A wear monitoring system for a planetary gear reduction device

Abstract

The present application provides a wear monitoring system for a planetary gear reduction device, which relates to the field of gear detection technology, including: a first image acquisition module that acquires a first wear image set for a central gear; a second image acquisition module that acquires a second wear image set for M planetary gears; a first operating status evaluation module and a second operating status evaluation module that determine first and second transmission-related indicators in combination with equipment operating parameters and a wear image set; a gear health status judgment module that loads similar wear instances and establishes a gear wear evaluation model in combination with a wear image set; a transmission overload analysis module that performs transmission overload analysis based on transmission-related indicators and issues an overload warning instruction. The present application solves the technical problem that the prior art cannot monitor the actual wear status of multiple gears in real time and locate specific wear locations, resulting in insufficient detection accuracy, and improves the operating reliability and transmission efficiency of the planetary gear reduction device.

Description

Technical Field

[0001] The present application relates to the technical field of gear detection, and in particular to a wear monitoring system for a planetary gear reduction device. Background Art

[0002] Planetary gear reduction devices are widely used in mechanical transmission systems. They are particularly suitable for high-load, high-precision industrial applications due to their large transmission ratio, compact structure, and strong load-bearing capacity. The device is usually composed of a central gear, multiple planetary gears, and an outer gear ring. During long-term operation, the gear components in the planetary gear system are susceptible to wear. If not monitored and maintained in a timely manner, it may lead to a decrease in transmission efficiency or even equipment failure.

[0003] Existing planetary gear wear detection methods mainly include vibration monitoring, temperature monitoring, noise monitoring, oil monitoring, etc. These methods indirectly evaluate the wear of gears by analyzing the parameters of the equipment in operation. The vibration monitoring method uses sensors to detect the vibration signal of the gear, which can reflect the wear status in real time, but is easily disturbed by external noise and structural resonance; the temperature monitoring method determines the wear by detecting the temperature change of the equipment, but its response is delayed and cannot detect early wear in time; the noise monitoring method relies on sound signals to analyze abnormal wear, which is easily affected by environmental noise and difficult to accurately determine the degree of wear; the oil monitoring method evaluates wear by analyzing the wear particles in the lubricating oil, but it requires regular sampling and cannot achieve real-time monitoring.

[0004] In general, the existing planetary gear wear detection methods have limited monitoring accuracy, making it difficult to directly and accurately evaluate the actual wear status of the gears, and unable to monitor multiple gear components simultaneously; at the same time, they lack accurate wear location means, making it impossible to accurately diagnose specific gear components, and easily miss wear problems of individual gears. In addition, some detection methods have lags and cannot detect early wear problems in a timely manner, thus affecting the safety and reliability of the equipment. Summary of the invention

[0005] The present application provides a wear monitoring system for a planetary gear reduction device, which solves the technical problem that the existing wear detection technology cannot monitor the actual wear status of multiple gears in real time and lacks accurate wear positioning means, resulting in insufficient accuracy in planetary gear wear detection. The application achieves the technical effect of accurately identifying the wear position and wear status and improving the operating reliability and transmission efficiency of the planetary gear reduction device.

[0006] In view of the above problems, the present application provides a wear monitoring system for a planetary gear reduction device, the system comprising: a first image acquisition module, the first image acquisition module is used to connect to an image acquisition device before the planetary gear reduction device is started, and collect a first wear image set for the central gear; a second image acquisition module, the second image acquisition module is used to collect a second wear image set for the M planetary gears, the second wear image set includes a wear image subset corresponding to the M planetary gears; a first operating status evaluation module, the first operating status evaluation module is used to introduce the equipment operating parameters of the planetary gear reduction device after the planetary gear reduction device is started, and evaluate the operating status in combination with the first wear image set to determine a first transmission-related index; a second operating status evaluation module, the second operating status evaluation module is used to According to the equipment operating parameters of the planetary gear reduction device, the operating status is evaluated in combination with the second wear image set to determine the second transmission related index; a gear health status judgment module, the gear health status judgment module is used to load the same wear instance of the planetary gear reduction device, and establish a gear wear evaluation model in combination with the first wear image set and the second wear image set, and the gear wear evaluation model is used to judge the gear health status of the M planetary gears; a transmission overload analysis module, the transmission overload analysis module is used to perform transmission overload analysis according to the first transmission related index and the second transmission related index if the gear health status of any one of the M planetary gears is judged to be abnormal, and issue an overload warning instruction, the overload warning instruction includes an overload position, and the overload position is used to locate the planetary gear in a wear overload state.

