Gear gluing failure real-time evaluation system and method based on star sensor network

Abstract

The invention relates to a gear gluing failure real-time evaluation system and method based on a star sensor network, and belongs to the technical field of gear gluing failure evaluation. Comprising a test gear box, a temperature sensor, a vibration sensor, a box body monitoring node, a gear monitoring node and a test gear which are arranged on a shaft of the test gear box, a relay node and an upper computer carrying Qt design software, the system is used for converging and forwarding data collected by the gear monitoring node and the box monitoring node, a star-shaped wireless sensor network topological structure is formed through Wi-Fi modules configured by the gear monitoring node, the box monitoring node, the relay node and the upper computer, signals are collected synchronously, the service states of gears, bearings and gear boxes can be reflected accurately, and the service quality of the gears, the bearings and the gear boxes is improved. The star-shaped wireless sensor network has flexible networking capability, non-unpacking judgment of the gear gluing bearing capability test is realized by observing whether the change of a multi-dimensional signal characteristic value exceeds a specific threshold value or not, and the test efficiency is improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of gear agglutination failure assessment, and relates to a gear agglutination failure real-time assessment system and method based on a star-shaped sensor network. Background Art

[0002] Gear scuffing is a severe adhesive damage to the tooth surface caused by thermal-mechanical coupling, a serious failure form in which local surface material is transferred from one tooth surface to another. Gear scuffing failure is a common failure form in gear transmission systems, which directly affects the reliability and life of the equipment.

[0003] Traditional assessment methods often rely on periodic unpacking inspections, where damage is assessed by observing the tooth surface. This results in long test cycles, low efficiency, and an inability to monitor the evolution of bonding under dynamic loads in real time. Existing monitoring technologies, such as wired sensor systems, are difficult to implement reliably in high-speed rotating components due to complex wiring and susceptibility to mechanical motion interference. Furthermore, existing methods often focus on monitoring a single parameter and lack the multi-dimensional, simultaneous collection and analysis of gear body temperature, tooth root stress, bearing temperature, and housing vibration, leading to one-sided assessment results.

[0004] Therefore, there is an urgent need for an efficient and reliable system to achieve real-time online assessment of gear scuffing failure. Summary of the Invention

[0005] In view of this, the present invention provides a real-time evaluation system and method for gear bonding failure based on a star-shaped sensor network in order to solve the problems that the existing monitoring methods focus on single parameter monitoring and lack multi-dimensional synchronous acquisition and analysis, resulting in one-sided evaluation results. At the same time, the wired sensor system in the monitoring method is difficult to be stably applied in high-speed rotating parts due to complex wiring and susceptibility to mechanical motion interference, and the traditional evaluation methods rely on regular unpacking inspections, resulting in long test cycles, low efficiency and inability to monitor the evolution of bonding under dynamic loads in real time.

[0006] In order to achieve the above object, the present invention provides the following technical solutions:

[0007] A real-time assessment system for gear bonding failure based on a star-shaped sensor network includes a test gearbox, a temperature sensor, a vibration sensor, a box monitoring node, a gear monitoring node and a test gear arranged on the shaft of the test gearbox, a relay node, and a host computer equipped with Qt design software. The relay node is arranged on the upper end cover of the test gearbox and is used to aggregate and forward data collected by the gear monitoring node and the box monitoring node. Wi-Fi modules configured on the gear monitoring node, the box monitoring node, the relay node, and the host computer form a star-shaped wireless sensor network topology.

[0008] Furthermore, the Wi-Fi modules of the gear monitoring node, the box monitoring node and the host computer are set to STA mode, and the Wi-Fi module of the relay node is set to AP mode.

[0009] Furthermore, the star-shaped wireless sensor network is specifically as follows: the host computer first connects to the relay node to obtain a fixed IP address, and then the gear monitoring node and the box monitoring node connect to the relay node, and transmits the monitoring data to the host computer through the fixed IP address and port number of the host computer using the TCP / IP protocol.

