Aviation Gear Life Prediction Method Based on Wear Fault Mechanism Model Correction Test

Abstract

The present invention belongs to the technical field of gear fault and life prediction, and particularly relates to an aviation gear life prediction method based on a wear fault mechanism model correction test, which includes: S1. Calculating the wear life of the aviation gear according to the Archard adhesive wear model, and establishing a first aviation gear life prediction model; S2. Conducting an aviation gear wear life test to obtain the corrected test data of the aviation gear service life; S3. Correcting the physical correction model of the aviation gear wear fault to establish a second aviation gear life prediction model; S4. Completing the prediction of the aviation gear service life according to the second aviation gear life prediction model. The present invention studies the failure analysis, life prediction, and damage evolution law of the aviation gear through the aviation gear fault physical model correction test, provides a life test verification and comprehensive evaluation scheme based on the quantitative characterization of the damage evolution law by the aviation gear wear amount, and completes the prediction of the aviation gear service life.

Description

Technical Field

[0001] The present invention belongs to the technical field of gear fault and life prediction, and particularly relates to an aviation gear life prediction method based on a modified test of a wear fault mechanism model. Background Art

[0002] The rapid development of fields such as aircraft, new energy vehicles, precision industrial robots, and high-speed rail transit has increased the demand for high-performance aviation gear transmission devices. Wear is one of the most direct causes leading to the destruction of tooth surface integrity, resulting in vibration, noise, and even failure of the aviation gear system. Tooth surface wear is a dynamic cumulative process of tooth profile material damage and shedding, existing throughout the entire service life cycle of the aviation gear transmission system. Slight tooth surface wear will change the meshing characteristics of the aviation gear pair, reduce the accuracy of the transmission system, and increase the transmission error. Excessive tooth surface wear will lead to vibration and noise, increase the dynamic load of the aviation gear pair, and accelerate the occurrence of other failure forms, such as pitting and tooth breakage. Therefore, in-depth research on the tooth surface wear characteristics of high-performance aviation gears can provide a theoretical basis for vibration reduction, noise reduction, and tooth surface failure analysis of the aviation gear system, and is also an inevitable requirement for the development of the aviation gear transmission system towards high power density, high precision, and lightweight, which is crucial for the stability and reliability of the equipment.

[0003] The Taylor-Laplace-Berger wear theory is a type of wear theory model, which has the following two characteristics:

[0004] (1) In the phenomenon of surface wear, model analysis and fitting methods are helpful for further studying the mechanical wear change laws of different surface materials and abrasives, and improving the scientificity and efficiency of the wear fracture phenomenon.

[0005] (2) Surface wear is a complex process. For complex surface wear phenomena, this theory not only conducts theoretical analysis but also establishes a prediction model, which can study the development trend of wear from a quantitative perspective.

[0006] The dimensional parameters of typical aviation gears include: inner hole diameter, thickness, pressure angle, module, number of teeth, pitch diameter, tooth height, helix direction, and accuracy grade. Under the working load conditions, the wear life calculation of aviation gears can usually be carried out based on the Archard adhesive wear model. It is necessary to conduct research on the frequently occurring fault problems in the actual use of typical aviation gear products, so as to quantitatively analyze the fault failure of aviation gears. Summary of the Invention

[0007] Aiming at the deficiencies of the prior art, the present invention provides an aviation gear life prediction method based on a wear fault mechanism model correction test. The life of the aviation gear is predicted based on the physical model of the wear fault of the aviation gear based on the Archard adhesive wear model. Through the wear fault physical model correction test of the aviation gear, the failure analysis, life prediction, and damage evolution law of the aviation gear are studied, and a life test verification and comprehensive evaluation scheme for quantitatively characterizing the damage evolution law of the aviation gear based on the wear amount of the aviation gear is provided to complete the prediction of the service life of the aviation gear.

[0008] To achieve the above object, the present invention discloses the following technical solutions: An aviation gear life prediction method based on a wear fault mechanism model correction test, which includes:

[0009] S1: Calculate the wear life of the aviation gear according to the Archard adhesive wear model, and establish the first aviation gear life prediction model;

[0010] Based on the actual working conditions of the aviation gear, it is analyzed that the failure form of the aviation gear is wear. Based on the Archard adhesive wear model, the first aviation gear life prediction model is obtained as:

[0011]

[0012] where, T1 is the prediction result of the first aviation gear life; H is the hardness of the aviation gear material; V is the wear volume of the aviation gear; K is the wear coefficient of the aviation gear; C is the material type parameter of the aviation gear; v is the average speed of the aviation gear; P is the contact stress of the aviation gear;

