Split detachable long-endurance gear wireless multi-dimensional signal monitoring system and method

Abstract

The invention relates to a split detachable long-endurance gear wireless multi-dimensional signal monitoring system, which belongs to the technical field of gear test devices, and comprises a gear box, a test device fixedly connected with the gear box, a sensor for acquiring a gear box signal, a WiFi repeater and an upper computer, the sensor comprises a temperature sensor, a strain gauge and a vibration sensor; the gearbox comprises a transmission shaft to be tested and a test gear to be tested arranged on the transmission shaft to be tested, the testing device and the end face of the test gear to be tested are attached and coaxially fixed on the test gear to be tested, and the testing device and the end face of the test gear to be tested are attached and are fixedly connected in a split mode. Disassembly and assembly of the testing device in a narrow gearbox space are facilitated, and rapid block maintenance can be carried out without disassembly of the transmission shaft when a fault occurs subsequently; the temperature sensor, the strain gauge, the vibration sensor and a built-in circuit board of the testing device realize acquisition of temperature, stress, torque, vibration signals and electric quantity information, and signal enhancement, stabilization and collection are realized.

Description

Technical Field

[0001] The invention belongs to the technical field of gear test devices and relates to a split and detachable long-life gear wireless multi-dimensional signal monitoring system and method. Background Art

[0002] As a key component of the transmission system, gears are widely used in aerospace, wind power, machine tools and other fields. Their service performance directly determines the stability, reliability and safety of the transmission system of high-end equipment. In the low-speed and heavy-load gearbox environment, the vibration shock is strong, the torque is large, and the gears are ultra-compact. They are prone to pitting, wear and bonding failures, and the risk factor increases sharply. The monitoring of multi-dimensional signals is the guarantee for their safe service.

[0003] Traditional signal monitoring instruments are bulky and highly dependent on the environment. It is difficult to balance the size of the test device, the diversity of functions, and the reliability of the test in a small environment. The existing test system mainly uses slip ring monitoring, which is complicated to install and wire, and is prone to problems such as poor contact, slip ring wear and heating. There are many devices on the conventional gear working site, and the signals interfere with each other. The internal space of the gearbox is small, and there will be a lot of oil and dirt after operation, making it extremely inconvenient to disassemble and assemble the monitoring equipment and difficult to repair subsequent faults. In addition, the on-site equipment does not operate continuously, resulting in the inability to determine the power level during use. Summary of the invention

[0004] In view of this, in order to solve the problems of traditional monitoring methods, such as bulky equipment, inconvenient disassembly and assembly, difficult maintenance, unstable signals and inability to judge the power level, the present invention provides a split and detachable long-life gear wireless multi-dimensional signal monitoring system and method.

[0005] In order to achieve the above object, the present invention provides the following technical solutions:

[0006] A split and detachable long-life gear wireless multi-dimensional signal monitoring system, comprising a gear box, a test device fixedly connected to the gear box, a sensor for collecting gear box signals, a WiFi repeater and a host computer;

[0007] Sensors include temperature sensors, strain gauges, and vibration sensors;

[0008] The gearbox includes a transmission shaft to be tested and a test gear to be tested arranged on the transmission shaft to be tested. The test device and the end face of the test gear to be tested are coaxially fixed on the test gear to be tested, and the test device and the end face of the test gear to be tested are fitted and fixedly connected in a split manner.

[0009] Furthermore, the testing device and the end face of the gear to be tested are arranged in two blocks, upper and lower.

[0010] Furthermore, a point hole is provided on the test device, and bolt holes are provided at positions corresponding to the point hole on the end face of the gear to be tested.

[0011] Furthermore, the testing device includes a cover plate, a battery fixing plate, a chassis, a circuit board, a rechargeable battery, a power display screen, a power switch, a power charging port, a connector, bolts and nuts, wherein the bolts are adapted to the point holes and bolt holes, and a small hole is opened on the cover plate.

