Gear fatigue damage early warning method and system based on equivalent stress

Abstract

The invention relates to the technical field of gear fatigue damage early warning, and discloses a gear fatigue damage early warning method and system based on equivalent stress, and the system comprises a determination module which is configured to determine an initial early warning threshold value of a to-be-monitored gear according to the equivalent stress; the judgment optimization module is configured to collect historical operation data of the gear to be monitored, determine an optimization coefficient of the initial early warning threshold value according to the historical operation data and obtain an optimized early warning threshold value; the judgment compensation module is configured to judge whether to compensate the optimized early warning threshold value or not based on the environment characteristic value; collecting defect data of each monitoring area, determining a compensation coefficient for optimizing an early warning threshold based on the defect data, and obtaining a compensation early warning threshold; and the early warning module is configured to perform gear fatigue damage early warning on the to-be-monitored gear according to the compensation early warning threshold value. According to the invention, the accuracy and reliability of gear fatigue damage early warning are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of gear fatigue damage warning, and specifically, to a gear fatigue damage warning method and system based on equivalent stress. Background Art

[0002] As a crucial transmission component in mechanical equipment, the operating condition of gears directly affects the overall performance and service life of the equipment. However, during operation, gears are prone to fatigue damage due to various loads and environmental factors, which may affect the stability and safety of the equipment.

[0003] Traditional gear fatigue damage warning technologies mainly rely on manual inspection and empirical judgment. This method is not only time-consuming and laborious but also results in low accuracy and reliability of gear fatigue damage warning.

[0004] Therefore, it is necessary to design a gear fatigue damage warning method and system based on equivalent stress to solve the problems existing in the current technology. Summary of the Invention

[0005] In view of this, the present invention proposes a gear fatigue damage warning method and system based on equivalent stress, aiming to improve the accuracy and reliability of gear fatigue damage warning.

[0006] On the one hand, the present invention proposes a gear fatigue damage warning system based on equivalent stress, including: A determination module, configured to determine a gear to be monitored, collect tooth surface contact stress data of the gear to be monitored, calculate the equivalent stress of the gear to be monitored based on the tooth surface contact stress data, and determine an initial warning threshold of the gear to be monitored according to the equivalent stress; A judgment and optimization module, configured to collect historical operation data of the gear to be monitored, analyze the historical operation data, and judge whether to optimize the initial warning threshold based on the analysis result; if so, determine an optimization coefficient of the initial warning threshold according to the historical operation data and obtain an optimized warning threshold; A judgment and compensation module, configured to collect operation environment data of the gear to be monitored, obtain an environmental characteristic value, and judge whether to compensate the optimized warning threshold based on the environmental characteristic value; if so, divide the gear to be monitored into several monitoring regions, collect defect data of each monitoring region, determine a compensation coefficient of the optimized warning threshold based on the defect data, and obtain a compensated warning threshold; A warning module, configured to perform gear fatigue damage warning on the gear to be monitored according to the compensated warning threshold.

[0007] Further, when the determining module calculates the equivalent stress of the gear to be monitored based on the tooth surface contact stress data, it includes: Collect the fatigue limit data and strength limit data of the gear material of the gear to be monitored, and calculate the equivalent stress of the gear to be monitored according to the tooth surface contact stress data, the fatigue limit data of the gear material, and the strength limit data of the gear material; The equivalent stress is obtained by the following formula: ; where, σ eq represents the equivalent stress; σ H represents the tooth surface contact stress; σ -1 represents the stress amplitude of the gear material under the fatigue limit; σ b represents the strength limit of the gear material.

[0008] Further, when the determining module determines the initial warning threshold of the gear to be monitored according to the equivalent stress, it includes: Calculate the difference between the equivalent stress and the equivalent stress threshold, and record it as the stress difference; Compare the stress difference with the first stress difference and the second stress difference, and determine the initial warning threshold of the gear to be monitored according to the comparison result; where, the first stress difference is less than the second stress difference; When the stress difference is less than or equal to the first stress difference, determine that the initial warning threshold is the first warning threshold; When the stress difference is greater than the first stress difference and less than or equal to the second stress difference, determine that the initial warning threshold is the second warning threshold, and the second warning threshold is greater than the first warning threshold; When the stress difference is greater than the second stress difference, determine that the initial warning threshold is the third warning threshold, and the third warning threshold is greater than the second warning threshold.