[0013] S2: Conduct an aviation gear wear life test to obtain the corrected test data of the aviation gear service life;

[0014] First, conduct an aviation gear material property test. The hardness of the aviation gear surface is tested by a hardness tester to obtain the material type parameter C of the aviation gear. Then, conduct an aviation gear life preliminary test to test the wear process of the aviation gear to determine the wear test life value Y of the aviation gear. Finally, conduct a parameter correction test for the aviation gear wear fault mechanism model. In the aviation gear wear test, the wear amount of the aviation gear is detected with Y / 5 as the detection period to obtain the corrected test data of the aviation gear service life, specifically: the wear volume V of the aviation gear, the material type parameter C of the aviation gear, the contact stress P of the aviation gear, and the average speed v of the aviation gear;

[0015] S3: Correct the aviation gear wear fault physical correction model to establish the second aviation gear life prediction model;

[0016] Based on the service life test data of the aviation gear in step S2, substitute the wear coefficient K of the aviation gear determined in this step S1; since the wear coefficient K of the aviation gear has a logarithmic linear relationship with the aviation gear material type parameter C, the average speed v of the aviation gear, and the contact stress P of the aviation gear, establish the physical correction model of the aviation gear wear fault as:

[0017] ln(k) = a1*P + a2*v + a3*C;

[0018] where a1 is the first parameter of the physical correction model of the aviation gear wear fault; a2 is the second parameter of the physical correction model of the aviation gear wear fault; a3 is the third parameter of the physical correction model of the aviation gear wear fault;

[0019] Modify the first aviation gear life prediction model in step S1 to obtain the second aviation gear life prediction model, specifically:

[0020]

[0021] where T2 is the prediction result of the second aviation gear life;

[0022] S4: Complete the prediction of the service life of the aviation gear according to the second aviation gear life prediction model;

[0023] Input the aviation gear material hardness H, the aviation gear wear volume V, the average speed v of the aviation gear, the contact stress P of the aviation gear, and the aviation gear material type parameter C into the second aviation gear life prediction model determined in step S3 to obtain the final prediction result of the service life of the aviation gear.

[0024] Optionally, the Archard adhesive wear model in step S1 is:

[0025]

[0026] where: L is the wear distance of the aviation gear.

[0027] Optionally, the main purpose of the aviation gear material property test in step S2 is to measure the hardness of the meshing surface of the used aviation gear; take a to-be-tested aviation gear and measure the hardness of the meshing surface of the aviation gear at 4 different positions through a hardness tester, and take the average value of the 4 hardnesses as the hardness H of the aviation gear wear life test.

[0028] Optionally, in the aviation gear life preliminary test in step S2, simulate the actual working conditions of the aviation gear through the test, obtain the wear amount when the aviation gear fails, and further calculate the aviation gear wear volume V.

[0029] Optionally, the specific steps of the aviation gear life preliminary test are:

[0030] S211: Check the surface finish of the aviation gear to be tested;

[0031] S212: Install the aviation gear to be tested in the test reduction mechanism according to the assembly requirements. After installation, ensure that the reduction mechanism runs smoothly without jamming. At the same time, measure relevant parameters to meet the assembly conditions;

[0032] S213: Fix the test reduction mechanism. Convert the load value of the aviation gear in the test profile into the force value on the butterfly plate, and load the butterfly plate. Fix the test reduction mechanism on the test bench;

[0033] S214: Adsorb the vibration sensors on the outer shell of the test reduction mechanism through magnetic adsorption seats. The specific positions are at the closest points to the aviation gear to be tested, with one sensor longitudinally and one transversely. Connect them to the acquisition board and the acquisition instrument through signal lines;

[0034] S215: During the test, send commands to the test reduction mechanism through the special software of the testing equipment to conduct a 20° - 40° movement test; at the same time, turn on the signal acquisition software to collect vibration signals in real time;

[0035] S216: During the test, every X times, pause the test, disassemble the aviation gear to be tested, clean it, and measure and record its wear amount; observe the difference value between two adjacent wear amounts. If the difference value is less than 5%, increase the interval times to n*X times; if the difference value is greater than 10%, decrease the interval times to (1 / n)*X times; n is an integer greater than 1;

[0036] S217: After measurement, reinstall the aviation gear to be tested in the test reduction mechanism according to the assembly requirements and continue the test.

[0037] S218: When the wear amount of the aviation gear reaches the failure criterion condition, stop the test, replace the aviation gear to be tested, and conduct the next set of tests;

[0038] S219: Repeat steps S211 - S218 until the test is completed;

[0039] Preferably, in the parameter correction test of the aviation gear wear fault mechanism model in step S2, obtain the data results required for correcting the physical model of the aviation gear wear fault. The parameters to be measured are the wear amount of the aviation gear, the load of the aviation gear, and the rotational speed. Further calculate the contact stress P of the aviation gear and the average speed v of the aviation gear.

