A gear fatigue damage early warning method and system based on equivalent stress

Abstract

The present 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. The system comprises: a determination module configured to determine an initial early warning threshold for a gear to be monitored based on the equivalent stress; a judgment and optimization module configured to collect historical operating data of the gear to be monitored, determine an optimization coefficient of the initial early warning threshold based on the historical operating data, and obtain an optimized early warning threshold; a judgment and compensation module configured to determine whether to compensate the optimized early warning threshold based on environmental characteristic values; collect defect data for each monitoring area, determine a compensation coefficient for the optimized early warning threshold based on the defect data, and obtain a compensated early warning threshold; and an early warning module configured to issue a gear fatigue damage early warning for the gear to be monitored based on the compensated early warning threshold. The present invention improves the accuracy and reliability of gear fatigue damage early warning.

Description

Technical Field

[0001] The present invention relates to the technical field of gear fatigue damage early warning, and in particular to a gear fatigue damage early 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 susceptible to fatigue damage due to the various loads and environmental factors they are subjected to, which can affect the stability and safety of the equipment.

[0003] Traditional gear fatigue damage warning technology mainly relies on manual detection and experience judgment. This method is not only time-consuming and labor-intensive, 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 current technology. Summary of the Invention

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

[0006] In one aspect, the present invention provides a gear fatigue damage early warning system based on equivalent stress, comprising:

[0007] a determination module configured to determine a gear to be monitored, collect tooth surface contact stress data of the gear to be monitored, calculate an 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;

[0008] a judgment and optimization module configured to collect historical operating data of the gear to be monitored, analyze the historical operating data, and determine whether to optimize the initial warning threshold based on the analysis result; if so, determine an optimization coefficient of the initial warning threshold based on the historical operating data, and obtain an optimized warning threshold;

[0009] a judgment and compensation module configured to collect operating environment data of the gear to be monitored and obtain environmental characteristic values, and determine whether to compensate the optimized warning threshold based on the environmental characteristic values; if so, divide the gear to be monitored into a plurality of monitoring areas, collect defect data of each of the monitoring areas, determine a compensation coefficient for the optimized warning threshold based on the defect data, and obtain a compensated warning threshold;

[0010] The early warning module is configured to provide a gear fatigue damage early warning for the gear to be monitored according to the compensation early warning threshold.

[0011] Furthermore, when the determination module calculates the equivalent stress of the gear to be monitored based on the tooth surface contact stress data, it includes:

[0012] 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 based on the tooth surface contact stress data, gear material fatigue limit data and gear material strength limit data;

[0013] The equivalent stress is obtained by the following formula:

[0014] ;

[0015] Among them, σ eq represents the equivalent stress; σ H represents the tooth surface contact stress; σ -1 Indicates the stress amplitude of the gear material at the fatigue limit; σ b Indicates the strength limit of the gear material.

[0016] Furthermore, when the determination module determines the initial warning threshold of the gear to be monitored according to the equivalent stress, it includes:

[0017] Calculating the difference between the equivalent stress and the equivalent stress threshold, and recording it as the stress difference;

[0018] Comparing the stress difference value with a first stress difference value and a second stress difference value, and determining an initial warning threshold value of the gear to be monitored according to the comparison result; wherein the first stress difference value is smaller than the second stress difference value;

[0019] When the stress difference value is less than or equal to the first stress difference value, determining the initial warning threshold value as the first warning threshold value;

[0020] When the stress difference value is greater than the first stress difference value and less than or equal to the second stress difference value, determining that the initial warning threshold is a second warning threshold value, and the second warning threshold value is greater than the first warning threshold value;

[0021] When the stress difference value is greater than the second stress difference value, the initial warning threshold is determined to be a third warning threshold, and the third warning threshold is greater than the second warning threshold.

