Gearbox body vibration frequency response analysis system

Abstract

The invention discloses a gearbox body vibration frequency response analysis system, and relates to the technical field of gearbox detection, the gearbox body vibration frequency response analysis system comprises a gearbox body detection center, the gearbox body detection center is in communication connection with a vibration signal acquisition module, a frequency response effect analysis module and a resonance suppression early warning module, and the modules are in electric signal connection; and the vibration signal acquisition module is used for acquiring vibration signals of the gearbox body under different working conditions and performing frequency domain analysis and modal analysis on the gearbox body. According to the method, through modal analysis and frequency response effect analysis, the inherent frequency and vibration characteristics of the gearbox body can be comprehensively evaluated, abnormal resonance points having potential threats to structural safety are identified, and a reasonable resonance suppression strategy is provided, so that the structural strength of the gearbox body is enhanced, and the service life of the gearbox body is prolonged. The structure damage or failure risk caused by resonance is reduced, the service life of the gearbox body is prolonged, and the use safety of the gearbox body is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of gearbox detection, in particular to a gearbox housing vibration frequency response analysis system. BACKGROUND

[0002] The gearbox is a key component in the automobile transmission system, its main function is to change the power transmission of the engine through different gear ratios, so that the vehicle can obtain appropriate power output under different driving conditions, with the continuous development of automobile technology, the gearbox gradually develops towards high efficiency, low noise and long service life, under this background, the vibration analysis of the gearbox housing is particularly important, which is directly related to the comfort, durability and noise level of the vehicle.

[0003] For example, a gearbox housing vibration frequency response analysis method disclosed in Chinese patent No. CN117195433A includes modifying based on the geometric parameters of each gear, obtaining the tooth profile curve parameters of each gear after modification, and performing involute cylindrical helical gear three-dimensional modeling on each gear to construct the physical model and parameters of the gearbox transmission system.

[0004] In the prior art, the influence of gear modification on gearbox housing vibration noise is compared to provide a basis for effectively suppressing the vibration noise of the gearbox and improving the vibration performance of the vehicle. However, due to the numerous vibration excitation sources of the gearbox, if the natural frequency of the gearbox housing is close to the excitation frequency, resonance will occur, which will cause the structure amplitude to increase significantly, leading to structural damage or failure. Therefore, how to analyze the vibration frequency response characteristics of the gearbox housing under different working conditions, identify the resonance point, and evaluate the influence of resonance on the safety of the structure, and take appropriate measures to avoid or weaken the resonance phenomenon, is the problem to be solved by the present application. Therefore, a gearbox housing vibration frequency response analysis system is proposed. SUMMARY

[0005] The present application aims to provide a gearbox housing vibration frequency response analysis system to solve the problems raised in the background art.

[0006] To solve the above technical problems, the technical solution adopted by the present application is: A gearbox housing vibration frequency response analysis system, comprising a gearbox housing detection center, the gearbox housing detection center is communicatively connected with a vibration signal acquisition module, a frequency response effect analysis module and a resonance suppression early warning module, wherein the modules are electrically connected; The vibration signal acquisition module is used to collect the vibration signals of the gearbox housing under different working conditions, and to perform frequency domain analysis and modal analysis on the gearbox housing to identify the vibration frequency response characteristics and natural vibration frequency of the gearbox housing; The frequency response effect analysis module is configured to analyze the obtained vibration frequency response characteristics and natural vibration frequency, identify resonance points, and calculate resonance performance coefficients to determine abnormal resonance points that have an impact on the safety of the structure. The resonance suppression early warning module is configured to perform early warning on the abnormal resonance points according to the frequency response effect analysis result, and respond to a corresponding resonance suppression strategy.

[0007] Further improvements of the technical scheme of the present application are as follows: the vibration signal acquisition module comprises a signal acquisition and processing unit, a frequency domain analysis unit, and a modal analysis unit. The signal acquisition and processing unit is configured to acquire vibration signals of the gearbox housing through the deployed sensors, and perform filtering, noise reduction, and amplification preprocessing operations on the acquired vibration signals to improve signal quality, reduce the influence of interference signals through signal processing, and improve the signal-to-noise ratio of the vibration signals. The frequency domain analysis unit is configured to perform frequency domain analysis on the preprocessed vibration signals, convert the time domain vibration signals into frequency domain signals, and obtain the vibration frequency response characteristics of the gearbox housing at different frequencies, including vibration amplitude, phase, stress response, and damping ratio. The modal analysis unit is configured to analyze the natural frequency and modal shape characteristics of the gearbox housing through finite element analysis technology, and identify the natural vibration frequency of the gearbox housing.

[0008] Further improvements of the technical scheme of the present application are as follows: the signal acquisition and processing unit specifically comprises: A plurality of sensors are deployed to perceive the vibration of the gearbox housing through physical contact and acquire original vibration signals, wherein the sensors convert mechanical vibration signals into electrical signals and contain vibration information of the gearbox housing under different working conditions. The acquired original vibration signals are preprocessed, including filtering, noise reduction, and amplification preprocessing operations. The preprocessed vibration signals are transmitted to the frequency domain analysis unit and the modal analysis unit for further analysis of the vibration frequency response characteristics and the natural vibration frequency.

