Ship lift large-modulus gear rack stress monitoring device and method
By combining laser monitoring and parametric finite element simulation, the gear bracket deformation is directly measured and the pressure of the hydro-pneumatic spring is adjusted in real time, which solves the problem of accuracy in gear rack force detection and achieves smooth operation and reduced wear of the ship lift.
Patent Information
- Application Number
- CN202510967966.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-07-14
- Publication Date
- 2025-09-16
AI Technical Summary
The existing gear rack force detection method cannot take into account the influence of gear bracket deformation, resulting in inaccurate detection results. It is impossible to determine whether the upper or lower tooth surface is under force, and it is impossible to adjust the hydraulic spring pressure in real time, affecting the smooth operation of the ship lift.
A laser monitoring array, monitoring module, equivalent strain contact module and stress contact module are combined with parametric finite element simulation to directly measure the deformation of the gear bracket and adjust the liquid-pneumatic spring pressure in real time. Dynamic control is achieved through the main control module to ensure that the gear meshing area is not subjected to stress.
It achieves accurate and efficient gear rack force detection, reduces wear, ensures smooth operation of the ship lift, simplifies module layout and signal transmission, and improves detection accuracy and real-time adjustment capabilities.
Smart Images
Figure CN120651408A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the field of ship lift monitoring, and in particular to a device and method for monitoring the force of a large-module gear rack of a ship lift. Background Art
[0002] As an important navigation facility, the ship lift is responsible for the rapid passage of ships through the dam. Among them, the large rack and pinion climbing ship lift is the most technically difficult and complex system of all types of ship lifts. The rack and pinion, as the driving mechanism of the ship lift, only needs to overcome unbalanced loads, inertia and motion resistance to ensure the smooth lifting and lowering operation of the ship lift.
[0003] During the docking process between the ship lift and the upper and lower lockheads, the ship compartment undergoes longitudinal displacement. When the rack and pinion are engaged and stressed, the combined relative displacement along the tooth width accelerates wear and failure of the rack and pinion. Because the rack and pinion are embedded and cannot be replaced, damage can lead to significant equipment defects, seriously impacting navigation. Existing methods for detecting rack and pinion force indirectly measure the force applied to the gear bracket system, connecting the bottom beam and the hydraulic spring to the measuring shaft. This measurement does not account for structural deformation of the gear bracket itself, and it cannot determine whether the force is acting on the upper or lower tooth surface. Summary of the Invention
[0004] The technical problem to be solved by the present invention is to provide a large-module gear rack force monitoring device and method for a ship lift. Taking into account the influence of the deformation of the gear bracket on the force of the gear rack, the detection adopts a method combining direct measurement with parametric finite element simulation to achieve accurate and efficient detection; and the real-time dynamic adjustment of the liquid-gas spring pressure can be achieved according to the detection structure to ensure that the gear rack is not subjected to force when the ship compartment is docked with the upper and lower gates.
[0005] In order to solve the above technical problems, the technical solution adopted by the present invention is: A ship lift large-module gear rack force monitoring device, comprising a laser monitoring array, a monitoring module, an equivalent strain contact module, a stress contact module and a main control module; Under the calibration conditions, a finite element model is constructed using a laser monitoring array and an equivalent strain contact module; The stress contact module is used to monitor the gear stress state in real time when the hydraulic spring is under pressure relief and pressure filling, as well as the gear and rack transmission state; The monitoring module is used to monitor the pressure value of the rodless chamber of the liquid-gas spring and the dynamic expansion and contraction of the piston rod of the liquid-gas spring; The main control module controls the hydraulic system to dynamically control and adjust the pressure of the hydro-pneumatic spring, so that the gear tooth meshing area is free from stress.
[0006] The laser monitoring array is arranged on the bearing surface of the gear bracket displacement adaptation mechanism tube; the laser monitoring array is used to obtain the three-dimensional deformation of the gear bracket. .
[0007] The laser monitoring array includes three groups of laser Doppler vibrometers, which are arranged spirally along the outer cylindrical surface of the tube bearing and are distributed at equal angles in the axial direction and at equal distances in the radial direction of the tube bearing.
