Repairing and remanufacturing method for fatigue failure part of gear reducer motor based on virtual simulation

Abstract

The invention discloses a method for repairing and remanufacturing a fatigue failure part of a gear reducer motor based on virtual simulation, which comprises the following steps of: 1, analyzing a virtual simulation manufacturing model of the gear reducer motor, 2, evaluating a repairing model method of the fatigue failure part, 3, carrying out multi-target composite surface repairing and regeneration manufacturing optimization design, and 4, carrying out multi-target composite surface repairing and regeneration manufacturing optimization design. And constructing a regeneration manufacturing part failure condition, value evaluation and repair scheme mapping model. A fusion layer is added, key technical parameters with the maximum influence degree are extracted to serve as a repairing model feature judgment basis of the virtual manufacturing simulation technology, the performance and reliability of a product or a system are improved, and the reliability of the product or the system is improved through a part failure condition, value evaluation and a repairing scheme mapping model. And a virtual simulation method is used for predicting system design, manufacturing information and fault parameters of a regenerative manufacturing repair model and a multi-target composite surface part repair method of an overall gear motor.

Description

Technical Field

[0001] The invention relates to the technical field of motor repair and remanufacturing, and in particular to a repair and remanufacturing method for fatigue-failed components of a gear reduction motor based on virtual simulation. Background Art

[0002] The gear reduction motor achieves a certain deceleration purpose by driving the large gear through the small gear on the input shaft of the gear reducer to drive the electric motor, internal combustion engine or other high-speed power. It adopts a multi-stage structure to greatly reduce the speed and thus increase the output torque. Based on the pilot demonstration, product certification, technology promotion, and standard construction of electromechanical product remanufacturing in the past decade, it is urgent to further focus on key equipment with important strategic roles and huge economic driving potential, carry out high-end intelligent remanufacturing with high technology content, high reliability requirements, and high added value as core characteristics, and promote the research and development, application, and industrialization promotion of high-end intelligent remanufacturing common technologies and special equipment such as deep automated non-destructive disassembly, flexible intelligent forming processing, and intelligent non-destructive testing and evaluation. Traditional remanufacturing evaluation and decision-making rely on the actual situation of returned products or components, and the usage mode and statistical failure data are single.

[0003] Virtual manufacturing technology can grasp the actual situation of the product manufacturing process at each stage of product design and development, and identify possible problems at each stage. This can reduce the R&D cycle and R&D capital, respond to the market quickly, and adapt to the requirements of modern manufacturing for products. However, in the actual production environment, it is challenging to obtain a robust and reliable virtual solution because there are limiting factors such as fewer metrological samples for development models, process drift over time, and the impact of regular and temporary maintenance activities on equipment. Therefore, how to analyze the manufacturing resource model, manufacturing environment model, product process model and virtual prototype model based on the multi-level characteristic damage parameters obtained by the simulation design of the gear reduction motor regeneration manufacturing process, reduce manufacturing costs and thus improve production efficiency, is one of the main problems that need to be solved. Summary of the invention

[0004] The technical problem to be solved by the present invention is to overcome the existing defects and provide a repair and remanufacturing method for fatigue-failed components of a gear reduction motor based on virtual simulation, which can effectively solve the problems in the background technology.

[0005] To achieve the above object, the present invention provides the following technical solution: a repair and remanufacturing method for fatigue failure components of a gear reduction motor based on virtual simulation, comprising the following steps: Step 1: Virtual simulation manufacturing model analysis of gear reduction motor.

[0006] Specifically, first create a virtual simulation assembly model of the integral gear reduction motor, build the structural mechanics relationship between different components, and identify parts that are prone to failure and key failure points. Based on the preliminary analysis of the reducer wear failure mechanism model, the failure acceleration physical equation is fitted and regressed. Use a virtual material model to simulate the performance of different materials and fully consider the influence of materials in the simulation. Based on computer simulation technology, the production process is uniformly modeled. In the product design stage, the entire future manufacturing process of the product and its impact on product design are simulated in real time and in parallel, and product performance, cost, and manufacturability are predicted, so that the resources of the factory and workshop can be reasonably allocated.

[0007] Step 2: Evaluation of the repair model method for fatigue-failed components.

[0008] By evaluating the performance of parts, we can build a mapping relationship between part information and value system, and determine the repair value information model of parts. According to the repair value information model and failure evaluation system, we can formulate corresponding repair plans. We can use virtual simulation technology to evaluate different repair plans, consider different options for material repair, and evaluate the impact of repair materials on part performance. We can deeply analyze the cost-effectiveness of various repair plans, including material, modal and data optimization costs, to determine the most economical plan.

[0009] Step three: Multi-objective composite surface repair and regeneration manufacturing optimization design.