[0040] Preferably, the specific steps of the parameter correction test of the aviation gear wear fault mechanism model are as follows:

[0041] S221: Check the surface finish of the aviation gear to be tested;

[0042] S222: Install the aviation gear to be tested in the test reduction mechanism according to the assembly requirements. After installation, ensure that the reduction mechanism operates smoothly without jamming. At the same time, measure relevant parameters to meet the assembly conditions.

[0043] S223: Fix the test reduction mechanism. Convert the load value of the aviation gear in the test profile into the force value of the butterfly plate, and load the butterfly plate. Fix the test reduction mechanism on the test bench.

[0044] S224: Adsorb the vibration sensors on the outer shell of the test reduction mechanism through magnetic suction seats. The specific positions are at the nearest places to the aviation gear to be tested, with one sensor longitudinally and one transversely. Connect them to the acquisition board and the acquisition instrument through signal lines.

[0045] S225: During the test, send commands to the test reduction mechanism through the special software of the detection equipment to conduct a 20° - 40° movement test. At the same time, open the signal acquisition software to collect vibration signals in real time.

[0046] S226: During the test, every Y / 5 times, pause the test, disassemble the aviation gear to be tested, clean it, measure its wear amount and record it. After measurement, reinstall the aviation gear to be tested in the test reduction mechanism according to the assembly requirements and continue the test.

[0047] S227: When the wear amount of the aviation gear reaches the failure standard, stop the test, replace the aviation gear to be tested, and conduct the next group of tests.

[0048] S228: Repeat steps S221 - S227 until the test is completed.

[0049] Preferably, the first parameter a1 of the physical correction model for aviation gear wear failure, the second parameter a2 of the physical correction model for aviation gear wear failure, and the third parameter a3 of the physical correction model for aviation gear wear failure in step S3 are determined by least - squares fitting.

[0050] Compared with the prior art, the present invention has the following beneficial effects:

[0051] (1) The present invention establishes an aviation gear life prediction model based on the physical model of aviation gear wear failure of the Archard adhesive wear model. Through the physical model correction test of aviation gear failure, the improvement of the aviation gear life prediction model is completed, and the service life prediction of aviation gear is completed.

[0052] (2) The present invention conducts research on the failure analysis, life prediction, damage evolution law, etc. of aviation gears, provides a life test verification and comprehensive evaluation scheme for quantitatively characterizing the damage evolution law of aviation gears based on the wear amount of aviation gears, and determines the failure criterion threshold of aviation gears through a life preliminary test, providing a basis for the modification test of the wear fault physical model of aviation gears.

[0053] (3) The present invention selects the load and speed of aviation gears as the stress profile to conduct a modification test on the wear fault physical model of aviation gears, and modifies the wear fault physical model of aviation gears according to the wear amount values of aviation gears of load, speed, and time collected during the test process. Brief Description of the Drawings

[0054] Figure 1 is a flowchart of the aviation gear life prediction method based on the wear fault mechanism model modification test of the present invention;

[0055] Figure 2 is a physical diagram of an aviation gear for the aviation gear wear life test of the present invention;

[0056] Figure 3 is a flowchart of the comprehensive evaluation scheme of the present invention. Detailed Embodiments

[0057] The exemplary embodiments, features, and aspects of the present invention will be described in detail below with reference to the drawings. The same reference numerals in the drawings denote elements having the same or similar functions. Although various aspects of the embodiments are shown in the drawings, the drawings do not have to be drawn to scale unless otherwise specified.

[0058] The present invention provides an aviation gear life prediction method based on a wear fault mechanism model modification test. As Figure 1 shown, calculate the wear life of aviation gears according to the Archard adhesive wear model, and establish a first aviation gear life prediction model; conduct an aviation gear wear life test to obtain the modified test data of the aviation gear service life; modify the aviation gear wear fault physical modification model to establish a second aviation gear life prediction model; and complete the prediction of the aviation gear service life according to the second aviation gear life prediction model.

[0059] The present invention conducts research on the aviation gears of the planetary reduction assembly in a certain type of test reduction mechanism. This planetary reduction assembly transmits the rotation of the input-side motor shaft to the output-side channel assembly to achieve the purpose of speed reduction. The exhaust volume of the aircraft cockpit is adjusted by changing the flow area of the output-side valve, and the pressure in the aircraft cockpit is adjusted. By conducting life tests on aviation gears under different test conditions, a wear fault physical model of aviation gears is built, and the coefficients in the model are modified, so as to provide support for the life prediction and evaluation of aviation gears in the aircraft cockpit reduction mechanism.