[0022] Furthermore, when the judgment optimization module judges whether to optimize the initial warning threshold based on the analysis result, it includes:

[0023] Analyzing the historical operation data to obtain historical abnormal operation records;

[0024] Classifying the historical abnormal operation records, and obtaining historical abnormal stress values ​​and occurrence frequencies corresponding to each type of historical abnormal operation records;

[0025] 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 value and the occurrence frequency;

[0026] Whether to optimize the initial warning threshold is determined according to the historical abnormal stress mean value and the historical abnormal stress maximum fluctuation value.

[0027] Furthermore, when the judgment optimization module judges whether to optimize the initial warning threshold according to the historical abnormal stress mean value and the historical abnormal stress maximum fluctuation value, it includes:

[0028] Comparing the historical abnormal stress mean with the historical abnormal stress mean threshold, and comparing the historical abnormal stress maximum fluctuation value with the historical abnormal stress maximum fluctuation threshold, and judging whether to optimize the initial warning threshold according to the comparison results;

[0029] If the historical abnormal stress mean is greater than or equal to the historical abnormal stress mean threshold and / or the historical abnormal stress maximum fluctuation value is greater than or equal to the historical abnormal stress maximum fluctuation threshold, it is determined that the initial warning threshold is to be optimized;

[0030] Otherwise, it is determined not to optimize the initial warning threshold.

[0031] Furthermore, 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, including:

[0032] Taking the historical abnormal stress mean value and the historical abnormal stress maximum fluctuation value as a feature combination;

[0033] Matching the feature combination with a preset optimization coefficient mapping table to obtain an optimization coefficient corresponding to the feature combination;

[0034] The product value of the optimization coefficient and the initial warning threshold is used as the optimization warning threshold.

[0035] Furthermore, when the judgment compensation module judges whether to compensate the optimized warning threshold based on the environmental characteristic value, it includes:

[0036] Comparing the environmental characteristic value with the environmental characteristic threshold, and determining whether to compensate the optimized warning threshold according to the comparison result;

[0037] When the environmental characteristic value is greater than or equal to the environmental characteristic threshold, determining to compensate the optimized warning threshold;

[0038] When the environmental characteristic value is less than the environmental characteristic threshold, it is determined that the optimization warning threshold is not compensated.

[0039] Furthermore, the judgment and compensation module collects defect data of each of the monitoring areas, determines the compensation coefficient of the optimized warning threshold based on the defect data, and obtains the compensation warning threshold, including:

[0040] Extracting features from the defect data of each monitoring area to obtain a regional defect feature value;

[0041] Performing weighted calculation on all the regional defect characteristic values ​​to obtain a comprehensive defect characteristic value;

[0042] Comparing the comprehensive defect characteristic value with a first defect characteristic value and a second defect characteristic value, and determining a compensation coefficient for the optimized warning threshold value according to the comparison result; wherein the first defect characteristic value is smaller than the second defect characteristic value;

[0043] When the comprehensive defect characteristic value is less than or equal to the first defect characteristic value, determining the compensation coefficient to be the first compensation coefficient;

[0044] 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, determining the compensation coefficient to be a second compensation coefficient, and the second compensation coefficient is greater than the first compensation coefficient;

[0045] When the comprehensive defect characteristic value is greater than the second defect characteristic value, determining the compensation coefficient to be a third compensation coefficient, wherein the third compensation coefficient is greater than the second compensation coefficient;

[0046] The product value of the optimized warning threshold and the compensation coefficient is used as the compensation warning threshold.

[0047] Furthermore, when the early warning module performs a gear fatigue damage early warning on the gear to be monitored according to the compensation early warning threshold, it includes:

[0048] Real-time monitoring of the current stress value of the gear to be monitored;

[0049] Comparing the current stress value with the compensation warning threshold;

[0050] When the current stress value is greater than or equal to the compensation warning threshold, a warning signal is triggered to issue a gear fatigue damage warning to the gear to be monitored;

[0051] 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.