[0010] Based on the feature point extraction model and the component repair model, a remanufacturing plan for the overall gear reduction motor is formulated according to a multi-objective strategy, covering the replacement of non-repairable parts, the repair of repairable parts, and the secondary surface treatment of normal parts. According to different design requirements, a multi-objective optimization algorithm is used through virtual simulation technology to conduct detailed analysis and comparison of different design schemes, further improve the design to meet complex target requirements, and finally conduct actual manufacturing and testing to verify the accuracy of the virtual model and the effectiveness of the repair plan.

[0011] Step 4: Build a mapping model of failure status, value assessment, and repair solutions for recycled manufacturing parts.

[0012] Use convolutional neural networks to extract failure features and establish a product failure degree judgment system. Study the mapping relationship between different failure conditions and repairable values, propose an information model for remanufacturing value assessment, and realize a mapping model for the failure condition, value assessment, and repair plan of reproduced parts.

[0013] As a preferred technical solution of the present invention, in step one, the method for identifying parts that are prone to failure and key failure points includes finite element statics analysis and multi-body dynamics simulation, wherein the finite element statics analysis includes but is not limited to rated working condition load spectrum, structural dangerous parts, stress spectrum of dangerous parts, and material fatigue characteristics, and the multi-body dynamics simulation includes but is not limited to torsional transmission, vibration analysis, modal analysis, and data optimization.

[0014] As a preferred technical solution of the present invention, in step 2, the content of part performance evaluation includes but is not limited to structural strength evaluation, failure mode evaluation, and fatigue damage evaluation; the value system evaluation includes but is not limited to material value evaluation, process difficulty evaluation, and repair difficulty evaluation.

[0015] As a preferred technical solution of the present invention, in step 2, the repair solution includes but is not limited to special welding, laser cladding, additive manufacturing, carburizing and quenching, WPC, and nano-coating.

[0016] As a preferred technical solution of the present invention, in step three, the content of the multi-objective strategy includes clarifying the processing process, clarifying the remanufacturing parameters, and clarifying the design requirements based on the parts evaluation results, and then performing algorithm optimization on the remanufacturing parameters.

[0017] As a preferred technical solution of the present invention, in step four, the failure condition judgment process of the regenerated manufactured parts is data collection, data processing, and parameter extraction, wherein the data collection method includes but is not limited to optical detection, X-ray detection, and ultrasonic detection; the data processing includes but is not limited to visual recognition, feature extraction, and machine learning; the parameter extraction content is external morphology, internal defects, and ultrasonic detection data.

[0018] As a preferred technical solution of the present invention, in step four, the value assessment method is to determine the mapping relationship between failure conditions and remanufacturing value through the remanufacturing case database, adaptive variable step-size interference inspection, composite interference matrix, and disassembly sequence generation algorithm.

[0019] As a preferred technical solution of the present invention, in step 4, the method for formulating the repair plan is to determine the final repair plan through the remanufacturing case database, improved ant colony algorithm, multi-classification SVM algorithm, and decision tree algorithm.

[0020] Compared with the prior art, the invention has the following beneficial effects: the repair and remanufacturing method for fatigue failure parts of gear reduction motors based on virtual simulation adopts the method of adding fusion layers to extract the key technical parameters with the greatest impact as the basis for judging the repair model characteristics of virtual manufacturing simulation technology, thereby improving the performance and reliability of products or systems, so as to achieve the optimal design of damaged structures, regeneration manufacturing repair, process flow schemes, equipment and material allocation of gear reduction motors. Through the model of part failure status, value assessment, and repair scheme mapping, the virtual simulation method is used to predict the system design, manufacturing information and fault parameters of the regeneration manufacturing repair model and the multi-objective composite surface component repair method of the overall reduction motor.

[0021] The data structure and organization of design information are extracted from the simulated manufacturing. Adjacent components and related fasteners are identified and stored in the computer accordingly. Many characteristic value information such as fastener type, basic size type and connection size value are retrieved. By considering factors such as material, volume, end face runout to determine whether the component is to be remanufactured, reused or replaced with a new component, product quality design can have a substantial impact on remanufacturing feasibility assessment and design feedback. The feasibility assessment method of remanufacturing technology based on product design information, using simulation optimization methods and virtual manufacturing technology to develop a data structure organization for remanufacturing assessment has important application value and potential.