[0010] Furthermore, the gear monitoring node is annular as a whole, including a device shell composed of a base, a battery fixing plate and a cover plate, and a PCB board, a battery and a sleeve installed in the device shell. The PCB board is fixedly connected to the base of the device shell, the battery is fixedly installed in the cover plate of the device shell, the PCB board and the battery are electrically connected through wires, the sleeve is fixedly connected to the device shell by bolts, and the sleeve is connected to the shaft of the test gear box by a flat key to ensure the axial and circumferential fixation of the gear monitoring node.

[0011] Furthermore, the temperature sensor includes a first temperature sensor unit and a second temperature sensor unit; the first temperature sensor unit and the second temperature sensor unit are respectively fixed on the tooth end face of the test gear and the bearing outer ring of the test gear box, and are respectively electrically connected to the gear monitoring node and the box monitoring node through connectors.

[0012] Furthermore, the vibration sensor includes a first vibration sensor unit and a second vibration sensor unit; the first vibration sensor unit and the second vibration sensor unit are respectively fixed to the PCB board and the box body of the test gear box, and are respectively electrically connected to the gear monitoring node and the box body monitoring node through connectors.

[0013] A real-time assessment method for gear scuffing failure based on a star-shaped sensor network includes the following steps:

[0014] S1. Attach temperature sensors to the tooth end faces of the test gear and the outer ring of the bearing of the test gearbox, and fix vibration sensors to the PCB board and the test gearbox body.

[0015] S2. Install the test gear and gear monitoring node on the shaft of the test gearbox, and electrically connect the gear monitoring node, box monitoring node, temperature sensor, and vibration sensor through connectors to collect signals such as the test gear body temperature, test gear vibration, bearing outer ring temperature, and test gearbox box vibration. Place the relay node on the upper end cover of the test gearbox, and the host computer receives the collected data.

[0016] S3. Set up the test process according to the test standard, load the gears with the lever weight, heat the oil and start the motor, and perform the gear bonding load capacity test according to the set test conditions.

[0017] S4. Turn on the power of the gear monitoring node and the box monitoring node, observe the signal change curve in real time, and judge whether the test gear has adhesive failure by observing whether the change of the signal characteristic value exceeds the threshold in real time.

[0018] Furthermore, step S4 is specifically as follows: the temperature rise rate is extracted in real time as the characteristic value of the temperature signal, and the calculation method is as follows: the difference between the current temperature data collected each time and the temperature value of the previous 1000 sampled data is calculated, and then divided by the time interval used to collect 1000 data; the peak-to-peak value and root mean square of the vibration time domain characteristic value are extracted in real time as the characteristic value of the vibration signal; the temperature rise rate, peak-to-peak value and root mean square are all set with corresponding failure thresholds. In the same load level test, if a signal characteristic value exceeds the threshold, it is judged that the gear has failed by bonding, and after the load level test is completed, the gear is unpacked and observed for bonding condition, and a record is made.

[0019] The beneficial effects of the present invention are:

[0020] 1. The present invention discloses a real-time assessment system for gear bonding failure based on a star-shaped sensor network. By attaching temperature sensors to the tooth end faces of the test gear and the bearing outer ring of the test gearbox, and fixing vibration sensors to the PCB board and the test gearbox body, the system can synchronously collect signals such as the test gear body temperature, gear vibration, bearing outer ring temperature, and test gearbox body vibration, and accurately reflect the service status of the gears, bearings, and gearbox.

[0021] 2. The present invention discloses a real-time assessment system for gear bonding failure based on a star-shaped sensor network. The gear monitoring nodes, box monitoring nodes, relay nodes, and host computers are all equipped with Wi-Fi modules to form a star-shaped wireless sensor network topology structure. The system has flexible networking capabilities. According to test requirements, the system can support the replacement or addition or reduction of monitoring nodes without affecting other monitoring nodes.

[0022] 3. The present invention discloses a real-time assessment system for gear bonding failure based on a star-shaped sensor network. This system can assess gear bonding failure by observing whether the change in the characteristic value of a multi-dimensional signal exceeds a specific threshold, thereby realizing non-disassembly judgment of the gear bonding load-bearing capacity test, improving test efficiency, and having the advantages of quantifiable service status and high efficiency.

