Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 9

Search results for: gearbox

9 Optimal Calculation of Partial Transmission Ratios of Four-Step Helical Gearboxes for Getting Minimal Gearbox Length

Authors: Vu Ngoc Pi

Abstract:

This paper presents a new study on the applications of optimization and regression analysis techniques for optimal calculation of partial ratios of four-step helical gearboxes for getting minimal gearbox length. In the paper, basing on the moment equilibrium condition of a mechanic system including four gear units and their regular resistance condition, models for determination of the partial ratios of the gearboxes are proposed. In particular, explicit models for calculation of the partial ratios are proposed by using regression analysis. Using these models, the determination of the partial ratios is accurate and simple.

Keywords: Gearbox design; optimal design; helical gearbox, transmission ratio.

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8 Singular Value Decomposition Based Optimisation of Design Parameters of a Gearbox

Authors: Mehmet Bozca

Abstract:

Singular value decomposition based optimisation of geometric design parameters of a 5-speed gearbox is studied. During the optimisation, a four-degree-of freedom torsional vibration model of the pinion gear-wheel gear system is obtained and the minimum singular value of the transfer matrix is considered as the objective functions. The computational cost of the associated singular value problems is quite low for the objective function, because it is only necessary to compute the largest and smallest singular values (μmax and μmin) that can be achieved by using selective eigenvalue solvers; the other singular values are not needed. The design parameters are optimised under several constraints that include bending stress, contact stress and constant distance between gear centres. Thus, by optimising the geometric parameters of the gearbox such as, the module, number of teeth and face width it is possible to obtain a light-weight-gearbox structure. It is concluded that the all optimised geometric design parameters also satisfy all constraints.

Keywords: Singular value, optimisation, gearbox, torsional vibration.

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7 Quality Control of Automotive Gearbox Based On Vibration Signal Analysis

Authors: Nilson Barbieri, Bruno Matos Martins, Gabriel de Sant'Anna Vitor Barbieri

Abstract:

In more complex systems, such as automotive gearbox, a rigorous treatment of the data is necessary because there are several moving parts (gears, bearings, shafts, etc.), and in this way, there are several possible sources of errors and also noise. The basic objective of this work is the detection of damage in automotive gearbox. The detection methods used are the wavelet method, the bispectrum; advanced filtering techniques (selective filtering) of vibrational signals and mathematical morphology. Gearbox vibration tests were performed (gearboxes in good condition and with defects) of a production line of a large vehicle assembler. The vibration signals are obtained using five accelerometers in different positions of the sample. The results obtained using the kurtosis, bispectrum, wavelet and mathematical morphology showed that it is possible to identify the existence of defects in automotive gearboxes.

Keywords: Automotive gearbox, mathematical morphology, wavelet, bispectrum.

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6 A Study on Optimal Determination of Partial Transmission Ratios of Helical Gearboxes with Second-Step Double Gear-Sets

Authors: Vu Ngoc Pi

Abstract:

In this paper, a study on the applications of the optimization and regression techniques for optimal calculation of partial ratios of helical gearboxes with second-step double gear-sets for minimal cross section dimension is introduced. From the condition of the moment equilibrium of a mechanic system including three gear units and their regular resistance condition, models for calculation of the partial ratios of helical gearboxes with second-step double gear-sets were given. Especially, by regression analysis, explicit models for calculation of the partial ratios are introduced. These models allow determining the partial ratios accurately and simply.

Keywords: Gearbox design, optimal design, helical gearbox, transmission ratio.

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5 Vehicle Gearbox Fault Diagnosis Based On Cepstrum Analysis

Authors: Mohamed El Morsy, Gabriela Achtenová

Abstract:

Research on damage of gears and gear pairs using vibration signals remains very attractive, because vibration signals from a gear pair are complex in nature and not easy to interpret. Predicting gear pair defects by analyzing changes in vibration signal of gears pairs in operation is a very reliable method. Therefore, a suitable vibration signal processing technique is necessary to extract defect information generally obscured by the noise from dynamic factors of other gear pairs.This article presents the value of cepstrum analysis in vehicle gearbox fault diagnosis. Cepstrum represents the overall power content of a whole family of harmonics and sidebands when more than one family of sidebands is present at the same time. The concept for the measurement and analysis involved in using the technique are briefly outlined. Cepstrum analysis is used for detection of an artificial pitting defect in a vehicle gearbox loaded with different speeds and torques. The test stand is equipped with three dynamometers; the input dynamometer serves asthe internal combustion engine, the output dynamometers introduce the load on the flanges of the output joint shafts. The pitting defect is manufactured on the tooth side of a gear of the fifth speed on the secondary shaft. Also, a method for fault diagnosis of gear faults is presented based on order Cepstrum. The procedure is illustrated with the experimental vibration data of the vehicle gearbox. The results show the effectiveness of Cepstrum analysis in detection and diagnosis of the gear condition.