[0022] Integrating virtual simulation technology into the digital manufacturing system can realize the digital management of the manufacturing process and obtain a more intelligent regenerative manufacturing intelligent process and quality assessment system. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a flow chart of virtual simulation manufacturing model analysis of the gear reduction motor of the present invention; Figure 2 A flow chart of evaluation factors for the repair model method of the present invention; Figure 3 This is a multi-objective composite surface repair optimization design flow chart of the present invention; Figure 4 The present invention is a flowchart of the failure condition, value assessment, and repair solution mapping model. DETAILED DESCRIPTION

[0024] The technical solutions in the embodiments of the present invention are described clearly and completely below. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0025] See also Figure 1-4The present invention provides a technical solution: a repair and remanufacturing method for fatigue failure components of a gear reduction motor based on virtual simulation, comprising the following steps: Step 1: Virtual simulation manufacturing model analysis of gear reduction motor.

[0026] Create a virtual simulation assembly model of the integral gear reduction motor, build the structural mechanics relationship between different components, and identify parts prone to failure and key failure points. Based on the preliminary analysis of the reducer wear failure mechanism model, fit and regression analysis of the failure acceleration physical equation. Use virtual material models to simulate the performance of different materials and fully consider the influence of materials in the simulation. Based on computer simulation technology, unified modeling of production processes such as design and manufacturing is carried out. In the product design stage, the entire future manufacturing process of the product and its impact on product design are simulated in real time and in parallel, and product performance, cost, and manufacturability are predicted, so that the resources of the factory and workshop can be reasonably allocated to minimize the product development cycle and cost.

[0027] Specifically, methods for identifying parts prone to failure and key failure points include finite element statics analysis and multi-body dynamics simulation, wherein the finite element statics analysis includes but is not limited to rated operating condition load spectrum, structural dangerous parts, stress spectrum of dangerous parts, and material fatigue characteristics; the multi-body dynamics simulation includes but is not limited to torsional transmission, vibration analysis, modal analysis, and data optimization.

[0028] Step 2: Evaluation of the repair model method for fatigue-failed components.

[0029] By evaluating the performance of parts, we can build a mapping relationship between part information and value system, and determine the repair value information model of parts. According to the repair value information model and failure evaluation system, we can formulate corresponding repair plans. We can use virtual simulation technology to evaluate different repair plans, consider different options for material repair, and evaluate the impact of repair materials on part performance. We can deeply analyze the cost-effectiveness of various repair plans, including material, modal and data optimization costs, to determine the most economical plan.

[0030] Specifically, the content of part performance evaluation includes but is not limited to structural strength evaluation, failure mode evaluation, and fatigue damage evaluation. The value system evaluation includes but is not limited to material value evaluation, process difficulty evaluation, and repair difficulty evaluation. Repair solutions include but are not limited to special welding, laser cladding, additive manufacturing, carburizing and quenching, WPC, and nano-coating.

[0031] Step three: Multi-objective composite surface repair and regeneration manufacturing optimization design.

[0032] Based on the feature point extraction model and the component repair model, a remanufacturing plan for the overall gear reduction motor is formulated according to a multi-objective strategy, covering the replacement of non-repairable parts, the repair of repairable parts, and the secondary surface treatment of normal parts. According to different design requirements, a multi-objective optimization algorithm is used through virtual simulation technology to conduct detailed analysis and comparison of different design schemes, and further improve the design to meet complex target requirements. Actual manufacturing and testing are carried out to verify the accuracy of the virtual model and the effectiveness of the repair plan.

[0033] Specifically, the multi-objective strategy includes clarifying the processing technology, remanufacturing parameters, and design requirements based on the parts evaluation results, and then optimizing the remanufacturing parameters through algorithms.

[0034] Step 4: Build a mapping model of failure status, value assessment, and repair solutions for recycled manufacturing parts.

[0035] Use convolutional neural networks to extract failure features and establish a product failure degree judgment system. Study the mapping relationship between different failure conditions and repairable values, and propose an information model for remanufacturing value assessment. Realize a mapping model for the failure condition, value assessment, and repair plan of reproduced parts.

[0036] Specifically, the failure status judgment process of recycled manufacturing parts is data collection, data processing, and parameter extraction, wherein the data collection methods include but are not limited to optical detection, X-ray detection, and ultrasonic detection; data processing includes but is not limited to visual recognition, feature extraction, and machine learning; the parameter extraction content includes external morphology, internal defects, and ultrasonic detection data.

[0037] The value assessment method is to determine the mapping relationship between failure conditions and remanufacturing value through the remanufacturing case database, adaptive variable step-size interference inspection, composite interference matrix, and disassembly sequence generation algorithm.

[0038] The method for formulating the repair plan is to determine the final repair plan through the remanufacturing case database, improved ant colony algorithm, multi-classification SVM algorithm, and decision tree algorithm.