[0060] The method for predicting the service life of the aviation gear of the present invention specifically includes the following steps:

[0061] Step S1: Calculate the wear life of the aviation gear according to the Archard adhesive wear model, and establish the first aviation gear life prediction model.

[0062] Analyze according to the actual working conditions of the aviation gear to determine that the failure mode is wear, and obtain the first aviation gear life prediction model based on the Archard adhesive wear model; the Archard adhesive wear model is:

[0063]

[0064] Where: L is the wear distance of the aviation gear.

[0065] When the service life of the aviation gear is characterized by the usage time T, its life is related to the hardness H of the aviation gear material, the wear volume V of the aviation gear, the wear coefficient K of the aviation gear, the average speed v of the aviation gear, and the contact stress P of the aviation gear; the first aviation gear life prediction model obtained is:

[0066]

[0067] Where, T1 is the prediction result of the life of the first aviation gear; H is the hardness of the aviation gear material; V is the wear volume of the aviation gear; K is the wear coefficient of the aviation gear; C is the material type parameter of the aviation gear; v is the average speed of the aviation gear; P is the contact stress of the aviation gear.

[0068] The hardness H of the aviation gear material refers to the hardness of the tooth surface, which is obtained by testing with a hardness tester. The wear volume V of the aviation gear is an input condition for judging the failure of the aviation gear and is measured by a super-depth-of-field microscope in the experiment. The average speed v of the aviation gear represents the relative sliding speed of the meshing surface of the aviation gear; it is calculated by the following formula:

[0069] v = πD t n × sinα;

[0070] Where, D t is the pitch diameter of the aviation gear; n is the actual operating speed of the aviation gear; α is the pressure angle of the aviation gear.

[0071] The contact stress P of the aviation gear is obtained by converting the force on the butterfly plate at the output end of the test reduction mechanism. Since the contact stress P of the aviation gear needs to be converted through the force on the butterfly plate, the transmission efficiency η of the test reduction mechanism is required. Given that the output torque is N o , the torque of the aviation gear calculated according to the transmission efficiency is:

[0072] N z = ηNo ;

[0073] Among them, η is the transmission efficiency from the aviation gear to the output end; N z is the torque of the aviation gear.

[0074] As Figure 2 shown in the physical diagram of the aviation gear 1 for the aviation gear wear life test of the present invention, the specific parameters of the aviation gear 1 are shown in Table 1. A total of 9 aviation gear samples are required in the embodiment of the present invention.

[0075] Table 1 The parameters of the aviation gear are as follows

[0076]

[0077] In the embodiment of the present invention, the motor output shaft of the test reduction mechanism starts with a first-stage spur gear drive, a first-stage worm and worm gear drive, a two-stage planetary reduction assembly drive, and a first-stage spur gear drive. The transmission efficiency is calculated as follows:

[0078] The value of the transmission efficiency: for the worm helical gear: 0.3 - 0.4, for the planetary gear mechanism: 0.95 - 0.98, for the spur gear drive: 0.98; η' = 0.98×0.3×0.95×0.95×0.98 = 0.2600283; the transmission ratio from the motor to this aviation gear is 67 / 20230, and the efficiency is 0.98×0.3×0.95 = 0.2793; the transmission ratio from this aviation gear to the butterfly plate is 17 / 252, and the efficiency is 0.95*0.98 = 0.931. Then the transmission efficiency η from the aviation gear to the output end is 0.931.

[0079] Furthermore, calculate the contact stress P of the aviation gear as:

[0080]

[0081] Among them, A s is the tooth engagement area.

[0082] Step S2: Conduct the aviation gear wear life test to obtain the corrected test data of the aviation gear service life.

[0083] First, conduct the aviation gear material property test. Measure the hardness of the aviation gear surface through a hardness tester. The main purpose of the aviation gear material property test is to measure the hardness of the meshing surface of the used aviation gear; take a test aviation gear and measure the hardness of the meshing surface of the aviation gear at 4 different positions through a hardness tester, and take the average value of the 4 hardnesses as the hardness H of the aviation gear wear life test to obtain the aviation gear material type parameter C.

[0084] Then, the life test of aviation gears is carried out to test the wear process of aviation gears. The life test of aviation gears simulates the actual working conditions of aviation gears, obtains the wear volume when aviation gears fail, further calculates the wear volume V of aviation gears, and determines the life value Y of aviation gear wear test. The test conditions of the life test of aviation gear wear mainly include: test conditions such as load and speed. The test conditions of the test are set to the rated value, and the test temperature is set to room temperature. The specific test conditions are shown in Table 2.

