Gear dynamic parameter in-situ testing device based on wireless power supply

Abstract

The invention discloses a gear dynamic parameter in-situ testing device based on wireless power supply. The gear dynamic parameter in-situ testing device comprises a wireless power supply system, a sensor, a data processing system, a data transmission system and an upper computer, the wireless power supply system is used for providing electric energy for the sensor and the data acquisition system; the sensor is used for collecting dynamic parameters of the gear; the data processing system is used for processing the gear dynamic parameters; the data transmission system is used for transmitting the processed gear dynamic parameters to an upper computer in a wireless transmission manner; and the upper computer is used for visually displaying the processed dynamic parameters of the gear. The problem of long-time test operation and maintenance of the rotating gear in a complex narrow space is solved, and long-time in-situ test of dynamic parameters of the gear can be ensured.

Description

Technical Field

[0001] The present invention belongs to the technical field of gear condition monitoring, and in particular relates to an in-situ testing device for gear dynamic parameters based on wireless power supply. Background Art

[0002] Gears are core components of power transmission systems and their equipment, and their service condition directly impacts the stability and reliability of the entire equipment. Temperature, stress, vibration, and other signals can be used to assess the operating status of gears. Therefore, testing these temperature, stress, and vibration signals during gear service provides real-time insights into the gear's service state, preventing failures. This is crucial for improving the stability, reliability, and safety of the entire equipment.

[0003] When a gear transmission is rotating, signals are typically transmitted through slip rings and measured using a tester. However, the signals are susceptible to interference during transmission, affecting the accuracy of the test results. Highly integrated test devices, due to their compact size, can be mounted on the gear shaft and operate synchronously with the gears. However, most test devices rely on conductive slip rings or lithium batteries for power. Traditional power supply methods are unable to meet the requirements of long-term testing and maintenance of rotating gears in complex and confined spaces. Ensuring reliable power supply to the test device during gear operation has become an urgent issue for gear dynamic parameter testing equipment.

[0004] Therefore, there is an urgent need for an in-situ gear dynamic parameter testing device based on wireless power supply to achieve long-term and stable testing of gear dynamic parameters under rotating conditions. Summary of the Invention

[0005] In order to solve the above technical problems, the present invention proposes an in-situ testing device for gear dynamic parameters based on wireless power supply, which can realize long-term and stable testing of gear dynamic parameters under rotating conditions.

[0006] To achieve the above objectives, the present invention provides an in-situ testing device for dynamic parameters of gears based on wireless power supply, comprising: a wireless power supply system, a sensor, a data processing system, a data transmission system and a host computer;

[0007] The wireless power supply system is used to provide power to sensors and data acquisition systems;

[0008] The sensor is used to collect dynamic parameters of the gear;

[0009] The data processing system is used to process the dynamic parameters of the gear;

[0010] The data transmission system is used to transmit the processed gear dynamic parameters to the host computer using wireless transmission;

[0011] The host computer is used to visualize the processed gear dynamic parameters.

[0012] Optionally, the wireless power supply system includes: a power supply module, a transmitting module and a receiving module;

[0013] The power extraction module is used to trick the target voltage value;

[0014] The transmitting module is used to convert direct current into high-frequency alternating current so that the transmitting coil generates an alternating magnetic field;

[0015] The receiving module is used to induce an alternating current from the alternating magnetic field using a receiving coil, and convert the alternating current into a direct current using a rectifier and filter circuit.

[0016] Optionally, power supply for sensors and data acquisition systems includes:

[0017] When the transmitting module is connected to direct current, the high-frequency inverter circuit converts the direct current into high-frequency alternating current. The transmitting coil and the compensation capacitor in the loop resonate, and the transmitting coil generates an alternating magnetic field based on the alternating current. The receiving coil in the receiving module induces an alternating current because it is in the magnetic field generated by the transmitting coil. The rectifier and filter circuit converts the alternating current into direct current, and after processing by the voltage stabilization circuit, provides stable direct current to the load.