[0052] Compared with the prior art, the beneficial effect of the present invention is that the beneficial effect of the gear fatigue damage warning system based on equivalent stress provided by the present invention is that it improves the accuracy and reliability of the gear fatigue damage warning. By comprehensively considering the tooth surface contact stress, historical operating data and operating environment data, the present invention can dynamically adjust the warning threshold, thereby more accurately reflecting the actual operating status of the gear. Dividing the gear into multiple monitoring areas and collecting defect data in each area further enhances the pertinence and sensitivity of the warning system. This comprehensive warning strategy helps to timely detect potential damage to the gear, provides strong support for equipment maintenance and management, effectively extends the service life of the gear, and reduces the risk of failure due to gear fatigue damage.

[0053] In another aspect, the present invention also proposes a gear fatigue damage early warning method based on equivalent stress, comprising the following steps:

[0054] S100: determining a gear to be monitored, collecting tooth surface contact stress data of the gear to be monitored, calculating an equivalent stress of the gear to be monitored based on the tooth surface contact stress data, and determining an initial warning threshold of the gear to be monitored according to the equivalent stress;

[0055] S200: collecting historical operating data of the gear to be monitored, analyzing the historical operating data, and determining whether to optimize the initial warning threshold based on the analysis result; if so, determining an optimization coefficient of the initial warning threshold based on the historical operating data, and obtaining an optimized warning threshold;

[0056] S300: Collecting operating environment data of the gear to be monitored and obtaining environmental characteristic values, and determining whether to compensate the optimized warning threshold based on the environmental characteristic values; if so, dividing the gear to be monitored into a plurality of monitoring areas, collecting defect data of each monitoring area, determining a compensation coefficient for the optimized warning threshold based on the defect data, and obtaining a compensated warning threshold;

[0057] S400: Performing a gear fatigue damage warning on the gear to be monitored according to the compensation warning threshold.

[0058] It is understandable that the above-mentioned gear fatigue damage warning method and system based on equivalent stress have the same beneficial effects and will not be described in detail here. BRIEF DESCRIPTION OF THE DRAWINGS

[0059] Various other advantages and benefits will become apparent to those skilled in the art upon reading the detailed description of the preferred embodiment below. The accompanying drawings are for illustration purposes only and are not to be considered as limiting the present invention. The same reference symbols are used throughout the drawings to represent the same components. In the drawings:

[0060] Figure 1 A structural block diagram of a gear fatigue damage early warning system based on equivalent stress provided by an embodiment of the present invention;

[0061] Figure 2 This is a flowchart of a gear fatigue damage early warning method based on equivalent stress provided by an embodiment of the present invention. DETAILED DESCRIPTION

[0062] Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present disclosure are shown in the accompanying 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 to enable a more thorough understanding of the present disclosure and to fully convey the scope of the present disclosure to those skilled in the art. It should be noted that, unless there is a conflict, the embodiments of the present disclosure 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 accompanying drawings and in conjunction with the embodiments.

[0063] See Figure 1 As shown, in some embodiments of the present application, this embodiment provides a gear fatigue damage early warning system based on equivalent stress, including:

[0064] a determination module configured to determine a gear to be monitored, collect tooth surface contact stress data of the gear to be monitored, calculate an 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;

[0065] a judgment and optimization module configured to collect historical operating data of the gear to be monitored, analyze the historical operating data, and determine whether to optimize the initial warning threshold based on the analysis result; if so, determine an optimization coefficient of the initial warning threshold based on the historical operating data, and obtain an optimized warning threshold;

[0066] a judgment and compensation module configured to collect operating environment data of the gear to be monitored and obtain environmental characteristic values, and determine whether to compensate the optimized warning threshold based on the environmental characteristic values; if so, divide the gear to be monitored into a plurality of monitoring areas, collect defect data of each of the monitoring areas, determine a compensation coefficient for the optimized warning threshold based on the defect data, and obtain a compensated warning threshold;

[0067] The early warning module is configured to provide a gear fatigue damage early warning for the gear to be monitored according to the compensation early warning threshold.