[0012] Furthermore, the circuit board includes an upper circuit board and a lower circuit board; the upper circuit board and the lower circuit board both include a power module, a power display module, a main control module and a WiFi module, and the upper circuit board and the lower circuit board are both equipped with an STM32G474RBT3 main control chip and an ESP07S WiFi chip.

[0013] Furthermore, the upper circuit board also includes a temperature information acquisition module; the lower circuit board also includes a stress signal acquisition module, a vibration signal acquisition module and a torque signal acquisition module.

[0014] Furthermore, the temperature sensor uses a patch PT100 platinum resistor and an inserted PT100 platinum resistor to collect the temperature signal of the tooth side and the temperature signal inside the tooth of the test gear; the strain gauge uses a ZA120-05AA250 foil strain gauge and a BF350-3EB foil strain gauge to collect the stress signal of the tooth root of the test gear and the torque signal of the transmission shaft to be tested; the vibration sensor uses an ADXL357 accelerometer to collect vibration signals.

[0015] Furthermore, an inserted PT100 platinum resistor is embedded in a through hole on the end face of the gear to be tested.

[0016] Furthermore, the WiFi repeater includes an ESP8266 serial port module and a power supply.

[0017] Furthermore, the host computer is programmed based on LabVIEW.

[0018] A method for wireless multi-dimensional signal monitoring of a split and detachable long-life gear comprises the following steps:

[0019] S1: Fit the test device to the end face of the gear to be tested, and screw the bolts into the positioning holes of the test device and the corresponding threaded holes on the end face of the gear to be tested to achieve split fixing of the test device;

[0020] S2: A patch PT100 platinum resistor is attached to the tooth side of the gear to be tested and an insert-type PT100 platinum resistor is embedded in the end face of the gear to be tested, a ZA120-05AA250 foil strain gauge is attached to the tooth root of the gear to be tested and a BF350-3EB foil strain gauge is attached to the transmission shaft to be tested, the patch PT100 platinum resistor lead wire and the connector are matched to connect the patch PT100 platinum resistor and the circuit board, the insert-type PT100 platinum resistor lead wire is directly connected to the circuit board through the small hole opened on the cover plate, and the ZA120-05AA250 foil strain gauge and the BF350-3EB foil strain gauge lead wire and the connector are matched to connect the ZA120-05AA250 foil strain gauge and the BF350-3EB foil strain gauge and the circuit board;

[0021] S3: Install the gear to be tested, confirm that the test device is firmly fixed, place the WiFi repeater close to the gear box, turn on the power switch of the test device, and start the test after connecting it to the host computer;

[0022] S4: The host computer, WiFi repeater and test device are in the same WiFi environment. At this time, the WiFi repeater can collect signal information in the circuit board and send it to the host computer for real-time dynamic display of temperature, stress, vibration, torque signal and power information.

[0023] The beneficial effects of the present invention are:

[0024] 1. The present invention discloses a split and detachable long-life gear wireless multi-dimensional signal monitoring system and method. The test device and the end face of the gear to be tested are fitted and fixed in a split manner, and are arranged in upper and lower blocks, which is convenient for disassembly and installation of the test device in a narrow gear box space. In case of subsequent failure, rapid block repair can be carried out without disassembling the transmission shaft. Multiple rechargeable batteries are used to enhance battery life and environmental protection, providing an effective and practical monitoring method for the service performance of gears in low-speed and heavy-load gear box environments.

[0025] 2. The present invention discloses a split and detachable long-life gear wireless multi-dimensional signal monitoring system and method, which collects temperature, stress, torque, vibration signal and power information through temperature sensors, strain gauges, vibration sensors and built-in circuit boards of test devices. After being processed by the circuit boards, the signals are transmitted to the WiFi repeater to enhance, stabilize and aggregate the signals, and finally sent to the host computer for real-time dynamic display.

[0026] 3. The present invention discloses a split and detachable long-life gear wireless multi-dimensional signal monitoring system and method, which can monitor signals such as noise and metal debris by performing simple circuit board updates and sensor selection based on the monitoring of temperature, stress, vibration and torque signals.

