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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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High-precision gyro-stabilized control of a gear-driven platform with a floating gear tension device

《机械工程前沿（英文）》 2021年 第16卷 第3期   页码 487-503 doi: 10.1007/s11465-021-0635-5

摘要： This study presents an improved compound control algorithm that substantially enhances the anti-disturbance performance of a gear-drive gyro-stabilized platform with a floating gear tension device. The tension device can provide a self-adjustable preload to eliminate the gap in the meshing process. However, the weaker gear support stiffness and more complex meshing friction are also induced by the tension device, which deteriorates the control accuracy and the ability to keep the aim point of the optical sensors isolated from the platform motion. The modeling and compensation of the induced complex nonlinearities are technically challenging, especially when base motion exists. The aim of this research is to cope with the unmeasured disturbances as well as the uncertainties caused by the base lateral motion. First, the structural properties of the gear transmission and the friction-generating mechanism are analyzed, which classify the disturbances into two categories: Time-invariant and time-varying parts. Then, a proportional-integral controller is designed to eliminate the steady-state error caused by the time-invariant disturbance. A proportional multiple-integral-based state augmented Kalman filter is proposed to estimate and compensate for the time-varying disturbance that can be approximated as a polynomial function. The effectiveness of the proposed compound algorithm is demonstrated by comparative experiments on a gear-drive pointing system with a floating gear tension device, which shows a maximum 76% improvement in stabilization precision.

关键词： inertially stabilized platform     floating gear tension device     nonlinear friction     disturbance compensation     proportional multiple-integral observer    

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齿轮测量技术100年——回顾与展望

石照耀,费业泰,谢华锟

《中国工程科学》 2003年 第5卷 第9期   页码 13-17

摘要：

全面概述了过去100年齿轮测量技术的发展历程，给出了6件标志性事情；着重论述了测量原理的演变、实现测量原理技术方式的发展以及测量结果的表述与利用；介绍了当今CNC齿轮测量中心的原理、组成和特点；结合90年代以来齿轮测量技术领域中几股新潮流，展望了未来齿轮测量技术的一些研究方向。

关键词： 齿轮     齿轮测量     齿轮误差     齿轮测量仪器    

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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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Russian school of the theory and geometry of gearing: Its origin and golden period (1935 --1975)

Dmitry BABICHEV,Sergey LAGUTIN,Natalya BARMINA

《机械工程前沿（英文）》 2016年 第11卷 第1期   页码 44-59 doi: 10.1007/s11465-015-0360-z

摘要：

During the second half of the twentieth century, Soviet scientists were among the world leaders in the theory and geometry of gearing or the theoretical fundamentals of designing gears and gear-cutting tools. The authors of the current paper review works related to the development of the theory of gearing (TG) written in Russian from the mid-1930s to the present. Overall, the review covers more than 400 publications of nearly 200 authors (among more than 1000 studied works). This review involves some works on gear strength and accuracy to attract more experts.

This paper presents a short list of works from the seventeenth century to the nineteenth century and discusses the basic concepts of the TG. This paper also includes a review of more than 160 papers in Russian for the period of 1935–1975, which is the “golden age” of the TG. The main features and achievements during this period are also considered.

The distinctive feature of this review is the use of diagrams that visually present TG experts and the dates and themes of their published works. The diagrams also show the following aspects: 1) The most popular and important themes in a specific period, 2) the most important publications on the themes of interest to readers, and 3) the direction of the works and scope of interests of every researcher.

关键词： theory of gearing (TG)     gear geometry     generating surface     gear synthesis     gear analysis    

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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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Experimental investigation of fatigue behavior of spur gear in altered tooth-sum gearing

H. K. SACHIDANANDA, Joseph GONSALVIS, H. R. PRAKASH

《机械工程前沿（英文）》 2012年 第7卷 第3期   页码 268-278 doi: 10.1007/s11465-012-0331-6

摘要：

This paper deals with the contact stress, power loss, and pitting of spur gear tooth in altered tooth-sum gearing for a tooth-sum of 100 teeth when altered by±4% tooth-sum. Analytical and experimental methods were performed to investigate and compare the altered tooth-sum gearing against the standard tooth-sum gearing. The experiments were performed using a power recirculating type test rig. The tooth loads for the experimental investigations were determined considering the surface durability of gears. A clear picture of the surface damage was obtained using a scanning electron microphotograph. The negative alteration in the tooth-sum performed better than the positive alteration in a tooth-sum operating between specified center distances.