[0008] The gear bracket three-dimensional deformation The calculation formula is as follows: ; Where: is the laser wavelength, 、 is the phase difference between the x and y directions, is the elastic modulus of the tube bearing material, is the cross-sectional area of the tube bearing, It is the real-time load of the gas spring.
[0009] The monitoring module includes a pressure sensor and a laser displacement sensor. The pressure sensor is installed in the valve station next to the cylinder of the gas spring to detect the pressure value of the rodless chamber of the oil cylinder. The laser displacement sensor is installed at the end of the piston rod of the gas spring to measure the dynamic expansion and contraction of the spring. .
[0010] The equivalent strain contact module includes a flexible strain waveguide layer and an electric control module. The flexible strain waveguide layer is attached to the surface of the rack. A spiral strain waveguide channel is etched on the surface of the flexible strain waveguide layer. A distributed fiber grating sensor is integrated in the spiral strain waveguide channel. The distributed fiber grating sensor is used to measure the equivalent strain of the tooth surface contact area in real time. The electronic control module is installed on the side wall of the rack to provide an independent power supply and complete wireless signal transmission with the main control module.
[0011] The pitch of the helical strain waveguide channel is P, and the module of the gear 10 is m. The relationship between P and m is as follows: .
[0012] The flexible strain waveguide layer in the equivalent strain contact module is arranged on the upper and lower tooth surfaces of multiple teeth on the corresponding racks and located at the downstream docking elevation H1 of the cabin, the cabin off-duty process elevation H2 of the cabin, and the upstream docking elevation H3 of the cabin.
[0013] The stress contact module includes a piezoelectric film array and a self-powered signal processing module. The piezoelectric film array is composed of multiple groups of orthogonally arranged flexible piezoelectric films. The piezoelectric film array is attached to the tooth surface and tooth root transition area of the gear.
[0014] A method for monitoring the force of a large-module gear rack of a ship lift based on gear bracket deformation includes the following steps: S1: Monitoring module layout: The flexible strain waveguide layer is attached to the rack surface and arranged along the upper and lower tooth surfaces of some racks at the downstream docking elevation, the off-duty process elevation, and the upstream docking elevation. The piezoelectric film array is attached to all tooth surfaces and tooth root transition areas of the gear. The laser Doppler vibrometer is placed on the bearing surface of the gear bracket displacement adaptation mechanism. The laser displacement sensor and pressure sensor are installed on the hydro-pneumatic spring. S2: Parameter calibration: Real-time measurement of the equivalent strain of the tooth surface contact area when the hydraulic spring is in the charging and depressurizing states when the ship compartment is in the upstream docking, the off-duty process and the downstream docking. and gear bracket 3D deformation ; Construct finite element model and simulate and calculate equivalent strain of tooth contact area simultaneously , three-dimensional deformation of gear bracket , compare the relative deviation between the measured value and the simulated value in the finite element model to see if it is less than 5%, use data assimilation technology to update the boundary conditions of the finite element model and realize parameter calibration; S3: Gear stress monitoring: The stress contact module is used to monitor the normal stress of the tooth surface and the shear stress of the tooth root in real time. At the same time, the finite element model is used to simulate and calculate the normal stress of the tooth surface and the shear stress of the tooth root. The difference between the measured value and the simulated value is compared to see whether it meets the requirements. If the deviation value is greater than 5%, return to step S2 to continue parameter calibration; if the deviation value is less than 5%, the main control module is used to display the cloud map of the normal stress of the tooth surface and the shear stress of the tooth root in the finite element simulation results in real time; based on the real-time display of the cloud map of the normal stress of the tooth surface and the shear stress of the tooth root, it can be intuitively judged whether the upper tooth surface or the lower tooth surface is subjected to stress and the magnitude of the stress; S4: Adjustment of the pressure of the gas spring: When the gas spring is in the pressure relief state, the pressure of the rodless cavity is the design initial value FF>0. According to the gear stress monitoring result in step S3, the main control module drives the hydraulic system to realize dynamic control and adjustment of the pressure of the gas spring to ensure that the tooth surface meshing area of the gear is not stressed: when the meshing surface on the gear is detected to be stressed, the pressure of the rodless cavity is continuously relieved until both the upper and lower meshing surfaces of the gear are free of stress, and then the pressure relief is stopped; when the lower meshing surface of the gear is detected to be stressed, the pressure of the rodless cavity is increased until both the upper and lower meshing surfaces of the gear are free of stress, and then the pressure charging is stopped; S5: Real-time measurement of spring dynamic expansion and contraction :Real-time measurement of spring dynamic expansion and contraction during gear stress monitoring and hydro-pneumatic spring pressure adjustment If the expansion and contraction exceeds the design value, the system will shut down for protection.