[0018] Optionally, the transmitting module includes: a control circuit, an isolation circuit, a drive circuit, a full-bridge inverter circuit, a first compensation network and a transmitting coil;

[0019] The control circuit is used to use a PWM control chip to generate two complementary PWM waves as control signals for the switch tubes of the full-bridge inverter circuit;

[0020] The isolation circuit is used to isolate the control circuit from the full-bridge inverter circuit using an optical coupling isolation chip;

[0021] The driving circuit is used to drive the full-bridge inverter circuit using a half-bridge chip;

[0022] The full-bridge inverter circuit is used to convert direct current into high-frequency alternating current, wherein the RC snubber circuit in the full-bridge inverter circuit is used to suppress the spike voltage exceeding the threshold value caused by the inductive load in the full-bridge inverter circuit;

[0023] The first compensation network is used to reduce the loss of the wireless power supply system and improve the transmission efficiency of the power supply system;

[0024] The transmitting coil is used to generate an alternating magnetic field.

[0025] Optionally, the receiving module includes: a receiving coil, a second compensation network, a rectifier and filter circuit, and a voltage stabilizing circuit;

[0026] The receiving coil is used to induce an alternating current from the alternating magnetic field;

[0027] The second compensation network is used to reduce the loss of the wireless power supply system and improve the transmission efficiency of the power supply system;

[0028] The rectifier and filter circuit is used to convert the alternating current into direct current;

[0029] The voltage stabilizing circuit is used to perform voltage stabilization operation on the direct current.

[0030] Optionally, the dynamic parameters of the gears collected include:

[0031] Platinum thermal resistors, strain gauges and triaxial accelerometers are used to collect gear temperature, stress and vibration data respectively.

[0032] Optionally, the data processing system includes: a three-wire bridge circuit, an analog-to-digital converter, a microcontroller and a Wheatstone bridge;

[0033] The three-wire bridge circuit is used to convert the resistance change of the PT100 temperature sensor into a voltage signal;

[0034] The analog-to-digital converter is used to amplify and convert the weak analog signals output by the temperature and stress measurement circuits;

[0035] The microcontroller is used to process the collected temperature, stress and vibration data;

[0036] The Wheatstone bridge is used to convert the deformation of the strain gauge into a voltage signal.

[0037] Optionally, the data transmission system includes: a test Wi-Fi module and a relay Wi-Fi module;

[0038] The test Wi-Fi module is located on the data acquisition circuit board, and the relay Wi-Fi module is placed outside the gear box to enhance the signal.

[0039] Optionally, the testing device further includes: a rotor assembly and a stator assembly, wherein the stator assembly is fixed to the bottom of the gear box, and the rotor assembly is fixed to the shaft via a connecting sleeve and rotates synchronously with the gear.

[0040] Compared with the prior art, the present invention has the following advantages and technical effects:

[0041] The PT100 platinum thermal resistance, strain gauge and ADXL357 three-axis accelerometer on the data acquisition circuit board are attached to the gear to collect gear temperature, stress and vibration data to realize in-situ measurement. The rotor assembly of the test device is fixed on the gear shaft through the spline and rotates synchronously with the gear. The data collected by the data acquisition circuit board in the rotor assembly is sent to the upper computer in a wireless transmission mode through the Wi-Fi module. The upper computer converts the received data into a visual curve to realize in-situ testing of the dynamic parameters of the gear under rotation. BRIEF DESCRIPTION OF DRAWINGS

[0042] The accompanying drawings, which form a part of the present application, are intended to provide further understanding of the present application, and are used to interpret the application together with the description of the illustrative embodiments of the present application, and do not constitute improper limitations to the present application. In the drawings:

[0043] Figure 1 is a structure diagram of a gear dynamic parameter in-situ testing device based on wireless power supply according to an embodiment of the present application;

[0044] Figure 2 is a power supply module circuit principle diagram of a wireless power supply system according to an embodiment of the present application;