[0009] Further, when the judgment and optimization module judges whether to optimize the initial warning threshold based on the analysis result, it includes: Analyze the historical operation data to obtain historical abnormal operation records; Classify the historical abnormal operation records, and obtain the historical abnormal stress values and occurrence frequencies corresponding to each type of historical abnormal operation records; Calculate the historical abnormal stress mean value and the historical abnormal stress maximum fluctuation value of the gear to be monitored based on the historical abnormal stress values and occurrence frequencies; Judge whether to optimize the initial warning threshold according to the historical abnormal stress mean value and the historical abnormal stress maximum fluctuation value.

[0010] Furthermore, when the judgment and optimization module determines whether to optimize the initial warning threshold according to the historical abnormal stress mean value and the historical maximum abnormal stress fluctuation value, it includes: Compare the historical abnormal stress mean value with the historical abnormal stress mean value threshold respectively, and compare the historical maximum abnormal stress fluctuation value with the historical maximum abnormal stress fluctuation threshold. Determine whether to optimize the initial warning threshold according to the comparison results; If the historical abnormal stress mean value is greater than or equal to the historical abnormal stress mean value threshold and / or the historical maximum abnormal stress fluctuation value is greater than or equal to the historical maximum abnormal stress fluctuation threshold, it is determined to optimize the initial warning threshold; Otherwise, it is determined not to optimize the initial warning threshold.

[0011] Furthermore, when the judgment and optimization module determines the optimization coefficient of the initial warning threshold according to the historical operation data and obtains the optimized warning threshold, it includes: Take the historical abnormal stress mean value and the historical maximum abnormal stress fluctuation value as a feature combination; Match the feature combination with a preset optimization coefficient mapping table to obtain the optimization coefficient corresponding to the feature combination; Take the product value of the optimization coefficient and the initial warning threshold as the optimized warning threshold.

[0012] Furthermore, when the judgment and compensation module determines whether to compensate the optimized warning threshold based on the environmental characteristic value, it includes: Compare the environmental characteristic value with the environmental characteristic threshold, and determine whether to compensate the optimized warning threshold according to the comparison result; When the environmental characteristic value is greater than or equal to the environmental characteristic threshold, it is determined to compensate the optimized warning threshold; When the environmental characteristic value is less than the environmental characteristic threshold, it is determined not to compensate the optimized warning threshold.

[0013] Furthermore, when the judgment and compensation module collects the defect data of each monitoring area, determines the compensation coefficient of the optimized warning threshold based on the defect data, and obtains the compensated warning threshold, it includes: Extract features from the defect data of each monitoring area to obtain regional defect characteristic values; Perform weighted calculation on all the regional defect characteristic values to obtain a comprehensive defect characteristic value; Compare the comprehensive defect eigenvalue with the first defect eigenvalue and the second defect eigenvalue, and determine the compensation coefficient of the optimized warning threshold according to the comparison result; wherein, the first defect eigenvalue is less than the second defect eigenvalue; When the comprehensive defect eigenvalue is less than or equal to the first defect eigenvalue, determine that the compensation coefficient is the first compensation coefficient; When the comprehensive defect eigenvalue is greater than the first defect eigenvalue and less than or equal to the second defect eigenvalue, determine that the compensation coefficient is the second compensation coefficient, and the second compensation coefficient is greater than the first compensation coefficient; When the comprehensive defect eigenvalue is greater than the second defect eigenvalue, determine that the compensation coefficient is the third compensation coefficient, and the third compensation coefficient is greater than the second compensation coefficient; Take the product value of the optimized warning threshold and the compensation coefficient as the compensation warning threshold.

[0014] Further, when the warning module performs gear fatigue damage warning on the gear to be monitored according to the compensation warning threshold, it includes: Real-time monitor the current stress value of the gear to be monitored; Compare the current stress value with the compensation warning threshold; When the current stress value is greater than or equal to the compensation warning threshold, trigger a warning signal to perform gear fatigue damage warning on the gear to be monitored; When the current stress value is less than the compensation warning threshold, determine that the gear to be monitored is in a normal operation state and no warning is performed.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: The beneficial effects of the gear fatigue damage warning system based on equivalent stress provided by the present invention are that it improves the accuracy and reliability of gear fatigue damage warning. By comprehensively considering the tooth surface contact stress, historical operation data, and operating environment data, the present invention can dynamically adjust the warning threshold, thereby more accurately reflecting the actual operating state of the gear. Dividing the gear into multiple monitoring areas and collecting defect data of each area further enhances the pertinence and sensitivity of the warning system. This comprehensive warning strategy helps to detect potential damage to the gear in a timely manner, provides strong support for the maintenance and management of equipment, effectively extends the service life of the gear, and reduces the risk of failures caused by gear fatigue damage.