[0085] Table 2 Aircraft gear life test conditions

[0086] Specimen Name Load Rotational Speed Sample Size Aviation Gear 0.07 Nm 18.5 rpm 1

[0087] During the test of the embodiment of the present invention, the vibration of the aviation gear in the longitudinal and transverse directions is monitored in real time, and the mapping relationship between the signal characteristics and the wear amount of the aviation gear is established by processing the vibration signal. The test equipment used is shown in Table 3.

[0088] Table 3 Test vibration signal monitoring equipment

[0089] Equipment Model Quantity Usage Vibration Sensor BK4533 - B - 001 4 Measure Vibration Signal Magnetic Mount / 4 Sensor Installation Acquisition Board PXIe - 4492 1 Collect Vibration Signal Acquisition Instrument NIPXIe - 1082 1 Collect Vibration Signal

[0090] The wear of aviation gears is measured by ultra-depth-of-field microscope in the life test. The equipment has the characteristics of high pixel, ultra-high performance image processing, ultra-clear, etc. It can perform real-time depth synthesis of stereoscopic micro specimens and realize automatic measurement of three-dimensional shapes; and it can perform real-time depth measurement on the acquired images. The system parameters of ultra-depth-of-field microscope are:

[0091] 1) Shooting element: 1 / 1.8-inch CMOS image sensor, effective pixel 1600 (H) × 1200 (V);

[0092] 2) Scanning system: line-by-line scanning;

[0093] 3) Frame rate: 28F / s (maximum);

[0094] 4) Electronic shutter: automatic, manual, 1 / 60, 1 / 120, 1 / 250, 1 / 500, 1 / 1000, 1 / 2000, 1 / 5000, 1 / 9000, 1 / 19000;

[0095] 5) Image format: JPEG when compressed, TIFF when uncompressed;

[0096] 6) Pixel pitch: 0.2652 (H) × 0.2652 (V) mm;

[0097] 7) Maximum measurement size: 3 (H) × 2.5 (V) mm.

[0098] The specific steps of the life test of aviation gears are as follows:

[0099] Step S211: Check the surface finish of the aviation gear to be tested.

[0100] Step S212: Install the aviation gear to be tested in the test reduction mechanism according to the assembly requirements. After the installation is completed, the reduction mechanism should be ensured to run smoothly without sticking. At the same time, relevant parameters should be measured to meet the assembly conditions.

[0101] Step S213: Fix the test reduction mechanism, convert the load value of the aviation gear in the test section into the force value of the butterfly plate, load the butterfly plate, and fix the test reduction mechanism on the test bench. Connect the controller to the test reduction mechanism as required, set the electrical stress to 28V, and the ambient temperature to the laboratory temperature.

[0102] Step S214: The vibration sensor is adsorbed on the test reduction mechanism housing through a magnetic seat, and the specific position is located closest to the aviation gear to be tested, with one sensor each in the longitudinal direction and the transverse direction, and connected to the acquisition board and the acquisition instrument through signal lines.

[0103] Step S215: During the test, the dedicated software for the ARINC429 detection equipment test is used to send instructions to the test deceleration mechanism to perform a 20° to 40° motion test; at the same time, the signal acquisition software is opened to collect the vibration signal in real time.

[0104] Step S216: During the test, the test is paused every X times, with the initial value set to 5000, and the aviation gear to be tested is disassembled, cleaned, and its wear is measured and recorded; the difference between two adjacent wear amounts is observed, and if the difference is less than 5%, the interval number is increased to n*X times; if the difference is greater than 10%, the interval number is reduced to (1 / n)*X times; n is an integer greater than 1.

[0105] Step S217: After the measurement is completed, the aviation gear to be tested is reinstalled in the test reduction mechanism according to the assembly requirements, and the test is continued.

[0106] Step S218: When the wear amount of the aviation gear reaches the failure criterion condition, the test is stopped, the aviation gear to be tested is replaced, and the next set of tests is carried out.

[0107] Step S219: Repeat steps S211 to S218 until the test is completed.

[0108] The following steps should be followed to stop the life test:

[0109] 1) Operate the signal acquisition software to stop vibration signal acquisition;

[0110] 2) Operate the test-specific software to stop the operation of a certain electromechanical product;

[0111] 3) Remove the load applied to a certain electromechanical product;

[0112] In the life test, the test parameter test method is as follows:

[0113] 1) During the life test, the parameters to be measured are the wear amount, load and rotation speed of the aviation gear.

[0114] 2) The test equipment should dynamically record the product test data to facilitate the analysis of the abnormal cause and test status recovery when the product or equipment operates abnormally during the life test.