[0027] 4. The present invention discloses a split and detachable long-life gear wireless multi-dimensional signal monitoring system and method, which can not only be applied to low-speed and heavy-load gearboxes, but can also be used more widely after slight adjustments according to different gearbox working conditions and structures.

[0028] Other advantages, objectives and features of the present invention will be described in the following description to some extent, and to some extent, will be obvious to those skilled in the art based on the following examination and study, or can be taught from the practice of the present invention. The objectives and other advantages of the present invention can be realized and obtained through the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to make the purpose, technical solutions and advantages of the present invention more clear, the present invention will be described in detail below in conjunction with the accompanying drawings, wherein:

[0030] Figure 1 It is an overall schematic diagram of a split and detachable long-life gear wireless multi-dimensional signal monitoring system of the present invention;

[0031] Figure 2 It is a detailed diagram of the gear to be tested and the transmission shaft to be tested in a split and detachable long-life gear wireless multi-dimensional signal monitoring system of the present invention;

[0032] Figure 3 This is a partial enlarged view of a split and detachable long-life gear wireless multi-dimensional signal monitoring system of the present invention;

[0033] Figure 4 It is an exploded schematic diagram of a test device in a split and detachable long-life gear wireless multi-dimensional signal monitoring system of the present invention;

[0034] Figure 5 This is a detailed diagram of the cover plate in a split and detachable long-life gear wireless multi-dimensional signal monitoring system of the present invention;

[0035] Figure 6 A detailed diagram of a battery fixing plate in a split and detachable long-life gear wireless multi-dimensional signal monitoring system of the present invention;

[0036] Figure 7 A detailed diagram of the chassis in a split and detachable long-endurance gear wireless multi-dimensional signal monitoring system of the present invention;

[0037] Figure 8 This is a circuit layout diagram of a circuit board in a split and detachable long-life gear wireless multi-dimensional signal monitoring system of the present invention.

[0038] Figure markings: 1-gearbox, 2-test gear to be tested, 3-transmission shaft to be tested, 4-test device, 5-WiFi repeater, 6-host computer, 7-plug-in PT100 platinum resistor, 8-chip PT100 platinum resistor, 9-power switch, 10-power charging port, 11-ZA120-05AA250 foil strain gauge, 12-BF350-3EB foil strain gauge, 13-bolt, 14-chassis, 15-battery fixing plate, 16-cover plate, 17-connector, 18-circuit board, 19-rechargeable battery, 20-power display screen, 21-nut, 22-vibration sensor. DETAILED DESCRIPTION

[0039] The following describes the embodiments of the present invention by specific examples, and those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the illustrations provided in the following embodiments only illustrate the basic concept of the present invention in a schematic manner, and the following embodiments and features in the embodiments can be combined with each other without conflict.

[0040] Among them, the drawings are only used for illustrative explanations, and they only represent schematic diagrams rather than actual pictures, and should not be understood as limitations on the present invention. In order to better illustrate the embodiments of the present invention, some parts of the drawings may be omitted, enlarged or reduced, and do not represent the size of actual products. For those skilled in the art, it is understandable that some well-known structures and their descriptions in the drawings may be omitted.

[0041] The same or similar numbers in the drawings of the embodiments of the present invention correspond to the same or similar parts; in the description of the present invention, it should be understood that if the terms "upper", "lower", "left", "right", "front", "rear", etc. indicate the orientation or position relationship, they are based on the orientation or position relationship shown in the drawings, which is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation. Therefore, the terms describing the position relationship in the drawings are only used for illustrative purposes and cannot be understood as limiting the present invention. For ordinary technicians in this field, the specific meanings of the above terms can be understood according to specific circumstances.

[0042] like Figure 1-Figure 8The illustrated embodiment shows a split and detachable long-life gear wireless multi-dimensional signal monitoring system, comprising a gear box 1, a test device 4, an insertable PT100 platinum resistor 7, a patch PT100 platinum resistor 8, a ZA120-05AA250 foil strain gauge 11, a BF350-3EB foil strain gauge 12, a sensor and a WiFi repeater 5 and a host computer 6, wherein the WiFi repeater 5 comprises an ESP8266 serial port module and a power supply, and the host computer 6 is programmed based on LabVIEW.