[0023] Other advantages, objects, and features of the present invention will be described in part in the following description and, in part, will be apparent to those skilled in the art upon examination of the following description or may be learned from practice of the present invention. The objects and other advantages of the present invention may be realized and obtained through the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to make the purpose, technical solutions and advantages of the present invention more clear, the present invention will be described in detail below with reference to the accompanying drawings, in which:

[0025] Figure 1 This is a schematic structural diagram of a real-time assessment system for gear agglutination failure based on a star-shaped sensor network according to the present invention;

[0026] Figure 2 This is an exploded diagram of a gear monitoring node in a real-time assessment system for gear agglutination failure based on a star-shaped sensor network according to the present invention;

[0027] Figure 3 This is a wireless communication structure diagram of a star-shaped wireless sensor network in a real-time assessment system for gear bonding failure based on a star-shaped sensor network of the present invention;

[0028] Figure 4 This is a graph showing the temperature test of the gear body at different load levels in this embodiment;

[0029] Figure 5 This is a graph showing the change in gear temperature rise rate at the failure load level of this embodiment;

[0030] Figure 6 This is a gear vibration test curve diagram under different loads of level 1 to 9 in this embodiment;

[0031] Figure 7 This is a graph showing the peak-to-peak value and root mean square (RMS) variation of gear vibration at the failure load level of this embodiment;

[0032] Figure 8 The present invention is a flow chart of a method for real-time evaluation of gear agglutination failure based on a star-shaped sensor network.

[0033] Figure markings: 1. Box monitoring node; 2. Gear monitoring node; 3. Relay node; 4. Host computer; 5. Temperature sensor; 6. Vibration sensor; 7. Test gear; 8. Test gear box; 9. Sleeve; 10. Connector; 11. PCB board; 12. Battery; 13. Device housing. DETAILED DESCRIPTION

[0034] The following describes the embodiments of the present invention by means of specific examples, and those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the illustrations provided in the following embodiments are only schematic illustrations of the basic concept of the present invention, and the following embodiments and features in the embodiments can be combined with each other without conflict.

[0035] like Figure 1 The system shown is a real-time assessment system for gear bonding failure based on a star-shaped sensor network, comprising a test gearbox 8, a temperature sensor 5, a vibration sensor 6, a box monitoring node 1, a gear monitoring node 2 and a test gear 7 arranged on the shaft of the test gearbox 8, a relay node 3 and a host computer 4 equipped with Qt design software. The relay node 3 is arranged on the upper end cover of the test gearbox 8 and is used to aggregate and forward data collected by the gear monitoring node 2 and the box monitoring node 1. The Wi-Fi modules configured on the gear monitoring node 2, the box monitoring node 1, the relay node 3 and the host computer 4 form a star-shaped wireless sensor network topology.

[0036] like Figure 3 As shown, the Wi-Fi modules of the gear monitoring node 2, the box monitoring node 1 and the host computer 4 are set to STA mode, and the Wi-Fi module of the relay node 3 is set to AP mode. The host computer 4 first connects to the relay node 3 to obtain a fixed IP address, and then the gear monitoring node 2 and the box monitoring node 1 connect to the relay node 3. Through the fixed IP address 192.168.4.2 and port number 8080 of the host computer 4, the TCP / IP protocol is used to transmit the monitoring data to the host computer 4, forming a star-shaped wireless sensor network.

[0037] like Figure 2 As shown, the gear monitoring node 2 is annular as a whole, including a device housing 13 composed of a base, a battery fixing plate and a cover plate, and a PCB board 11, a battery 12 and a sleeve 9 installed in the device housing 13. The PCB board 11 is fixedly connected to the base of the device housing 13, and the battery 12 is fixedly installed in the cover plate of the device housing 13. The PCB board 11 and the battery 12 are electrically connected through a wire, and the sleeve 9 is fixedly connected to the device housing 13 by bolts. The sleeve 9 is connected to the shaft of the test gear box 8 by a flat key to ensure the axial and circumferential fixation of the gear monitoring node 2.

[0038] The temperature sensor 5 is a temperature resistance sensor including a first temperature sensor unit and a second temperature sensor unit, model PT100. The first temperature sensor unit and the second temperature sensor unit are respectively fixed on the tooth end face of the test gear 7 and the bearing outer ring of the test gear box 8, and are respectively electrically connected to the gear monitoring node 2 and the box monitoring node 1 through the connector 10; the vibration sensor 6 is a MEMS sensor including a first vibration sensor unit and a second vibration sensor unit, model ADXL357. The first vibration sensor unit and the second vibration sensor unit are respectively fixed on the PCB board 11 in the gear monitoring node 2 and the box body of the test gear box 8, and are respectively electrically connected to the gear monitoring node 2 and the box monitoring node 1 through the connector 10.