[0015] The present invention provides a large-module gear rack force monitoring device and method for a ship lift, which has the following technical effects: 1) The monitoring device of the present invention takes into account the influence of gear bracket deformation on the force of gear rack, and adopts a method combining direct measurement with parametric finite element simulation to achieve accurate and efficient detection.
[0016] 2) The monitoring method of the present invention can realize real-time dynamic adjustment of the pressure of the hydraulic spring according to the detection structure, ensuring that the gear rack is not subjected to stress when the ship compartment is docked with the upper and lower gate heads.
[0017] 3) The gear tooth surface stress contact module of the present invention adopts a self-powered signal processing module to simplify the connection between the gear rotating part and the main control module.
[0018] 4) The equivalent strain contact module of the present invention is only arranged on the tooth surface of part of the elevation, and does not need to be arranged throughout the entire process. The module adopts independent power supply and wireless transmission with the main control module. The equivalent strain contact module is only used for parameter calibration. The module is arranged under the premise of ensuring detection accuracy.
[0019] 5) By setting the objective function, the measured stress , measured strain Parameter inverse verification of simulation calculated stress in finite element model and strain The values can be used to obtain accurate stress distribution in the gear rack meshing area and strain distribution in the gear carrier.
[0020] 7) The fiber Bragg grating strain equation takes into account the effect of temperature change on strain, which is used to compensate for and correct strain and improve strain detection accuracy.
[0021] 8) The gear rack force monitoring method accurately measures the gear stress value after parameter calibration, adjusts the hydraulic spring pressure in real time according to the stress value, and measures the dynamic expansion and contraction of the spring in real time to ensure that the gear rack is not subjected to stress in the non-meshing state, thereby reducing the wear of the gear rack caused by the longitudinal displacement of the ship cabin during the docking of the ship lift with the upper and lower lock heads. BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The present invention will be further described below with reference to the accompanying drawings and examples: Figure 1 It is a structural diagram of the system functional modules in the present invention.
[0023] Figure 2 It is a layout diagram of the present invention.
[0024] Figure 3 It is a layout diagram of the monitoring module in the present invention.
[0025] Figure 4It is a layout diagram of the medium-effect transformer contact module of the present invention.
[0026] Figure 5 It is a partially enlarged front view of the medium-effect strain contact module of the present invention.
[0027] Figure 6 It is a layout diagram of the stress contact module in the present invention.
[0028] Figure 7 yes Figure 6 A local enlarged schematic diagram of point A in the middle.
[0029] Figure 8 This is a diagram of the stress contact module structure of the present invention.
[0030] Figure 9 This is a diagram showing the composition of the main control module in the present invention.
[0031] In the figure: laser monitoring array 1, monitoring module 2, equivalent strain contact module 3, stress contact module 4, finite element model 5, main control module 6, liquid-gas spring 7, gear bracket 8, rack 9, gear 10, gear bracket displacement adaptation mechanism tube bearing 101, laser Doppler vibrometer 102, pressure sensor 201, laser displacement sensor 202, flexible strain waveguide layer 301, spiral strain waveguide channel 302, distributed fiber Bragg grating sensor 303, electronic control module 304, piezoelectric film array 401, self-powered signal processing module 402, piezoelectric film unit 4011, center electrode 4012, edge electrode 4013, charge difference amplification circuit 4014, vortex electrode 4015, integrated energy harvesting circuit 4021, adaptive filtering unit 4022. DETAILED DESCRIPTION
[0032] like Figure 1 As shown, a large-module gear rack force monitoring device for a ship lift includes a laser monitoring array 1, a monitoring module 2, an equivalent strain contact module 3, a stress contact module 4, a finite element model 5 and a main control module 6.