[0043] Reference Figure 2 The gearbox 1 includes a gear to be tested 2 and a transmission shaft to be tested 3, wherein the gear to be tested 2 is arranged on the transmission shaft to be tested 3. Eight threaded holes and three countersunk holes are evenly provided on the end face of the gear to be tested 2, and a point hole is provided on the test device 4, which corresponds to the threaded hole, and is used for the split-type fixing of the test device 4 as a whole and the gear to be tested 2 and the embedded fixing of the inserted PT100 platinum resistor 7. The test device is fixed on the test gear to be tested by the same axis with the end face of the test gear to be tested, and the test device is fixed with the end face of the test gear to be tested by split-type fixing, and is arranged in two upper and lower blocks.

[0044] Reference Figure 3-Figure 4 As shown, the test device 3 includes a cover plate 16, a battery fixing plate 15, a chassis 14, a circuit board 18, a rechargeable battery 19, a power display screen 20, a power switch 9, a power charging port 10, a connector 17, bolts 13 and nuts 21, wherein the bolts 13 are adapted to the point holes and the threaded holes.

[0045] Reference Figure 5 As shown, the cover plate 16 is provided with 16 installation positions for rechargeable batteries 19, 18 bolt installation holes, 8 bolt installation holes are used for the overall fixed installation of the test device 4, 10 bolt installation holes are used for the battery fixing bolt installation, and there are 2 installation positions for the power display screen 20 on the right side.

[0046] Reference Figure 6 As shown, the battery fixing plate 15 is used to fix the rechargeable battery 19.

[0047] Reference Figure 7 As shown, the chassis 14 is provided with 18 bolt mounting holes, 8 of which are used for the overall fixed installation of the test device 4, and 10 of which are used for the fixing bolt installation of the circuit board 18. There are 2 power switch 9 positions and 2 power charging port 10 positions on the right side, 2 connector mounting holes are distributed on the upper periphery of the chassis, and 8 connector mounting holes are distributed on the lower periphery. After the connector 17 is inserted and fixed, the sensor lead cooperates with it to connect the sensor and the circuit board 18.

[0048] Reference Figure 8As shown, the circuit board 18 includes an upper circuit board and a lower circuit board. The upper circuit board includes a power module, a temperature signal acquisition module, a main control module and a WiFi module; the lower circuit board includes a power module, a stress signal acquisition module, a vibration signal acquisition module, a torque signal acquisition module, a main control module and a WiFi module. The upper circuit board and the lower circuit board are each equipped with an STM32G474RBT3 main control chip and an ESP07S WiFi chip. The plug-in PT100 platinum resistor 7 is embedded in the end face through hole of the test gear 2 to be tested, and the surface-mount PT100 platinum resistor 8 and the plug-in PT100 platinum resistor 7 are used to collect the tooth side temperature signal and the tooth internal temperature signal of the test gear 2 to be tested. The ZA120-05AA250 foil strain gauge 11 and the BF350-3EB foil strain gauge 12 are used to collect the root stress signal of the test gear 2 to be tested and the torque signal of the transmission shaft 3 to be tested. The vibration sensor 22 uses an ADXL357 accelerometer to collect vibration signals.