[0045] Figure 3 is a transmitting module circuit principle diagram of a wireless power supply system according to an embodiment of the present application;

[0046] Figure 4 is a receiving module circuit principle diagram of a wireless power supply system according to an embodiment of the present application;

[0047] Figure 5 is a structure diagram of a test device rotor assembly and stator assembly according to an embodiment of the present application;

[0048] Figure 6 is a transmitting coil and receiving coil diagram of a wireless power supply system according to an embodiment of the present application;

[0049] Figure 7 is a data acquisition circuit board diagram according to an embodiment of the present application. DETAILED DESCRIPTION

[0050] It should be noted that the embodiments in the present application and the features in the embodiments can be combined with each other without conflict. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0051] It should be noted that the steps shown in the flowcharts of the accompanying drawings can be executed in a computer system such as a set of computer-executable instructions, and that, although a logical order is shown in the flowcharts, in some cases, the steps shown or described can be executed in an order different from that shown here.

[0052] This embodiment proposes an in-situ testing device for dynamic parameters of gears based on wireless power supply, such as Figure 1 As shown, it specifically includes: wireless power supply system, sensor, data processing system, data transmission system and host computer;

[0053] Wireless power supply system for providing power to sensors and data acquisition systems;

[0054] Sensors, used to collect dynamic parameters of gears;

[0055] Data processing system, used to process gear dynamic parameters;

[0056] A data transmission system for transmitting the processed gear dynamic parameters to a host computer using wireless transmission;

[0057] The host computer is used to visualize the processed gear dynamic parameters.

[0058] Furthermore, the wireless power supply system includes: a power taking module, a transmitting module and a receiving module;

[0059] Power extraction module, used to trick out the target voltage value;

[0060] The transmitting module is used to convert direct current into high-frequency alternating current so that the transmitting coil generates an alternating magnetic field;

[0061] The receiving module is used to use the receiving coil to induce an alternating current from the alternating magnetic field, and use the rectification and filtering circuit to convert the alternating current into direct current.

[0062] Among them, the power supply module is used to induce +12V voltage.

[0063] The transmitting module mainly consists of a control circuit, an isolation circuit, a drive circuit, a full-bridge inverter circuit, a compensation network, and a transmitting coil, which converts direct current into high-frequency alternating current to enable the transmitting coil to generate an alternating magnetic field.

[0064] The receiving module mainly consists of a receiving coil, a compensation network, a rectifier and filter circuit, and a voltage stabilizing circuit. The receiving coil induces an alternating current because it is in the alternating magnetic field generated by the transmitting coil. The rectifier and filter circuit converts the alternating current into direct current, which is further processed by the voltage stabilizing circuit to provide stable direct current for the acquisition system.

[0065] Furthermore, the transmitting module includes: a control circuit, an isolation circuit, a driving circuit, a full-bridge inverter circuit, a first compensation network and a transmitting coil;

[0066] The control circuit is used to use the PWM control chip to generate two complementary PWM waves as control signals for the switch tubes of the full-bridge inverter circuit;

[0067] An isolation circuit is used to isolate the control circuit from the full-bridge inverter circuit using an optocoupler isolation chip;

[0068] A drive circuit for driving a full-bridge inverter circuit using a half-bridge chip;

[0069] A full-bridge inverter circuit is used to convert direct current into high-frequency alternating current. The RC snubber circuit in the full-bridge inverter circuit is used to suppress the spike voltage exceeding the threshold value caused by the inductive load in the full-bridge inverter circuit.

[0070] The first compensation network is used to reduce the loss of the wireless power supply system and improve the transmission efficiency of the power supply system;

[0071] Transmitting coil, used to generate alternating magnetic field.

[0072] Specifically, the power supply module includes a USB Type-C interface and an XSP16 decoy chip, which can be used to induce a 12V voltage.