[0115] 3) The wear amount is detected using an ultra-depth-of-field microscope.

[0116] Finally, a parameter correction test of the aviation gear wear failure mechanism model was carried out. In the aviation gear wear test, the wear amount of the aviation gear was detected with a detection cycle of Y / 5, and the data results required for the correction of the physical model of aviation gear wear failure were obtained. The parameters to be measured were the wear amount of the aviation gear, the aviation gear load and the rotational speed, and the aviation gear service life correction test data were determined, specifically: aviation gear wear volume V, aviation gear material type parameter C, aviation gear contact stress P and aviation gear average speed v.

[0117] The experimental conditions of the parameter correction test of the aviation gear wear model in the parameter correction test of the aviation gear wear failure mechanism model mainly include: test conditions such as load and speed. Considering the actual working environment of the aviation gear under study, the temperature in this test is set to room temperature, and the load and speed are selected as stress profiles. Two stress levels are set under each profile. The specific test profiles are shown in Table 4.

[0118] Table 4. Test profile of aviation gear model parameter correction

[0119] Serial Number Load Rotational Speed Sample Size 1 0.24 Nm 22.2 rpm 2 2 0.07 Nm 14.8 rpm 2 3 0.24 Nm 14.8 rpm 2 4 0.07 Nm 22.2 rpm 2

[0120] The parameter correction test of the aviation gear wear failure mechanism model is described in detail. The specific steps are as follows:

[0121] Step S221: Check the surface finish of the aviation gear to be tested.

[0122] Step S222: Install the aviation gear to be tested in the test reduction mechanism according to the assembly requirements. After the installation is completed, the reduction mechanism should run smoothly without sticking. At the same time, relevant parameters should be measured to meet the assembly conditions.

[0123] Step S223: Fix the test reduction mechanism, convert the load value of the aviation gear in the test section into the force value of the butterfly plate, load the butterfly plate, and fix the test reduction mechanism on the test bench.

[0124] Step S224: Adsorb the vibration sensor on the housing of the test reduction mechanism through a magnetic suction base. The specific position is at the closest point to the aviation gear to be tested, with one sensor longitudinally and one transversely, and connect them to the acquisition board and the acquisition instrument through signal lines.

[0125] Step S225: During the test process, send instructions to the test reduction mechanism through the special software of the detection equipment to conduct a 20° - 40° movement test; at the same time, turn on the signal acquisition software to collect vibration signals in real time.

[0126] Step S226: During the test process, every Y / 5 times, pause the test, disassemble the aviation gear to be tested, clean it, measure its wear amount and record it; after the measurement, reinstall the aviation gear to be tested in the test reduction mechanism according to the assembly requirements and continue the test.

[0127] Step S227: When the wear amount of the aviation gear reaches the failure standard, stop the test, replace the aviation gear to be tested, and conduct the next group of tests.

[0128] Step S228: Repeat steps S221 - S227 until the test is completed.

[0129] The stop life test should be operated according to the following steps:

[0130] 1) Operate the signal acquisition software to stop collecting vibration signals.

[0131] 2) Operate the special test software to stop the movement of the test reduction mechanism.

[0132] 3) Remove the load applied to the test reduction mechanism.

[0133] Step S3: Modify the physical correction model of the aviation gear wear fault and establish the second aviation gear life prediction model.

[0134] Based on the aviation gear service life test data in step S2, substitute the aviation gear wear coefficient K determined in step S1 of this step; since the aviation gear wear coefficient K has a logarithmic linear relationship with the aviation gear material type parameter C, the average speed v of the aviation gear, and the contact stress P of the aviation gear, establish the physical correction model of the aviation gear wear fault, specifically:

[0135] ln(K) = a1 * P + a2 * v + a3 * C;

[0136] Among them, a1 is the first parameter of the physical correction model of the aviation gear wear fault; a2 is the second parameter of the physical correction model of the aviation gear wear fault; a3 is the third parameter of the physical correction model of the aviation gear wear fault.

[0137] The first parameter a1 of the physical correction model for the wear failure of aviation gears, the second parameter a2 of the physical correction model for the wear failure of aviation gears, and the third parameter a3 of the physical correction model for the wear failure of aviation gears are all determined by least squares fitting.

[0138] Modify the first aviation gear life prediction model in step S1 to obtain the second aviation gear life prediction model, specifically:

[0139]

[0140] Among them, T2 is the predicted result of the life of the second aviation gear.

[0141] Step S4: Predict the service life of the aviation gear according to the second aviation gear life prediction model.