[0007] One or more technical solutions provided in this application have at least the following technical effects or advantages:

[0008] Before the planetary gear reduction device is started, the first image acquisition module is connected to the image acquisition device, and the first wear image set is collected for the central gear to provide the preliminary wear condition of the central gear, and provide basic data for the subsequent evaluation of the transmission state of the central gear. The second image acquisition module collects the second wear image set for the M planetary gears, and the second wear image set includes the wear image subsets corresponding to the M planetary gears, and provides accurate wear data for the subsequent transmission state evaluation of each planetary gear. After the planetary gear reduction device is started, the first operation state evaluation module introduces the equipment operation parameters of the planetary gear reduction device, combines the first wear image set to evaluate the operation state, and determines the first transmission-related index; the second operation state evaluation module evaluates the operation state according to the equipment operation parameters of the planetary gear reduction device and combines the second wear image set to determine the second transmission-related index. These two state evaluation modules combine the equipment operation parameters and the wear image to evaluate the transmission efficiency of the central gear and the M planetary gears, and determine the operation state of each gear. The gear health state judgment module loads the same wear example of the planetary gear reduction device, combines the first wear image set and the second wear image set, establishes a gear wear evaluation model, judges the gear health state of the M planetary gears, and realizes early wear identification. If the gear health status of any one of the M planetary gears is judged to be abnormal, the transmission overload analysis module performs transmission overload analysis based on the first transmission-related indicator and the second transmission-related indicator, and issues an overload warning instruction. The overload warning instruction includes an overload position, and the overload position is used to locate the planetary gear in a worn overload state, thereby preventing equipment damage caused by severe overload.

[0009] In summary, this application integrates all the above modules to form a comprehensive planetary gear reduction device wear monitoring system. The system realizes comprehensive monitoring of multiple gears by synchronously collecting wear images of the central gear and the planetary gears, overcoming the limitation that the traditional method can only monitor a single component; by combining with the operating parameters to evaluate the operating status, it can more accurately reflect the transmission efficiency and wear status of the gears, solving the problem that the existing methods are difficult to accurately judge the degree of wear; with the help of the gear health status judgment module and the transmission unbalanced load analysis module, the gear components with wear and unbalanced load are accurately located, the early wear and unbalanced load problems are quickly identified, and warnings are issued in time to avoid unbalanced loads further exacerbating gear wear, thereby improving the operating reliability and transmission efficiency of the planetary gear reduction device.

[0010] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application, it can be implemented in accordance with the contents of the specification. In order to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are listed below. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 A schematic structural diagram of a wear monitoring system for a planetary gear reduction device provided in an embodiment of the present application;

[0012] Figure 2 A schematic diagram of a flow chart of determining a first set of associated factors in a wear monitoring system for a planetary gear reduction device provided in an embodiment of the present application;

[0013] Figure 3 A flow chart of the degree of eccentric load corresponding to an eccentric load warning instruction marked in a wear monitoring system of a planetary gear reduction device provided in an embodiment of the present application.

[0014] Explanation of the accompanying drawings: first image acquisition module 10 , second image acquisition module 20 , first operating status evaluation module 30 , second operating status evaluation module 40 , gear health status judgment module 50 , transmission unbalanced load analysis module 60 . DETAILED DESCRIPTION

[0015] The embodiment of the present application provides a wear monitoring system for a planetary gear reduction device, which solves the technical problem that the existing wear detection technology is unable to monitor the actual wear status of multiple gears in real time and lacks accurate wear positioning means, resulting in insufficient accuracy in planetary gear wear detection. The embodiment of the present application achieves the technical effect of accurately identifying the wear position and wear status and improving the operating reliability and transmission efficiency of the planetary gear reduction device.

[0016] like Figure 1 As shown, an embodiment of the present application provides a wear monitoring system for a planetary gear reduction device, the system is used to synchronously monitor a central gear of the planetary gear reduction device and M planetary gears rotating around the central gear, the system comprising:

[0017] The first image acquisition module 10 is used to connect to an image acquisition device before the planetary gear reduction device is started, and to acquire a first wear image set for the central gear.

[0018] Specifically, before the planetary gear reduction device is started, the first image acquisition module 10 acquires an image of the center gear by connecting one or more image acquisition devices. These image acquisition devices can be high-resolution industrial cameras, cameras or microscopes, etc., which are used to record the wear of the gears and obtain high-quality image data. The module summarizes the acquired image data into a first wear image set, which is used to record the wear of the center gear before the equipment is started, including the degree of wear, position, etc. The module establishes the initial state of the center gear wear through high-precision image data before the equipment is operated, providing basic data for subsequent transmission efficiency evaluation and wear monitoring.

[0019] The second image acquisition module 20 is used to acquire a second wear image set for the M planetary gears, wherein the second wear image set includes a wear image subset corresponding to the M planetary gears.