[0068] It is understandable that the beneficial effect of the gear fatigue damage warning system based on equivalent stress provided by this embodiment is that it improves the accuracy and reliability of the gear fatigue damage warning. By comprehensively considering the tooth surface contact stress, historical operating data, and operating environment data, this embodiment can dynamically adjust the warning threshold to more accurately reflect the actual operating status of the gear. Dividing the gear into multiple monitoring areas and collecting defect data in 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 equipment maintenance and management, effectively extends the service life of the gear, and reduces the risk of failure due to gear fatigue damage.

[0069] 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:

[0070] 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 based on the tooth surface contact stress data, gear material fatigue limit data and gear material strength limit data;

[0071] The equivalent stress is obtained by the following formula:

[0072] ;

[0073] Among them, σ eq represents the equivalent stress; σ H represents the tooth surface contact stress; σ -1 Indicates the stress amplitude of the gear material at the fatigue limit; σ b Indicates the strength limit of the gear material.

[0074] It's understandable that the calculation of equivalent stress is based on tooth contact stress and the fatigue and ultimate strength limits of the gear material. Tooth contact stress is one of the primary stresses experienced by gears during operation, reflecting the interaction between gear tooth surfaces. The fatigue and ultimate strength limits of the gear material, on the other hand, are inherent mechanical properties of the material and determine the maximum stress level the gear can withstand under long-term operation. By comprehensively considering these three factors, a more accurate assessment of the gear stress state can be achieved, providing a more reliable basis for the subsequent determination of warning thresholds.

[0075] Specifically, when the determination module determines the initial warning threshold of the gear to be monitored according to the equivalent stress, it includes:

[0076] Calculating the difference between the equivalent stress and the equivalent stress threshold, and recording it as the stress difference;

[0077] Comparing the stress difference value with a first stress difference value and a second stress difference value, and determining an initial warning threshold value of the gear to be monitored according to the comparison result; wherein the first stress difference value is smaller than the second stress difference value;

[0078] When the stress difference value is less than or equal to the first stress difference value, determining the initial warning threshold value as the first warning threshold value;

[0079] When the stress difference value is greater than the first stress difference value and less than or equal to the second stress difference value, determining that the initial warning threshold is a second warning threshold value, and the second warning threshold value is greater than the first warning threshold value;

[0080] When the stress difference value is greater than the second stress difference value, the initial warning threshold is determined to be a third warning threshold, and the third warning threshold is greater than the second warning threshold.

[0081] In this embodiment, the equivalent stress threshold is a preset safety stress level used to measure whether the gear is close to its fatigue damage limit.

[0082] 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.

[0083] In this embodiment, the first, second, and third warning thresholds are all set between the equivalent stress and the equivalent stress threshold, and correspond to different stress difference ranges. This setting ensures that the warning system can respond promptly and accurately to gears under different stress states.

[0084] In this embodiment, the first and second stress differences are determined based on extensive experimental data and gear operating experience. They represent the risk 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.

[0085] Specifically, when the judgment optimization module judges whether to optimize the initial warning threshold based on the analysis result, it includes:

[0086] Analyzing the historical operation data to obtain historical abnormal operation records;

[0087] Classifying the historical abnormal operation records, and obtaining historical abnormal stress values ​​and occurrence frequencies corresponding to each type of historical abnormal operation records;

[0088] 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 value and the occurrence frequency;

[0089] Whether to optimize the initial warning threshold is determined according to the historical abnormal stress mean value and the historical abnormal stress maximum fluctuation value.

[0090] In this embodiment, the types of historical abnormal operation records include, but are not limited to, overload, overheating, and abnormal vibration. Each type of historical abnormal operation record reflects the operation of the gear under different stress conditions. By classifying these records and calculating the historical abnormal stress value and occurrence frequency for each type, a deeper understanding of the historical operating status of the gear can be obtained.

[0091] In this embodiment, the historical abnormal stress mean is obtained by the following formula:

[0092] ;

[0093] Among them, σ mcan represents the mean value of historical abnormal stress; σ i represents the historical abnormal stress value corresponding to the i-th historical abnormal operation record; f i Indicates the occurrence frequency of the i-th historical abnormal operation record.