[0033] Under the calibration working condition, a parameterized finite element model 5 of the gear-carrier system is constructed by using the laser monitoring array 1 and the equivalent strain contact module 3; The stress contact module 4 monitors in real time the force on the gear 10 when the gas spring 7 is under pressure relief and pressure filling, and when the gear 10 and the rack 9 are under transmission.
[0034] The monitoring module 2 is used to monitor the pressure value of the rodless chamber of the gas-liquid spring 7 and the dynamic expansion and contraction amount of the piston rod of the gas-liquid spring 7 .
[0035] The main control module 6 controls the hydraulic system to dynamically control and adjust the pressure of the hydro-pneumatic spring 7, ensuring that the tooth surface meshing area of the gear 10 is not subjected to stress, thereby avoiding relative sliding of the gear rack along the tooth width direction when the ship compartments are docked.
[0036] The laser monitoring array 1 is arranged on the surface of the gear bracket displacement adaptation mechanism tube bearing 101. The laser monitoring array 1 includes three groups of laser Doppler vibrometers 102. The three groups of laser Doppler vibrometers 102 form a triangulation network to invert the three-dimensional deformation of the gear bracket by phase difference method. .
[0037] Three sets of laser Doppler vibrometers 102 are arranged in a spiral pattern along the outer cylindrical surface of the tube bearing, equidistantly spaced along the axial direction and at equal distances along the radial direction. These three sets of laser Doppler vibrometers 102 form a triangular network, enabling simultaneous measurement and inversion of deformation in the X, Y, and Z directions using phase difference methods, achieving precise measurement.
[0038] Three-dimensional deformation of gear bracket The calculation formula is as follows: (2); Where: The laser wavelength is 632.8nm, 、 is the phase difference between the x and y directions, is the elastic modulus of the tube bearing material, is the cross-sectional area of the tube bearing, It is the real-time load of the gas spring.
[0039] The monitoring module 2 includes a pressure sensor 201 and a laser displacement sensor 202. The pressure sensor 201 is installed in the valve station next to the cylinder of the gas spring 7 and is used to detect the pressure value of the rodless chamber of the cylinder. ; The laser displacement sensor 202 is set at the end of the piston rod of the gas spring 7 to measure the dynamic expansion and contraction of the spring .
[0040] The equivalent strain contact module 3 includes a flexible strain waveguide layer 301, which is attached to the surface of the rack 9 (the tooth surface is represented by a). The flexible strain waveguide layer 301 is composed of a polyvinylidene fluoride-carbon nanotube composite material, and a spiral strain waveguide channel 302 is etched on its surface. Its pitch is P and the channel depth is h. The channel depth h is equal to the thickness of the hardened layer on the tooth surface. The interface between the hardened layer and the substrate is a transition zone of mechanical properties. Due to the different elastic moduli of the materials on both sides, interference with strain transmission is avoided. The consistent values can improve the accuracy and reliability of measuring the true strain of the tooth surface. A distributed fiber grating sensor 303 is integrated in the spiral strain waveguide channel 302. The distributed fiber grating sensor 303 is used to measure the equivalent strain of the tooth surface contact area in real time. .
[0041] The calculation formula of the fiber Bragg grating strain equation is as follows: (4); Where: is the wavelength change of the fiber Bragg grating sensor, is the strain sensitivity coefficient, which is related to the elastic-optical coefficient and grating period of the fiber Bragg grating. The equivalent strain is directly measured by the distributed fiber Bragg grating sensor 303 in the flexible strain waveguide layer 301. is the temperature sensitivity coefficient, which is affected by the thermal expansion coefficient of the material and the thermo-optical effect. is the temperature change.
[0042] The equivalent strain of the tooth contact area is directly measured by the distributed fiber Bragg grating sensor 303 ; Equivalent strain in tooth contact area It directly measures the rack tooth surface, and Temperature compensation is taken into account for the equivalent strain.