[0020] Specifically, before the planetary gear reduction device is started, the second image acquisition module 20 uses the same image acquisition device to synchronously shoot and record the M planetary gears. Wherein, M is a positive integer, which represents the number of planetary gears in the planetary gear reduction device. The acquired image data will be summarized into a second wear image set, which contains M wear image subsets, and the image data corresponding to each planetary gear constitutes its separate wear image subset. The second image acquisition module 20 accurately captures the wear state of each planetary gear, providing a multi-dimensional image data basis for subsequent transmission efficiency evaluation and wear monitoring.

[0021] The first operating status evaluation module 30 is used to introduce the equipment operating parameters of the planetary gear reduction device after the planetary gear reduction device is started, evaluate the operating status in combination with the first wear image set, and determine the first transmission-related index.

[0022] Specifically, after the planetary gear reduction device is started, the first operating status evaluation module 30 first obtains the equipment operating parameters of the planetary gear reduction device, including speed, torque, temperature, load, etc. These equipment operating parameters are real-time data or set parameters when the planetary gear reduction device is started and running, reflecting the operating status of the equipment. Then, the module compares these equipment operating parameters with the wear image of the central gear collected previously, monitors and evaluates the current operating status of the central gear in real time, and generates a first transmission-related index. The first transmission-related index is a performance index reflecting the transmission effect of the central gear obtained by evaluating the wear condition and operating parameters of the central gear.

[0023] Further, such as Figure 2 As shown, the first operating status evaluation module 30 in the embodiment of the present application is also used to perform the following steps:

[0024] Under standard operating conditions, the tooth profile accuracy of the center gear is obtained; the operating status is evaluated through the tooth profile accuracy of the center gear in combination with the equipment operating parameters of the planetary gear reduction device and the first wear image set, and the transmission smoothness factor is extracted; based on the transmission smoothness factor, a first associated factor set is determined, and the first transmission associated indicator is a key feature in the first associated factor set.

[0025] Specifically, under standard operating conditions, the tooth profile accuracy of the central gear is first obtained by high-precision measuring equipment. This tooth profile accuracy refers to the degree of fit between the tooth profile of the gear and the standard shape. It is usually determined by measuring the tooth thickness, tooth pitch, tooth height, etc. of the gear through a laser interferometer or a gear measuring machine. The tooth profile accuracy determines the meshing effect of the gear. Then, the first operating state evaluation module 30 combines the tooth profile accuracy, the real-time collected equipment operating parameters and the first wear image set to evaluate the operating state of the central gear and identify multiple factors affecting the transmission stability, namely, transmission stability factors. These transmission stability factors can be gear wear, equipment vibration, friction, etc. By analyzing and quantifying the extracted transmission stability factors, the module generates a first associated factor set, which includes multiple factors related to transmission efficiency, such as gear wear, load, speed, temperature change, etc. The contribution of each factor in the first associated factor set to the transmission efficiency is further analyzed, and one or more of the most representative key features are determined to generate a first transmission related index. This index can fully reflect the operating state of the central gear, especially in terms of transmission stability and efficiency.

[0026] Furthermore, the first operating status evaluation module 30 in the embodiment of the present application is also used to perform the following steps:

[0027] The first associated factor set is used to divide the first dynamic factor subset and the first static factor subset; the transmission efficiency corresponding to the first dynamic factor subset and the tooth profile accuracy corresponding to the first static factor subset are combined to obtain the rotational meshing accuracy of the central gear, and the rotational meshing accuracy is associated and mapped with the first static rotational dynamic factor subset in the first associated factor set; according to the rotational meshing accuracy of the central gear and in combination with the transmission smoothness factor, the first static rotational dynamic factor subset is determined.

[0028] Specifically, by analyzing the first set of associated factors, it is divided into two subsets: the first dynamic factor subset and the first static factor subset. Factors that directly affect the transmission efficiency, such as load changes and temperature fluctuations, are classified into the first dynamic factor subset, and factors that affect the tooth profile accuracy, such as the geometric dimensions and material properties of the gears, are classified into the first static factor subset. By combining the data in these two subsets, the module uses data analysis software to calculate the rotational meshing accuracy of the central gear. The rotational meshing accuracy reflects the meshing performance of the gear under different loads and operating conditions. Then, the first set of associated factors is further analyzed to establish an association mapping between the first static factor subset and the first dynamic factor subset. Based on the rotational meshing accuracy and the transmission smoothness factor, through regression analysis or neural network model, determine which static factors have a significant impact on the transmission efficiency under specific dynamic conditions, and combine these factors to form the first static-to-dynamic factor subset.

[0029] Through the above steps, the first operating status evaluation module 30 not only deeply analyzes the operating status of the planetary gear reduction device, but also accurately identifies the key factors affecting the rotational meshing accuracy, providing an important basis for subsequent transmission load imbalance analysis.