[0094] In this embodiment, the maximum fluctuation value of the historical abnormal stress refers to the difference between the maximum value and the minimum value of all the historical abnormal stress values, which reflects the stress fluctuation range experienced by the gear during its historical operation.

[0095] Specifically, when the judgment optimization module judges whether to optimize the initial warning threshold according to the historical abnormal stress mean value and the historical abnormal stress maximum fluctuation value, it includes:

[0096] Comparing the historical abnormal stress mean with the historical abnormal stress mean threshold, and comparing the historical abnormal stress maximum fluctuation value with the historical abnormal stress maximum fluctuation threshold, and judging whether to optimize the initial warning threshold according to the comparison results;

[0097] If the historical abnormal stress mean is greater than or equal to the historical abnormal stress mean threshold and / or the historical abnormal stress maximum fluctuation value is greater than or equal to the historical abnormal stress maximum fluctuation threshold, it is determined that the initial warning threshold is to be optimized;

[0098] Otherwise, it is determined not to optimize the initial warning threshold.

[0099] In this embodiment, the historical abnormal stress mean threshold and the historical abnormal stress maximum 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 operating conditions.

[0100] It's understandable that when the historical average abnormal stress value is high or the historical maximum abnormal stress fluctuation value is large, it indicates that the gear may have experienced a large stress shock or long-term stress accumulation during its historical operation, which may lead to an increased risk of fatigue damage to the gear. Therefore, in this case, it is necessary to optimize the initial warning threshold to improve the sensitivity and accuracy of the warning system.

[0101] 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:

[0102] Taking the historical abnormal stress mean value and the historical abnormal stress maximum fluctuation value as a feature combination;

[0103] Matching the feature combination with a preset optimization coefficient mapping table to obtain an optimization coefficient corresponding to the feature combination;

[0104] The product value of the optimization coefficient and the initial warning threshold is used as the optimization warning threshold.

[0105] In this embodiment, a preset optimization coefficient mapping table records the correspondence between different feature combinations and optimization coefficients. This table, derived from extensive experimental data and gear operation experience, helps the optimization module quickly and accurately determine the optimization coefficient that matches the current historical abnormal stress mean and the historical maximum abnormal stress fluctuation. Let's denote the feature combination (a, b), and its corresponding optimization coefficient in the preset optimization coefficient mapping table is c.

[0106] In this embodiment, if (a, b) = (380, 40), then c = 1.2; if (a, b) = (420, 60), then c = 1.5, and so on.

[0107] Specifically, when the judgment compensation module judges whether to compensate the optimized warning threshold based on the environmental characteristic value, it includes:

[0108] Comparing the environmental characteristic value with the environmental characteristic threshold, and determining whether to compensate the optimized warning threshold according to the comparison result;

[0109] When the environmental characteristic value is greater than or equal to the environmental characteristic threshold, determining to compensate the optimized warning threshold;

[0110] When the environmental characteristic value is less than the environmental characteristic threshold, it is determined that the optimization warning threshold is not compensated.

[0111] In this embodiment, the environmental characteristic value refers to a comprehensive quantitative indicator of parameters such as the temperature, humidity, and dust concentration in the environment in which the gear operates. These environmental factors have a significant impact on the operating state and fatigue damage of the gear. For example, high temperatures can cause gear material properties to degrade, accelerating gear wear and fatigue damage; high humidity and dust concentration can increase the risk of corrosion and wear on the gear surface.

[0112] In this embodiment, the environmental characteristic value is preferably the ambient temperature.

[0113] In this embodiment, the environmental characteristic threshold is determined based on a large amount of experimental data and gear operation experience, and represents the maximum environmental stress level that the gear can withstand under normal operating conditions.

[0114] It is understandable that when the ambient temperature is high, the performance of the gear material may be affected, resulting in an increased risk of gear fatigue damage. Therefore, in this case, it is necessary to compensate for the optimized warning threshold to improve the sensitivity and accuracy of the warning system.