[0049] The assembly process of the split detachable long-life gear wireless multi-dimensional signal monitoring system is as follows: the power supply end is set on the device cover 16, the rechargeable battery 19 is installed on the cover 16 through the battery slot, and is fixed by the battery fixing plate 15 with the bolts 13 and nuts 21. When the rechargeable batteries 19 in the upper and lower parts of the test device 4 are connected to the leads, 8 rechargeable batteries 19 are connected in parallel. The power supply voltage is 3.7 V, the positive power line is disconnected, and the power supply and power off are controlled by the power switch 9. Finally, the power supply end of the circuit board 18 is connected through the power lead. First, buckle the battery fixing plate 15 on the cover 16, then buckle the circuit board 18 on the chassis 14, align the threaded holes, and fix the battery fixing plate 15-cover 16 and the circuit board 18-chassis 14 with 3 evenly distributed bolts 13 on the upper and lower circumferences. The test device 4 needs to be connected to the sensor through the connector 17 for testing. Start welding, use wire strippers to expose a small part of metal at one end of the lead, use wire clamps to buckle the metal terminal onto the metal lead, insert the terminal with the lead into the connector 17, install the connector 17 with the lead on the corresponding position of the test device chassis 14, select the appropriate lead length at the other end of the connector 17 according to the distance of the sensor welding point and expose the metal lead, and weld at the corresponding welding point of the circuit board 18. After welding, buckle the battery fixing plate 15-cover plate 16, and fix the entire device with 4 bolts 13 through the remaining threaded holes on the upper and lower parts of the test device 4. When the test device 4 is used to monitor the signal of the oil-spray lubricated gearbox 1, it is necessary to apply a layer of electronic sealant on the circuit board 18 after welding the lead to prevent oil from penetrating into the circuit board 18 and insulate it at the same time. After assembling the shell, apply silicone to the gap of the shell to prevent oil from entering the inside.

[0050] The invention discloses a wireless multi-dimensional signal monitoring method for a split and detachable long-life gear, comprising the following steps:

[0051] S1: fit the test device 4 to the end surface of the gear 2 to be tested, and screw the bolts 13 into the positioning holes of the test device and the corresponding threaded holes on the end surface of the gear 2 to be tested to achieve split fixation of the test device 4.

[0052] S2: The patch type PT100 platinum resistor 8 is attached to the tooth side of the test gear 2 to be tested and the plug-in type PT100 platinum resistor 7 is embedded in the end face of the test gear 2 to be tested, the ZA120-05AA250 foil strain gauge 11 is attached to the tooth root position of the test gear 2 to be tested and the BF350-3EB foil strain gauge 12 is attached to the transmission shaft 3 to be tested, the lead wire of the patch type PT100 platinum resistor 8 cooperates with the connector 17 to connect the patch type PT100 platinum resistor 8 and the circuit board 18, the lead wire of the plug-in type PT100 platinum resistor 7 is directly connected to the circuit board 18 through the small hole opened on the cover plate 16, and the lead wires of the ZA120-05AA250 foil strain gauge 11 and the BF350-3EB foil strain gauge 12 cooperate with the connector 17 to connect the ZA120-05AA250 foil strain gauge 11 and the BF350-3EB foil strain gauge 12 and the circuit board 18.

[0053] S3: Install the gear 2 to be tested, confirm that the test device 4 is firmly fixed, place the WiFi repeater 5 close to the gear box 1, turn on the power switch 9 of the test device, and start the test after connecting with the host computer 6.

[0054] S4: The host computer 6, WiFi repeater 5 and test device 4 are in the same WiFi environment. At this time, the WiFi repeater 5 can collect signal information in the circuit board 18, send it to the host computer 6, and then perform real-time dynamic display of temperature, stress, vibration, torque signal and power information.

[0055] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solution of the present invention can be modified or replaced by equivalents without departing from the purpose and scope of the technical solution, which should be included in the scope of the claims of the present invention.

Claims

1. A split and detachable long-life gear wireless multi-dimensional signal monitoring system, characterized in that: It includes a gearbox, a test device fixedly connected to the gearbox, a sensor for collecting gearbox signals, a WiFi repeater and a host computer; The sensors include temperature sensors, strain gauges and vibration sensors; The gear box comprises a transmission shaft to be tested and a test gear to be tested arranged on the transmission shaft to be tested, a test device and an end face of the test gear to be tested are coaxially fixed on the test gear to be tested, and the test device and the end face of the test gear to be tested are fitted in a split fixed connection.