[0039] like Figure 8As shown, a real-time assessment method for gear scuffing failure based on a star-shaped sensor network is applied to the above-mentioned real-time assessment system for gear scuffing failure based on a star-shaped sensor network, comprising the following steps:

[0040] S1. Paste the temperature sensor 5 on the tooth end face of the test gear 7 and the bearing outer ring of the test gear box 8, and fix the vibration sensor 6 on the PCB board 11 and the box body of the test gear box 8.

[0041] S2. Install the test gear 7 and the gear monitoring node 2 on the shaft of the test gearbox 8, and electrically connect the gear monitoring node 2, the box monitoring node 1, the temperature sensor 5, and the vibration sensor 6 through the connector 10 to respectively collect signals such as the test gear 7 body temperature, the test gear 7 vibration, the bearing outer ring temperature, and the box vibration. The relay node 3 is placed on the upper end cover of the test gearbox 8, and the host computer 4 receives the collected data.

[0042] S3. Set up the test process according to the FZG A / 8.3 / 90 test standard described in GB / Z 13672-2022 "Test method for bearing capacity of gear abrasion", perform step-by-step loading with weights, heat the oil temperature to 90°C, set the motor speed to 1450 r / min and start, and conduct the gear abrasion bearing capacity test according to the set test conditions.

[0043] S4. Turn on the power of gear monitoring node 2 and box monitoring node 1, observe the signal change curve in real time, and judge whether the test gear 7 has glue failure by observing whether the change of the signal characteristic value exceeds the threshold. If it does not exceed the set threshold, increase the test load level by one level and continue the test. If it exceeds the set threshold, unpack and check the gear failure degree. Specifically:

[0044] The temperature rise rate is extracted in real time as the characteristic value of the temperature signal. The calculation method is as follows: calculate the difference between the current temperature data collected each time and the temperature value of the previous 1000 sampled data, and then divide it by the time interval used to collect 1000 data. Figure 4 The temperature test curves of the gear body under different load levels 1 to 9 are shown in the figure. At low load levels, the steady-state temperature of the gear body is lower than the oil temperature and shows a downward trend over time. At high load levels, the steady-state temperature of the gear body gradually increases from 80.1°C to 125.8°C. In the 9th load level test, the temperature signal suddenly changes from 125°C to 140°C. Figure 5 As shown in the figure, the temperature rise rate, a characteristic value of the temperature curve of the gear body, was extracted. At about 820 s in the 9th load level, the characteristic value of the temperature rise rate fluctuated significantly and exceeded the failure threshold. It was determined that the test gear had undergone bonding failure at this time. After the test at this load level, the gear bonding condition was observed and recorded by unpacking.

[0045] The peak-to-peak value and root mean square of the vibration time domain eigenvalues are extracted in real time as the vibration signal eigenvalues, such as Figure 6 As shown in Figure 1, as the load level and loading torque increase, the vibration amplitude gradually increases and remains relatively stable. At the 9th load level, the vibration amplitude is significantly enlarged. Figure 7 As shown in the figure, the peak-to-peak value and root mean square value of the gear vibration acceleration curve were extracted. At the 9th load level, the peak-to-peak value increased from 42.96g to 68.86g, and the root mean square value increased from 4.69g to 6.61g, with an increase of 60.3% and 40.9% respectively. It was judged that the gear had glue failure. After the test at this load level, the gear was unpacked and the glue condition was observed and recorded.

[0046] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention can be modified or replaced by equivalents without departing from the purpose and scope of the technical solutions, which should all be included in the scope of the claims of the present invention.

Claims

1. A real-time assessment system for gear scuffing failure based on a star-shaped sensor network, characterized in that: The system includes a test gearbox, a temperature sensor, a vibration sensor, a box monitoring node, a gear monitoring node and a test gear arranged on the test gearbox shaft, a relay node and a host computer equipped with Qt design software. The relay node is arranged on the upper end cover of the test gearbox and is used to aggregate and forward data collected by the gear monitoring node and the box monitoring node. The Wi-Fi modules configured on the gear monitoring node, the box monitoring node, the relay node and the host computer form a star-shaped wireless sensor network topology.