[0073] The control circuit in the transmitter module uses the integrated PWM control chip SG3525 to generate two complementary PWM waves as the control signals for the switching tubes of the full-bridge inverter circuit. To prevent the high voltage in the inverter circuit from interfering with the low voltage of the control circuit through the drive circuit, the optocoupler isolation chip 6N137 is used to isolate the control circuit from the inverter circuit. To enhance the drive signal and improve the drive capability, the drive circuit uses the IR2210 half-bridge driver chip, and two IR2110 half-bridge chips are used to drive the full-bridge inverter circuit. The full-bridge inverter circuit is used as the high-frequency inverter circuit of the transmitter module, and buffer circuits are connected in parallel on both sides of the inverter circuit switching tube to suppress the high peak voltage caused by the inductive load in the full-bridge inverter circuit.

[0074] Furthermore, the receiving module includes: a receiving coil, a second compensation network, a rectifier and filter circuit, and a voltage stabilizing circuit;

[0075] a receiving coil for inducing an alternating current from the alternating magnetic field;

[0076] The second compensation network is used to reduce the loss of the wireless power supply system and improve the transmission efficiency of the power supply system;

[0077] Rectifier and filter circuit, used to convert alternating current into direct current;

[0078] The voltage stabilizing circuit is used to stabilize the DC power.

[0079] Specifically, a single-phase bridge uncontrolled rectifier circuit is used for rectification in the receiving module. Since the system operates at high frequency, a fast recovery diode needs to be used as the rectifier diode; the rectified voltage needs to be filtered through a filter circuit, and a capacitor is connected in parallel after the rectifier circuit to reduce ripple; after rectification and filtering, the linear regulator further stabilizes the voltage and supplies power to the load.

[0080] Furthermore, the collection of gear dynamic parameters includes:

[0081] Platinum thermal resistors, strain gauges and triaxial accelerometers are used to collect gear temperature, stress and vibration data respectively.

[0082] Specifically, the sensor includes three PT100 platinum thermal resistors, four BAB120-3AA strain gauges, and an ADXL357 three-axis accelerometer.

[0083] Furthermore, the data processing system includes: a PT100 three-wire bridge circuit, an ADS1220 analog-to-digital converter, an STM32F405RGT6 microcontroller, etc.;

[0084] A three-wire bridge circuit is used to convert the resistance change of the PT100 temperature sensor into a voltage signal;

[0085] Analog-to-digital converter, used to amplify and convert the weak analog signals output by the temperature and stress measurement circuit;

[0086] a microcontroller for processing the collected temperature, stress, and vibration data;

[0087] Wheatstone bridge circuit, used to convert the deformation of the strain gauge into a voltage signal.

[0088] Furthermore, the data transmission system includes: a test Wi-Fi module and a relay Wi-Fi module;

[0089] The test Wi-Fi module is located on the data acquisition circuit board, and the relay Wi-Fi module is placed outside the gearbox to enhance the signal.

[0090] Furthermore, the testing device also includes: a rotor assembly and a stator assembly, the stator assembly is fixed to the bottom of the gear box, and the rotor assembly is fixed to the shaft through a connecting sleeve and rotates synchronously with the gear.

[0091] Specifically, the rotor includes a receiving coil, a receiving circuit, a data acquisition circuit board, a sensor plug, a connecting sleeve, a housing consisting of a base plate and a cover plate, bolts and nuts, and the stator includes a transmitting coil, a transmitting circuit and a transmitting coil fixing bracket.

[0092] The present embodiment will be described below with reference to the accompanying drawings:

[0093] like Figure 2 As shown in the figure, the wireless power supply system power module uses a 16-pin Type-C interface. The CC1 and CC2 pins are pulled down to ground through a 5.1kΩ resistor. Since the operating voltage of the XSP16 chip is 3.3V, the Type-C output voltage is stepped down to 3.3V through the HT7133 linear regulator. In order to prevent the V adjacent to the CC1 and CC2 pins from being damaged when the Type-C line is inserted obliquely, the power supply module is connected to the 16-pin Type-C interface. BUS To prevent the pins from pumping high voltage into the chip and damaging it, add a 470Ω resistor between the CC1 and CC2 pins of the Type-C port and the CC1 and CC2 pins of the XSP16 chip. When the XSP16 chip is in the 12V range, the MOD1 and MOD3 pins are pulled down to ground through 10Ω resistors, and the MOD2 pin is left floating.