2. A split and detachable long-life gear wireless multi-dimensional signal monitoring system as claimed in claim 1, characterized in that: The testing device and the end surface of the gear to be tested are arranged in two upper and lower blocks.

3. A split and detachable long-life gear wireless multi-dimensional signal monitoring system as claimed in claim 1, characterized in that: The testing device is provided with a point hole, and the end surface of the gear to be tested is provided with bolt holes at positions corresponding to the point hole.

4. A split and detachable long-life gear wireless multi-dimensional signal monitoring system as claimed in claim 3, characterized in that: The testing device includes a cover plate, a battery fixing plate, a chassis, a circuit board, a rechargeable battery, a power display screen, a power switch, a power charging port, a connector, bolts and nuts, wherein the bolts are adapted to the point holes and the bolt holes, and a small hole is opened on the cover plate.

5. A split and detachable long-life gear wireless multi-dimensional signal monitoring system as claimed in claim 4, characterized in that: The circuit board includes an upper circuit board and a lower circuit board; the upper circuit board and the lower circuit board both include a power module, a power display module, a main control module and a WiFi module, and the upper circuit board and the lower circuit board are both equipped with an STM32G474RBT3 main control chip and an ESP07S WiFi chip.

6. A split and detachable long-life gear wireless multi-dimensional signal monitoring system as claimed in claim 5, characterized in that: The upper circuit board also includes a temperature information acquisition module; the lower circuit board also includes a stress signal acquisition module, a vibration signal acquisition module and a torque signal acquisition module.

7. A split and detachable long-life gear wireless multi-dimensional signal monitoring system as claimed in claim 6, characterized in that: The temperature sensor uses a patch PT100 platinum resistor and an inserted PT100 platinum resistor to collect the temperature signal of the side of the gear to be tested and the temperature signal inside the tooth; the strain gauge uses a ZA120-05AA250 foil strain gauge and a BF350-3EB foil strain gauge to collect the root stress signal of the gear to be tested and the torque signal of the transmission shaft to be tested; the vibration sensor uses an ADXL357 accelerometer to collect vibration signals.

8. A split and detachable long-life gear wireless multi-dimensional signal monitoring system as claimed in claim 7, characterized in that: The inserted PT100 platinum resistor is embedded in the through hole of the end face of the gear to be tested.

9. The split and detachable long-life gear wireless multi-dimensional signal monitoring system as claimed in claim 1, characterized in that: The WiFi repeater includes an ESP8266 serial port module and a power supply.

10. The monitoring method of the split and detachable long-life gear wireless multi-dimensional signal monitoring system as claimed in claim 6, characterized in that: The following steps are involved: S1: Fit the test device to the end face of the gear to be tested, and screw the bolts into the positioning holes of the test device and the corresponding threaded holes on the end face of the gear to be tested to achieve split fixing of the test device; S2: Attach the patch type PT100 platinum resistor to the tooth side of the gear to be tested and embed the plug-in type PT100 platinum resistor in the end face of the gear to be tested, attach the ZA120-05AA250 foil strain gauge to the tooth root of the gear to be tested and attach the BF350-3EB foil strain gauge to the transmission shaft to be tested, the patch type PT100 platinum resistor lead wire cooperates with the test device and the connector to connect the patch type PT100 platinum resistor to the circuit board, the plug-in type PT100 platinum resistor lead wire is directly connected to the circuit board through the small hole opened on the cover plate, and the ZA120-05AA250 foil strain gauge and the BF350-3EB foil strain gauge lead wire cooperate with the connector to connect the ZA120-05AA250 foil strain gauge and the BF350-3EB foil strain gauge to the circuit board; S3: Install the gear to be tested, confirm that the test device is firmly fixed, place the WiFi repeater close to the gear box, turn on the power switch of the test device, and start the test after connecting it to the host computer; S4: The host computer, WiFi repeater and test device are in the same WiFi environment. At this time, the WiFi repeater can collect signal information in the circuit board and send it to the host computer for real-time dynamic display of temperature, stress, vibration, torque signal and power information.

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