关键词： spur gear     power recirculating test rig     altered tooth-sum gearing     scanning electron microscopy (SEM)    

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Mesh relationship modeling and dynamic characteristic analysis of external spur gears with gear wear

《机械工程前沿（英文）》 2022年 第17卷 第1期   页码 9-9 doi: 10.1007/s11465-021-0665-z

摘要： Gear wear is one of the most common gear failures, which changes the mesh relationship of normal gear. A new mesh relationship caused by gear wear affects meshing excitations, such as mesh stiffness and transmission error, and further increases vibration and noise level. This paper aims to establish the model of mesh relationship and reveal the vibration characteristics of external spur gears with gear wear. A geometric model for a new mesh relationship with gear wear is proposed, which is utilized to evaluate the influence of gear wear on mesh stiffness and unloaded static transmission error (USTE). Based on the mesh stiffness and USTE considering gear wear, a gear dynamic model is established, and the vibration characteristics of gear wear are numerically studied. Comparison with the experimental results verifies the proposed dynamic model based on the new mesh relationship. The numerical and experimental results indicate that gear wear does not change the structure of the spectrum, but it alters the amplitude of the meshing frequencies and their sidebands. Several condition indicators, such as root-mean-square, kurtosis, and first-order meshing frequency amplitude, can be regarded as important bases for judging gear wear state.

关键词： gear wear     mesh relationship     mesh stiffness     transmission error     vibration characteristics    

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Mathematical model and manufacture programming of loxodromic-type normal circular-arc spiral bevel gear

Zhenyun DUAN, Houjun CHEN, Zhilan JU, Jian LIU

《机械工程前沿（英文）》 2012年 第7卷 第3期   页码 312-321 doi: 10.1007/s11465-012-0308-5

摘要：

In this paper, loxodromic-type normal circular-arc spiral bevel gear is proposed as a novel application of the circular-arc tooth profile at the gear transmission with intersecting axes. Based on the principle of molding-surface conjugation, the study develops a mathematical model for the tooth alignment curve and the computational flow at the design stage to enable the generation of the tooth surface. Machining of the tooth surface is then carried out to determine the interference-free tool path of the numerical control (NC). Moreover, a pair of loxodromic-type normal circular-arc spiral bevel gears is manufactured on computer numerical control (CNC) machine tools. The proposed theory and method are experimentally investigated, and the obtained results primarily reflect the superior performance of the proposed novel gear.

关键词： loxodrome     circular-arc tooth profile     Wildhaber-Novikov (W-N) gear     spiral bevel gear    

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Effect of inlet box on performance of axial flow fans

LI Jingyin, TIAN Hua, YUAN Xiaofang

《能源前沿（英文）》 2008年 第2卷 第4期   页码 390-394 doi: 10.1007/s11708-008-0087-1

摘要： Numerical investigations on 3D flow fields in an axial flow fan with and without an inlet box have been extensively conducted, focusing on the variation of fan performance caused by the internal flow fields and the velocity evenness at the exit of the inlet box. It is interesting to find that although the inlet box is well designed in accordance with basic design principles, there is a flow separation region in it. Furthermore, this flow separation and the resulting uneven velocity distribution at the exit lead to some decrease in the efficiency and an increase in the total pressure rise of the fan. This research shows that the inlet box needs further improvement and such a check on the flow fields is of value for the design of inlet boxes.

关键词： box     velocity distribution     accordance     Numerical     variation    

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Design optimization of a wind turbine gear transmission based on fatigue reliability sensitivity

Genshen LIU, Huaiju LIU, Caichao ZHU, Tianyu MAO, Gang HU

《机械工程前沿（英文）》 2021年 第16卷 第1期   页码 61-79 doi: 10.1007/s11465-020-0611-5

摘要： Fatigue failure of gear transmission is one of the key factors that restrict the performance and service life of wind turbines. One of the major concerns in gear transmission under random loading conditions is the disregard of dynamic fatigue reliability in conventional design methods. Various issues, such as overweight structure or insufficient fatigue reliability, require continuous improvements in the reliability-based design optimization (RBDO) methodology. In this work, a novel gear transmission optimization model based on dynamic fatigue reliability sensitivity is developed to predict the optimal structural parameters of a wind turbine gear transmission. In the model, the dynamic fatigue reliability of the gear transmission is evaluated based on stress–strength interference theory. Design variables are determined based on the reliability sensitivity and correlation coefficient of the initial design parameters. The optimal structural parameters with the minimum volume are identified using the genetic algorithm in consideration of the dynamic fatigue reliability constraints. Comparison of the initial and optimized structures shows that the volume decreases by 3.58% while ensuring fatigue reliability. This work provides new insights into the RBDO of transmission systems from the perspective of reliability sensitivity.