[0009] Further improvements of the technical scheme of the present application are as follows: the frequency domain analysis unit specifically comprises: The frequency domain analysis unit receives the preprocessed vibration signals, wherein the preprocessed vibration signals are time domain vibration signals containing vibration information of the gearbox housing under different working conditions, and then converts the time domain vibration signals into frequency domain signals through a fast Fourier transform (FFT) algorithm, decomposes the time domain vibration signals into a combination of a series of sine waves and cosine waves, and each wave contains a specific frequency, amplitude, and phase. After converting the time-domain signal into the frequency-domain signal, the frequency spectrum of the vibration amplitude is analyzed, the vibration amplitude spectrum of the vibration signal is obtained by calculating the vibration amplitude corresponding to each frequency component, wherein the vibration amplitude spectrum of the vibration signal reflects the intensity of different frequency components, that is, the amplitude of the vibration signal at each frequency, and then the main frequency component of the gearbox body vibration and the relative intensity of the main frequency component are identified by analyzing the amplitude spectrum; On the basis of the analysis of the vibration amplitude, the phase spectrum and stress response analysis of the vibration signal are carried out, the alignment of different frequency components in time is determined, the phase change rule of the vibration signal at different frequencies is understood, the phase information of different frequency components is determined, and the stress state of the gearbox body in the vibration process is evaluated by calculating the stress value corresponding to the frequency-domain signal, and then the damping ratio is calculated and analyzed by comparing the amplitude attenuation at different frequencies, and the change trend of the damping ratio with the frequency is determined. After the analysis of the amplitude spectrum and the phase spectrum is completed, the vibration frequency response characteristics of the gearbox body are extracted, including the vibration amplitude, the phase, the stress response and the damping ratio parameters, and then the reference values of the vibration frequency response characteristic parameters are determined in combination with the design standard of the gearbox body, and the vibration frequency response difference coefficient is obtained, and the deviation degree of the vibration frequency response characteristics of the gearbox body is analyzed.

[0010] The further improvement of the technical scheme of the application is that the modal analysis unit specifically comprises: An accurate finite element model is established by using the finite element software according to the actual geometric size and material properties of the gearbox body, wherein the finite element model comprises each component, the connection mode and the boundary condition of the gearbox body, so that the model can accurately reflect the actual structural characteristics of the gearbox body; After the finite element model is established, the finite element model is meshed, and the boundary conditions and the load are applied to the finite element model to simulate the constraint state of the gearbox body in the actual work, wherein the boundary conditions include fixed support and free end, and the load includes the self-weight of the gearbox body and external force; The modal analysis of the gearbox body finite element model is carried out by using the modal solving function of the finite element software, the natural frequency and the corresponding modal shape of the gearbox body are obtained by solving the eigenvalue problem, so as to analyze the natural frequency and the modal shape amplitude of each modal, and then the damping ratio of each modal is calculated according to the modal analysis result, wherein the natural frequency is the natural frequency of the gearbox body in free vibration, and the modal shape is the vibration form of the gearbox body at each natural frequency; The results obtained by solving the modal are analyzed in detail, the natural frequency and the modal shape characteristics of the gearbox body are extracted, the modal shape amplitude, the natural frequency and the damping ratio under different modes are compared, the main vibration frequency identification value is obtained, and the main vibration frequency of the gearbox body is identified.

[0011] The further improvement of the technical scheme of the present application is that the frequency response effect analysis module comprises a resonance point identification unit and a resonance effect evaluation unit. The resonance point identification unit is used for comparing the vibration frequency response characteristic obtained through frequency domain analysis with the natural frequency obtained through modal analysis, identifying the resonance point, and finding out the resonance frequency that may occur in the gearbox housing under different working conditions. The resonance effect evaluation unit is used for analyzing the influence of resonance on the structural safety, fatigue life, noise and vibration level of the gearbox housing, calculating the resonance effect coefficient, evaluating the damage caused by resonance to the structure, and determining the abnormal resonance point.

[0012] The further improvement of the technical scheme of the present application is that the resonance point identification unit specifically comprises: The vibration frequency obtained through frequency domain analysis and the natural frequency obtained through modal analysis are received and compared one by one, and the frequency point that is similar or coincides with each other is the potential resonance point. For each potential resonance point, the vibration amplitude, phase and damping ratio parameters are further analyzed, and the resonance point confirmation coefficient is calculated to confirm whether the potential resonance point is a real resonance point. According to the comparison, verification and analysis results, the resonance frequency occurring in the gearbox housing under different working conditions is identified and listed, and the corresponding working condition is indicated.

