Devices and methods for identifying and measuring gear eccentricity faults

Abstract

This invention discloses a device for isolating and measuring gear eccentricity faults, including a base, a support plate fixedly mounted on the base, a servo motor fixedly mounted on the support plate, a rotating shaft fixedly mounted on the output shaft of the servo motor, and an encoder and the gear to be tested sleeved on the rotating shaft; a clamping plate is also provided on the base, and an eddy current sensor is connected to the clamping plate through a connecting rod, with the eddy current sensor positioned close to the gear to be tested. This invention also discloses a method for isolating and measuring gear eccentricity faults. By effectively isolating, measuring, and quantifying gear eccentricity, the source of eccentricity error can be traced, allowing for correction and improvement from the source of gear processing. This fundamentally reduces the impact of eccentricity error on gear accuracy during gear manufacturing and processing, ensuring excellent gear performance in transmission.

Description

Technical Field

[0001] This invention belongs to the field of mechanical dynamics technology, specifically relating to a device for separating and measuring gear eccentricity faults, and also to a method for separating and measuring gear eccentricity faults. Background Technology

[0002] During gear machining, factors such as manufacturing errors in the gear blank, manufacturing, grinding, and installation errors in the cutting tool, installation errors in the machined parts, and the precision errors of the machine tool itself all affect the machining accuracy of the gears, causing machining errors and thus affecting the performance of gear transmission. Among these, eccentricity error, as a long-period error in reducers, is one of the most common and important sources of gear error. Gear eccentricity mainly consists of two types of eccentricity: geometric eccentricity introduced by the position error of the rotation shaft and kinematic eccentricity caused by transmission errors. These two types of eccentricity often overlap, existing in the form of mixed eccentricity, which is a common error form in gear systems. Both geometric eccentricity and kinematic eccentricity ultimately affect the magnitude of the gear meshing line error, thus affecting the gear motion accuracy: geometric eccentricity causes radial offset and uneven indexing between the actual gear ring position and the ideal position, thus affecting the gear rotation angle error and ultimately affecting the gear motion accuracy; while kinematic eccentricity causes tooth profile displacement, ultimately also affecting the gear motion accuracy. Moreover, gear eccentricity not only affects the transmission accuracy of the gear, but its long-term existence can also cause other gear failures, such as tooth surface wear, which will seriously reduce the service life of the gear.

[0003] Considering the superposition and mixing of gear eccentricity and the difficulty of separating them, current theoretical and applied research on gear eccentricity faults treats them as a single category for analysis, diagnosis, and repair, failing to fundamentally reduce eccentricity errors and propose solutions. Currently, few studies trace the root causes of both types of eccentricity faults, employing specific techniques and methods to compensate for or qualitatively analyze the error. Therefore, this invention aims to explore the fundamental causes of gear eccentricity and conduct quantitative analysis, hoping to separate and correct it at its source, thereby effectively improving gear machining accuracy. Summary of the Invention

[0004] The purpose of this invention is to provide a device for identifying and measuring gear eccentricity faults, which has the ability to analyze both geometric and kinematic eccentricity of gears.

[0005] Another object of the present invention is to provide a method for identifying and measuring gear eccentricity faults.

[0006] The technical solution adopted in this invention is a device for separating and measuring gear eccentricity faults, including a base, on which a support plate and a tail bracket are fixedly mounted. A servo motor is fixedly mounted on the side of the support plate near the tail bracket. The output shaft of the servo motor is fixedly connected to one end of a rotating shaft, and the other end of the rotating shaft is inserted into the tail bracket. An encoder is sleeved on the rotating shaft. The gear to be tested is sleeved on the rotating shaft between the encoder and the tail bracket. A clamping plate is also provided on the base, and an eddy current sensor is connected to the clamping plate through a connecting rod. The eddy current sensor is located close to the gear to be tested.

[0007] The present invention is further characterized in that: on the base, the bearing plate and the tail bracket are also fixedly connected to one end of the intermediate bracket, and the other end of the intermediate bracket is sleeved on the rotating shaft between the servo motor and the encoder.