[0030] The second operating status evaluation module 40 is used to evaluate the operating status according to the equipment operating parameters of the planetary gear reduction device in combination with the second wear image set, and determine the second transmission related index.

[0031] Specifically, the second operating status evaluation module 40 obtains the equipment operating parameters of the planetary gear reduction device, and uses the same method as above to evaluate the operating status of each planetary gear in combination with the second wear image set to determine one or more second transmission-related indicators. These second transmission-related indicators are obtained by evaluating the wear conditions and operating parameters of multiple planetary gears and are performance indicators that reflect the overall transmission efficiency and meshing accuracy of the planetary gears.

[0032] Similar to the first operating state evaluation module 30, the second operating state evaluation module 40 obtains the tooth profile accuracy of the M planetary gears; evaluates the operating state through the tooth profile accuracy of the M planetary gears, combined with the equipment operating parameters of the planetary gear reduction device and the second wear image set, and extracts the transmission stability factor; based on the transmission stability factor, determines the second associated factor set, and the second transmission associated index is the key feature in the second associated factor set. By analyzing the second associated factor set, determine the second static-to-dynamic factor subset.

[0033] The gear health status judgment module 50 is used to load similar wear instances of the planetary gear reduction device, and to establish a gear wear assessment model in combination with the first wear image set and the second wear image set. The gear wear assessment model is used to judge the gear health status of the M planetary gears.

[0034] Specifically, the similar wear instance is the wear data of the known equipment or system similar to the current planetary gear. These data are usually from the historical database, covering the wear conditions of similar equipment under similar working conditions, as reference examples. The gear health status judgment module 50 first loads the similar wear instances from the historical database, uses these similar wear instances as the learning basis of the model, and then uses machine learning algorithms, such as random forests, support vector machines, etc., to train on the historical wear instances to establish a gear wear assessment model. The gear wear assessment model is a model built based on data and algorithms, which is used to assess the wear degree and health status of the gear. The first wear image set and the second wear image set of the current device are used as input data and input into the gear wear assessment model to judge the gear health status. The model identifies the wear characteristics of the gear, and compares the wear condition of the current gear with the existing wear patterns in the similar wear instances, and judges the gear health status of each planetary gear of the current device, that is, whether the gear is in a normal wear state or there is a risk of abnormal wear.

[0035] Further, in the embodiment of the present application, the second transmission-related index is a key feature in the second associated factor set, and the gear health status judgment module 50 is further used to perform the following steps:

[0036] After the planetary gear reduction device is started, a first static-to-dynamic factor subset in the first association factor set and a second static-to-dynamic factor subset in the second association factor set are obtained; and at the same time, model parameters of the gear wear assessment model are adjusted.

[0037] Specifically, the gear health status judgment module 50 extracts respective static-to-dynamic factor subsets from the first set of associated factors and the second set of associated factors, combines the extracted first and second static-to-dynamic factor subsets, and uses an online learning algorithm, such as online stochastic gradient descent or small batch gradient descent, to adjust the model parameters of the gear wear assessment model in real time, such as the model weight, learning rate, etc., so that the model is more adapted to the current operating environment and equipment status, so as to improve the prediction accuracy of the gear health status.

[0038] The gear health status judgment module 50 constructs a gear wear assessment model and combines historical wear instances with current image data to achieve scientific judgment on the health status of M planetary gears, which can detect potential wear problems early and improve the accuracy of gear wear monitoring.

[0039] The transmission unbalanced load analysis module 60 is used to perform transmission unbalanced load analysis according to the first transmission-related indicator and the second transmission-related indicator if the gear health status of any one of the M planetary gears is judged to be abnormal, and issue an unbalanced load warning instruction, wherein the unbalanced load warning instruction includes an unbalanced load position, and the unbalanced load position is used to locate the planetary gear in a worn unbalanced load state.

[0040] Specifically, when the gear health status judgment module 50 determines that the health status of a planetary gear is abnormal, the transmission overload analysis module 60 is started to obtain the transmission related index data provided by the first and second operating status evaluation modules 40. Then, the module compares these data to analyze whether the transmission efficiency and meshing accuracy of each planetary gear are uniform. Normally, when the gear health status of a planetary gear is abnormal, it means that the wear of the gear causes uneven load distribution, which in turn causes the transmission overload problem of the entire planetary gear reduction device. The module finds the specific location of the uneven load by comparing the load conditions of each gear. And issues an overload warning instruction, which not only reminds maintenance personnel that there is a problem with the planetary gear reduction device, but also provides a specific overload position to help quickly locate the planetary gear that is in a state of wear or abnormal load.

[0041] The transmission off-load analysis module 60 can effectively warn and solve the off-load problem in the planetary gear reduction device through accurate transmission-related index analysis and off-load positioning, thereby ensuring the smooth operation of the entire planetary gear reduction device.