[0094] like Figure 3 As shown in the figure, the wireless power supply system transmitter module uses the integrated PWM control chip SG3525 to generate two complementary PWM waves. The output square wave frequency is 90kHz and the dead time is 0.3μs. The control circuit is isolated from the inverter circuit by the optocoupler isolation chip 6N137. The full-bridge inverter circuit is driven by two IR2110 half-bridge chips. The switch tube in the full-bridge inverter circuit uses the IRF540 MOS tube. A 200Ω resistor and a 10nF capacitor are connected in parallel between the source and drain of the switch tube to absorb excessive voltage spikes. A 10kΩ bleeder resistor is connected in parallel between the gate and source of the switch tube to provide a parasitic capacitance charge discharge channel.

[0095] like Figure 4 As shown in the figure, the wireless power supply system receiving module selects a single-phase bridge uncontrolled rectifier circuit for rectification, and the rectifier diode uses the STTH2R06 ultra-fast recovery diode. 330μF and 100nF capacitors are connected in parallel after the rectifier circuit to reduce ripple. After rectification and filtering, the current is further stabilized by the 78N05G-AB3-R linear regulator to power the load, with an output voltage of 5V and a maximum output current of 300mA.

[0096] like Figure 5 As shown, the cover and base plates of the rotor assembly have an inner diameter of 60 mm and an outer diameter of 105 mm, with an overall axial dimension of 19 mm. The cover plate has an annular groove with an inner diameter of 70 mm, an outer diameter of 80 mm, and a depth of 1 mm for attaching and securing the receiving coil. The stator assembly's mounting bracket for the transmitting coil is 110 mm long, 60 mm wide, and 165 mm high, with a central hole of 68 mm in diameter. The bracket also has an annular groove with an inner diameter of 70 mm, an outer diameter of 80 mm, and a depth of 1 mm for attaching and securing the transmitting coil.

[0097] like Figure 6 As shown, the transmitting and receiving coils are wound with 100 strands of Litz wire, each with a diameter of 0.1 mm. The temperature resistance of the Litz wire is 180°C. The inner diameter of the transmitting and receiving coils is 70 mm, and each layer has 6 turns, for a total of 3 layers.

[0098] like Figure 7 As shown in the figure, the inner diameter of the data acquisition circuit board is 60mm and the outer diameter is 100mm. The circuit board integrates three temperature channels, two stress channels, and a three-axis accelerometer. The positions of the power module, temperature acquisition module, stress acquisition module, vibration acquisition module, main control chip, and test Wi-Fi module on the circuit board are shown in the figure. Figure 7 shown.

[0099] The device of this embodiment is not only applicable to gears, but also to high-speed rotating parts such as shafts and bearings.

[0100] The above are merely preferred embodiments of the present application, but the scope of protection of the present application is not limited thereto. Any changes or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in this application should be included in the scope of protection of the present application. Therefore, the scope of protection of the present application should be based on the scope of protection of the claims.

Claims

1. A gear dynamic parameter in-situ testing device based on wireless power supply, characterized in that: include: Wireless power supply system, sensor, data processing system, data transmission system and host computer; The wireless power supply system is used to provide power to sensors and data acquisition systems; The sensor is used to collect dynamic parameters of the gear; The data processing system is used to process the dynamic parameters of the gear; The data transmission system is used to transmit the processed gear dynamic parameters to the host computer using wireless transmission; The host computer is used to visualize the processed gear dynamic parameters.