2. The real-time assessment system for gear scuffing failure based on a star-shaped sensor network according to claim 1, characterized in that: The Wi-Fi modules of the gear monitoring node, box monitoring node and host computer are set to STA mode, and the Wi-Fi module of the relay node is set to AP mode.

3. The real-time assessment system for gear scuffing failure based on a star-shaped sensor network according to claim 2, characterized in that: The star-shaped wireless sensor network is specifically as follows: the host computer first connects to the relay node to obtain a fixed IP address, and then the gear monitoring node and the box monitoring node connect to the relay node, and transmits the monitoring data to the host computer through the host computer's fixed IP address and port number using the TCP / IP protocol.

4. The real-time assessment system for gear scuffing failure based on a star-shaped sensor network according to claim 1, characterized in that: The gear monitoring node is annular as a whole, and includes a device shell composed of a base, a battery fixing plate and a cover plate, and a PCB board, a battery and a sleeve installed in the device shell. The PCB board is fixedly connected to the base of the device shell, and the battery is fixedly installed in the cover plate of the device shell. The PCB board and the battery are electrically connected through wires, and the sleeve is fixedly connected to the device shell by bolts. The sleeve is connected to the shaft of the test gear box by a flat key to ensure the axial and circumferential fixation of the gear monitoring node.

5. The real-time assessment system for gear scuffing failure based on a star-shaped sensor network according to claim 1, characterized in that: The temperature sensor includes a first temperature sensor unit and a second temperature sensor unit; the first temperature sensor unit and the second temperature sensor unit are respectively fixed on the tooth end face of the test gear and the bearing outer ring of the test gear box, and are respectively electrically connected to the gear monitoring node and the box monitoring node through connectors.

6. The real-time assessment system for gear scuffing failure based on a star-shaped sensor network according to claim 1, characterized in that: The vibration sensor includes a first vibration sensor unit and a second vibration sensor unit; the first vibration sensor unit and the second vibration sensor unit are respectively fixed to the PCB board and the box body of the test gear box, and are respectively electrically connected to the gear monitoring node and the box body monitoring node through connectors.

7. A real-time assessment method for gear scuffing failure based on a star-shaped sensor network, characterized in that: The following steps are involved: S1. Attach temperature sensors to the tooth end faces of the test gear and the outer ring of the bearing of the test gearbox, and fix vibration sensors to the PCB board and the test gearbox body. S2. Install the test gear and gear monitoring node on the shaft of the test gearbox, and electrically connect the gear monitoring node, box monitoring node, temperature sensor, and vibration sensor through connectors to collect the test gear body temperature, test gear vibration, bearing outer ring temperature, and test gearbox box vibration signals. Place the relay node on the upper end cover of the test gearbox, and the host computer receives the collected data. S3. Set up the test process according to the test standard, load the gears with the lever weight, heat the oil and start the motor, and perform the gear bonding load capacity test according to the set test conditions. S4. Turn on the power of the gear monitoring node and the box monitoring node, observe the signal change curve in real time, and judge whether the test gear has adhesive failure by observing whether the change of the signal characteristic value exceeds the threshold in real time.

8. The method for real-time assessment of gear scuffing failure based on a star-shaped sensor network according to claim 7, characterized in that: Specifically, step S4 comprises: extracting the temperature rise rate as the characteristic value of the temperature signal in real time, and calculating the difference between the current temperature data collected each time and the temperature value of the previous 1000 sampled data, and then dividing the difference by the time interval used to collect the 1000 data; extracting the peak-to-peak value and the root mean square of the vibration time domain characteristic values in real time as the characteristic values of the vibration signal; setting corresponding failure thresholds for the temperature rise rate, the peak-to-peak value and the root mean square. In the same load level test, if a certain signal characteristic value exceeds the threshold, it is determined that the gear has suffered from bonding failure, and after the load level test is completed, the gear is unpacked and the bonding condition of the gear is observed and recorded.

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