[0042] Furthermore, the transmission load distribution change corresponding to the first static-to-dynamic factor subset in the first association factor set in the embodiment of the present application corresponds to the transmission ratio vector and the transmission phase vector between the center gear-first planetary gear, the center gear-second planetary gear,..., the center gear-Mth planetary gear.

[0043] Specifically, the change in transmission load distribution refers to the change in the distribution of transmission load between gears due to friction, wear, uneven load, etc. during the operation of the planetary gear reduction device. The transmission ratio vector is a vector that reflects the transmission efficiency or load distribution ratio between the central gear and each planetary gear. The transmission phase vector is a vector that represents the transmission phase relationship between the central gear and each planetary gear, reflecting the synchronization between the central gear and each planetary gear, or the timing and angle difference of relative rotation.

[0044] As the planetary gear reduction device operates, the gears wear out, and the load distribution between the central gear and the M planetary gears may no longer be uniform, resulting in eccentric load or load transfer, and changes in the transmission load distribution. The load distribution ratio between the central gear and each planetary gear can be determined by calculating the transmission ratio vector. Each planetary gear corresponds to a transmission ratio vector, which indicates the load share of the planetary gear in the overall transmission. By analyzing the transmission phase vector between each gear, the synchronization between the gears can be monitored. If the phase vector shows that the phase difference between the gears is too large, it means that the planetary gear reduction device is not stable, and there may be wear or other abnormal conditions. Through the transmission ratio vector and the transmission phase vector, the mechanical relationship between the gears can be monitored in real time to determine the changes in the transmission load distribution of the planetary gear reduction device.

[0045] Furthermore, the transmission load eccentricity analysis module 60 of the embodiment of the present application is also used to perform the following steps:

[0046] After the center gear rotates one circle, the transmission ratio vectors between the center gear-first planetary gear, the center gear-second planetary gear, ..., and the center gear-Mth planetary gear are obtained; based on the transmission ratio vectors between the center gear-first planetary gear, the center gear-second planetary gear, ..., and the center gear-Mth planetary gear, the relative position relationship of the M planetary gears is extracted, and the relative position relationship includes a transmission angle and a transmission arc length; through the relative position relationship of the M planetary gears, the transmission phase vectors between the center gear-first planetary gear, the center gear-second planetary gear, ..., and the center gear-Mth planetary gear are obtained.

[0047] Specifically, after the central gear rotates one circle, the transmission load eccentricity analysis module 60 monitors the transmission ratio vector between the central gear and each planetary gear. These vectors can be obtained by detecting the changes in gear position and angle through high-speed camera equipment, position sensors or laser rangefinders, and are used to calculate load and efficiency distribution. Then, the module extracts the spatial positions between the M planetary gears and between them and the central gear, that is, the relative position relationship, according to the force conditions of each planetary gear. The relative position relationship is described by the transmission angle and the transmission arc length, reflecting the relative displacement and relative rotation of the gears in the transmission system. Through these positional relationships, the module calculates the phase difference of each gear, that is, the transmission phase vector. The transmission phase vector is used to analyze the rotation synchronization between the planetary gear and the central gear to ensure that the operating rhythm of each gear is consistent. If the phase of a planetary gear is significantly different from that of other gears, the module can identify the synchronization problem of the gear and then issue an eccentricity alarm.

[0048] For example, in a planetary gear reduction device, after the sun gear completes one rotation, the module obtains that the transmission ratio vector between the sun gear and the first planetary gear is 1:4, and the transmission ratio vector between the sun gear and the second planetary gear is 1:3. Through further analysis, it is extracted that the transmission angle difference between the first planetary gear and the second planetary gear is 30°, and the transmission arc length difference is 5mm. Based on these relative position relationships, the module calculates the transmission phase vector between the sun gear and the first planetary gear and the second planetary gear.

[0049] Furthermore, the transmission load eccentricity analysis module 60 of the embodiment of the present application is also used to perform the following steps:

[0050] A theoretical relative position relationship is introduced, wherein the theoretical relative position relationship includes a theoretical transmission angle and a theoretical transmission arc length; the theoretical relative position relationship and the transmission phase vectors between the center gear and the first planetary gear, the center gear and the second planetary gear, ..., and the center gear and the Mth planetary gear are compared to generate a transmission load distribution map; in the transmission load distribution map, the overload position corresponding to the overload warning instruction is visually marked.