[0039] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A repair and remanufacturing method for fatigue failure components of gear reduction motors based on virtual simulation, characterized in that: The following steps are involved: Step 1: Virtual simulation manufacturing model analysis of gear reduction motor; Specifically, firstly, a virtual simulation assembly model of the integral gear reduction motor is created, the structural mechanics relationship between different components is constructed, and the parts prone to failure and key failure points are identified; Based on the preliminary analysis of the reducer wear failure mechanism model, the fitting and regression analysis of the failure acceleration physical equation; Use virtual material models to simulate the performance of different materials and fully consider the impact of materials in simulation; Based on computer simulation technology, the production process is uniformly modeled. In the product design stage, the entire future manufacturing process of the product and its impact on product design are simulated in real time and in parallel, and product performance, cost, and manufacturability are predicted, so that the resources of the factory and workshop can be reasonably allocated. Step 2: Evaluation of the repair model method for fatigue-failed components; By evaluating the performance of parts, the mapping relationship between part information and value system is constructed to determine the information model of the repair value of parts; Formulate corresponding repair plans based on the repair value information model and failure assessment system; Use virtual simulation technology to evaluate different repair schemes, consider different options for material repair, and evaluate the impact of repair materials on part performance; conduct in-depth analysis of the cost-effectiveness of various repair schemes, including material, modal and data optimization costs, to determine the most economical solution; Step 3: Multi-objective composite surface repair and regeneration manufacturing optimization design; Based on the feature point extraction model and the component repair model, a remanufacturing plan for the overall gear reduction motor is formulated according to a multi-objective strategy, covering the replacement of non-repairable parts, the repair of repairable parts, and the secondary surface treatment of normal parts; According to different design requirements, multi-objective optimization algorithms are used through virtual simulation technology to conduct detailed analysis and comparison of different design schemes, further improve the design to meet complex target requirements, and finally conduct actual manufacturing and testing to verify the accuracy of the virtual model and the effectiveness of the repair scheme; Step 4: Construct a mapping model of failure status, value assessment, and repair solutions for recycled manufacturing parts; Use convolutional neural networks to extract failure features and establish a product failure degree judgment system; study the mapping relationship between different failure conditions and repairable values, propose an information model for remanufacturing value assessment, and realize a mapping model for the failure condition, value assessment, and repair plan of reproduced parts.

2. The method for repairing and remanufacturing fatigue failure components of a gear reduction motor based on virtual simulation according to claim 1 is characterized in that: In the step 1, the method for identifying parts prone to failure and key failure points includes finite element statics analysis and multi-body dynamics simulation, wherein the finite element statics analysis includes but is not limited to rated working condition load spectrum, structural dangerous parts, stress spectrum of dangerous parts, and material fatigue characteristics, and the multi-body dynamics simulation includes but is not limited to torsional transmission, vibration analysis, modal analysis, and data optimization.

3. The method for repairing and remanufacturing fatigue failure components of a gear reduction motor based on virtual simulation according to claim 1 is characterized in that: In the step 2, the content of the part performance evaluation includes but is not limited to structural strength evaluation, failure mode evaluation, and fatigue damage evaluation; the value system evaluation includes but is not limited to material value evaluation, process difficulty evaluation, and repair difficulty evaluation.

4. The method for repairing and remanufacturing fatigue failure components of a gear reduction motor based on virtual simulation according to claim 1 is characterized in that: In step 2, the repair scheme includes but is not limited to special welding, laser cladding, additive manufacturing, carburizing and quenching, WPC, and nano-coating.

5. The method for repairing and remanufacturing fatigue failure components of a gear reduction motor based on virtual simulation according to claim 1 is characterized in that: In the step three, the content of the multi-objective strategy includes clarifying the processing process, clarifying the remanufacturing parameters, and clarifying the design requirements based on the parts evaluation results, and then optimizing the remanufacturing parameters by algorithm.

6. The method for repairing and remanufacturing fatigue failure components of a gear reduction motor based on virtual simulation according to claim 1 is characterized in that: In step 4, the failure condition judgment process of the regenerated manufactured parts is data collection, data processing, and parameter extraction, wherein the data collection method includes but is not limited to optical detection, X-ray detection, and ultrasonic detection; the data processing includes but is not limited to visual recognition, feature extraction, and machine learning; the parameter extraction content includes external morphology, internal defects, and ultrasonic detection data.

7. The method for repairing and remanufacturing fatigue failure components of a gear reduction motor based on virtual simulation according to claim 1 is characterized in that: In the step 4, the value assessment method is to determine the mapping relationship between failure status and remanufacturing value through the remanufacturing case database, adaptive variable step-length interference inspection, composite interference matrix, and disassembly sequence generation algorithm.

8. The method for repairing and remanufacturing fatigue failure components of a gear reduction motor based on virtual simulation according to claim 1 is characterized in that: In the step 4, the method for formulating the repair plan is to determine the final repair plan through the remanufacturing case database, improved ant colony algorithm, multi-classification SVM algorithm, and decision tree algorithm.

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