[0013] The further improvement of the technical scheme of the present application is that the resonance effect evaluation unit specifically comprises: Based on the identified resonance point, the influence of the resonance point on the structural safety of the gearbox housing is further analyzed, the stress analysis of the resonance point of the gearbox housing is performed in combination with the finite element analysis method, the corresponding stress ratio index is obtained, and it is judged whether the stress exceeds the allowable stress range of the material. The fatigue life of the gearbox housing under the resonance condition is calculated through the fatigue analysis theory based on the stress analysis results of the resonance point, the influence of resonance on the fatigue life of the gearbox housing is evaluated, and then the fatigue life evaluation index is obtained by comparing with the designed fatigue life, and the gearbox housing part that fails in advance due to resonance is identified. The influence of the resonance point on the noise and vibration level of the gearbox housing is analyzed, the change of the vibration amplitude, phase and damping ratio parameters is evaluated, it is determined whether the resonance point will cause the noise and vibration level to increase significantly, and the resonance point influence index is obtained by comparing the vibration data under different working conditions, and the influence of the resonance point on the gearbox housing is evaluated. The vibration amplitude, damping ratio and natural frequency of the resonance point are comprehensively analyzed, the reference values of the vibration amplitude, damping ratio and natural frequency are extracted, the stress at the resonance point is combined with the allowable stress ratio of the material, the resonance efficiency coefficient is calculated, the damage caused by the identified resonance point to the gearbox body structure is evaluated, compared with the preset abnormal resonance threshold, whether the resonance point is abnormal is determined, and the frequency, working condition and influence on the structure and performance of the abnormal resonance point are recorded.

[0014] Further improvement of the technical scheme of the application is that the expression of the resonance efficiency coefficient is as follows: In the formula, is the resonance efficiency coefficient, used for evaluating the damage caused by the resonance point to the gearbox body structure, is the total number of analyzed resonance points, is the first vibration amplitude at the first resonance point, is the average value of the first vibration amplitude, is the reference vibration amplitude, is the damping ratio at the first resonance point, is the reference damping ratio, is the vibration frequency at the first resonance point, is the reference vibration frequency, is the stress at the first resonance point, is the allowable stress of the material, The value range of is between 0 and 1, when , it means that the influence of the resonance point on the gearbox body structure can be ignored, when , it means that the influence of the resonance point on the gearbox body structure reaches the maximum value, which may cause significant structural damage.

[0015] Further improvement of the technical scheme of the application is that the resonance suppression early warning module comprises a real-time monitoring early warning unit and a resonance suppression strategy unit. The real-time monitoring early warning unit is used for providing real-time monitoring and early warning functions, tracking the vibration state of the gearbox body, and automatically issuing a warning when an abnormal resonance point is determined, to ensure rapid response to potential resonance risks. The resonance suppression strategy unit is used for matching the corresponding resonance suppression strategy from the preset structure design library for the identified and warned abnormal resonance point, to provide targeted suggestions and guide the design, manufacture and maintenance of the gearbox body, and reduce the influence of resonance on structural safety. ​The resonance suppression early warning module specifically comprises: The vibration state of the gearbox body is continuously tracked by the real-time monitoring early warning unit, and the abnormal vibration mode is identified in combination with the determined abnormal resonance point; According to the determined abnormal resonance point, the early warning mechanism is started, the early warning signal is sent through the sound and light alarm and the system notification mode, and the detailed information of the abnormal resonance point is recorded; The resonance suppression strategy unit receives the early warning signal, searches the resonance suppression strategy matched with the identified abnormal resonance point from the pre-set structure design library, and provides targeted suggestions for the design, manufacture and maintenance of the gearbox body; The resonance suppression strategy unit transmits the matched resonance suppression strategy to the relevant personnel, guides the implementation of specific operations, and continuously tracks and monitors the vibration state of the gearbox body to evaluate the effect of the suppression strategy.

[0016] Due to the adoption of the above technical scheme, the present application has the following technical progress compared with the prior art: The present application provides a gearbox body vibration frequency response analysis system, which can comprehensively evaluate the natural frequency and vibration characteristics of the gearbox body through modal analysis and frequency response effect analysis, identify abnormal resonance points that pose potential threats to structural safety, and propose reasonable resonance suppression strategies, thereby enhancing the structural strength of the gearbox body, reducing the risk of structural damage or failure caused by resonance, and improving the service life and safety of the gearbox body.

[0017] The present application provides a gearbox body vibration frequency response analysis system, which can monitor the vibration state of the gearbox body, identify potential resonance points using frequency domain analysis and modal analysis, and then analyze the influence of resonance on structural safety through a resonance efficiency evaluation unit, calculate the resonance efficiency coefficient, and evaluate the damage caused by resonance to the structure, so as to timely discover and warn potential structural safety problems and ensure the stability and reliability of the gearbox body under various working conditions. BRIEF DESCRIPTION OF DRAWINGS

[0018] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the drawings needed in the embodiments will be briefly introduced as follows. Obviously, the drawings in the following description are only some embodiments described in the present application, and other drawings can also be obtained by those skilled in the art based on these drawings.

[0019] Figure 1 The system function module diagram of the present application is shown in the figure. Figure 2 The working flowchart of the resonance efficiency evaluation unit of the present application is shown in the figure. DETAILED DESCRIPTION

[0020] In order to make the purposes, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are some but not all of the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the protection scope of the present application.