[0008] Another technical solution adopted in this invention is a method for separating and measuring gear eccentricity faults, which uses the aforementioned device for separating and measuring gear eccentricity faults and is implemented according to the following steps:

[0009] Step 1. Obtain the number of teeth z, module m, pressure angle c, and tooth width b of the gear 7 to be tested;

[0010] Step 2. Calculate the tooth pitch p, addendum circle diameter da, dedendum circle diameter df, pitch circle diameter d, addendum ha, dedendum hf, and total tooth height h of the gear 7 to be tested;

[0011] Step 3. Using a data acquisition card and a device for separating and measuring gear eccentricity faults, synchronously acquire the pulse signal diagram and vibration signal diagram of the gear under test 7 within the same cycle;

[0012] Step 4. Combine and slice the pulse signal diagram and vibration signal diagram within the same period from Step 3 to obtain a sliced ​​pulse signal diagram;

[0013] Step 5. Enlarge the slice pulse signal image from Step 4 to obtain the morphological features and synchronous pulse signal image;

[0014] Step 6. Perform envelope analysis on the morphological features and synchronous pulse signal diagrams from Step 5, and draw the gear vibration signal tooth tip distribution diagram.

[0015] Step 7. Obtain the maximum value D of the gear tooth tip amplitude using the gear vibration signal tooth tip distribution diagram from Step 6. max And the minimum value D of the tooth tip amplitude min ;

[0016] Step 8. Calculate the minimum geometric eccentricity e of the gear under test. 几 min;

[0017] Step 9. Calculate the adjacent angle β between each tooth of the gear under test.齿间 ;

[0018] Step 10. Calculate the angle γ between the centerline of two adjacent teeth and the tip of the tooth with the largest amplitude.

[0019] Step 11. Calculate the maximum geometric eccentricity e of the gear under test. 几 max;

[0020] Step 12. Enlarge the shape feature signal and synchronous pulse signal diagram from Step 5 to obtain the encoder cycle number diagram between two random teeth and read the inter-tooth error;

[0021] Step 13. Convert the inter-tooth error into inter-tooth angle error and plot the change diagram of gear motion error;

[0022] Step 14. Use Fourier curve fitting to eliminate other measurement errors introduced by equipment accuracy issues and external interference, plot the motion error change fitting graph, and obtain the comprehensive motion eccentricity.

[0023] Another feature of the technical solution of the present invention is that:

[0024] The formula for calculating the tooth pitch p in step 2 is shown in (1):

[0025] ········(1;

[0026] The formula for calculating the tip circle diameter da is shown in (2):

[0027] ········(2)

[0028] The formula for calculating the root circle diameter df is shown in (3):

[0029] ····(2;

[0030] The formula for calculating the pitch circle diameter d is shown in (4):

[0031] ········(4;

[0032] The formula for calculating the tooth tip height ha is shown in (5):

[0033] ·····(5);

[0034] The formula for calculating the tooth root height hf is shown in (6):

[0035] ····(6;

[0036] The formula for calculating the total tooth height h is shown in (7):

[0037] ········(7).

[0038] In step 8, the minimum geometric eccentricity e 几 The formula for calculating min is shown in (8):

[0039] (8).

[0040] In step 9, the adjacent angle β between each tooth 齿间 The calculation formula is shown in (9):

[0041] β 齿间 = ·········(9).

[0042] The angle between the center line of two adjacent teeth and the tip of the tooth with the largest amplitude The calculation formula is shown in (10):

[0043] ············(10).

[0044] Maximum geometric eccentricity e 几 The formula for calculating max is shown in (11):

[0045] ··········(11).