[0115] Specifically, the judgment and compensation module collects defect data of each monitoring area, determines the compensation coefficient of the optimized warning threshold based on the defect data, and obtains the compensation warning threshold, including:

[0116] Extracting features from the defect data of each monitoring area to obtain a regional defect feature value;

[0117] Performing weighted calculation on all the regional defect characteristic values ​​to obtain a comprehensive defect characteristic value;

[0118] Comparing the comprehensive defect characteristic value with a first defect characteristic value and a second defect characteristic value, and determining a compensation coefficient for the optimized warning threshold value according to the comparison result; wherein the first defect characteristic value is smaller than the second defect characteristic value;

[0119] When the comprehensive defect characteristic value is less than or equal to the first defect characteristic value, determining the compensation coefficient to be the first compensation coefficient;

[0120] 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, determining the compensation coefficient to be a second compensation coefficient, and the second compensation coefficient is greater than the first compensation coefficient;

[0121] When the comprehensive defect characteristic value is greater than the second defect characteristic value, determining the compensation coefficient to be a third compensation coefficient, wherein the third compensation coefficient is greater than the second compensation coefficient;

[0122] The product value of the optimized warning threshold and the compensation coefficient is used as the compensation warning threshold.

[0123] 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.

[0124] In this embodiment, the regional defect characteristic value refers to a comprehensive quantitative index of parameters such as the type and size of gear defects in each monitoring area. Defect types include cracks, wear, and corrosion.

[0125] The regional defect characteristic value is obtained by the following formula:

[0126] ;

[0127] Among them, D k represents the defect characteristic value of the kth monitoring area; P kj represents the quantitative value of the j-th type of defect in the k-th monitoring area; ω j represents the weight corresponding to the j-th type of defect; n represents the number of defect types.

[0128] In this embodiment, the comprehensive defect characteristic value is a weighted sum of the defect characteristic values ​​of all monitoring areas, which reflects the overall defect status of the gear. By weighted summing the defect characteristic values ​​of each monitoring area, a more comprehensive and accurate gear defect assessment result can be obtained.

[0129] In this embodiment, the first and second defect characteristic values ​​are determined based on extensive experimental data and gear operating experience. They represent the fatigue damage risk of the gear at varying defect levels. By comparing these combined defect characteristic values ​​with a preset defect characteristic value threshold, the current defect condition of the gear can be determined and an appropriate compensation factor can be selected accordingly.

[0130] Specifically, when the early warning module performs gear fatigue damage early warning on the gear to be monitored according to the compensation early warning threshold, it includes:

[0131] Real-time monitoring of the current stress value of the gear to be monitored;

[0132] Comparing the current stress value with the compensation warning threshold;

[0133] When the current stress value is greater than or equal to the compensation warning threshold, a warning signal is triggered to issue a gear fatigue damage warning to the gear to be monitored;

[0134] 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.

[0135] Understandably, real-time monitoring is key to ensuring the early warning system's ability to promptly respond to changes in gear condition. By continuously collecting and analyzing gear stress data, the system can detect any abnormal stress fluctuations and issue timely warning signals. When the current stress value reaches or exceeds the compensation warning threshold, the early warning module immediately triggers a warning signal, notifying relevant personnel of the potential gear damage risk and initiating appropriate maintenance or repair measures. This early warning mechanism helps prevent sudden failures caused by gear fatigue damage and ensures stable equipment operation. Furthermore, the system avoids unnecessary warnings for gears in normal operating conditions, reducing false alarms and interference, and improving the accuracy and reliability of the early warning system.

