词： digital twin     gearbox     model construction     model updating     physical–virtual interaction    

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Intelligent fault diagnostic system based on RBR for the gearbox of rolling mills

Lixin GAO, Lijuan WU, Yan WANG, Houpei WEI, Hui YE

《机械工程前沿（英文）》 2010年 第5卷 第4期   页码 483-490 doi: 10.1007/s11465-010-0118-6

摘要： This paper presents an intelligent system that is necessary for diagnostic accuracy and efficiency in the iron and steel industry. A rule-based reseaning (RBR) intelligent diagnostic system has been developed based on many successful diagnostic applications. It can solve the difficulty in knowledge acquisition and has more precision. Its application results prove that the usability of the system is good and it will increasingly attain perfection.

关键词： rule-based reasoning     fault diagnosis     intelligent system     gear box    

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Application of python-based Abaqus preprocess and postprocess technique in analysis of gearbox vibration

Guilian YI, Yunkang SUI, Jiazheng DU

《机械工程前沿（英文）》 2011年 第6卷 第2期   页码 229-234 doi: 10.1007/s11465-011-0128-z

摘要：

To reduce vibration and noise, a damping layer and constraint layer are usually pasted on the inner surface of a gearbox thin shell, and their thicknesses are the main parameters in the vibration and noise reduction design. The normal acceleration of the point on the gearbox surface is the main index that can reflect the vibration and noise of that point, and the normal accelerations of different points can reflect the degree of the vibration and noise of the whole structure. The K-S function is adopted to process many points’ normal accelerations as the comprehensive index of the vibration characteristics of the whole structure, and the vibration acceleration level is adopted to measure the degree of the vibration and noise. Secondary development of the Abaqus preprocess and postprocess on the basis of the Python scripting programming automatically modifies the model parameters, submits the job, and restarts the analysis totally, which avoids the tedious work of returning to the Abaqus/CAE for modifying and resubmitting and improves the speed of the preprocess and postprocess and the computational efficiency.

关键词： Abaqus secondary development     Python language     vibration and noise reduction     K-S function     vibration acceleration level    

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Fault diagnosis of spur gearbox based on random forest and wavelet packet decomposition

Diego CABRERA,Fernando SANCHO,René-Vinicio SÁNCHEZ,Grover ZURITA,Mariela CERRADA,Chuan LI,Rafael E. VÁSQUEZ

《机械工程前沿（英文）》 2015年 第10卷 第3期   页码 277-286 doi: 10.1007/s11465-015-0348-8

摘要：

This paper addresses the development of a random forest classifier for the multi-class fault diagnosis in spur gearboxes. The vibration signal’s condition parameters are first extracted by applying the wavelet packet decomposition with multiple mother wavelets, and the coefficients’ energy content for terminal nodes is used as the input feature for the classification problem. Then, a study through the parameters’ space to find the best values for the number of trees and the number of random features is performed. In this way, the best set of mother wavelets for the application is identified and the best features are selected through the internal ranking of the random forest classifier. The results show that the proposed method reached 98.68% in classification accuracy, and high efficiency and robustness in the models.

关键词： fault diagnosis     spur gearbox     wavelet packet decomposition     random forest    

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Tacholess order-tracking approach for wind turbine gearbox fault detection

Yi WANG, Yong XIE, Guanghua XU, Sicong ZHANG, Chenggang HOU

《机械工程前沿（英文）》 2017年 第12卷 第3期   页码 427-439 doi: 10.1007/s11465-017-0452-z

摘要：

Monitoring of wind turbines under variable-speed operating conditions has become an important issue in recent years. The gearbox of a wind turbine is the most important transmission unit; it generally exhibits complex vibration signatures due to random variations in operating conditions. Spectral analysis is one of the main approaches in vibration signal processing. However, spectral analysis is based on a stationary assumption and thus inapplicable to the fault diagnosis of wind turbines under variable-speed operating conditions. This constraint limits the application of spectral analysis to wind turbine diagnosis in industrial applications. Although order-tracking methods have been proposed for wind turbine fault detection in recent years, current methods are only applicable to cases in which the instantaneous shaft phase is available. For wind turbines with limited structural spaces, collecting phase signals with tachometers or encoders is difficult. In this study, a tacholess order-tracking method for wind turbines is proposed to overcome the limitations of traditional techniques. The proposed method extracts the instantaneous phase from the vibration signal, resamples the signal at equiangular increments, and calculates the order spectrum for wind turbine fault identification. The effectiveness of the proposed method is experimentally validated with the vibration signals of wind turbines.