2. The in-situ gear dynamic parameter testing device based on wireless power supply according to claim 1 is characterized in that: The wireless power supply system includes: a power supply module, a transmitting module and a receiving module; The power extraction module is used to induce a target voltage value, wherein the target voltage value is used to provide power to the control circuit, the drive circuit, and the full-bridge inverter circuit; The transmitting module is used to convert direct current into high-frequency alternating current so that the transmitting coil generates an alternating magnetic field; The receiving module is used to induce an alternating current from the alternating magnetic field using a receiving coil, and convert the alternating current into a direct current using a rectifier and filter circuit.

3. The in-situ gear dynamic parameter testing device based on wireless power supply according to claim 2, characterized in that: Providing power to sensors and data acquisition systems includes: When the transmitting module is connected to direct current, the high-frequency inverter circuit converts the direct current into high-frequency alternating current. The transmitting coil and the compensation capacitor in the loop resonate, and the transmitting coil generates an alternating magnetic field based on the alternating current. The receiving coil in the receiving module induces an alternating current because it is in the magnetic field generated by the transmitting coil. The rectifier and filter circuit converts the alternating current into direct current, and after processing by the voltage stabilization circuit, provides stable direct current to the load.

4. The in-situ gear dynamic parameter testing device based on wireless power supply according to claim 2, characterized in that: The transmitting module includes: a control circuit, an isolation circuit, a drive circuit, a full-bridge inverter circuit, a first compensation network and a transmitting coil; The control circuit is used to use a PWM control chip to generate two complementary PWM waves as control signals for the switch tubes of the full-bridge inverter circuit; The isolation circuit is used to isolate the control circuit from the full-bridge inverter circuit using an optical coupling isolation chip; The driving circuit is used to drive the full-bridge inverter circuit using a half-bridge chip; The full-bridge inverter circuit is used to convert direct current into high-frequency alternating current, wherein the RC snubber circuit in the full-bridge inverter circuit is used to suppress the spike voltage exceeding the threshold value caused by the inductive load in the full-bridge inverter circuit; The first compensation network is used to reduce the loss of the wireless power supply system and improve the transmission efficiency of the power supply system; The transmitting coil is used to generate an alternating magnetic field.

5. The in-situ gear dynamic parameter testing device based on wireless power supply according to claim 2, characterized in that: The receiving module includes: a receiving coil, a second compensation network, a rectifier and filter circuit, and a voltage stabilizing circuit; The receiving coil is used to induce an alternating current from the alternating magnetic field; The second compensation network is used to reduce the loss of the wireless power supply system and improve the transmission efficiency of the power supply system; The rectifier and filter circuit is used to convert the alternating current into direct current; The voltage stabilizing circuit is used to perform voltage stabilization operation on the direct current.

6. The in-situ gear dynamic parameter testing device based on wireless power supply according to claim 1, characterized in that: Gear dynamic parameters collected include: Platinum thermal resistors, strain gauges and triaxial accelerometers are used to collect gear temperature, stress and vibration data respectively.

7. The in-situ gear dynamic parameter testing device based on wireless power supply according to claim 6, characterized in that: The data processing system includes: a three-wire bridge circuit, an analog-to-digital converter, a microcontroller and a Wheatstone bridge; The three-wire bridge circuit is used to convert the resistance change of the PT100 temperature sensor into a voltage signal; The analog-to-digital converter is used to amplify and convert the weak analog signals output by the temperature and stress measurement circuits; The microcontroller is used to process the collected temperature, stress and vibration data; The Wheatstone bridge is used to convert the deformation of the strain gauge into a voltage signal.

8. The in-situ gear dynamic parameter testing device based on wireless power supply according to claim 1, characterized in that: The data transmission system includes: a test Wi-Fi module and a relay Wi-Fi module; The test Wi-Fi module is located on the data acquisition circuit board, and the relay Wi-Fi module is placed outside the gear box to enhance the signal.

9. The in-situ gear dynamic parameter testing device based on wireless power supply according to claim 1, characterized in that: The testing device further comprises: a rotor assembly and a stator assembly, wherein the stator assembly is fixed to the bottom of the gear box, and the rotor assembly is fixed to the shaft through a connecting sleeve and rotates synchronously with the gear.

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