[0136] See Figure 2 As shown, in some embodiments of the present application, this embodiment provides a gear fatigue damage early warning method based on equivalent stress, comprising the following steps:

[0137] S100: determining a gear to be monitored, collecting tooth surface contact stress data of the gear to be monitored, calculating an equivalent stress of the gear to be monitored based on the tooth surface contact stress data, and determining an initial warning threshold of the gear to be monitored according to the equivalent stress;

[0138] S200: collecting historical operating data of the gear to be monitored, analyzing the historical operating data, and determining whether to optimize the initial warning threshold based on the analysis result; if so, determining an optimization coefficient of the initial warning threshold based on the historical operating data, and obtaining an optimized warning threshold;

[0139] S300: Collecting operating environment data of the gear to be monitored and obtaining environmental characteristic values, and determining whether to compensate the optimized warning threshold based on the environmental characteristic values; if so, dividing the gear to be monitored into a plurality of monitoring areas, collecting defect data of each monitoring area, determining a compensation coefficient for the optimized warning threshold based on the defect data, and obtaining a compensated warning threshold;

[0140] S400: Performing a gear fatigue damage warning on the gear to be monitored according to the compensation warning threshold.

[0141] Those skilled in the art will appreciate that the embodiments of the present application may be provided as methods, systems, or computer program products. Therefore, the present application may take the form of an entirely hardware embodiment, an entirely software embodiment, or an embodiment combining software and hardware. Furthermore, the present application may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to magnetic disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0142] The present application is described with reference to the flowcharts and / or block diagrams of the methods, devices (systems) and computer program products according to the embodiments of the present application. It should be understood that each process and / or box in the flowchart and / or block diagram, as well as the combination of processes and / or boxes in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 a process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0143] These computer program instructions may 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 produce an article of manufacture comprising an instruction device, which implements the process Figure 1 a process or multiple processes and / or boxes Figure 1 The function specified in one or more boxes.

[0144] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operational steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing the instructions executed on the computer or other programmable device for implementing the process. Figure 1 a process or multiple processes and / or boxes Figure 1 The steps for the function specified in one or more boxes.

[0145] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, ordinary technicians in the field should understand that the specific implementation methods of the present invention can still be modified or replaced by equivalents. Any modification or equivalent replacement that does not depart from the spirit and scope of the present invention should be covered by the scope of protection of the claims of the present invention.

Claims

1. A gear fatigue damage early warning system based on equivalent stress, characterized in that: include: a determination module configured to determine a gear to be monitored, collect tooth surface contact stress data of the gear to be monitored, calculate an 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 operating data of the gear to be monitored, analyze the historical operating data, and determine whether to optimize the initial warning threshold based on the analysis result; If so, determining the optimization coefficient of the initial warning threshold according to the historical operation data, and obtaining the optimized warning threshold; a judgment and compensation module configured to collect operating environment data of the gear to be monitored and obtain environmental characteristic values, and determine whether to compensate the optimized warning threshold based on the environmental characteristic values; If yes, the gear to be monitored is divided into several monitoring areas, defect data of each monitoring area is collected, a compensation coefficient of the optimized warning threshold is determined based on the defect data, and a compensated warning threshold is obtained; an early warning module, configured to provide a gear fatigue damage early warning for the gear to be monitored according to the compensation early warning threshold; When the judgment compensation module judges whether to compensate the optimized warning threshold based on the environmental characteristic value, it includes: Comparing the environmental characteristic value with the environmental characteristic threshold, and determining 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, determining to compensate the optimized warning threshold; When the environmental characteristic value is less than the environmental characteristic threshold, determining not to compensate the optimized warning threshold; When the judgment and compensation module collects defect data of each monitoring area, determines the compensation coefficient of the optimized warning threshold based on the defect data, and obtains the compensation warning threshold, it includes: Extracting features from the defect data of each monitoring area to obtain a regional defect feature value; Performing weighted calculation on all the regional defect characteristic values ​​to obtain a comprehensive defect characteristic value; Comparing the comprehensive defect characteristic value with a first defect characteristic value and a second defect characteristic value, and determining a compensation coefficient for the optimized warning threshold value according to the comparison result; wherein the first defect characteristic value is smaller than the second defect characteristic value; When the comprehensive defect characteristic value is less than or equal to the first defect characteristic value, determining the compensation coefficient to be 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, determining the compensation coefficient to be a 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, determining the compensation coefficient to be a third compensation coefficient, wherein the third compensation coefficient is greater than the second compensation coefficient; The product value of the optimized warning threshold and the compensation coefficient is used as the compensation warning threshold.