关键词： wind turbine     variable-speed operating conditions     Vold-Kalman filtering     tacholess order tracking    

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Fault feature extraction of planet gear in wind turbine gearbox based on spectral kurtosis and time wavelet

Yun KONG, Tianyang WANG, Zheng LI, Fulei CHU

《机械工程前沿（英文）》 2017年 第12卷 第3期   页码 406-419 doi: 10.1007/s11465-017-0419-0

摘要：

Planetary transmission plays a vital role in wind turbine drivetrains, and its fault diagnosis has been an important and challenging issue. Owing to the complicated and coupled vibration source, time-variant vibration transfer path, and heavy background noise masking effect, the vibration signal of planet gear in wind turbine gearboxes exhibits several unique characteristics: Complex frequency components, low signal-to-noise ratio, and weak fault feature. In this sense, the periodic impulsive components induced by a localized defect are hard to extract, and the fault detection of planet gear in wind turbines remains to be a challenging research work. Aiming to extract the fault feature of planet gear effectively, we propose a novel feature extraction method based on spectral kurtosis and time wavelet energy spectrum (SK-TWES) in the paper. Firstly, the spectral kurtosis (SK) and kurtogram of raw vibration signals are computed and exploited to select the optimal filtering parameter for the subsequent band-pass filtering. Then, the band-pass filtering is applied to extrude periodic transient impulses using the optimal frequency band in which the corresponding SK value is maximal. Finally, the time wavelet energy spectrum analysis is performed on the filtered signal, selecting Morlet wavelet as the mother wavelet which possesses a high similarity to the impulsive components. The experimental signals collected from the wind turbine gearbox test rig demonstrate that the proposed method is effective at the feature extraction and fault diagnosis for the planet gear with a localized defect.

关键词： wind turbine     planet gear fault     feature extraction     spectral kurtosis     time wavelet energy spectrum    

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Review of the damage mechanism in wind turbine gearbox bearings under rolling contact fatigue

Yun-Shuai SU, Shu-Rong YU, Shu-Xin LI, Yan-Ni HE

《机械工程前沿（英文）》 2019年 第14卷 第4期   页码 434-441 doi: 10.1007/s11465-018-0474-1

摘要： Wind turbine gearbox bearings fail with the service life is much shorter than the designed life. Gearbox bearings are subjected to rolling contact fatigue (RCF) and they are observed to fail due to axial cracking, surface flaking, and the formation of white etching areas (WEAs). The current study reviewed these three typical failure modes. The underlying dominant mechanisms were discussed with emphasis on the formation mechanism of WEAs. Although numerous studies have been carried out, the formation of WEAs remains unclear. The prevailing mechanism of the rubbing of crack faces that generates WEAs was questioned by the authors. WEAs were compared with adiabatic shear bands (ASBs) generated in the high strain rate deformation in terms of microstructural compositions, grain refinement, and formation mechanism. Results indicate that a number of similarities exist between them. However, substantial evidence is required to verify whether or not WEAs and ASBs are the same matters.

关键词： rolling contact fatigue (RCF)     white etching area (WEA)     white etching crack (WEC)     adiabatic shear band (ASB)    

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Multiple fault separation and detection by joint subspace learning for the health assessment of wind turbine gearboxes