[0043] Preferably, the relationship between the pitch P of the helical strain waveguide channel 302 etched on the surface of the flexible strain waveguide layer 301 and the module m of the gear 10 is as shown in Formula 6: (6); Where: z1 and z2 are the number of teeth of the gear and rack respectively.
[0044] The relationship between the pitch and the module set in Equation (6) can synchronize the spiral period of the waveguide channel with the distribution period of the gear teeth, ensuring that the fiber Bragg grating sensor can evenly cover the strain area of each tooth and avoid measurement blind spots caused by geometric misalignment.
[0045] The electronic control module 304 is mounted on the side wall of the rack 9. It is used to provide an independent power supply and complete wireless signal transmission with the main control module 6. The equivalent strain contact module 3 is independently powered by the electronic control module 304, and the signals collected by the module are transmitted to the main control module 6 via wireless signals.
[0046] Preferably, the flexible strain waveguide layer 301 in the equivalent strain contact module 3 is arranged on the upper and lower tooth surfaces of multiple teeth ≥ 4 on the corresponding rack 9 and located at the downstream docking elevation H1 of the cabin, the cabin off-duty process elevation H2 and the upstream docking elevation H3 of the cabin.
[0047] The four tooth areas near the downstream docking elevation H1, the off-duty process elevation H2 and the upstream docking elevation H3 are the main parking and acceleration and deceleration areas during the operation of the ship lift. The tooth stress conditions in this area can truly reflect the stress conditions of the gear rack, ensuring full coverage of the data collection range.
[0048] The stress contact module 4 includes a piezoelectric film array 401 and a self-powered signal processing module 402 .
[0049] The piezoelectric film array 401 is composed of multiple groups of orthogonally arranged flexible piezoelectric films. The piezoelectric film array 401 is attached to the tooth surface and tooth root transition area of the gear 10 to collect the tooth surface normal stress fluctuation signal and the tooth root shear stress signal in real time.
[0050] The self-powered signal processing module 402 includes an integrated energy harvesting circuit 4021 and an adaptive filtering unit 4022 . The self-powered signal processing module 402 is powered by the mechanical energy conversion of the piezoelectric film array 401 and performs time domain noise reduction processing on the original signal.
[0051] Preferably, each piezoelectric film unit 4011 in the piezoelectric film array 401 has a diamond topology, with the center electrode 4012 and edge electrodes 4013 forming a gradient electric field, and the charge differential amplifier circuit 4014 separating the normal stress and tangential stress components. The piezoelectric film in the tooth root transition region adopts a spiral layout, and the vortex electrode 4015 is used to capture the anisotropic strain characteristics of the stress concentration area.
[0052] Preferably, the integrated energy harvesting circuit 4021 in the self-powered signal processing module 402 adopts nonlinear impedance matching technology to convert the wide-band vibration energy output by the piezoelectric film 4011 into a stable DC power supply; the adaptive filtering unit 4022 dynamically separates the gear meshing fundamental frequency and high-frequency noise components based on the wavelet packet entropy threshold algorithm.
[0053] The piezoelectric film array 401 can measure both stress and strain.
[0054] The measured strain is obtained by measuring the piezoelectric film array 401 in the stress contact module 4 . The gear tooth surface stress measured by the stress contact module 4 is recorded as the measured stress .
[0055] The simulated stress is obtained by simulation analysis of finite element model 5 , simulation calculation strain .
[0056] Calculating stress with simulation , simulation calculation strain and measured stress , measured strain The objective function is to minimize the absolute value of the difference between and . As shown in formula (5), the stress distribution in the gear rack meshing area and the strain distribution in the gear bracket are obtained through parameter inverse verification.
[0057] (5).
[0058] Although the meshing force of the gear and rack is mutual, due to the different materials and structures of the gear and rack, and The values are different.
[0059] Finite element model 5 is a finite element simulation model based on the secondary development of the commercial simulation software ANSYS platform. It calls the pre-processing module, solver and post-processing module inside ANSYS, and realizes the parameterized input of the sensor measured values through secondary development as boundary conditions.