[0046] The beneficial effects of this invention are: the method for separating and measuring gear eccentricity faults of this invention, by effectively separating, measuring and quantifying gear eccentricity, can trace the source of eccentricity error, and can correct and improve it from the source of gear processing, fundamentally reducing the impact of eccentricity error on gear accuracy during gear manufacturing and processing, and ensuring the excellent performance of gears in transmission. Attached Figure Description

[0047] Figure 1 This is a schematic diagram of the device for separating and measuring gear eccentricity faults according to the present invention;

[0048] Figure 2 These are pulse signal diagrams and vibration signal diagrams within the same cycle in Embodiment 1 of the gear eccentricity fault separation and measurement method of the present invention;

[0049] Figure 3 This is a slice pulse signal diagram from Embodiment 1 of the gear eccentricity fault separation and measurement method of the present invention;

[0050] Figure 4This is a diagram showing the morphological features and synchronous pulse signals in Embodiment 1 of the gear eccentricity fault separation and measurement method of the present invention;

[0051] Figure 5 This is a distribution diagram of gear vibration signal at the tooth tip in Embodiment 3 of the gear eccentricity fault separation and measurement method of the present invention;

[0052] Figure 6 This is a diagram showing the number of encoder cycles between two teeth in Embodiment 3 of the gear eccentricity fault separation and measurement method of the present invention;

[0053] Figure 7 This is a diagram showing the change in gear motion error in Embodiment 3 of the gear eccentricity fault separation and measurement method of the present invention;

[0054] Figure 8 This is a fitting graph of motion error variation in Embodiment 3 of the gear eccentricity fault separation and measurement method of the present invention;

[0055] The components include: 1. base; 2. bearing plate; 3. servo motor; 4. intermediate support; 5. encoder; 6. tail support; 7. gear to be tested; 8. clamping plate; 9. connecting rod; 10. eddy current sensor; and 11. rotating shaft. Detailed Implementation

[0056] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0057] Devices for identifying and measuring gear eccentricity faults, such as Figure 1 As shown, the device includes a base 1, on which a support plate 2 and a tail bracket 6 are fixedly mounted. A servo motor 3 is fixedly mounted on the side of the support plate 2 near the tail bracket 6. The output shaft of the servo motor 3 is fixedly connected to one end of a rotating shaft 11, and the other end of the rotating shaft 11 is inserted into the tail bracket 6. An encoder 5 is sleeved on the rotating shaft 11. A gear 7 to be tested is sleeved between the encoder 5 and the tail bracket 6 on the rotating shaft 11. A clamping plate 8 is also provided on the base 1. An eddy current sensor 10 is connected to the clamping plate 8 through a connecting rod 9. The position of the eddy current sensor 10 is close to the gear 7 to be tested.

[0058] On the base 1, the support plate 2 and the tail bracket 6 are also fixed to one end of the intermediate bracket 4, and the other end of the intermediate bracket 4 is sleeved on the rotating shaft 11 between the servo motor 3 and the encoder 5.

[0059] The method for isolating and measuring gear eccentricity faults, using the aforementioned device for isolating and measuring gear eccentricity faults, is implemented according to the following steps:

[0060] Step 1. Obtain the number of teeth z, module m, pressure angle c, and tooth width b of the gear 7 to be tested;

[0061] Step 2. Calculate the tooth pitch p, addendum circle diameter da, dedendum circle diameter df, pitch circle diameter d, addendum ha, dedendum hf, and total tooth height h of the gear 7 to be tested;

[0062] The formula for calculating tooth pitch p is shown in (1):

[0063] ········(1;

[0064] The formula for calculating the tip circle diameter da is shown in (2):

[0065] ········(2)

[0066] The formula for calculating the root circle diameter df is shown in (3):

[0067] ····(3;

[0068] The formula for calculating the pitch circle diameter d is shown in (4):

[0069] ·······(4;

[0070] The formula for calculating the tooth tip height ha is shown in (5):

[0071] ······(5);

[0072] The formula for calculating the root height hf is shown in (6):

[0073] ····(6;

[0074] The formula for calculating the total tooth height h is shown in (7):

[0075] ·······(7).

[0076] Step 3. Using a data acquisition card and a device for separating and measuring gear eccentricity faults, synchronously acquire the pulse signal diagram and vibration signal diagram of the gear under test 7 within the same cycle;

[0077] Step 4. Combine and slice the pulse signal diagram and vibration signal diagram within the same period from Step 3 to obtain a sliced ​​pulse signal diagram;

[0078] Step 5. Enlarge the slice pulse signal image from Step 4 to obtain the morphological features and synchronous pulse signal image;

[0079] Step 6. Perform envelope analysis on the morphological features and synchronous pulse signal diagrams from Step 5, and draw the gear vibration signal tooth tip distribution diagram.