[0016] On the other hand, the present invention also proposes a gear fatigue damage warning method based on equivalent stress, including the following steps: S100: Determine the gear to be monitored, collect the tooth surface contact stress data of the gear to be monitored, calculate the equivalent stress of the gear to be monitored based on the tooth surface contact stress data, and determine the initial warning threshold of the gear to be monitored according to the equivalent stress; S200: Collect the historical operation data of the gear to be monitored, analyze the historical operation data, and judge whether to optimize the initial warning threshold based on the analysis result; if so, determine the optimization coefficient of the initial warning threshold according to the historical operation data, and obtain the optimized warning threshold; S300: Collect the operation environment data of the gear to be monitored, obtain the environmental characteristic value, and judge whether to compensate the optimized warning threshold based on the environmental characteristic value; if so, divide the gear to be monitored into several monitoring areas, collect the defect data of each monitoring area, determine the compensation coefficient of the optimized warning threshold based on the defect data, and obtain the compensated warning threshold; S400: Perform gear fatigue damage warning on the gear to be monitored according to the compensated warning threshold.

[0017] It can be understood that the above-mentioned gear fatigue damage warning method and system based on equivalent stress have the same beneficial effects, which will not be elaborated here. Description of the Drawings

[0018] By reading the following detailed description of the preferred embodiments, various other advantages and benefits will become clear to those of ordinary skill in the art. The drawings are only for the purpose of showing the preferred embodiments and are not considered as limiting the present invention. Moreover, throughout the drawings, the same reference numerals are used to represent the same components. In the drawings: Figure 1 is the structural block diagram of the gear fatigue damage warning system based on equivalent stress provided by the embodiment of the present invention; Figure 2 is the flowchart of the gear fatigue damage warning method based on equivalent stress provided by the embodiment of the present invention. Detailed Embodiments

[0019] The following will describe the exemplary embodiments of the present disclosure in more detail with reference to the drawings. Although the exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided so that the present disclosure can be more thoroughly understood and the scope of the present disclosure can be fully communicated to those skilled in the art. It should be noted that, without conflict, the embodiments in the present invention and the features in the embodiments can be combined with each other. The present invention will be described in detail below with reference to the drawings and in combination with the embodiments.

[0020] Refer toFigure 1 As shown in Figure 1 , in some embodiments of the present application, this embodiment provides a gear fatigue damage warning system based on equivalent stress, including: A determination module, configured to determine a gear to be monitored, collect tooth surface contact stress data of the gear to be monitored, calculate the equivalent stress of the gear to be monitored based on the tooth surface contact stress data, and determine an initial warning threshold of the gear to be monitored according to the equivalent stress; A judgment and optimization module, configured to collect historical operation data of the gear to be monitored, analyze the historical operation data, and judge whether to optimize the initial warning threshold based on the analysis result; if so, determine an optimization coefficient of the initial warning threshold according to the historical operation data, and obtain an optimized warning threshold; A judgment and compensation module, configured to collect operation environment data of the gear to be monitored, obtain an environmental characteristic value, and judge whether to compensate the optimized warning threshold based on the environmental characteristic value; if so, divide the gear to be monitored into several monitoring areas, collect defect data of each monitoring area, determine a compensation coefficient of the optimized warning threshold based on the defect data, and obtain a compensated warning threshold; A warning module, configured to perform gear fatigue damage warning on the gear to be monitored according to the compensated warning threshold.

[0021] It can be understood that the beneficial effect of the gear fatigue damage warning system based on equivalent stress provided in this embodiment lies in improving the accuracy and reliability of gear fatigue damage warning. By comprehensively considering tooth surface contact stress, historical operation data, and operation environment data, this embodiment can dynamically adjust the warning threshold, so as to more accurately reflect the actual operation state of the gear. Dividing the gear into multiple monitoring areas and collecting defect data of each area further enhances the pertinence and sensitivity of the warning system. This comprehensive warning strategy helps to timely detect potential damage of the gear, provides strong support for the maintenance and management of equipment, effectively extends the service life of the gear, and reduces the failure risk caused by gear fatigue damage.

[0022] Specifically, when the determination module calculates the equivalent stress of the gear to be monitored based on the tooth surface contact stress data, it includes: Collect gear material fatigue limit data and gear material strength limit data of the gear to be monitored, and calculate the equivalent stress of the gear to be monitored according to the tooth surface contact stress data, gear material fatigue limit data, and gear material strength limit data; The equivalent stress is obtained by the following formula: ; where, σ eq represents the equivalent stress; σH represents the tooth surface contact stress; σ -1 represents the stress amplitude of the gear material under the fatigue limit; σ b represents the strength limit of the gear material.