[0021] As shown in Embodiment 1, Figure 1 , Figure 2 The present application provides a gearbox housing vibration frequency response analysis system, comprising a gearbox housing detection center, which is communicatively connected with a vibration signal acquisition module, a frequency response effect analysis module and a resonance suppression early warning module, wherein the modules are electrically connected; The vibration signal acquisition module is used for collecting vibration signals of the gearbox housing under different working conditions, and performing frequency domain analysis and modal analysis on the gearbox housing to identify the vibration frequency response characteristics and the natural vibration frequency of the gearbox housing. The vibration signal acquisition module comprises a signal acquisition and processing unit, a frequency domain analysis unit and a modal analysis unit. The signal acquisition and processing unit is used for collecting vibration signals of the gearbox housing through the deployed sensors, and performing filtering, noise reduction and amplification preprocessing operations on the collected vibration signals to improve the signal quality. Through signal processing, the influence of interference signals is reduced, and the signal-to-noise ratio of the vibration signals is improved. A plurality of sensors are deployed to perceive the vibration condition of the gearbox housing through physical contact and obtain the original vibration signals. The sensors convert the mechanical vibration signals into electrical signals, which contain vibration information of the gearbox housing under different working conditions. The collected original vibration signals are preprocessed, including filtering, noise reduction and amplification preprocessing operations. The digital filtering method is used for filtering processing to remove high-frequency noise and low-frequency drift. The cutoff frequency is set to retain the effective components in the signal and suppress the interference of irrelevant components. On the basis of filtering processing, an adaptive noise reduction method is used to further reduce random noise and interference in the signal and improve the signal-to-noise ratio. The signal is finely processed, and then the amplification multiple is controlled to amplify the noise-reduced signal to improve the signal amplitude and ensure that the signal is not distorted during amplification. The preprocessed vibration signals are transmitted to the frequency domain analysis unit and the modal analysis unit for further analysis of the vibration frequency response characteristics and the natural vibration frequency. The frequency domain analysis unit is used for frequency domain analysis on the pre-processed vibration signal, converts the time domain vibration signal into a frequency domain signal, and obtains the vibration frequency response characteristics of the gearbox housing under different frequencies, including vibration amplitude, phase, stress response, and damping ratio. The frequency domain analysis unit receives the pre-processed vibration signal, wherein the pre-processed vibration signal is a time domain vibration signal containing vibration information of the gearbox housing under different working conditions. Then, the time domain vibration signal is converted into a frequency domain signal through a fast Fourier transform (FFT) algorithm, and the time domain vibration signal is decomposed into a combination of a series of sine waves and cosine waves, each wave containing a specific frequency, amplitude, and phase. After the time domain signal is converted into a frequency domain signal, the frequency spectrum of the vibration amplitude is analyzed, the vibration amplitude spectrum of the vibration signal is obtained by calculating the vibration amplitude corresponding to each frequency component, wherein the vibration amplitude spectrum reflects the intensity of different frequency components, i.e., the amplitude of the vibration signal at each frequency. Then, the main frequency components of the gearbox housing vibration and the relative intensity of the main frequency components are identified by analyzing the amplitude spectrum. On the basis of the vibration amplitude analysis, the phase spectrum and stress response analysis of the vibration signal are performed to determine the alignment of different frequency components in time, understand the phase change rule of the vibration signal under different frequencies, determine the phase information of different frequency components, and evaluate the stress state of the gearbox housing during the vibration process by calculating the stress value corresponding to the frequency domain signal. Then, the damping ratio is calculated and analyzed by comparing the amplitude attenuation at different frequencies to determine the trend of the damping ratio with the frequency. After the amplitude spectrum and phase spectrum analysis are completed, the vibration frequency response characteristics of the gearbox housing are extracted, including the vibration amplitude, phase, stress response, and damping ratio parameters. Then, the reference values of the vibration frequency response characteristic parameters are determined in combination with the design standards of the gearbox housing, and the vibration frequency response difference coefficient is obtained to analyze the deviation degree of the vibration frequency response characteristics of the gearbox housing. The expression of the vibration frequency response difference coefficient is as follows: ; In the formula, is the vibration frequency response difference coefficient, which is used to evaluate the deviation degree between the vibration frequency response characteristics of the gearbox housing and the reference values, is the total number of frequency points analyzed, is the vibration amplitude of the th frequency point, is the phase of the th frequency point, is the damping ratio of the th frequency point, is the stress response of the th frequency point, is the phase reference value, is the damping ratio reference value, is the stress response reference value, The value range is between 0 and 1. When the vibration frequency response characteristics are completely consistent with the reference value, there is no deviation. When the value is at its maximum, it indicates that the vibration frequency response characteristics deviate from the reference value. The modal analysis unit is used to analyze the natural frequencies and modal shape characteristics of the gearbox housing using finite element analysis (FEM) technology. It identifies the natural vibration frequencies of the gearbox housing and uses FEM software to establish an accurate FEM model based on the actual geometric dimensions and material properties of the gearbox housing. This FEM model includes all components of the housing, connection methods, and boundary conditions, ensuring that the model accurately reflects the actual structural characteristics of the housing. After establishing the FEM model, it is meshed, and boundary conditions and loads are applied to simulate the constraint state of the gearbox housing during actual operation. Boundary conditions include fixed supports and free ends, and loads include the self-weight of the gearbox housing and external forces. Modal analysis was performed on the finite element model of the gearbox housing using the modal solving function of finite element software. By solving the eigenvalue problem, the natural frequencies and corresponding mode shapes of the housing were obtained to analyze the natural frequencies and mode shape amplitudes of each mode. Then, based on the modal analysis results, the damping ratio of each mode was calculated. The natural frequencies are the natural frequencies of the gearbox housing during free vibration, and the mode shapes are the vibration patterns of the gearbox housing at each natural frequency. The results obtained from the modal solving were analyzed in detail to extract the natural frequencies and mode shape characteristics of the gearbox housing. The mode shape amplitudes, natural frequencies, and damping ratios under different modes were compared to obtain the main vibration frequency identification values ​​and identify the main vibration frequencies of the housing. The expression for the main vibration frequency identification value is as follows: ; In the formula, These are the primary vibration frequency identification values, used to assess the main vibration frequencies of the gearbox housing. The total number of modal orders analyzed. For the first The mode shape amplitude of a first-order mode reflects the contribution of that mode to the vibration. For the first The natural frequencies of the first mode. To reference the natural frequency, the target frequency from the design standard is used. For the first Damping ratio of the first mode, For reference damping ratio, the target damping ratio in the design standard is used. The value range is between 0 and 1. When, it indicates that no mode significantly contributes to the dominant vibrational frequency. At this time, it is shown that the contribution of all modes to the main vibration frequency reaches the maximum value; a frequency response effect analysis module, configured to perform frequency response effect analysis on the obtained vibration frequency response characteristic and the natural vibration frequency, identify resonance points and calculate resonance performance coefficients, and determine abnormal resonance points that have an impact on the safety of the structure; a resonance suppression early warning module, configured to perform early warning on the abnormal resonance points according to the frequency response effect analysis result, and respond to a corresponding resonance suppression strategy.