Keywords: Cepstrum analysis, fault diagnosis, gearbox.

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4 Creeping Control Strategy for Direct Shift Gearbox Based on the Investigation of Temperature Variation of the Wet Clutch

Authors: Biao Ma, Jikai Liu, Man Chen, Jianpeng Wu, Liyong Wang, Changsong Zheng

Abstract:

Proposing an appropriate control strategy is an effective and practical way to address the overheat problems of the wet multi-plate clutch in Direct Shift Gearbox under the long-time creeping condition. To do so, the temperature variation of the wet multi-plate clutch is investigated firstly by establishing a thermal resistance model for the gearbox cooling system. To calculate the generated heat flux and predict the clutch temperature precisely, the friction torque model is optimized by introducing an improved friction coefficient, which is related to the pressure, the relative speed and the temperature. After that, the heat transfer model and the reasonable friction torque model are employed by the vehicle powertrain model to construct a comprehensive co-simulation model for the Direct Shift Gearbox (DSG) vehicle. A creeping control strategy is then proposed and, to evaluate the vehicle performance, the safety temperature (250 ℃) is particularly adopted as an important metric. During the creeping process, the temperature of two clutches is always under the safety value (250 ℃), which demonstrates the effectiveness of the proposed control strategy in avoiding the thermal failures of clutches.

Keywords: Creeping control strategy, direct shift gearbox, temperature variation, wet clutch.

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3 Modern Vibration Signal Processing Techniques for Vehicle Gearbox Fault Diagnosis

Authors: Mohamed El Morsy, Gabriela Achtenová

Abstract:

This paper presents modern vibration signalprocessing techniques for vehicle gearbox fault diagnosis, via the wavelet analysis and the Squared Envelope (SE) technique. The wavelet analysis is regarded as a powerful tool for the detection of sudden changes in non-stationary signals. The Squared Envelope (SE) technique has been extensively used for rolling bearing diagnostics. In the present work a scheme of using the Squared Envelope technique for early detection of gear tooth pit. The pitting defect is manufactured on the tooth side of a fifth speed gear on the intermediate shaft of a vehicle gearbox. The objective is to supplement the current techniques of gearbox fault diagnosis based on using the raw vibration and ordered signals. The test stand is equipped with three dynamometers; the input dynamometer serves as the internal combustion engine, the output dynamometers introduce the load on the flanges of output joint shafts. The gearbox used for experimental measurements is the type most commonly used in modern small to mid-sized passenger cars with transversely mounted powertrain and front wheel drive; a five-speed gearbox with final drive gear and front wheel differential. The results show that the approaches methods are effective for detecting and diagnosing localized gear faults in early stage under different operation conditions, and are more sensitive and robust than current gear diagnostic techniques.

Keywords: Wavelet analysis, Squared Envelope, gear faults.

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2 Simulation of Die Casting Process in an Industrial Helical Gearbox Flange Die

Authors: Mehdi Modabberifar, Behrouz Raad, Bahman Mirzakhani

Abstract:

Flanges are widely used for connecting valves, pipes and other industrial devices such as gearboxes. Method of producing a flange has a considerable impact on the manner of their involvement with the industrial engines and gearboxes. By Using die casting instead of sand casting and machining for manufacturing flanges, production speed and dimensional accuracy of the parts increases. Also, in die casting, obtained dimensions are close to final dimensions and hence the need for machining flanges after die casting process decreases which makes a significant savings in raw materials and improves the mechanical properties of flanges. In this paper, a typical die of an industrial helical gearbox flange (size ISO 50) was designed and die casting process for producing this type of flange was simulated using ProCAST software. The results of simulation were used for optimizing die design. Finally, using the results of the analysis, optimized die was built.

Keywords: Die casting, finite element, flange.

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1 Vibration, Lubrication and Machinery Consideration for a Mixer Gearbox Related to Iran Oil Industries

Authors: Omid A. Zargar

Abstract:

In this paper, some common gearboxes vibration analysis methods and condition monitoring systems are explained. In addition, an experimental gearbox vibration analysis is discussed through a critical case history for a mixer gearbox related to Iran oil industry. The case history also consists of gear manufacturing (machining) recommendations, lubrication condition of gearbox and machinery maintenance activities that caused reduction in noise and vibration of the gearbox. Besides some of the recent patents and innovations in gearboxes, lubrication and vibration monitoring systems explained. Finally micro pitting and surface fatigue in pinion and bevel of mentioned horizontal to vertical gearbox discussed in details.

Keywords: Gear box, condition monitoring, time wave form (TWF), fast Fourier transform (FFT), gear mesh frequency (GMF), Shock Pulse measurement (SPM), bearing condition unit (BCU), pinion, bevel gear, micro pitting, surface fatigue.

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