Zhaohui DU, Xuefeng CHEN, Han ZHANG, Yanyang ZI, Ruqiang YAN

《机械工程前沿（英文）》 2017年 第12卷 第3期   页码 333-347 doi: 10.1007/s11465-017-0435-0

摘要：

The gearbox of a wind turbine (WT) has dominant failure rates and highest downtime loss among all WT subsystems. Thus, gearbox health assessment for maintenance cost reduction is of paramount importance. The concurrence of multiple faults in gearbox components is a common phenomenon due to fault induction mechanism. This problem should be considered before planning to replace the components of the WT gearbox. Therefore, the key fault patterns should be reliably identified from noisy observation data for the development of an effective maintenance strategy. However, most of the existing studies focusing on multiple fault diagnosis always suffer from inappropriate division of fault information in order to satisfy various rigorous decomposition principles or statistical assumptions, such as the smooth envelope principle of ensemble empirical mode decomposition and the mutual independence assumption of independent component analysis. Thus, this paper presents a joint subspace learning-based multiple fault detection (JSL-MFD) technique to construct different subspaces adaptively for different fault patterns. Its main advantage is its capability to learn multiple fault subspaces directly from the observation signal itself. It can also sparsely concentrate the feature information into a few dominant subspace coefficients. Furthermore, it can eliminate noise by simply performing coefficient shrinkage operations. Consequently, multiple fault patterns are reliably identified by utilizing the maximum fault information criterion. The superiority of JSL-MFD in multiple fault separation and detection is comprehensively investigated and verified by the analysis of a data set of a 750 kW WT gearbox. Results show that JSL-MFD is superior to a state-of-the-art technique in detecting hidden fault patterns and enhancing detection accuracy.

关键词： joint subspace learning     multiple fault diagnosis     sparse decomposition theory     coupling feature separation     wind turbine gearbox    

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Effect of friction coefficients on the dynamic response of gear systems

Lingli JIANG, Zhenyong DENG, Fengshou GU, Andrew D. BALL, Xuejun LI

《机械工程前沿（英文）》 2017年 第12卷 第3期   页码 397-405 doi: 10.1007/s11465-017-0415-4

摘要：

The inevitable deterioration of the lubrication conditions in a gearbox in service can change the tribological properties of the meshing teeth. In turn, such changes can significantly affect the dynamic responses and running status of gear systems. This paper investigates such an effect by utilizing virtual prototype technology to model and simulate the dynamics of a wind turbine gearbox system. The change in the lubrication conditions is modeled by the changes in the friction coefficients, thereby indicating that poor lubrication causes not only increased frictional losses but also significant changes in the dynamic responses. These results are further demonstrated by the mean and root mean square values calculated by the simulated responses under different friction coefficients. In addition, the spectrum exhibits significant changes in the first, second, and third harmonics of the meshing components. The findings and simulation method of this study provide theoretical bases for the development of accurate diagnostic techniques.

关键词： dynamic response     friction coefficient     wind loads     wind turbine gearbox    

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Weak characteristic information extraction from early fault of wind turbine generator gearbox

Xiaoli XU, Xiuli LIU

《机械工程前沿（英文）》 2017年 第12卷 第3期   页码 357-366 doi: 10.1007/s11465-017-0423-4

摘要：

Given the weak early degradation characteristic information during early fault evolution in gearbox of wind turbine generator, traditional singular value decomposition (SVD)-based denoising may result in loss of useful information. A weak characteristic information extraction based on µ-SVD and local mean decomposition (LMD) is developed to address this problem. The basic principle of the method is as follows: Determine the denoising order based on cumulative contribution rate, perform signal reconstruction, extract and subject the noisy part of signal to LMD and µ-SVD denoising, and obtain denoised signal through superposition. Experimental results show that this method can significantly weaken signal noise, effectively extract the weak characteristic information of early fault, and facilitate the early fault warning and dynamic predictive maintenance.

关键词： wind turbine generator gearbox     µ-singular value decomposition     local mean decomposition     weak characteristic information extraction     early fault warning    

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based structural optimization and experimental investigation of the planet carrier in wind turbine gearbox

Pengxing YI,Lijian DONG,Tielin SHI

《机械工程前沿（英文）》 2014年 第9卷 第4期   页码 354-367 doi: 10.1007/s11465-014-0319-5

摘要：

To improve the dynamic performance and reduce the weight of the planet carrier in wind turbine gearbox, a multi-objective optimization method, which is driven by the maximum deformation, the maximum stress and the minimum mass of the studied part, is proposed by combining the response surface method and genetic algorithms in this paper. Firstly, the design points’ distribution for the design variables of the planet carrier is established with the central composite design (CCD) method. Then, based on the computing results of finite element analysis (FEA), the response surface analysis is conducted to find out the proper sets of design variable values. And a multi-objective genetic algorithm (MOGA) is applied to determine the direction of optimization. As well, this method is applied to design and optimize the planet carrier in a 1.5 MW wind turbine gearbox, the results of which are validated by an experimental modal test. Compared with the original design, the mass and the stress of the optimized planet carrier are respectively reduced by 9.3% and 40%. Consequently, the cost of planet carrier is greatly reduced and its stability is also improved.