[0022] Embodiment 2, as shown in Figure 1 , Figure 2 the application provides a technical solution based on embodiment 1: preferably, the frequency response effect analysis module includes a resonance point identification unit and a resonance performance evaluation unit; The resonance point identification unit is configured to compare the vibration frequency response characteristic obtained by frequency domain analysis with the natural frequency obtained by modal analysis, identify resonance points, find out the resonance frequencies that may occur in the gearbox housing under different working conditions, receive the vibration frequency response characteristic obtained by frequency domain analysis and the natural frequency obtained by modal analysis, compare the vibration frequency obtained by frequency domain analysis with the natural frequency obtained by modal analysis one by one, find out the frequency points that are similar or coincide with each other, that is, the potential resonance points, further analyze the vibration amplitude, phase and damping ratio parameters of each potential resonance point, calculate the resonance point confirmation coefficient to confirm whether the potential resonance point is a real resonance point, and according to the comparison, verification and analysis results, identify and list the resonance frequencies that occur in the gearbox housing under different working conditions, and mark the corresponding working conditions; The expression of the resonance point confirmation coefficient is as follows: ; In the formula, is the resonance point confirmation coefficient, which is used to evaluate whether the potential resonance point is a real resonance point, is the total number of frequency points analyzed, is the phase of the i th frequency point, is the phase reference value, is the vibration amplitude of the i th frequency point, is the reference vibration amplitude, is the damping ratio of the i th frequency point, is the reference damping ratio, , the value range of is between 0 and 1, when , it indicates that the frequency point is completely mismatched with the characteristics of the resonance point and is not a resonance point, and when , it indicates that the frequency point is completely matched with the characteristics of the resonance point and is a real resonance point; ​​​The resonance performance evaluation unit is used to analyze the impact of resonance on the structural safety, fatigue life, noise and vibration levels of the gearbox housing, calculate the resonance performance coefficient, assess the damage caused by resonance to the structure, identify abnormal resonance points, and further analyze the impact of the resonance points on the structural safety of the gearbox housing based on the identified resonance points. Combined with the finite element analysis method, stress analysis is performed on the resonance points of the gearbox housing to obtain the relative stress ratio index and determine whether the stress exceeds the allowable stress range of the material. The expression for the relative stress ratio exponent is as follows: ; In the formula, The relative stress ratio index is used to assess the relative relationship between the stress at the resonance point and the allowable stress. The total number of resonance points analyzed. For the first The first resonance point at the _ ... One principal stress, For the first The average value of the principal stresses, The allowable stress of the material is determined according to the specifications. A safety factor, ranging from 1.2 to 2, is used to account for uncertainties in the material's performance during use. The value range is between 0 and 1. When the stress at the resonance point is much lower than the allowable stress, the structure is safe. When the stress at the resonance point is close to or reaches the allowable stress, there may be a risk of structural failure. Based on the stress analysis results of the comprehensive resonance point, the fatigue life of the gearbox under resonance conditions is calculated using fatigue analysis theory. The impact of resonance on the fatigue life of the gearbox is evaluated, and then compared with the fatigue life required by the design to obtain the fatigue life evaluation index and identify the gearbox parts that fail prematurely due to resonance. The expression for the fatigue life evaluation index is as follows: ; In the formula, The fatigue life evaluation index indicates the number of cycles the gearbox housing can withstand under resonance conditions. The total number of resonance points analyzed. For the first The stress amplitude at each resonance point For the first The fatigue limit stress at each resonance point Here, is a material constant representing the relationship between stress amplitude and fatigue life. For the first The plastic strain amplitude at each resonance point the fatigue strain strength of the material, the tensile strength of the material at the resonance point, the average stress at the resonance point, a material constant representing the influence of the average stress on the fatigue life, the value of which ranges between 0 and 1, when it indicates that the gearbox housing under resonance conditions cannot withstand any number of cycles and there is an immediate risk of failure, when it indicates that the gearbox housing under resonance conditions can withstand the maximum number of cycles required by the design and the fatigue life reaches the design