关键词： gear transmission     fatigue reliability     reliabi-lity sensitivity     parameter optimization    

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On subsurface box-shaped lined tunnel under incident SH-wave propagation

《结构与土木工程前沿（英文）》 2021年 第15卷 第4期   页码 948-960 doi: 10.1007/s11709-021-0740-x

摘要： In this paper, a half-plane time-domain boundary element method is applied to obtain the seismic ground response, including a subsurface box-shaped lined tunnel deployed in a linear homogenous elastic medium exposed to obliquely incident SH-waves. Only the boundary around the tunnel is required to be discretized. To prepare an appropriate model by quadratic elements, a double-node procedure is used to receive dual boundary fields at corners as well as change the direction of the normal vector. After encoding the method in a previously confirmed computer program, a numerical study is carried out to sensitize some effective parameters, including frequency content and incident wave angle for obtaining a surface response. The depth and impedance ratio of the lining are assumed to be unvaried. The responses are illustrated in the time and frequency domains as two/three-dimensional graphs. The results showed that subsurface openings with sharp corners distorted the propagation path of the anti-plane waves to achieve the critical states on the ground surface. The present approach can be proposed to civil engineers for preparing simple underground box-shaped models with angular boundaries.

关键词： box-lined tunnel     half-plane BEM     surface response     SH-wave     time-domain    

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Contact fatigue life prediction of a bevel gear under spectrum loading

Pan JIA, Huaiju LIU, Caichao ZHU, Wei WU, Guocheng LU

《机械工程前沿（英文）》 2020年 第15卷 第1期   页码 123-132 doi: 10.1007/s11465-019-0556-8

摘要： Rolling contact fatigue (RCF) issues, such as pitting, might occur on bevel gears because load fluctuation induces considerable subsurface stress amplitudes. Such issues can dramatically affect the service life of associated machines. An accurate geometry model of a hypoid gear utilized in the main reducer of a heavy-duty vehicle is developed in this study with the commercial gear design software MASTA. Multiaxial stress–strain states are simulated with the finite element method, and the RCF life is predicted using the Brown–Miller–Morrow fatigue criterion. The patterns of fatigue life on the tooth surface are simulated under various loading levels, and the RCF curve is numerically generated. Moreover, a typical torque–time history on the driven axle is described, followed by the construction of program load spectrum with the rain flow method and the Goodman mean stress equation. The effects of various fatigue damage accumulation rules on fatigue life are compared and discussed in detail. Predicted results reveal that the Miner linear rule provides the most optimistic result among the three selected rules, and the Manson bilinear rule produces the most conservative result.

关键词： bevel gear     rolling contact fatigue (RCF)     multiaxial fatigue criterion     load spectrum     damage accumulation rule    

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Safety assessment for buried drainage box culvert under influence of underground connected aisle blasting

《结构与土木工程前沿（英文）》 2023年 第17卷 第2期   页码 191-204 doi: 10.1007/s11709-022-0906-1

摘要： Blasting engineering in complex urban environments is considered to influence the safety and stability of the overlying drainage box culvert structure owing to vibration. Therefore, field blasting and vibration tests were performed on the blasting engineering of the Wuhan Metro Line 8 connected aisle, and the LS-DYNA software was used to analyze the dynamic response characteristics of an underground drainage box culvert during the blasting test. The vibration response evolution law of the buried drainage box culvert under blasting vibration was investigated, and a safe surface control standard for the blast vibration of a drainage box culvert is proposed. The results reveal that the maximum tensile stress of the box culvert structure was 0.33 MPa. The peak particle velocity (PPV) and peak tensile stress (PTS) of the drainage box culvert decreased as the water level in the box culvert increased. Based on the relationship between the tensile stress of the box culvert, PPV of the box culvert, and PPV of the surface, it is proposed that the surface control velocity of the buried drainage box culvert is 1.36 cm/s.

关键词： drainage box culvert     underpass blasting     dynamic response     numerical simulation     safety assessment    

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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

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

High-precision gyro-stabilized control of a gear-driven platform with a floating gear tension device

期刊论文

齿轮测量技术100年——回顾与展望

石照耀,费业泰,谢华锟

期刊论文

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

期刊论文

Russian school of the theory and geometry of gearing: Its origin and golden period (1935 --1975)

Dmitry BABICHEV,Sergey LAGUTIN,Natalya BARMINA

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

Experimental investigation of fatigue behavior of spur gear in altered tooth-sum gearing

H. K. SACHIDANANDA, Joseph GONSALVIS, H. R. PRAKASH

期刊论文

Mesh relationship modeling and dynamic characteristic analysis of external spur gears with gear wear

期刊论文

Mathematical model and manufacture programming of loxodromic-type normal circular-arc spiral bevel gear

Zhenyun DUAN, Houjun CHEN, Zhilan JU, Jian LIU

期刊论文

Effect of inlet box on performance of axial flow fans

LI Jingyin, TIAN Hua, YUAN Xiaofang

期刊论文

Design optimization of a wind turbine gear transmission based on fatigue reliability sensitivity

Genshen LIU, Huaiju LIU, Caichao ZHU, Tianyu MAO, Gang HU

期刊论文

On subsurface box-shaped lined tunnel under incident SH-wave propagation

期刊论文

Contact fatigue life prediction of a bevel gear under spectrum loading

Pan JIA, Huaiju LIU, Caichao ZHU, Wei WU, Guocheng LU

期刊论文

Safety assessment for buried drainage box culvert under influence of underground connected aisle blasting

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