关键词： planet carrier     multi-objective optimization     genetic algorithms     wind turbine gearbox     modal experiment    

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Analysis of planetary gear transmission in non-stationary operations

Fakher CHAARI, Mohamed Slim ABBES, Fernando Viadero RUEDA, Alfonso Fernandez del RINCON, Mohamed HADDAR

《机械工程前沿（英文）》 2013年 第8卷 第1期   页码 88-94 doi: 10.1007/s11465-013-0361-8

摘要：

Planetary gearboxes operate usually in non-stationary conditions generated mainly by variable loads applied to these transmissions. In order to understand the dynamic behavior of planetary gearboxes in such conditions, a mathematic model is developed including driving unit, transmission and load. The variability of load induces a variable speed of the transmission which is taken into account when characterizing the main dynamic parameter of the transmission which is the mesh stiffness function. This function is not periodic following the variability of the transmission speed. The computation of the dynamic response shows an intimate relation between the vibration amplitude level and the load value. As the load increase the vibration level increase. A combined amplitude and frequency modulation is observed which is well characterized using Short Time Fourier transform more suited than the spectral analysis.

关键词： planetary gearbox     non-stationary conditions     variable load     dynamic response     time frequency analysis    

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标题 作者 时间 类型 操作

Gear fault diagnosis using gear meshing stiffness identified by gearbox housing vibration signals

期刊论文

Numerical analysis and experimental investigation of modal properties for the gearbox in wind turbine

Pengxing YI,Peng HUANG,Tielin SHI

期刊论文

Digital twin-assisted gearbox dynamic model updating toward fault diagnosis

期刊论文

Intelligent fault diagnostic system based on RBR for the gearbox of rolling mills

Lixin GAO, Lijuan WU, Yan WANG, Houpei WEI, Hui YE

期刊论文

Application of python-based Abaqus preprocess and postprocess technique in analysis of gearbox vibration

Guilian YI, Yunkang SUI, Jiazheng DU

期刊论文

Fault diagnosis of spur gearbox based on random forest and wavelet packet decomposition

Diego CABRERA,Fernando SANCHO,René-Vinicio SÁNCHEZ,Grover ZURITA,Mariela CERRADA,Chuan LI,Rafael E. VÁSQUEZ

期刊论文

Tacholess order-tracking approach for wind turbine gearbox fault detection

Yi WANG, Yong XIE, Guanghua XU, Sicong ZHANG, Chenggang HOU

期刊论文

Fault feature extraction of planet gear in wind turbine gearbox based on spectral kurtosis and time wavelet

Yun KONG, Tianyang WANG, Zheng LI, Fulei CHU

期刊论文

Review of the damage mechanism in wind turbine gearbox bearings under rolling contact fatigue

Yun-Shuai SU, Shu-Rong YU, Shu-Xin LI, Yan-Ni HE

期刊论文

Multiple fault separation and detection by joint subspace learning for the health assessment of wind turbine gearboxes

Zhaohui DU, Xuefeng CHEN, Han ZHANG, Yanyang ZI, Ruqiang YAN

期刊论文

Effect of friction coefficients on the dynamic response of gear systems

Lingli JIANG, Zhenyong DENG, Fengshou GU, Andrew D. BALL, Xuejun LI

期刊论文

Weak characteristic information extraction from early fault of wind turbine generator gearbox

Xiaoli XU, Xiuli LIU

期刊论文

based structural optimization and experimental investigation of the planet carrier in wind turbine gearbox

Pengxing YI,Lijian DONG,Tielin SHI

期刊论文

Analysis of planetary gear transmission in non-stationary operations

Fakher CHAARI, Mohamed Slim ABBES, Fernando Viadero RUEDA, Alfonso Fernandez del RINCON, Mohamed HADDAR

期刊论文