[0060] The finite element model 5 is installed in the main control module 6 as software.
[0061] Parameter inverse technology verification is an optimization technology that reversely adjusts the parameters in the finite element model 5 based on the test data.
[0062] According to the measured stress and measured strain Data and simulated stress obtained from finite element model 5 and simulated strain By comparison, the friction coefficient and contact stiffness parameters in the contact conditions between the rotating parts in the finite element model 5 and the elastic modulus, Poisson's ratio, and yield strength material property parameters of unconventional materials such as the self-lubricating bushing in the gear bracket are inferred.
[0063] The main control module 6 includes a signal acquisition module 601 , a communication module 602 , a finite element post-processing module 603 , a measurement data processing module 604 , a stress cloud map display module 605 , and a hydraulic system control module 606 .
[0064] The finite element post-processing module 603 is used to process the results of the simulation solution of the finite element model 5 to prepare for the visualization of the results.
[0065] The measurement data processing module 604 is used to process the sensor detection data in the monitoring module (2), the equivalent strain contact module (3), and the stress contact module (4) for reverse adjustment of the parameters in the finite element model 5.
[0066] The stress cloud diagram display module 605 is used to display and output the data in the finite element post-processing module 603, mainly displaying and outputting the stress cloud diagram of the gear rack.
[0067] The hydraulic system control module 606 is used to control the hydraulic system to achieve dynamic control and adjustment of the pressure of the hydraulic spring (7), so as to ensure that the tooth surface meshing area of the gear (10) is not subjected to stress.
[0068] Preferably, the calibration conditions in the present invention are different cabin water depth conditions with known hydraulic spring pressure and the cabin in the docked state. The cabin water depth variation range must be within the allowable range of the ship lift cabin docking design, and the water depth variation value gradient is 0.1m.
[0069] A method for monitoring the force of a large-module gear rack of a ship lift based on gear bracket deformation includes the following steps: S1: Monitoring module layout: The flexible strain waveguide layer 301 is attached to the surface of the rack 9 and is arranged along the upper and lower tooth surfaces of some racks at the downstream docking elevation, the off-duty process elevation and the upstream docking elevation of the cabin; the piezoelectric film array 401 is attached to all tooth surfaces and tooth root transition areas of the gear 10; the laser Doppler vibrometer 102 is arranged on the surface of the gear bracket displacement adaptation mechanism tube bearing 101; the laser displacement sensor 202 and the pressure sensor 201 are installed on the liquid-gas spring 7.
[0070] S2: Parameter calibration: When the ship compartment is at three elevations, namely upstream docking, off-duty process and downstream docking, the equivalent strain of the tooth surface contact area is measured in real time when the gas spring 7 is in the charging and depressurizing states. and gear bracket 3D deformation ; Construct finite element model 5 and simulate the equivalent strain of the tooth surface contact area simultaneously , three-dimensional deformation of gear bracket , compare the relative deviation between the measured value and the simulation calculated value in the finite element model 5 to see if it is less than 5%. Use data assimilation technology to update the boundary conditions of the finite element model to achieve parameter calibration.
[0071] The finite element model 5 was constructed by ANSYS software. Through the secondary development of ANSYS software, the objective function (5) was integrated into the finite element model 5, and the equivalent strain was obtained through simulation. , three-dimensional deformation of gear bracket The results are compared and iterated with the measured values, and the finite element model 5 is continuously optimized to finally obtain an accurate finite element model 5.
[0072] S3: Gear Stress Monitoring: The stress contact module 4 monitors the tooth surface normal stress and tooth root shear stress in real time. Simultaneously, the finite element model 5 simulates and calculates the tooth surface normal stress and tooth root shear stress. The difference between the measured and simulated values is compared to see if it meets the requirements. If the deviation is greater than 5%, the process returns to step S2 to continue parameter calibration. If the deviation is less than 5%, the main control module 6 displays the tooth surface normal stress and tooth root shear stress cloud maps from the finite element simulation results in real time. Based on the real-time display of the tooth surface normal stress and tooth root shear stress cloud maps, it is possible to intuitively determine whether the upper or lower tooth surface is experiencing stress, and the magnitude of the stress.
