Gear experiment device, gear electric breakdown experiment method and gear electric corrosion experiment method

Abstract

The invention discloses a gear experiment device, a gear electric breakdown experiment method and a gear electric corrosion experiment method.The gear experiment device comprises a gear experiment mechanical mechanism which comprises a gear box and a gear assembly, an installation cavity is formed in the gear box, and the gear assembly is detachably installed in the installation cavity; the gear assembly comprises a first rotating shaft, a second rotating shaft and two gear samples, and the two gear samples are mounted on the first rotating shaft and the second rotating shaft respectively; the power mechanism is connected with the first rotating shaft; the load loading mechanism is connected with the second rotating shaft; the voltage loading mechanism is electrically connected with the first rotating shaft and the second rotating shaft; the oil supply mechanism communicates with the mounting cavity; and the data acquisition mechanism is electrically connected with the load loading mechanism and the voltage loading mechanism and is used for acquiring experimental data. The gear experiment device can accurately simulate the actual operation condition of the gear in the generator gearbox integrated system, and can carry out accurate electric breakdown and electric corrosion experiments on the gear sample.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of gear experiment, and particularly relates to a gear experiment device, a gear electric breakdown experiment method and a gear electric corrosion experiment method. BACKGROUND

[0002] With the development of wind turbines towards deep sea and high power, the reliability requirement of wind turbines is higher and higher, the generator gearbox integrated structure of semi-direct drive wind turbines has advantages of high power density, high efficiency and high reliability, and has become the mainstream technical route of current offshore wind turbines, and the electric corrosion problem of bearings and gears in the generator gearbox integrated system has been a technical problem troubling the development of the industry.

[0003] In the generator gearbox integrated system, the generator is directly installed on the rotating shaft of the gearbox, and there is no bearing at the generator end, so the shaft voltage mainly affects the bearings and gears in the gearbox, especially the tapered roller bearings on the rotating shaft of the gearbox and the gears near the generator end. When the shaft voltage exceeds the oil film breakdown threshold between the bearings or gears, shaft current is generated, which causes electric breakdown and electric corrosion of the bearings and gears, and further causes performance deterioration or even failure of the generator gearbox integrated system, resulting in huge losses.

[0004] In order to explore the breakdown and electric corrosion failure mechanism of shaft current and seek effective anti-breakdown and electric corrosion solutions, theoretically, electric breakdown and electric corrosion experiments can be conducted on the entire generator gearbox integrated system prototype. However, due to experimental conditions and costs, directly using the entire generator gearbox integrated system prototype for experiments is too costly and cannot be universally applicable. However, if the bearings and gears in the generator gearbox integrated system are experimented separately, the experimental cost can be reduced.

[0005] There are two key problems in the current electric breakdown and electric corrosion experiments of the gears in the generator gearbox integrated system in the industry: first, there is a lack of experimental schemes and special devices for the electric breakdown and electric corrosion of the gears in the generator gearbox integrated system; second, the existing experimental platforms have limitations. For example, although the rolling and sliding dual-purpose basic electric corrosion damage friction and wear test bench developed by the existing research can expand the gear electric corrosion experiment method, it uses test rings and test blocks to replace real gears, which cannot accurately simulate the actual operating conditions of the gears in the generator gearbox integrated system, and thus cannot realize precise electric breakdown and electric corrosion experiments of the gears in the generator gearbox integrated system. SUMMARY

[0006] The present application aims to provide a gear experiment device, a gear electric breakdown experiment method and a gear electric corrosion experiment method to solve at least one aspect of the problems and defects in the background art.

[0007] To achieve the above-mentioned purpose, the present application provides the following technical solutions:

[0008] The gear experiment mechanical mechanism comprises a gear box and a gear assembly, the gear box is internally provided with a mounting cavity, the gear assembly is detachably mounted in the mounting cavity and is arranged in insulation isolation with the gear box; the gear assembly comprises a first rotating shaft, a second rotating shaft and two gear samples, the two gear samples are respectively detachably mounted on the first rotating shaft and the second rotating shaft;

[0009] The power mechanism is connected in insulation with the first rotating shaft and is used for driving the gear sample to rotate;

[0010] The load loading mechanism is connected in insulation with the second rotating shaft and is used for applying torque to the gear sample and monitoring the torque and rotating speed of the gear sample in real time;

[0011] The voltage loading mechanism is electrically connected with the first rotating shaft and the second rotating shaft and is used for driving the gear assembly to generate current flowing through the gear sample;

[0012] The oil supply mechanism is communicated with the mounting cavity and is used for inputting lubricating oil to the contact surface of the two gear samples; and

[0013] The data acquisition mechanism is electrically connected with the load loading mechanism and the voltage loading mechanism and is used for collecting experimental data.