[0023] It can be understood that the calculation of the equivalent stress is based on the tooth surface contact stress, the fatigue limit and the strength limit of the gear material. The tooth surface contact stress is one of the main stresses that the gear is subjected to during operation, which reflects the interaction force between the tooth surfaces of the gear. The fatigue limit and the strength limit of the gear material are the inherent mechanical properties of the material itself, which determine the maximum stress level that the gear can withstand during long-term operation. By comprehensively considering these three factors, the stress state of the gear can be more accurately evaluated, thereby providing a more reliable basis for determining the subsequent warning threshold.

[0024] Specifically, when the determination module determines the initial warning threshold of the gear to be monitored according to the equivalent stress, it includes: Calculate the difference between the equivalent stress and the equivalent stress threshold, and denote it as the stress difference; Compare the stress difference with the first stress difference and the second stress difference, and determine the initial warning threshold of the gear to be monitored according to the comparison result; wherein, the first stress difference is less than the second stress difference; When the stress difference is less than or equal to the first stress difference, determine that the initial warning threshold is the first warning threshold; When the stress difference is greater than the first stress difference and less than or equal to the second stress difference, determine that the initial warning threshold is the second warning threshold, and the second warning threshold is greater than the first warning threshold; When the stress difference is greater than the second stress difference, determine that the initial warning threshold is the third warning threshold, and the third warning threshold is greater than the second warning threshold.

[0025] In this embodiment, the equivalent stress threshold is a preset safety stress level, which is used to measure whether the gear is approaching its fatigue damage limit.

[0026] In this embodiment, the preferred value of the equivalent stress threshold is 80% of the maximum stress value that the gear material can withstand under fatigue testing.

[0027] In this embodiment, the first warning threshold, the second warning threshold and the third warning threshold are all set between the equivalent stress and the equivalent stress threshold, and respectively correspond to different stress difference ranges. Such a setting can ensure that the warning system can respond promptly and accurately to gears in different stress states.

[0028] In this embodiment, the first stress difference and the second stress difference are determined based on a large amount of experimental data and gear operation experience, and they represent the risk levels of gear fatigue damage under different stress states. By comparing these stress differences with the equivalent stress, the current stress state of the gear can be determined, and an appropriate warning threshold can be selected accordingly.

[0029] Specifically, when the judgment and optimization module determines whether to optimize the initial warning threshold based on the analysis result, it includes: Analyze the historical operation data to obtain historical abnormal operation records; Classify the historical abnormal operation records, and obtain the historical abnormal stress values and occurrence frequencies corresponding to each type of historical abnormal operation record; Calculate the historical abnormal stress mean value and the maximum historical abnormal stress fluctuation value of the gear to be monitored based on the historical abnormal stress values and occurrence frequencies; Judge whether to optimize the initial warning threshold according to the historical abnormal stress mean value and the maximum historical abnormal stress fluctuation value.

[0030] In this embodiment, the types of historical abnormal operation records include but are not limited to overload operation, overheat operation, abnormal vibration, etc. Each type of historical abnormal operation record reflects the operation conditions of the gear under different stress states. By classifying these records and calculating the historical abnormal stress values and occurrence frequencies of each type, the historical operation state of the gear can be understood more deeply.

[0031] In this embodiment, the historical abnormal stress mean value is obtained by the following formula: ; where, σ mcan represents the historical abnormal stress mean value; σ i represents the historical abnormal stress value corresponding to the i-th type of historical abnormal operation record; f i represents the occurrence frequency of the i-th type of historical abnormal operation record.

[0032] In this embodiment, the maximum historical abnormal stress fluctuation value refers to the difference between the maximum value and the minimum value among all historical abnormal stress values, which reflects the stress fluctuation range experienced by the gear during historical operation.

[0033] Specifically, when the judgment and optimization module judges whether to optimize the initial warning threshold according to the historical abnormal stress mean value and the maximum historical abnormal stress fluctuation value, it includes: Compare the historical abnormal stress mean value with the historical abnormal stress mean value threshold respectively, and compare the historical maximum abnormal stress fluctuation value with the historical maximum abnormal stress fluctuation threshold. Determine whether to optimize the initial warning threshold according to the comparison results; If the historical abnormal stress mean value is greater than or equal to the historical abnormal stress mean value threshold and / or the historical maximum abnormal stress fluctuation value is greater than or equal to the historical maximum abnormal stress fluctuation threshold, it is determined to optimize the initial warning threshold; Otherwise, it is determined not to optimize the initial warning threshold.