[0080] Step 7. Obtain the maximum value D of the tooth tip amplitude of the gear 7 under test by using the gear vibration signal tooth tip distribution diagram from Step 6. max And the minimum value D of the tooth tip amplitude min ;

[0081] Step 8. Calculate the minimum geometric eccentricity e of the gear 7 to be tested. 几 min;

[0082] Minimum geometric eccentricity e 几 The formula for calculating min is shown in (8):

[0083] (8);

[0084] Step 9. Calculate the adjacent angle β between each tooth of the gear 7 under test. 齿间 ;

[0085] β 齿间 = ·········(9;

[0086] Step 10. Calculate the angle between the centerline of two adjacent teeth and the tip of the tooth with the largest amplitude. ;

[0087] The angle between the center line of two adjacent teeth and the tip of the tooth with the largest amplitude The calculation formula is shown in (1)0:

[0088] ············(10);

[0089] Step 11. Calculate the maximum geometric eccentricity e of the gear 7 to be tested. 几 max; maximum geometric eccentricity e 几 The formula for calculating max is shown in (1)1:

[0090] ··········(11;

[0091] Step 12. Enlarge the shape feature signal and synchronous pulse signal diagram from Step 5 to obtain the encoder cycle number diagram between two random teeth and read the inter-tooth error;

[0092] Step 13. Convert the inter-tooth error into inter-tooth angle error and plot the change diagram of gear motion error;

[0093] Step 14. Use Fourier curve fitting to eliminate other measurement errors introduced by equipment accuracy issues and external interference, plot the motion error change fitting graph, and obtain the comprehensive motion eccentricity.

[0094] Example 1

[0095] A device for isolating and measuring gear eccentricity faults includes a base 1, on which a support plate 2 and a tail bracket 6 are fixedly mounted. A servo motor 3 is fixedly mounted on the side of the support plate 2 near the tail bracket 6. The output shaft of the servo motor 3 is fixedly connected to one end of a rotating shaft 11, and the other end of the rotating shaft 11 is inserted into the tail bracket 6. An encoder 5 is sleeved on the rotating shaft 11. A gear 7 to be tested is sleeved on the rotating shaft 11 between the encoder 5 and the tail bracket 6. A clamping plate 8 is also provided on the base 1. An eddy current sensor 10 is connected to the clamping plate 8 through a connecting rod 9. The position of the eddy current sensor 10 is close to the gear 7 to be tested.

[0096] Example 2

[0097] A device for isolating and measuring gear eccentricity faults includes a base 1, on which a support plate 2 and a tail bracket 6 are fixedly mounted. A servo motor 3 is fixedly mounted on the side of the support plate 2 near the tail bracket 6. The output shaft of the servo motor 3 is fixedly connected to one end of a rotating shaft 11, and the other end of the rotating shaft 11 is inserted into the tail bracket 6. An encoder 5 is sleeved on the rotating shaft 11. A gear 7 to be tested is sleeved on the rotating shaft 11 between the encoder 5 and the tail bracket 6. A clamping plate 8 is also provided on the base 1. An eddy current sensor 10 is connected to the clamping plate 8 through a connecting rod 9. The position of the eddy current sensor 10 is close to the gear 7 to be tested.

[0098] On the base 1, the support plate 2 and the tail bracket 6 are also fixed to one end of the intermediate bracket 4, and the other end of the intermediate bracket 4 is sleeved on the rotating shaft 11 between the servo motor 3 and the encoder 5.