[0014] The gear experiment device of the present application has simple structure and convenient operation, the gear experiment mechanical mechanism capable of realizing gear sample replacement, the power mechanism capable of driving the gear sample to rotate, the oil supply mechanism capable of forming an oil film layer at the meshing position of the gear sample, the load loading mechanism capable of applying torque to the gear sample, the voltage loading mechanism capable of applying voltage to the gear sample and the data acquisition mechanism capable of collecting experimental data, the actual operation condition of the gear of the generator gear box integrated system can be accurately simulated, so that high-precision electric breakdown experiment can be implemented on the gear sample.

[0015] In an embodiment of the present application, the gear samples are all involute helical gears or involute cylindrical gears.

[0016] In an embodiment of the present application, the sizes of the two gear samples are the same.

[0017] In an embodiment of the present application, the power mechanism comprises a speed-adjustable motor and a power insulation coupling, the speed-adjustable motor is connected with the first rotating shaft through the power insulation coupling.

[0018] In one embodiment of this application, the load loading mechanism includes a magnetic powder brake, a brake coupling, a torque and speed sensor, a torque measuring insulated coupling, and a brake controller; the magnetic powder brake is connected to the torque and speed sensor via the brake coupling; the torque and speed sensor is connected to the second rotating shaft via the torque measuring insulated coupling; both the torque and speed sensor and the magnetic powder brake are electrically connected to the data acquisition mechanism; and the brake controller is electrically connected to the magnetic powder brake.

[0019] In one embodiment of this application, the voltage loading mechanism includes a power supply measurement component, a first carbon brush component, and a second carbon brush component. The power supply measurement component, the first carbon brush component, the gear component, and the second carbon brush component are sequentially electrically connected to form a closed experimental circuit. The first carbon brush component is electrically connected to the first rotating shaft through contact, and the second carbon brush component is electrically connected to the second rotating shaft through contact.

[0020] In one embodiment of this application, the oil supply mechanism includes an oil tank, an oil inlet pipe assembly, an oil outlet pipe assembly, an oil inlet pump, an oil outlet pump, an oil temperature measurement module, an oil pressure measurement module, and a heat exchanger; the oil tank, the oil inlet pipe assembly, the oil outlet pipe assembly, and the gearbox are connected in series to form a closed oil supply circuit; the oil tank is an oil storage structure with oil heating and oil pressure regulation; the oil inlet pipe assembly includes a first oil pipe and an oil injection pipe, the oil injection pipe is located in the mounting cavity, the oil injection pipe extends along the axial direction of the gear sample, and the parts that mesh with the two gear samples are located at the same height. The oil injection pipe is provided with oil injection holes facing the meshing parts of the two gear samples; the two ends of the first oil pipe are connected to the oil tank and the oil injection pipe; the oil outlet pipe assembly includes a second oil pipe, the two ends of the second oil pipe are respectively connected to the oil tank and the bottom end of the mounting cavity; the oil inlet pump, the oil pressure measuring module and the heat exchanger are all provided on the first oil pipe; the oil outlet pump is provided on the second oil pipe; the oil temperature measuring module is provided in the oil supply circuit and is used to measure the lubricating oil temperature at the oil outlet end of the first oil pipe and the lubricating oil temperature at the oil inlet end of the second oil pipe.

[0021] In one embodiment of this application, a vibration sensor electrically connected to the data acquisition mechanism is further included, the vibration sensor being used to measure the vibration of the gear sample.

[0022] A method for testing the electrical breakdown of gears includes the following steps:

[0023] S10. Provide the gear experimental apparatus as described above, and perform pre-experiment preparation work on the gear experimental apparatus.

[0024] S20. Start the oil supply mechanism to lubricate the gear sample;

[0025] S30. Determine the working parameters and starting voltage of the electrical breakdown test. The working parameters of the electrical breakdown test include the rotational speed of the gear sample, the torque of the gear sample, and the frequency and magnitude of the simulated voltage applied to the gear sample. According to the working parameters of the electrical breakdown test, start and adjust the power mechanism, the load loading mechanism, and the voltage loading mechanism, and continue for a specified time. Then, while keeping the frequency of the simulated voltage, the rotational speed of the gear sample, and the torque of the gear sample constant, gradually increase the simulated voltage and monitor the change in the current flowing through the gear sample. Each time the simulated voltage is increased, continue for a specified time. When a sudden increase in current is detected, stop the experiment. Record the experimental data during the test.

[0026] S40. Replace the gear sample and repeat steps S20 to S30 continuously. The working parameters of the electrical breakdown test are adjusted according to the electrical breakdown test scheme for the replaced gear sample during the experiment.