[0034] In this embodiment, the historical abnormal stress mean value threshold and the historical maximum abnormal stress fluctuation threshold are determined based on a large amount of experimental data and gear operation experience, and they represent the stress level fluctuation range of the gear under normal operation conditions.

[0035] It can be understood that when the historical abnormal stress mean value is relatively high or the historical maximum abnormal stress fluctuation value is relatively large, it indicates that the gear may have experienced a large stress impact or long-term stress accumulation during the historical operation process, which may increase the risk of gear fatigue damage. Therefore, in this case, it is necessary to optimize the initial warning threshold to improve the sensitivity and accuracy of the warning system.

[0036] Specifically, when the judgment optimization module determines the optimization coefficient of the initial warning threshold according to the historical operation data and obtains the optimized warning threshold, it includes: Take the historical abnormal stress mean value and the historical maximum abnormal stress fluctuation value as a feature combination; Match the feature combination with the preset optimization coefficient mapping table to obtain the optimization coefficient corresponding to the feature combination; Take the product value of the optimization coefficient and the initial warning threshold as the optimized warning threshold.

[0037] In this embodiment, the preset optimization coefficient mapping table records the corresponding relationship between different feature combinations and optimization coefficients. This table is obtained based on a large amount of experimental data and gear operation experience, and it can help the judgment optimization module quickly and accurately determine the optimization coefficient that matches the current historical abnormal stress mean value and historical maximum abnormal stress fluctuation value. Denote the feature combination as (a, b), and the corresponding optimization coefficient in the preset optimization coefficient mapping table is c.

[0038] In this embodiment, if (a, b) = (380, 40), then c = 1.2; if (a, b) = (420, 60), then c = 1.5, and so on.

[0039] Specifically, when the judgment compensation module determines whether to compensate the optimized warning threshold based on the environmental characteristic value, it includes: Compare the environmental characteristic value with the environmental characteristic threshold, and determine whether to compensate the optimized warning threshold according to the comparison result; When the environmental characteristic value is greater than or equal to the environmental characteristic threshold, it is determined to compensate the optimized warning threshold; When the environmental characteristic value is less than the environmental characteristic threshold, it is determined not to compensate the optimized warning threshold.

[0040] In this embodiment, the environmental characteristic value refers to a comprehensive quantitative index of parameters such as the environmental temperature, humidity, and dust concentration in which the gear operates. These environmental factors have an important impact on the operating state and fatigue damage degree of the gear. For example, a high-temperature environment may cause a decrease in the material properties of the gear, accelerating the wear and fatigue damage of the gear; high humidity and dust concentration may increase the risk of corrosion and wear on the gear surface.

[0041] In this embodiment, the environmental characteristic value preferably is the environmental temperature.

[0042] In this embodiment, the environmental characteristic threshold is determined based on a large amount of experimental data and gear operation experience, and it represents the maximum environmental stress level that the gear can withstand under normal operating conditions.

[0043] It can be understood that when the environmental temperature is high, the properties of the gear material may be affected, resulting in an increased risk of fatigue damage to the gear. Therefore, in this case, it is necessary to compensate the optimized warning threshold to improve the sensitivity and accuracy of the warning system.

[0044] Specifically, when the judgment compensation module collects the defect data of each monitoring area, determines the compensation coefficient of the optimized warning threshold based on the defect data, and obtains the compensated warning threshold, it includes: Extract the features of the defect data of each monitoring area to obtain the regional defect characteristic value; Perform weighted calculation on all the regional defect characteristic values to obtain the comprehensive defect characteristic value; Compare the comprehensive defect characteristic value with the first defect characteristic value and the second defect characteristic value, and determine the compensation coefficient of the optimized warning threshold according to the comparison result; wherein, the first defect characteristic value is less than the second defect characteristic value; When the comprehensive defect characteristic value is less than or equal to the first defect characteristic value, determine that the compensation coefficient is the first compensation coefficient; When the comprehensive defect eigenvalue is greater than the first defect eigenvalue and less than or equal to the second defect eigenvalue, determine that the compensation coefficient is the second compensation coefficient, and the second compensation coefficient is greater than the first compensation coefficient; When the comprehensive defect eigenvalue is greater than the second defect eigenvalue, determine that the compensation coefficient is the third compensation coefficient, and the third compensation coefficient is greater than the second compensation coefficient; Take the product value of the optimized warning threshold and the compensation coefficient as the compensation warning threshold.