[0073] S4: Adjustment of the pressure of the gas spring: When the gas spring is in the pressure relief state, the pressure of the rodless cavity is the design initial value FF>0. According to the gear stress monitoring result in step S3, the hydraulic system is driven by the main control module 6 to realize dynamic control and adjustment of the pressure of the gas spring 7 to ensure that the tooth surface meshing area of the gear 10 is not subjected to stress: when it is detected that the meshing surface on the gear 10 is under stress, the pressure of the rodless cavity is continuously relieved until both the upper and lower meshing surfaces of the gear 10 are free from stress and then the pressure relief is stopped; when it is detected that the lower meshing surface of the gear is under stress, the rodless cavity is pressurized until both the upper and lower meshing surfaces of the gear are free from stress and then the pressure charging is stopped.
[0074] S5: Real-time measurement of spring dynamic expansion and contraction Real-time measurement of spring dynamic expansion and contraction during gear stress monitoring and hydro-pneumatic spring pressure adjustment If the expansion and contraction exceeds the design value, the system will shut down for protection.
Claims
1. A large-module gear rack force monitoring device for a ship lift, characterized by: It includes a laser monitoring array (1), a monitoring module (2), an equivalent strain contact module (3), a stress contact module (4) and a main control module (6); Under the calibration condition, a finite element model (5) is constructed by using a laser monitoring array (1) and an equivalent strain contact module (3); The stress contact module (4) is used to monitor in real time the stress state of the gear (10) in the pressure relief and pressure charging states of the gas spring (7) and the gear (10) and rack (9) transmission state; The monitoring module (2) is used to monitor the pressure value of the rodless chamber of the liquid-gas spring (7) and the dynamic expansion and contraction amount of the piston rod of the liquid-gas spring (7); The main control module (6) controls the hydraulic system to achieve dynamic control and adjustment of the pressure of the gas-liquid spring (7), thereby ensuring that the tooth surface meshing area of the gear (10) is free from stress.
2. The large-module gear rack force monitoring device for a ship lift according to claim 1, characterized in that: The laser monitoring array (1) is arranged on the surface of the gear bracket displacement adaptation mechanism tube bearing (101); the laser monitoring array (1) is used to obtain the three-dimensional deformation of the gear bracket. .
3. The large-module gear rack force monitoring device for a ship lift according to claim 2, characterized in that: The laser monitoring array (1) comprises three groups of laser Doppler vibrometers (102), which are arranged spirally along the outer cylindrical surface of the tube bearing and are distributed at equal angles and equal distances in the radial direction along the tube bearing.
4. The large-module gear rack force monitoring device for a ship lift according to claim 3, characterized in that: The gear bracket three-dimensional deformation The calculation formula is as follows: （2）； Where: is the laser wavelength, 、 is the phase difference between the x and y directions, is the elastic modulus of the tube bearing material, is the cross-sectional area of the tube bearing, It is the real-time load of the gas spring.
5. The large-module gear rack force monitoring device for a ship lift according to claim 4, characterized in that: The monitoring module (2) comprises a pressure sensor (201) and a laser displacement sensor (202), wherein the pressure sensor (201) is installed in a valve platform next to the cylinder body of the gas spring (7) and is used to detect the pressure value of the rodless chamber of the oil cylinder. The laser displacement sensor (202) is arranged at the piston rod end of the gas spring (7) to measure the dynamic expansion and contraction of the spring. .
6. The large-module gear rack force monitoring device for a ship lift according to claim 5, characterized in that: The equivalent strain contact module (3) comprises a flexible strain waveguide layer (301) and an electric control module (304). The flexible strain waveguide layer (301) is attached to the surface of the rack (9). A spiral strain waveguide channel (302) is etched on the surface of the flexible strain waveguide layer (301). A distributed fiber grating sensor (303) is integrated in the spiral strain waveguide channel (302). The distributed fiber grating sensor (303) is used to measure the equivalent strain of the tooth surface contact area in real time. The electric control module (304) is mounted on the side wall of the rack (9) and is used to provide an independent power supply and complete wireless signal transmission with the main control module (6).