2. The gear fatigue damage early warning system based on equivalent stress according to claim 1 is characterized in that: 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 based on 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 Indicates the stress amplitude of the gear material at the fatigue limit; σ b Indicates the strength limit of the gear material.

3. The gear fatigue damage early warning system based on equivalent stress according to claim 2 is characterized in that: 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 the equivalent stress threshold, and recording it as the stress difference; Comparing the stress difference value with a first stress difference value and a second stress difference value, and determining an initial warning threshold value of the gear to be monitored according to the comparison result; wherein the first stress difference value is smaller than the second stress difference value; When the stress difference value is less than or equal to the first stress difference value, determining the initial warning threshold value as the first warning threshold value; When the stress difference value is greater than the first stress difference value and less than or equal to the second stress difference value, determining that the initial warning threshold is a second warning threshold value, and the second warning threshold value is greater than the first warning threshold value; When the stress difference value is greater than the second stress difference value, the initial warning threshold is determined to be a third warning threshold, and the third warning threshold is greater than the second warning threshold.

4. The gear fatigue damage early warning system based on equivalent stress according to claim 3 is characterized in that: When the judgment 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 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 value and the occurrence frequency; Whether to optimize the initial warning threshold is determined according to the historical abnormal stress mean value and the historical abnormal stress maximum fluctuation value.

5. The gear fatigue damage early warning system based on equivalent stress according to claim 4 is characterized in that: When the judgment optimization module judges whether to optimize the initial warning threshold according to the historical abnormal stress mean value and the historical abnormal stress maximum fluctuation value, it includes: Comparing the historical abnormal stress mean with the historical abnormal stress mean threshold, and comparing the historical abnormal stress maximum fluctuation value with the historical abnormal stress maximum fluctuation threshold, and judging 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 threshold value and / or the historical abnormal stress maximum fluctuation value is greater than or equal to the historical abnormal stress maximum fluctuation threshold value, it is determined that the initial warning threshold value is to be optimized; Otherwise, it is determined not to optimize the initial warning threshold.

6. The gear fatigue damage early warning system based on equivalent stress according to claim 5 is characterized in that: 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: Taking the historical abnormal stress mean value and the historical abnormal stress maximum fluctuation value as a feature combination; Matching the feature combination with a preset optimization coefficient mapping table to obtain an optimization coefficient corresponding to the feature combination; The product value of the optimization coefficient and the initial warning threshold is used as the optimization warning threshold.

7. The gear fatigue damage early warning system based on equivalent stress according to claim 6 is characterized in that: When the early warning module performs a gear fatigue damage early warning on the gear to be monitored according to the compensation early 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, a warning signal is triggered to issue a gear fatigue damage warning to 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.

8. A gear fatigue damage early warning method based on equivalent stress, applied to the gear fatigue damage early warning system based on equivalent stress as claimed in any one of claims 1 to 7, characterized in that: include: 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 value of the gear to be monitored according to the equivalent stress; Collecting historical operating data of the gear to be monitored, analyzing the historical operating data, and determining whether to optimize the initial warning threshold based on the analysis result; If so, determining the optimization coefficient of the initial warning threshold according to the historical operation data, and obtaining the optimized warning threshold; Collecting operating environment data of the gear to be monitored and obtaining environmental characteristic values, and determining whether to compensate the optimized warning threshold based on the environmental characteristic values; If yes, the gear to be monitored is divided into several monitoring areas, defect data of each monitoring area is collected, a compensation coefficient of the optimized warning threshold is determined based on the defect data, and a compensated warning threshold is obtained; A gear fatigue damage warning is performed on the gear to be monitored according to the compensation warning threshold.

Images