[0051] Specifically, the theoretical relative position relationship refers to the relative position relationship between each gear in the planetary gear reduction device obtained according to the design parameters and theoretical calculations, including the theoretical transmission angle and the theoretical transmission arc length. The transmission load eccentricity analysis module 60 obtains the theoretical relative position relationship of the planetary gear reduction device, compares the theoretical data with the actual measured transmission phase vector, and generates a transmission load distribution map. The transmission load distribution map can be a two-dimensional or three-dimensional chart for displaying the position, phase and load distribution of each gear. In theory, the phase difference of the gears should be zero, that is, perfect synchronization, but in actual operation, the transmission phase vector between the central gear and each planetary gear will be affected by various factors, such as manufacturing errors, wear, load changes, etc., so there is a phase difference, resulting in abnormal load on a certain gear. Exemplarily, under normal design conditions, the theoretical transmission angle between the central gear and the first planetary gear is 45 degrees, and the transmission arc length is 50 mm. In actual operation, this angle may be 44 degrees and the arc length is 49 mm. In the transmission load distribution map, any area that deviates from the theoretical relative position relationship will be highlighted by a visual marker. For example, through color coding, the eccentric load position can be displayed in red, while the normal area is represented by green. In this way, the transmission eccentric load analysis module 60 can intuitively display the eccentric load position to the technician, so that the technician can take maintenance or adjustment measures in time.

[0052] Further, such as Figure 3 As shown, the transmission load eccentricity analysis module 60 in the embodiment of the present application is also used to perform the following steps:

[0053] If the gear health status of any one of the M planetary gears is judged to be abnormal, mark the abnormal planetary gear and N adjacent planetary gears, wherein the N adjacent planetary gears include N1 left adjacent planetary gears and N2 right adjacent planetary gears; for the abnormal planetary gear and the N1 left adjacent planetary gear among the N adjacent planetary gears, perform a transmission unbalanced load analysis according to the first transmission-related index and the second transmission-related index, and set a first unbalanced load degree sequence; for the abnormal planetary gear and the N2 right adjacent planetary gears among the N adjacent planetary gears, perform a transmission unbalanced load analysis according to the first transmission-related index and the second transmission-related index, and set a second unbalanced load degree sequence; based on the abnormal planetary gear and the N adjacent planetary gears, according to the first unbalanced load degree sequence and the second unbalanced load degree sequence, visually mark the unbalanced load degree corresponding to the unbalanced load warning instruction.

[0054] Specifically, when the gear health status judgment module 50 judges that the health status of any one of the M planetary gears is abnormal, the transmission load imbalance analysis module 60 first marks the abnormal gear, and determines the N1 left adjacent planetary gears and N2 right adjacent planetary gears adjacent to the left and right of the gear set according to the arrangement order or geometric relationship of the gear set and the detected abnormal position mark. Wherein, N, N1, N2 are positive integers, and N<M.

[0055] Next, the module performs transmission load imbalance analysis on the left adjacent planetary gear and the right adjacent planetary gear based on the first transmission-related index and the second transmission-related index determined previously, and evaluates and quantifies the degree of load imbalance by using the real-time operating parameters of the equipment collected by the sensor, the wear image, and the health status assessment model of the gear. Sort the N1 load imbalances according to the arrangement order of the left gear set to obtain the first load imbalance sequence. Sort the N2 load imbalances according to the arrangement order of the right gear set to obtain the second load imbalance sequence. Combining the first load imbalance sequence and the second load imbalance sequence of the abnormal planetary gear with the N adjacent planetary gears, the module visually marks them in the transmission load distribution map to intuitively display the load imbalance corresponding to the load imbalance warning instruction.

[0056] For example, in a planetary gear reduction device, the third planetary gear is judged to be in an abnormal health state. The module then marks the third gear and the two planetary gears adjacent to it on the left and right (assuming N=4, N1=N2=2). By analyzing the first and second transmission-related indicators, the module sets the first load eccentricity sequence to [0.8, 0.6], indicating the load eccentricity of the adjacent gear on the left; and sets the second load eccentricity sequence to [0.7, 0.5], indicating the load eccentricity of the adjacent gear on the right. The load eccentricity of the abnormal planetary gear and its adjacent gears is displayed by color coding in the transmission load distribution map to help maintenance personnel quickly locate the problem and take corresponding measures.

[0057] The transmission load eccentricity analysis module 60 can effectively identify and quantify the degree of load eccentricity of abnormal planetary gears and their adjacent gears through in-depth analysis and visual marking, making it easier for technicians to perform targeted maintenance and fault prevention.