7. The large-module gear rack force monitoring device for a ship lift according to claim 6, characterized in that: The pitch of the helical strain waveguide channel (302) is P, and the module of the gear 10 is m. The relationship between P and m is as follows: （6）。 8. The large-module gear rack force monitoring device for a ship lift according to claim 7, characterized in that: The flexible strain waveguide layer (301) in the equivalent strain contact module (3) is arranged on the corresponding rack (9) and is located on the upper and lower tooth surfaces of multiple teeth at the cabin downstream docking elevation H1, the cabin off-duty process elevation H2, and the cabin upstream docking elevation H3.
9. The large-module gear rack force monitoring device for a ship lift according to claim 8, characterized in that: The stress contact module (4) comprises a piezoelectric film array (401) and a self-powered signal processing module (402). The piezoelectric film array (401) is composed of a plurality of groups of orthogonally arranged flexible piezoelectric films. The piezoelectric film array (401) is attached to the tooth surface and tooth root transition zone of the gear (10).
10. The method for monitoring the force of a gear rack using a large-module gear rack monitoring device for a ship lift according to claim 9, comprising the following steps: S1: Monitoring module arrangement: The flexible strain waveguide layer (301) is attached to the surface of the rack (9) and arranged along the upper and lower tooth surfaces of the rack at the ship compartment downstream docking elevation, the ship compartment off-duty process elevation, and the ship compartment upstream docking elevation; the piezoelectric film array (401) is attached to all tooth surfaces and tooth root transition areas of the gear (10); the laser Doppler vibrometer (102) is arranged on the surface of the gear bracket displacement adaptation mechanism tube bearing (101); the laser displacement sensor (202) and the pressure sensor (201) are installed on the liquid-gas spring (7); S2: Parameter calibration: When the ship compartment is in the upstream docking, off-duty process and downstream docking three elevations, the equivalent strain of the gas spring (7) is measured in real time in the two states of pressure charging and pressure relief. and gear bracket 3D deformation ; Construct a finite element model (5) and simulate the equivalent strain of the tooth contact area simultaneously , three-dimensional deformation of gear bracket , compare the relative deviation between the measured value and the simulation value in the finite element model (5) to see if it is less than 5%, and use data assimilation technology to update the boundary conditions of the finite element model to achieve parameter calibration; S3: Gear stress monitoring: The stress contact module (4) is used to monitor the normal stress of the tooth surface and the shear stress of the tooth root in real time. At the same time, the finite element model (5) simulates and calculates the normal stress of the tooth surface and the shear stress of the tooth root. The difference between the measured value and the simulated value is compared to see whether it meets the requirements. If the deviation value is greater than 5%, the process returns to step S2 to continue parameter calibration. If the deviation value is less than 5%, the main control module (6) is used to display the cloud map of the normal stress of the tooth surface and the shear stress of the tooth root in the finite element simulation results in real time. S4: Adjustment of the pressure of the gas spring: When the gas spring is in the pressure relief state, the pressure of the rodless cavity is the design initial value FF>0. According to the gear stress monitoring result in step S3, the main control module (6) drives the hydraulic system to realize dynamic control and adjustment of the pressure of the gas spring (7), so as to ensure that the tooth surface meshing area of the gear (10) is not subjected to stress: when it is detected that the meshing surface on the gear (10) is subjected to stress, the pressure of the rodless cavity is continuously relieved until both the upper and lower meshing surfaces of the gear (10) are free from stress and then the pressure relief is stopped; when it is detected that the lower meshing surface of the gear is subjected to stress, the pressure of the rodless cavity is charged until both the upper and lower meshing surfaces of the gear are free from stress and then the pressure charging is stopped; S5: Real-time measurement of spring dynamic expansion and contraction :Real-time measurement of spring dynamic expansion and contraction during gear stress monitoring and hydro-pneumatic spring pressure adjustment If the expansion and contraction exceeds the design value, the system will shut down for protection.