[0099] Example 3

[0100] The method for separating and measuring gear eccentricity faults, using the device for separating and measuring gear eccentricity faults described in Example 2, is implemented according to the following steps:

[0101] Step 1. Obtain the number of teeth z, module m, pressure angle c, and tooth width b of the gear 7 to be tested;

[0102] Step 2. Calculate the tooth pitch p, addendum circle diameter da, dedendum circle diameter df, pitch circle diameter d, addendum ha, dedendum hf, and total tooth height h of the gear 7 to be tested;

[0103] The formula for calculating tooth pitch p is shown in (1):

[0104] ········(1;

[0105] The formula for calculating the tip circle diameter da is shown in (2):

[0106] ········(2;

[0107] The formula for calculating the root circle diameter df is shown in (3):

[0108] ····(3;

[0109] The formula for calculating the pitch circle diameter d is shown in (4):

[0110] ·······(4;

[0111] The formula for calculating the tooth tip height ha is shown in (5):

[0112] ······(5;

[0113] The formula for calculating the tooth root height hf is shown in (6):

[0114] ····(6;

[0115] The formula for calculating the total tooth height h is shown in (7):

[0116] ·······(7).

[0117] Step 3. Using a data acquisition card and a device for isolating and measuring gear eccentricity faults, synchronously acquire the pulse signal diagram and vibration signal diagram of the gear under test 7 within the same cycle, such as... Figure 2 As shown;

[0118] Step 4. Combine and slice the pulse signal graph and vibration signal graph within the same period from Step 3 to obtain a sliced ​​pulse signal graph, such as... Figure 3 As shown;

[0119] Step 5. Enlarge the sliced ​​pulse signal image from Step 4 to obtain the morphological features and synchronous pulse signal image, such as... Figure 4 As shown;

[0120] Step 6. Perform envelope analysis on the morphological feature signals in the morphological feature diagram and the synchronous pulse signal diagram from Step 5, and draw the gear vibration signal tooth tip distribution diagram, as shown below. Figure 5 As shown;

[0121] Step 7. Obtain the maximum value D of the tooth tip amplitude of the gear 7 under test by using the gear vibration signal tooth tip distribution diagram from Step 6. max And the minimum value D of the tooth tip amplitude min ;

[0122] Step 8. Calculate the minimum geometric eccentricity e of the gear 7 to be tested. 几 min;

[0123] Minimum geometric eccentricity e 几 The formula for calculating min is shown in (8):

[0124] (8);

[0125] Step 9. Calculate the adjacent angle β between each tooth of the gear 7 under test. 齿间 ;

[0126] β 齿间 = ·········(9;

[0127] Step 10. Calculate the angle between the centerline of two adjacent teeth and the tip of the tooth with the largest amplitude. ;

[0128] The angle between the center line of two adjacent teeth and the tip of the tooth with the largest amplitude The calculation formula is shown in (1)0:

[0129] ············(10);

[0130] Step 11. Calculate the maximum geometric eccentricity e of the gear 7 to be tested. 几 max; maximum geometric eccentricity e 几 The formula for calculating max is shown in (11):

[0131] ··········(11;

[0132] Step 12. Enlarge the morphological feature signal and synchronous pulse signal diagram from Step 5 to obtain the encoder cycle count diagram between two random teeth, as shown below. Figure 6 As shown, read the inter-tooth error;

[0133] Step 13. Convert the inter-tooth error into inter-tooth angular error and plot the change diagram of gear motion error, as shown below. Figure 7 As shown;

[0134] Step 14. Eliminate other measurement errors introduced by equipment accuracy issues and external interference through Fourier curve fitting, and plot the motion error change fitting graph, such as... Figure 8 As shown, the magnitude of the overall motion eccentricity is obtained.

Claims

1. A device for isolating and measuring gear eccentricity faults, characterized in that, The device includes a base (1), on which a support plate (2) and a tail bracket (6) are fixedly connected. A servo motor (3) is fixedly connected to one side of the support plate (2) near the tail bracket (6). The output shaft of the servo motor (3) is fixedly connected to one end of a rotating shaft (11), and the other end of the rotating shaft (11) is inserted into the tail bracket (6). An encoder (5) is sleeved on the rotating shaft (11). A gear to be tested (7) is sleeved between the encoder (5) and the tail bracket (6) on the rotating shaft (11). A clamping plate (8) is also provided on the base (1). An eddy current sensor (10) is connected to the clamping plate (8) through a connecting rod (9). The position of the eddy current sensor (10) is close to the gear to be tested (7).