[0045] In this embodiment, the preferred value of the first compensation coefficient is 1.05, the preferred value of the second compensation coefficient is 1.1, and the preferred value of the third compensation coefficient is 1.2.

[0046] In this embodiment, the regional defect eigenvalue refers to the comprehensive quantitative index of parameters such as the type and size of gear defects in each monitoring area. The defect types include cracks, wear, and corrosion.

[0047] The regional defect eigenvalue is obtained through the following formula: ; where D k represents the defect eigenvalue of the kth monitoring area; P kj represents the quantization value of the jth type of defect in the kth monitoring area; ω j represents the weight corresponding to the jth type of defect; n represents the number of defect types.

[0048] In this embodiment, the comprehensive defect eigenvalue is the weighted sum of the defect eigenvalues of all monitoring areas, which reflects the overall defect condition of the gear. By performing a weighted sum of the defect eigenvalues of each monitoring area, a more comprehensive and accurate gear defect assessment result can be obtained.

[0049] In this embodiment, the first defect eigenvalue and the second defect eigenvalue are determined based on a large amount of experimental data and gear operation experience, and they represent the fatigue damage risks of the gear under different defect degrees. By comparing these comprehensive defect eigenvalues with the preset defect eigenvalue thresholds, the current defect condition of the gear can be determined, and an appropriate compensation coefficient can be selected accordingly.

[0050] Specifically, when the warning module performs gear fatigue damage warning on the gear to be monitored according to the compensation warning threshold, it includes: Real-time monitor the current stress value of the gear to be monitored; Compare the current stress value with the compensation warning threshold; When the current stress value is greater than or equal to the compensation warning threshold, trigger a warning signal to perform gear fatigue damage warning on the gear to be monitored; When the current stress value is less than the compensation warning threshold, it is determined that the gear to be monitored is in a normal operating state and no warning is issued.

[0051] It can be understood that real-time monitoring is the key to ensuring that the warning system can respond promptly to changes in the gear state. By continuously collecting and analyzing the stress data of the gear, the system can capture any abnormal stress fluctuations and thus issue a warning signal in a timely manner. When the current stress value reaches or exceeds the compensation warning threshold, the warning module will immediately trigger a warning signal to notify relevant personnel to pay attention to the potential damage risk of the gear and take corresponding maintenance or repair measures. Such a warning mechanism helps to avoid sudden failures caused by fatigue damage of the gear and ensures the stable operation of the equipment. At the same time, for gears in a normal operating state, the system will not issue unnecessary warnings, thereby reducing false alarms and interference and improving the accuracy and reliability of the warning system.

[0052] Refer to Figure 2 As shown, in some embodiments of the present application, this embodiment provides a gear fatigue damage warning method based on equivalent stress, including the following steps: S100: Determine the gear to be monitored, collect the tooth surface contact stress data of the gear to be monitored, calculate the equivalent stress of the gear to be monitored based on the tooth surface contact stress data, and determine the initial warning threshold of the gear to be monitored according to the equivalent stress; S200: Collect the historical operation data of the gear to be monitored, analyze the historical operation data, and judge whether to optimize the initial warning threshold based on the analysis result; if so, determine the optimization coefficient of the initial warning threshold according to the historical operation data and obtain the optimized warning threshold; S300: Collect the operation environment data of the gear to be monitored, obtain the environmental characteristic value, and judge whether to compensate the optimized warning threshold based on the environmental characteristic value; if so, divide the gear to be monitored into several monitoring areas, collect the defect data of each monitoring area, determine the compensation coefficient of the optimized warning threshold based on the defect data, and obtain the compensation warning threshold; S400: Perform gear fatigue damage warning on the gear to be monitored according to the compensation warning threshold.

[0053] Those skilled in the art should understand that the embodiments of the present application can be provided as a method, a system, or a computer program product. Therefore, the present application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Moreover, the present application can take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) that contain computer-usable program code.

[0054] The present application is described with reference to the flowcharts and / or block diagrams of methods, apparatuses (systems), and computer program products according to the embodiments of the present application. It should be understood that each flow and / or block in the flowchart and / or block diagram can be implemented by computer program instructions, and the combination of the flows and / or blocks in the flowchart and / or block diagram can also be implemented. These computer program instructions can be provided to the processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing devices to generate a machine, so that the instructions executed by the processor of the computer or other programmable data processing devices generate a device for implementing the functions specified in Figure 1 one flow or multiple flows and / or blocks Figure 1 one block or multiple blocks.