[0058] In summary, the wear monitoring system of a planetary gear reduction device provided in the embodiment of the present application has the following technical effects:

[0059] Before the planetary gear reduction device is started, the first image acquisition module 10 is connected to the image acquisition device, and collects the first wear image set for the central gear, provides the preliminary wear condition of the central gear, and provides basic data for the subsequent evaluation of the transmission state of the central gear. The second image acquisition module 20 collects the second wear image set for the M planetary gears, and the second wear image set includes the wear image subsets corresponding to the M planetary gears, and provides accurate wear data for the subsequent transmission state evaluation of each planetary gear. After the planetary gear reduction device is started, the first operation state evaluation module 30 introduces the equipment operation parameters of the planetary gear reduction device, evaluates the operation state in combination with the first wear image set, extracts the transmission stability factor of the central gear, generates the first transmission-related index by analyzing the transmission stability factor, and accurately evaluates the operation state of the gear; the second operation state evaluation module 40 evaluates the operation state according to the equipment operation parameters of the planetary gear reduction device and the second wear image set, and determines the second transmission-related index. These two state evaluation modules evaluate the transmission efficiency of the central gear and the M planetary gears in combination with the equipment operation parameters and the wear image, and determine the operation state of each gear. The gear health status judgment module 50 loads the same wear instance of the planetary gear reduction device, combines the first wear image set and the second wear image set, establishes a gear wear assessment model, judges the gear health status of the M planetary gears, and realizes early wear identification. If the gear health status of any one of the M planetary gears is judged to be abnormal, the transmission load imbalance analysis module 60 performs transmission load imbalance analysis according to the first transmission related index and the second transmission related index, marks the abnormal gear and its left and right adjacent gears, and generates the first and second load imbalance degree sequences for these gears respectively; by comparing the theoretical and actual relative position relationship, a transmission load distribution map is generated, and the load imbalance degree and load imbalance position are visually marked in the map, and a load imbalance warning instruction is issued to help maintenance personnel quickly locate the planetary gears in a worn and unbalanced state and take corresponding measures.

[0060] In general, the embodiment of the present application integrates all the above modules to form a comprehensive planetary gear reduction device wear monitoring system. The system realizes comprehensive monitoring of multiple gears by synchronously collecting wear images of the central gear and the planetary gears, overcoming the limitation of the traditional method that can only monitor a single component; by combining with the operating parameters to evaluate the operating status, it can more accurately reflect the transmission efficiency and wear status of the gears, solving the problem that the existing methods are difficult to accurately judge the degree of wear; with the help of the gear health status judgment module 50 and the transmission load imbalance analysis module 60, the gear components with wear and load imbalance are accurately located, the early wear and load imbalance problems are quickly identified, and warnings are issued in time to avoid the load imbalance further exacerbating the gear wear, thereby improving the operating reliability and transmission efficiency of the planetary gear reduction device.

[0061] The above description of the disclosed embodiments enables those skilled in the art to implement or use the present application. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to the embodiments shown herein, but will conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A wear monitoring system for a planetary gear reduction device, characterized in that: The system is used for synchronously monitoring a central gear of a planetary gear reduction device and M planetary gears rotating around the central gear, and comprises: A first image acquisition module, wherein the first image acquisition module is used to connect to an image acquisition device before the planetary gear reduction device is started, and to acquire a first wear image set for the central gear; A second image acquisition module, the second image acquisition module is used to acquire a second wear image set for the M planetary gears, the second wear image set including a wear image subset corresponding to the M planetary gears; a first operating state evaluation module, wherein the first operating state evaluation module is used to introduce the equipment operating parameters of the planetary gear reduction device after the planetary gear reduction device is started, evaluate the operating state in combination with the first wear image set, and determine a first transmission-related index, wherein the first transmission-related index is a performance index reflecting the transmission effect of the central gear; a second operating state evaluation module, the second operating state evaluation module being used to evaluate the operating state according to the equipment operating parameters of the planetary gear reduction device in combination with the second wear image set, and determine a second transmission-related index, wherein the second transmission-related index is a performance index reflecting the overall transmission efficiency and meshing accuracy of the planetary gear; a gear health status judgment module, the gear health status judgment module is used to load the same wear instance of the planetary gear reduction device, and establish a gear wear assessment model in combination with the first wear image set and the second wear image set, the gear wear assessment model is used to judge the gear health status of the M planetary gears; A transmission overload analysis module, wherein the transmission overload analysis module is used to perform a transmission overload analysis according to the first transmission-related indicator and the second transmission-related indicator if the health status of the gear of any one of the M planetary gears is determined to be abnormal, and issue an overload warning instruction, wherein the overload warning instruction includes an overload position, and the overload position is used to locate the planetary gear in a worn and overloaded state.

2. A wear monitoring system for a planetary gear reduction device according to claim 1, characterized in that: The execution steps of the first operating status assessment module include: Under standard operating conditions, obtain the tooth profile accuracy of the central gear; By using the tooth profile accuracy of the central gear, combined with the equipment operating parameters of the planetary gear reduction device and the first wear image set, the operating state is evaluated to extract the transmission stability factor, which includes gear wear, equipment vibration and friction; Based on the transmission stability factor, a first set of associated factors is determined, wherein the first transmission associated index is a key feature in the first set of associated factors, wherein the first set of associated factors includes gear wear, load, rotation speed and temperature change.