standard; analyzing the influence of the resonance points on the noise and vibration levels of the gearbox housing, evaluating the changes in the vibration amplitude, phase and damping ratio parameters to determine whether the resonance points will cause a significant increase in noise and vibration levels, and obtaining a resonance point influence index by comparing the vibration data under different operating conditions to assess the influence of the resonance points on the gearbox housing; the expression of the resonance point influence index is as follows: ; wherein is the resonance point influence index used to assess the influence of the resonance points on the gearbox housing, is the total number of resonance points analyzed, is the vibration amplitude at the resonance point, is the average value of the vibration amplitude, is the reference vibration amplitude, is the damping ratio at the resonance point, is the reference damping ratio, is the natural frequency at the resonance point, is the reference natural frequency, the value of which ranges between 0 and 1, when it indicates that the influence of the resonance points on the gearbox housing can be neglected, when it indicates that the influence of the resonance points on the gearbox housing reaches a maximum value and can cause significant noise and vibration problems; The vibration amplitude, damping ratio and natural frequency of the resonance point are comprehensively analyzed, the reference values of the vibration amplitude, damping ratio and natural frequency are extracted, the stress at the resonance point is combined with the allowable stress ratio of the material, the resonance efficiency coefficient is calculated, the damage of the identified resonance point to the gearbox body structure is evaluated, the abnormal resonance threshold is compared, whether the resonance point is abnormal is determined, and the frequency, working condition and influence on the structure and performance of the abnormal resonance point are recorded. The expression of the resonance efficiency coefficient is as follows: ; In the formula, is the resonance efficiency coefficient, which is used to evaluate the damage of the resonance point to the gearbox body structure, is the total number of analyzed resonance points, is the th vibration amplitude at the th resonance point, is the average value of the th vibration amplitude, is the reference vibration amplitude, is the damping ratio at the th resonance point, is the reference damping ratio, is the vibration frequency at the th resonance point, is the reference vibration frequency, is the stress at the th resonance point, is the allowable stress of the material, The value range of is between 0 and 1, when , it means that the influence of the resonance point on the gearbox body structure can be ignored, when , it means that the influence of the resonance point on the gearbox body structure reaches the maximum value, which may cause significant structural damage. The resonance suppression early warning module includes a real-time monitoring early warning unit and a resonance suppression strategy unit. The real-time monitoring and early warning unit is configured to provide real-time monitoring and early warning functions, track the vibration state of the gearbox housing, and automatically issue a warning when an abnormal resonance point is determined, ensuring a rapid response to potential resonance risks. The resonance suppression strategy unit is configured to match corresponding resonance suppression strategies from a pre-set structural design library for the identified and warned abnormal resonance points, to provide targeted recommendations, and to provide guidance for the design, manufacture, and maintenance of the gearbox housing, thereby reducing the impact of resonance on structural safety. The real-time monitoring and early warning unit continuously tracks the vibration state of the gearbox housing, identifies abnormal vibration patterns in combination with the determined abnormal resonance points, and initiates a warning mechanism based on the determined abnormal resonance points. The warning mechanism issues a warning signal through audible and visual alarms and system notifications, and records detailed information about the abnormal resonance points. The resonance suppression strategy unit receives the warning signal and searches for resonance suppression strategies that match the identified abnormal resonance points from the pre-set structural design library, to provide targeted recommendations for the design, manufacture, and maintenance of the gearbox housing. The resonance suppression strategies include adjusting the geometry of the housing, adding damping materials, optimizing support structures, and the like. The resonance suppression strategy unit transmits the matched resonance suppression strategies to relevant personnel to guide the implementation of specific operations, and continuously tracks and monitors the vibration state of the gearbox housing to evaluate the effectiveness of the suppression strategies. If the vibration state improves significantly after the implementation of the resonance suppression strategies, the successful cases are recorded to provide experience support for subsequent strategy optimization and updates. If the resonance suppression strategies are ineffective, the resonance suppression strategies are adjusted or replaced to ensure that the impact of resonance on structural safety is effectively reduced.