2. The device for separating and measuring gear eccentricity faults according to claim 1, characterized in that, On the base (1), the bearing plate (2) and the tail bracket (6) are also fixed to one end of the intermediate bracket (4), and the other end of the intermediate bracket (4) is sleeved on the rotating shaft (11) between the servo motor (3) and the encoder (5).

3. A method for isolating and measuring gear eccentricity faults, characterized in that, The device for separating and measuring gear eccentricity faults as described in claim 1 or 2 is implemented according to the following steps: Step 1. Obtain the number of teeth z, module m, pressure angle c, and tooth width b of the gear to be tested (7); Step 2. Calculate the pitch p, addendum circle diameter da, dedendum circle diameter df, pitch circle diameter d, addendum ha, dedendum hf, and total height h of the gear to be tested (7); Step 3. Using a data acquisition card and a device for separating and measuring gear eccentricity faults, synchronously acquire the pulse signal diagram and vibration signal diagram of the gear under test (7) within the same cycle; Step 4. Combine and slice the pulse signal diagram and vibration signal diagram within the same period described in Step 3 to obtain a sliced ​​pulse signal diagram; Step 5. Enlarge the sliced ​​pulse signal image described in Step 4 to obtain the morphological features and synchronous pulse signal image; Step 6. Perform envelope analysis on the morphological feature signals in the morphological feature and synchronous pulse signal diagram described in Step 5, and draw the tooth tip distribution diagram of the gear vibration signal; Step 7. Obtain the maximum value D of the tooth tip amplitude of the gear under test (7) using the gear vibration signal tooth tip distribution diagram described in Step 6. max And the minimum value D of the tooth tip amplitude min ; step 8. Calculate the minimum geometric eccentricity e of the gear to be tested (7). 几 min; Step 9. Calculate the adjacent angle β between each tooth of the gear under test (7). 齿间 ; Step 10. Calculate the angle between the centerline of two adjacent teeth and the tip of the tooth with the largest amplitude. ; Step 11. Calculate the maximum geometric eccentricity e of the gear under test (7). 几 max; Step 12. Enlarge the topographic feature signal and synchronous pulse signal diagram described in Step 5 to obtain the encoder cycle number diagram between two random teeth and read the inter-tooth error; Step 13. Convert the inter-tooth error into inter-tooth angle error and plot the change diagram of gear motion error; Step 14. Use Fourier curve fitting to eliminate other measurement errors introduced by equipment accuracy issues and external interference, plot the motion error change fitting graph, and obtain the comprehensive motion eccentricity.

4. The method for separating and measuring gear eccentricity faults according to claim 3, characterized in that, The formula for calculating the tooth pitch p in step 2 is shown in (1): ·········（1）； The formula for calculating the tooth tip circle diameter da is shown in (2): ·········（2）； The formula for calculating the root circle diameter df is shown in (3): ····（3）； The formula for calculating the pitch circle diameter d is shown in (4): ·········（4）； The formula for calculating the tooth tip height ha is shown in (5): ·······（5）； The formula for calculating the tooth root height hf is shown in (6): ····（6）； The formula for calculating the total tooth height h is shown in (7): ·········（7）。 5. The method for separating and measuring gear eccentricity faults according to claim 3, characterized in that, In step 8, the minimum geometric eccentricity e 几 The formula for calculating min is shown in (8): （8）。 6. The method for separating and measuring gear eccentricity faults according to claim 3, characterized in that, In step 9, the adjacent angle β between each tooth 齿间 The calculation formula is shown in (9): β 齿间 = ··········（9）。 7. The method for separating and measuring gear eccentricity faults according to claim 3, characterized in that, In step 10, the angle between the centerline of two adjacent teeth and the tip of the tooth with the largest amplitude is... The calculation formula is shown in (10): ··············（10）。 8. The method for separating and measuring gear eccentricity faults according to claim 3, characterized in that, In step 11, the maximum geometric eccentricity e 几 The formula for calculating max is shown in (11): ············（11）。

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