3. A wear monitoring system for a planetary gear reduction device as claimed in claim 2, characterized in that: The execution steps of the first operating status assessment module also include: Dividing the first associated factor set into a first dynamic factor subset and a first static factor subset, wherein the first dynamic factor subset is factors that directly affect transmission efficiency, including load changes and temperature fluctuations, and the first static factor subset is factors that affect tooth profile accuracy, including geometric dimensions and material properties of gears; Combining the transmission efficiency corresponding to the first dynamic factor subset and the tooth profile accuracy corresponding to the first static factor subset to obtain the rotational meshing accuracy of the central gear, wherein the rotational meshing accuracy is associated with the first static-to-dynamic factor subset in the first associated factor set; According to the rotational meshing accuracy of the central gear and in combination with the transmission smoothness factor, a first static-to-dynamic factor subset is determined, wherein the first static-to-dynamic factor subset refers to static factors that affect the transmission efficiency of the central gear under specific dynamic conditions.

4. A wear monitoring system for a planetary gear reduction device as claimed in claim 3, characterized in that: The second transmission-related index is a key feature in the second related factor set, and the execution steps of the gear health status judgment module also include: After the planetary gear reduction device is started, a first static-to-dynamic factor subset in the first association factor set and a second static-to-dynamic factor subset in the second association factor set are obtained, wherein the second static-to-dynamic factor subset refers to factors that static factors affect the transmission efficiency of the planetary gear under specific dynamic conditions, and the second association factor set includes multiple factors related to the transmission efficiency of M planetary gears; At the same time, the model parameters of the gear wear assessment model are adjusted.

5. A wear monitoring system for a planetary gear reduction device as claimed in claim 4, characterized in that: The transmission load distribution corresponding to the first static rotational dynamic factor subset in the first set of associated factors corresponds to the transmission ratio vector between the center gear and the first planetary gear, the transmission ratio vector between the center gear and the second planetary gear, ..., the transmission ratio vector between the center gear and the Mth planetary gear, and the transmission load distribution corresponding to the first static rotational dynamic factor subset in the first set of associated factors corresponds to the transmission phase vector between the center gear and the first planetary gear, the transmission phase vector between the center gear and the second planetary gear, ..., the transmission phase vector between the center gear and the Mth planetary gear.

6. A wear monitoring system for a planetary gear reduction device as claimed in claim 5, characterized in that: The execution steps of the transmission eccentric load analysis module also include: After the sun gear rotates one circle, a transmission ratio vector between the sun gear and the first planetary gear, a transmission ratio vector between the sun gear and the second planetary gear, ..., a transmission ratio vector between the sun gear and the Mth planetary gear is obtained; Based on the transmission ratio vector between the central gear and the first planetary gear, the transmission ratio vector between the central gear and the second planetary gear, ..., the transmission ratio vector between the central gear and the Mth planetary gear, extracting the relative position relationship of the M planetary gears, wherein the relative position relationship includes a transmission angle and a transmission arc length; The transmission phase vectors between the central gear and the first planetary gear, the central gear and the second planetary gear, ..., and the central gear and the Mth planetary gear are obtained through the relative position relationship of the M planetary gears.

7. A wear monitoring system for a planetary gear reduction device as claimed in claim 6, characterized in that: The execution steps of the transmission eccentric load analysis module also include: Introducing a theoretical relative position relationship, wherein the theoretical relative position relationship includes a theoretical transmission angle and a theoretical transmission arc length; Comparing the theoretical relative position relationship, and the transmission phase vector between the central gear and the first planetary gear, the transmission phase vector between the central gear and the second planetary gear, ..., the transmission phase vector between the central gear and the Mth planetary gear, to generate a transmission load distribution map; In the transmission load distribution map, the eccentric load position corresponding to the eccentric load warning instruction is visually marked.

8. A wear monitoring system for a planetary gear reduction device as claimed in claim 7, characterized in that: The execution steps of the transmission eccentric load analysis module also include: If the gear health status of any one of the M planetary gears is determined to be abnormal, the abnormal planetary gear and N adjacent planetary gears are marked, wherein the N adjacent planetary gears include N1 left adjacent planetary gears and N2 right adjacent planetary gears; For the abnormal planetary gear and N1 left adjacent planetary gears among the N adjacent planetary gears, a transmission load imbalance analysis is performed according to the first transmission related index and the second transmission related index, and a first load imbalance degree sequence is set; For the abnormal planetary gear and N2 right adjacent planetary gears among the N adjacent planetary gears, a transmission load imbalance analysis is performed according to the first transmission related index and the second transmission related index, and a second load imbalance degree sequence is set; Based on the abnormal planetary gear and N adjacent planetary gears, the off-load degree corresponding to the off-load warning instruction is visually marked according to the first off-load degree sequence and the second off-load degree sequence.

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