[0023] The above is merely a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art can easily think of changes or replacements within the technical scope disclosed in the present application, which should be covered within the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

Claims

1. A gearbox housing vibration frequency response analysis system comprising a gearbox housing test centre, characterised in that: The gearbox body detection center is communicated with a vibration signal acquisition module, a frequency response effect analysis module and a resonance suppression early warning module, wherein the modules are connected by electrical signals; The vibration signal acquisition module is used to collect the vibration signals of the gearbox body under different working conditions, and perform frequency domain analysis and modal analysis on the gearbox body to identify the vibration frequency response characteristics and the natural vibration frequency of the gearbox body; The frequency response effect analysis module is used to analyze the vibration frequency response characteristics and the natural vibration frequency, identify the resonance points and calculate the resonance efficiency coefficient to determine the abnormal resonance points that affect the structural safety; The resonance suppression early warning module is used to give early warning to the abnormal resonance points according to the frequency response effect analysis results, and respond to the corresponding resonance suppression strategy.

2. The gearbox housing vibration frequency response analysis system of claim 1, wherein: The vibration signal acquisition module includes a signal acquisition and processing unit, a frequency domain analysis unit and a modal analysis unit; The signal acquisition and processing unit is used to collect the vibration signals of the gearbox body through the deployed sensors and perform preprocessing operations on the collected vibration signals; The frequency domain analysis unit is used to perform frequency domain analysis on the preprocessed vibration signals, convert the time domain vibration signals into frequency domain signals, obtain the vibration frequency response characteristics of the gearbox body under different frequencies, including the vibration amplitude, phase, stress response and damping ratio; The modal analysis unit is used to analyze the natural frequency and modal shape characteristics of the gearbox body through the finite element analysis technology to identify the natural vibration frequency of the gearbox body.

3. A gearbox housing vibration frequency response analysis system according to claim 2, characterised in that: The signal acquisition and processing unit specifically includes: A plurality of sensors are deployed to sense the vibration of the gearbox body through physical contact and obtain the original vibration signals, wherein the sensors convert the mechanical vibration signals into electrical signals, including the vibration information of the gearbox body under different working conditions; The collected original vibration signals are preprocessed, including filtering, noise reduction and amplification preprocessing operations; The preprocessed vibration signals are transmitted to the frequency domain analysis unit and the modal analysis unit for further analysis of the vibration frequency response characteristics and the natural vibration frequency.

4. The gearbox housing vibration frequency response analysis system of claim 3, wherein: The frequency domain analysis unit specifically includes: The frequency domain analysis unit receives the preprocessed vibration signals, wherein the preprocessed vibration signals are time domain vibration signals, and then the time domain vibration signals are converted into frequency domain signals through the fast Fourier transform algorithm, and the time domain vibration signals are decomposed into a combination of a series of sine waves and cosine waves, each wave containing a specific frequency, amplitude and phase; After converting the time domain signals into frequency domain signals, the frequency spectrum analysis of the vibration amplitude is performed, the vibration amplitude spectrum of the vibration signal is obtained by calculating the vibration amplitude corresponding to each frequency component, and then the main frequency component of the gearbox body vibration and the relative strength of the main frequency component are identified by analyzing the amplitude spectrum; On the basis of the analysis of the vibration amplitude, the phase spectrum and stress response of the vibration signal are analyzed to determine the alignment of different frequency components in time, understand the phase variation law of the vibration signal at different frequencies, determine the phase information of different frequency components, and evaluate the stress state of the gearbox housing during the vibration process by calculating the stress value corresponding to the frequency domain signal. Then, by comparing the amplitude attenuation at different frequencies, the damping ratio is calculated and analyzed to determine the trend of the damping ratio with frequency. After completing the analysis of the amplitude spectrum and the phase spectrum, the vibration frequency response characteristics of the gearbox housing are extracted, including the vibration amplitude, phase, stress response, and damping ratio parameters. Then, by combining the design standards of the gearbox housing, the reference values of the vibration frequency response characteristic parameters are determined, the vibration frequency response difference coefficient is obtained, and the deviation degree of the vibration frequency response characteristics of the gearbox housing is analyzed.

5. A gearbox vibration frequency response analysis system according to claim 4, characterised in that: The modal analysis unit specifically includes: A finite element model is established using finite element software based on the actual geometric dimensions and material properties of the gearbox housing. The finite element model includes the components, connection methods, and boundary conditions of the housing. After establishing the finite element model, the finite element model is meshed, and boundary conditions and loads are applied to the finite element model to simulate the constraint state of the gearbox housing in actual operation. The boundary conditions include fixed supports and free ends, and the loads include the self-weight of the gearbox housing and external forces. The modal analysis of the gearbox housing finite element model is performed using the modal solving function of the finite element software. By solving the eigenvalue problem, the natural frequency and corresponding modal shape of the housing are obtained to analyze the natural frequency and mode shape amplitude of each mode. Then, based on the modal analysis results, the damping ratio of each mode is calculated. The natural frequency is the natural frequency of the gearbox housing when it is free to vibrate, and the modal shape is the vibration pattern of the gearbox housing at each natural frequency. The results obtained by modal solving are analyzed in detail to extract the natural frequency and modal shape characteristics of the gearbox housing. The mode shape amplitude, natural frequency, and damping ratio at different modes are compared to obtain the main vibration frequency identification value and identify the main vibration frequency of the housing.