[0142] As Figure 3 shown is the flow chart of the comprehensive evaluation scheme of the present invention, which is used to describe the overall process of this scheme; at the end of this scheme, the hardness H of the aviation gear material, the wear volume V of the aviation gear, the average speed v of the aviation gear, the contact stress P of the aviation gear, and the material type parameter C of the aviation gear are input into the second aviation gear life prediction model determined in step S3 to obtain the final predicted result of the service life of the aviation gear.

[0143] The beneficial effects of the present invention are as follows: The embodiment of the present invention proposes an aviation gear life prediction method based on the modification test of the wear failure mechanism model. An aviation gear life prediction model is established based on the physical model of the wear failure of aviation gears based on the Archard adhesive wear model. Through the modification test of the aviation gear fault physical model, the improvement of the aviation gear life prediction model is completed; by studying the failure analysis, life prediction, damage evolution law, etc. of aviation gears, a life test verification and comprehensive evaluation scheme for quantitatively characterizing the damage evolution law of aviation gears based on the wear amount of aviation gears is provided, and the failure criterion threshold of aviation gears is determined through the life preliminary test, providing a basis for the modification test of the aviation gear wear fault physical model; the load and speed of the aviation gear are selected as the stress profile for the modification test of the aviation gear wear fault physical model, and the wear amount values of the aviation gear for load, speed, and time collected during the test are used to modify the aviation gear wear fault physical model, and finally the service life prediction of the aviation gear is completed; the prediction method proposed by the present invention is simple to operate and accurate in results, meeting the actual use requirements.

[0144] The above-described embodiments are only descriptions of the preferred embodiments of the present invention, and do not limit the scope of the present invention. Without departing from the design spirit of the present invention, various deformations and improvements made by those of ordinary skill in the art to the technical solutions of the present invention shall fall within the protection scope determined by the claims of the present invention.

Claims

1. An aviation gear life prediction method based on a wear failure mechanism model correction test, characterized in that: It includes: S1: Calculate the wear life of the aviation gear according to the Archard adhesive wear model, and establish the first aviation gear life prediction model; Based on the actual working conditions of the aviation gear, analyze and determine that the failure mode of the aviation gear is wear. Based on the Archard adhesive wear model, the first aviation gear life prediction model is obtained as: where T1 is the prediction result of the life of the first aviation gear; H is the hardness of the aviation gear material; V is the wear volume of the aviation gear; K is the wear coefficient of the aviation gear; C is the material type parameter of the aviation gear; v is the average speed of the aviation gear; P is the contact stress of the aviation gear. S2: Conduct the wear life test of the aviation gear to obtain the corrected test data of the service life of the aviation gear. First, conduct the material property test of the aviation gear. Use a hardness tester to test the hardness of the aviation gear surface to obtain the material type parameter C of the aviation gear. Then, conduct the life preliminary test of the aviation gear to test the wear process of the aviation gear and determine the wear test life value Y of the aviation gear. Finally, conduct the parameter correction test of the wear fault mechanism model of the aviation gear. In the aviation gear wear test, detect the wear amount of the aviation gear with Y / 5 as the detection period to obtain the corrected test data of the service life of the aviation gear, specifically: the wear volume V of the aviation gear, the material type parameter C of the aviation gear, the contact stress P of the aviation gear, and the average speed v of the aviation gear. S3: Correct the physical correction model of the aviation gear wear fault and establish the second aviation gear life prediction model. Based on the service life test data of the aviation gear in step S2, substitute and determine the wear coefficient K of the aviation gear in this step S1. Since the wear coefficient K of the aviation gear has a logarithmic linear relationship with the material type parameter C of the aviation gear, the average speed v of the aviation gear, and the contact stress P of the aviation gear, establish the physical correction model of the aviation gear wear fault as: ln(K) = a1*P + a2*v + a3*C; where a1 is the first parameter of the physical correction model of the aviation gear wear fault; a2 is the second parameter of the physical correction model of the aviation gear wear fault; a3 is the third parameter of the physical correction model of the aviation gear wear fault. Correct the first aviation gear life prediction model in step S1 to obtain the second aviation gear life prediction model, specifically: where T2 is the prediction result of the life of the second aviation gear. S4: Complete the prediction of the service life of the aviation gear according to the second aviation gear life prediction model. Input the hardness H of the aviation gear material, the wear volume V of the aviation gear, the average speed v of the aviation gear, the contact stress P of the aviation gear, and the material type parameter C of the aviation gear into the second aviation gear life prediction model determined in step S3 to obtain the final prediction result of the service life of the aviation gear.

2. The aviation gear life prediction method based on the wear fault mechanism model correction test according to claim 1, characterized in that: The Archard adhesive wear model in step S1 is: where: L is the wear distance of the aviation gear.