[0027] S50. Based on the recorded experimental data, calculate the minimum oil film thickness of the gear sample when it is electrically broken down under different electrical breakdown test parameters, and mark the minimum breakdown voltage of the gear sample under different electrical breakdown test parameters.

[0028] The gear electrical breakdown test method of the present invention, by employing the gear test apparatus as described above, enables high-precision electrical breakdown tests on gear samples, thereby significantly improving the reliability of the electrical breakdown test data.

[0029] A method for testing the electro-erosion of gears includes the following steps:

[0030] S10. Provide the gear experimental apparatus with a vibration sensor as described above, and perform pre-experiment preparation work on the gear experimental apparatus.

[0031] S20. Determine the working parameters of the electro-erosion test of the gear sample. The working parameters of the electro-erosion test include the rotational speed of the gear sample, the torque of the gear sample, and the frequency of the simulated voltage applied to the gear sample. Based on the working parameters of the electro-erosion test and the experimental results obtained by the gear electrical breakdown test method as described above, determine the minimum breakdown voltage of the gear sample. Set the magnitude of the simulated voltage based on the minimum breakdown voltage.

[0032] S30. Start the oil supply mechanism to lubricate the gear sample;

[0033] S40. Start the power mechanism, the voltage loading mechanism and the load loading mechanism. According to the working parameters of the electro-erosion experiment determined in step S20, adjust the torque and speed of the gear sample, as well as the magnitude and frequency of the simulated voltage applied to the gear sample. Keep the working parameters of the electro-erosion experiment unchanged and continue the experiment. Monitor the vibration changes of the gear sample in real time through the vibration sensor. When a sudden increase in vibration is detected, stop the experiment, observe the macro- and micro-morphology of the surface of the gear sample after the experiment, and record the relevant experimental data.

[0034] S50. Replace the gear sample and repeat steps S20 to S40 continuously. The working parameters of the electro-erosion test are adjusted according to the electro-erosion test plan for the replaced gear sample during the experiment.

[0035] S60. Analyze the experimental data.

[0036] The gear electro-erosion test method of the present invention, by employing the gear test device with vibration sensor as described above, can perform high-precision electro-erosion tests on gear samples, thereby significantly improving the reliability of electro-erosion test data. Attached Figure Description

[0037] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings.

[0038] Figure 1 This is a three-dimensional structural schematic diagram of a gear experimental apparatus according to an embodiment of this application;

[0039] Figure 2 This is a cross-sectional view of the gear testing mechanism of a gear testing apparatus according to an embodiment of this application;

[0040] Figure 3 This is a cross-sectional view of the first and second rotating shafts according to an embodiment of this application.

[0041] Figure 4 This is a schematic diagram of the first dust-blocking component being removed from the gearbox according to an embodiment of this application;

[0042] Figure 5 This is a schematic diagram of the second dust-blocking component being removed from the gearbox according to an embodiment of this application;

[0043] Figure 6 This is an exploded structural diagram of a gearbox according to an embodiment of this application;

[0044] Figure 7 This is a three-dimensional structural diagram of an assembly consisting of a gear assembly and a voltage loading mechanism according to an embodiment of this application;

[0045] Figure 8This is a three-dimensional structural schematic diagram of an assembly consisting of two gear samples and an oil supply mechanism, as shown in an embodiment of this application.

[0046] Figure 9 This is a three-dimensional structural schematic diagram of an assembly consisting of a first gear, a second gear, and a fuel injection pipe, according to an embodiment of this application.

[0047] Figure 10 This is a three-dimensional structural schematic diagram of a gear experimental apparatus according to another embodiment of this application.

[0048] Figure label:

[0049] 10. Gear experimental mechanism; 110. Insulating base; 11. Gearbox; 111. Upper cover; 1111. First semicircular hole; 112. Middle box; 1121. Second semicircular hole; 1122. Third semicircular hole; 113. Lower cover; 1131. Fourth semicircular hole; 114. First mounting hole; 115. Second mounting hole; 116. Third mounting hole; 117. Fourth mounting hole; 118. Mounting cavity; 12. First gear sample; 121. First rotating shaft; 1211. First stepped surface; 1212. Second stepped surface; 1213. 13. Third step surface; 13. Second gear sample; 131. Second shaft; 1311. Fourth step surface; 1312. Fifth step surface; 1313. Sixth step surface; 14. First bearing; 15. Second bearing; 16. Third bearing; 17. Fourth bearing; 18. First dustproof component; 181. First fixing protrusion; 19. Second dustproof component; 191. Second fixing protrusion; 101. First locking ring; 102. Second locking ring; 103. Third locking ring; 104. Fourth locking ring; 105. Fifth locking ring; 106. Sixth locking ring;