6. The gearbox housing vibration frequency response analysis system of claim 2, wherein: The frequency response effect analysis module includes a resonance point identification unit and a resonance efficiency evaluation unit. The resonance point identification unit compares the vibration frequency response characteristics obtained by frequency domain analysis with the natural frequency obtained by modal analysis to identify the resonance points. The resonance efficiency evaluation unit analyzes the influence of resonance on the structural safety, fatigue life, and noise and vibration level of the gearbox housing, calculates the resonance efficiency coefficient, evaluates the damage caused by resonance to the structure, and determines the abnormal resonance points.

7. A gearbox vibration frequency response analysis system according to claim 6, characterised in that: The resonance point identification unit specifically includes: The vibration frequency response characteristics obtained by frequency domain analysis and the natural frequency obtained by modal analysis are received, and the vibration frequencies obtained by frequency domain analysis and the natural frequencies obtained by modal analysis are compared one by one to find the frequency points that are similar or coincide, which are potential resonance points. For each potential resonance point, the vibration amplitude, phase, and damping ratio parameters are further analyzed, and the resonance point confirmation coefficient is calculated to confirm whether the potential resonance point is a true resonance point. According to the comparison, verification and analysis results, the resonance frequencies occurring in the gearbox housing under different working conditions are identified and listed, and the corresponding working condition conditions are noted.

8. A gearbox vibration frequency response analysis system according to claim 7, characterised in that: The resonance effect evaluation unit specifically includes: Based on the identified resonance points, further analyze the influence of the resonance points on the safety of the gearbox housing structure, combine the finite element analysis method to analyze the stress of the resonance points of the gearbox housing, obtain the corresponding stress ratio index, and judge whether the stress exceeds the allowable stress range of the material; Synthesize the stress analysis results of the resonance points, calculate the fatigue life of the housing under the resonance condition through the fatigue analysis theory, evaluate the influence of resonance on the fatigue life of the gearbox housing, and then compare it with the design requirement of fatigue life to obtain the fatigue life evaluation index, identify the parts of the gearbox housing that fail prematurely due to resonance; Analyze the influence of the resonance points on the noise and vibration level of the gearbox housing, evaluate the changes of vibration amplitude, phase and damping ratio parameters, determine whether the resonance points will cause a significant increase in noise and vibration level, and obtain the resonance point influence index by comparing the vibration data under different working conditions to evaluate the influence of the resonance points on the gearbox housing; Synthesize the vibration amplitude, damping ratio and natural frequency of the resonance points, and extract the reference values of the vibration amplitude, damping ratio and natural frequency, combine the stress ratio of the resonance points to the allowable stress of the material, calculate the resonance effect coefficient, evaluate the damage caused by the identified resonance points to the gearbox housing structure, compare it with the preset abnormal resonance threshold value to determine whether the resonance points are abnormal, and record the frequency, working condition and influence on the structure and performance of the abnormal resonance points.

9. A gearbox vibration frequency response analysis system according to claim 8, characterised in that: The expression of the resonance effect coefficient is as follows: ； In the formula, The resonance efficiency coefficient, The total number of resonance points analyzed. For the first The first resonance point at the _ ... Each vibration amplitude For the first The average value of each vibration amplitude, For reference vibration amplitude, For the first Damping ratio at each resonance point For reference damping ratio, For the first The vibration frequency at each resonance point For reference vibration frequency, For the first Stress at each resonance point The allowable stress of the material, The value range is between 0 and 1.

10. The gearbox housing vibration frequency response analysis system of claim 6, wherein: The resonance suppression early warning module includes a real-time monitoring early warning unit and a resonance suppression strategy unit; The real-time monitoring early warning unit is used to provide real-time monitoring and early warning functions, track the vibration state of the gearbox housing, and automatically issue a warning when an abnormal resonance point is determined; The resonance suppression strategy unit is used to match the corresponding resonance suppression strategy from the preset structure design library for the identified and warned abnormal resonance points to provide targeted suggestions; The resonance suppression early warning module specifically includes: The real-time monitoring early warning unit continuously tracks the vibration state of the gearbox housing, and identifies the abnormal vibration mode in combination with the determined abnormal resonance points; According to the determined abnormal resonance points, the early warning mechanism is started, and a warning signal is issued through sound and light alarm and system notification, and the detailed information of the abnormal resonance points is recorded; After receiving the warning signal, the resonance suppression strategy unit searches the resonance suppression strategy matching the identified abnormal resonance points from the preset structure design library, and provides targeted suggestions for the design, manufacture and maintenance of the gearbox housing; The resonance suppression strategy unit transmits the matched resonance suppression strategy to the relevant personnel to guide the implementation of specific operations, and continuously tracks and monitors the vibration state of the gearbox housing to evaluate the effect of the suppression strategy.

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