3. The aviation gear life prediction method based on the wear fault mechanism model correction test according to claim 1, characterized in that: The aviation gear material property test in step S2 is used to measure the hardness of the meshing surface of the used aviation gear. Take an aviation gear to be tested and measure the hardness of the meshing surface of the aviation gear at 4 different positions through a hardness tester. Take the average value of the 4 hardness values as the hardness H for the aviation gear wear life test.

4. The aviation gear life prediction method based on the wear fault mechanism model correction test according to claim 1, wherein: In the aviation gear life preliminary test in step S2, simulate the actual working conditions of the aviation gear through the test, obtain the wear amount when the aviation gear fails, and calculate the wear volume V of the aviation gear.

5. The aviation gear life prediction method based on the wear fault mechanism model correction test according to claim 4, wherein: The specific steps of the aviation gear life preliminary test are as follows: S211: Check the surface finish of the aviation gear to be tested; S212: Install the aviation gear to be tested in the test reduction mechanism according to the assembly requirements, and at the same time measure relevant parameters to meet the assembly conditions; S213: Fix the test reduction mechanism, convert the load value of the aviation gear in the test profile into the force value of the butterfly valve plate, and load the butterfly valve plate. The test reduction mechanism is fixed on the test bench; S214: Adsorb the vibration sensor on the outer shell of the test reduction mechanism through a magnetic adsorption seat. The specific positions are the closest to the aviation gear to be tested, with one sensor longitudinally and one transversely, and connect them to the acquisition board and the acquisition instrument through signal lines; S215: During the test, send instructions to the test reduction mechanism through the special software of the detection equipment to conduct a movement test of 20° - 40°; at the same time, turn on the signal acquisition software to collect vibration signals in real time; S216: During the test, every X times, pause the test, disassemble the aviation gear to be tested, clean it and then measure its wear amount and record it; observe the difference value between adjacent wear amounts. If the difference value is less than 5%, increase the interval times to n * X times; if the difference value is greater than 10%, reduce the interval times to (1 / n) * X times; n is an integer greater than 1; S217: After the measurement, reinstall the aviation gear to be tested in the test reduction mechanism according to the assembly requirements and continue the test; S218: When the wear amount of the aviation gear reaches the failure criterion condition, stop the test, replace the aviation gear to be tested, and conduct the next group of tests; S219: Repeat steps S211 - S218 until the test is completed.

6. The aviation gear life prediction method based on the wear fault mechanism model correction test according to claim 1, wherein: In the parameter correction test of the aviation gear wear fault mechanism model in step S2, obtain the data results required for correcting the aviation gear wear fault physical model. The parameters to be measured are the wear amount of the aviation gear, the load of the aviation gear, and the rotational speed, and further calculate the contact stress P of the aviation gear and the average speed v of the aviation gear.

7. The aviation gear life prediction method based on the wear fault mechanism model correction test according to claim 6, wherein: The specific steps of the parameter correction test of the aviation gear wear fault mechanism model are as follows: S221: Check the surface finish of the aviation gear to be tested; S222: Install the aviation gear to be tested in the test reduction mechanism according to the assembly requirements, and at the same time measure relevant parameters, which should meet the assembly conditions; S223: Fix the test reduction mechanism, convert the load value of the aviation gear in the test profile into the force value of the butterfly valve plate, and load the butterfly valve plate. The test reduction mechanism is fixed on the test bench; S224: Adsorb the vibration sensor on the housing of the test reduction mechanism through a magnetic suction base. The specific position is at the closest point to the aviation gear to be tested, with one sensor longitudinally and one transversely, and connect them to the acquisition board and the acquisition instrument through signal lines; S225: During the test, send instructions to the test reduction mechanism through the special software of the test equipment to conduct a 20° - 40° motion test; at the same time, turn on the signal acquisition software to collect vibration signals in real time; S226: During the test, every Y / 5 times, pause the test, disassemble the aviation gear to be tested, clean it, measure its wear amount and record it; after the measurement, reinstall the aviation gear to be tested in the test reduction mechanism according to the assembly requirements and continue the test; S227: When the wear amount of the aviation gear reaches the failure standard, stop the test, replace the aviation gear to be tested, and conduct the next set of tests; S228: Repeat steps S221 - S227 until the test is completed.

8. The aviation gear life prediction method based on the wear fault mechanism model correction test according to claim 1, characterized in that: The first parameter a1 of the physical correction model for the wear fault of the aviation gear, the second parameter a2 of the physical correction model for the wear fault of the aviation gear, and the third parameter a3 of the physical correction model for the wear fault of the aviation gear in step S3 are determined by least - squares fitting.

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