[0055] These computer program instructions can also be stored in a computer-readable memory that can direct a computer or other programmable data processing device to work in a specific manner, so that the instructions stored in the computer-readable memory generate a manufactured article including an instruction device, and the instruction device implements the functions specified in Figure 1 one flow or multiple flows and / or blocks Figure 1 one block or multiple blocks.

[0056] These computer program instructions can also be loaded onto a computer or other programmable data processing device, so that a series of operation steps are executed on the computer or other programmable device to generate a computer-implemented process. Thus, the instructions executed on the computer or other programmable device provide steps for implementing the functions specified in Figure 1 one flow or multiple flows and / or blocks Figure 1 one block or multiple blocks.

[0057] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit them. Although the present invention has been described in detail with reference to the above embodiments, those of ordinary skill in the art should understand that: still can modify the specific implementation manners of the present invention or make equivalent replacements, and any modification or equivalent replacement that does not depart from the spirit and scope of the present invention should be covered by the protection scope of the claims of the present invention.

Claims

1. A gear fatigue damage warning system based on equivalent stress, characterized in that, Including: A determination module, configured to determine a gear to be monitored, collect tooth surface contact stress data of the gear to be monitored, calculate the equivalent stress of the gear to be monitored based on the tooth surface contact stress data, and determine an initial warning threshold of the gear to be monitored according to the equivalent stress; A judgment and optimization module, configured to collect historical operation data of the gear to be monitored, analyze the historical operation data, and judge whether to optimize the initial warning threshold based on the analysis result; If so, determine an optimization coefficient of the initial warning threshold according to the historical operation data, and obtain an optimized warning threshold; A judgment and compensation module, configured to collect operation environment data of the gear to be monitored, obtain an environmental characteristic value, and judge whether to compensate the optimized warning threshold based on the environmental characteristic value; If so, divide the gear to be monitored into several monitoring areas, collect defect data of each monitoring area, determine a compensation coefficient of the optimized warning threshold based on the defect data, and obtain a compensated warning threshold; A warning module, configured to perform gear fatigue damage warning on the gear to be monitored according to the compensated warning threshold.

2. The gear fatigue damage warning system based on equivalent stress according to claim 1, wherein When the determination module calculates the equivalent stress of the gear to be monitored based on the tooth surface contact stress data, it includes: Collecting gear material fatigue limit data and gear material strength limit data of the gear to be monitored, and calculating the equivalent stress of the gear to be monitored according to the tooth surface contact stress data, gear material fatigue limit data, and gear material strength limit data; The equivalent stress is obtained by the following formula: ； Among them, σ eq represents the equivalent stress; σ H represents the tooth surface contact stress; σ -1 represents the stress amplitude of the gear material under the fatigue limit; σ b represents the strength limit of the gear material.

3. The gear fatigue damage warning system based on equivalent stress according to claim 2, wherein When the determination module determines the initial warning threshold of the gear to be monitored according to the equivalent stress, it includes: Calculating the difference between the equivalent stress and an equivalent stress threshold, and recording it as a stress difference; Comparing the stress difference with a first stress difference and a second stress difference, and determining the initial warning threshold of the gear to be monitored according to the comparison result; wherein, the first stress difference is less than the second stress difference; When the stress difference is less than or equal to the first stress difference, determining the initial warning threshold as a first warning threshold; When the stress difference is greater than the first stress difference and less than or equal to the second stress difference, determining the initial warning threshold as a second warning threshold, and the second warning threshold is greater than the first warning threshold; When the stress difference is greater than the second stress difference, determining the initial warning threshold as a third warning threshold, and the third warning threshold is greater than the second warning threshold.

4. The gear fatigue damage warning system based on equivalent stress according to claim 3, characterized in that, When the judgment and optimization module judges whether to optimize the initial warning threshold based on the analysis result, it includes: Analyzing the historical operation data to obtain historical abnormal operation records; Classifying the historical abnormal operation records, and obtaining the historical abnormal stress values and occurrence frequencies corresponding to each type of historical abnormal operation records; Calculating the historical abnormal stress mean value and historical abnormal stress maximum fluctuation value of the gear to be monitored based on the historical abnormal stress values and occurrence frequencies; Judge whether to optimize the initial warning threshold according to the historical abnormal stress mean value and the historical maximum abnormal stress fluctuation value.

5. The gear fatigue damage warning system based on equivalent stress according to claim 4, characterized in that, When the judgment and optimization module judges whether to optimize the initial warning threshold according to the historical abnormal stress mean value and the historical maximum abnormal stress fluctuation value, it includes: Compare the historical abnormal stress mean value with the historical abnormal stress mean value threshold respectively, compare the historical maximum abnormal stress fluctuation value with the historical maximum abnormal stress fluctuation threshold, and judge whether to optimize the initial warning threshold according to the comparison results; If the historical abnormal stress mean value is greater than or equal to the historical abnormal stress mean value threshold and / or the historical maximum abnormal stress fluctuation value is greater than or equal to the historical maximum abnormal stress fluctuation threshold, it is determined to optimize the initial warning threshold; Otherwise, it is determined not to optimize the initial warning threshold.

6. The gear fatigue damage warning system based on equivalent stress according to claim 5, wherein, When the judgment and optimization module determines the optimization coefficient of the initial warning threshold according to the historical operation data and obtains the optimized warning threshold, it includes: Take the historical abnormal stress mean value and the historical maximum abnormal stress fluctuation value as a feature combination; Match the feature combination with the preset optimization coefficient mapping table to obtain the optimization coefficient corresponding to the feature combination; Take the product value of the optimization coefficient and the initial warning threshold as the optimized warning threshold.

7. The gear fatigue damage warning system based on equivalent stress according to claim 6, wherein When the judgment and compensation module judges whether to compensate the optimized warning threshold based on the environmental characteristic value, it includes: Compare the environmental characteristic value with the environmental characteristic threshold, and judge whether to compensate the optimized warning threshold according to the comparison result; When the environmental characteristic value is greater than or equal to the environmental characteristic threshold, it is determined to compensate the optimized warning threshold; When the environmental characteristic value is less than the environmental characteristic threshold, it is determined not to compensate the optimized warning threshold.

8. The gear fatigue damage warning system based on equivalent stress according to claim 7, wherein When the judgment and compensation module collects the defect data of each monitoring area, determines the compensation coefficient of the optimized warning threshold based on the defect data, and obtains the compensated warning threshold, it includes: Extract features from the defect data of each monitoring area to obtain the regional defect characteristic value; Perform weighted calculation on all the regional defect characteristic values to obtain the comprehensive defect characteristic value; Compare the comprehensive defect characteristic value with the first defect characteristic value and the second defect characteristic value, and determine the compensation coefficient of the optimized warning threshold according to the comparison result; where the first defect characteristic value is less than the second defect characteristic value; When the comprehensive defect characteristic value is less than or equal to the first defect characteristic value, determine the compensation coefficient as the first compensation coefficient; When the comprehensive defect characteristic value is greater than the first defect characteristic value and less than or equal to the second defect characteristic value, determine the compensation coefficient as the second compensation coefficient, and the second compensation coefficient is greater than the first compensation coefficient; When the comprehensive defect characteristic value is greater than the second defect characteristic value, determine the compensation coefficient as the third compensation coefficient, and the third compensation coefficient is greater than the second compensation coefficient; Take the product value of the optimized warning threshold and the compensation coefficient as the compensated warning threshold.

9. The gear fatigue damage warning system based on equivalent stress according to claim 8, characterized in that, When the warning module performs gear fatigue damage warning on the gear to be monitored according to the compensation warning threshold, it includes: Real-time monitoring of the current stress value of the gear to be monitored; Comparing the current stress value with the compensation warning threshold; When the current stress value is greater than or equal to the compensation warning threshold, triggering a warning signal to perform gear fatigue damage warning on the gear to be monitored; When the current stress value is less than the compensation warning threshold, it is determined that the gear to be monitored is in a normal operating state and no warning is given.

10. A gear fatigue damage warning method based on equivalent stress, which is applied to the gear fatigue damage warning system based on equivalent stress according to any one of claims 1-9, and is characterized in that, It includes: Determine the gear to be monitored, collect the tooth surface contact stress data of the gear to be monitored, calculate the equivalent stress of the gear to be monitored based on the tooth surface contact stress data, and determine the initial warning threshold of the gear to be monitored according to the equivalent stress; Collect the historical operation data of the gear to be monitored, analyze the historical operation data, and judge whether to optimize the initial warning threshold based on the analysis result; If so, determine the optimization coefficient of the initial warning threshold according to the historical operation data and obtain the optimized warning threshold; Collect the operation environment data of the gear to be monitored, obtain the environmental characteristic value, and judge whether to compensate the optimized warning threshold based on the environmental characteristic value; If so, divide the gear to be monitored into several monitoring areas, collect the defect data of each monitoring area, determine the compensation coefficient of the optimized warning threshold based on the defect data, and obtain the compensation warning threshold; Perform gear fatigue damage warning on the gear to be monitored according to the compensation warning threshold.

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