[0050] 20. Power mechanism; 21. Adjustable speed motor; 22. Power insulated coupling;

[0051] 30. Loading mechanism; 31. Magnetic powder brake; 32. Brake coupling; 33. Torque-speed sensor; 34. Torque measuring insulated coupling; 35. Brake controller; 36. Water cooler;

[0052] 40. Voltage loading mechanism; 41. Signal generator; 42. Power amplifier; 43. First bracket; 44. First carbon brush; 45. First wire; 46. Second bracket; 47. Second carbon brush; 48. Second wire;

[0053] 50. Oil supply mechanism; 51. Oil tank; 52. First oil pipe; 53. First flange; 54. Injection pipe; 541. Injection hole; 55. Second oil pipe; 56. Second flange; 571. Inlet oil pump; 572. Outlet oil pump; 58. Oil pressure measurement module; 591. Inlet oil temperature sensor; 592. Outlet oil temperature sensor; 510. Heat exchanger;

[0054] 61. Torque and speed information acquisition and display; 62. Digital oscilloscope; 63. Vibration display;

[0055] 70. Vibration sensor. Detailed Implementation

[0056] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0057] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, front, back, left, right, etc., are based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0058] In the description of this invention, "several" means one or more, "more than" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. The use of "first" and "second" in the description is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0059] In the description of this invention, unless otherwise explicitly defined, terms such as "set up," "install," and "connect" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0060] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only for explaining the invention and are not intended to limit the invention; that is, the described embodiments are merely some embodiments of the invention, and not all embodiments. The components of the embodiments of the invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0061] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0062] Please see Figures 1 to 9 This is a gear testing apparatus for gear electrical breakdown testing as shown in an embodiment of the present invention, such as... Figure 1 As shown, the gear experimental device includes a gear experimental mechanical mechanism 10, a power mechanism 20, a load loading mechanism 30, a voltage loading mechanism 40, an oil supply mechanism 50, and a data acquisition mechanism.

[0063] like Figure 2 As shown, the gear experimental mechanism 10 includes a gearbox 11 and a gear assembly. The gearbox 11 has a mounting cavity 118, and the gear assembly is detachably installed in the mounting cavity 118 and insulated from the gearbox 11. The gear assembly includes a first rotating shaft 121, a second rotating shaft 131, and two gear samples. The two gear samples mesh to form a gear pair and are detachably installed on the first rotating shaft 121 and the second rotating shaft 131, respectively, so that the two gear samples can be removed from the first rotating shaft 121 and the second rotating shaft 131 for easy replacement of the gear samples during the experiment. The gear sample installed on the first rotating shaft 121 is designated as the first gear sample 12, and the gear sample installed on the second rotating shaft 131 is designated as the second gear sample 13. Figure 1 As shown, the power mechanism 20 is insulated from the first rotating shaft 121 and is used to drive the gear sample to rotate at an adjustable speed; the load loading mechanism 30 is insulated from the second rotating shaft 131 and is used to apply torque to the gear sample and monitor the torque and speed of the gear sample in real time; the voltage loading mechanism 40 is electrically connected to the first rotating shaft 121 and the second rotating shaft 131 and is used to drive the gear assembly to generate current flowing through the gear sample; the oil supply mechanism 50 is connected to the mounting cavity 118 and is used to provide lubricating oil to the meshing surfaces of the two gear samples so that an oil film layer can be formed on the meshing tooth surfaces of the gear samples; the voltage loading mechanism 40 is electrically connected to the gear assembly and is used to apply an adjustable voltage to the gear sample and monitor the change in current flowing through the gear sample in real time; the data acquisition mechanism is electrically connected to the load loading mechanism 30 and the voltage loading mechanism 40 and is used to acquire experimental data, including speed, torque, voltage, current, etc.

[0064] It should be noted that, due to the insulated isolation between the gear assembly and the gearbox 11, the insulated connection between the power mechanism 20 and the first rotating shaft 121, and the insulated connection between the load loading mechanism 30 and the second rotating shaft 131, when the voltage loading mechanism 40 applies voltage to the gear assembly, only a closed loop is formed: voltage loading mechanism 40 → first rotating shaft 121 → first gear sample 12 → second gear sample 13 → second rotating shaft 131 → voltage loading mechanism 40, thus ensuring the accuracy of the experimental results. During the experiment, lubricating oil was first supplied to the gear samples through the oil supply mechanism 50, forming a protective oil film layer on the surface of the two gear samples. Then, the power mechanism 20 was started to drive the two gear samples to rotate. Subsequently, the voltage loading mechanism 40 and the load loading mechanism 30 were started to apply a specified voltage and torque to the gear samples. During the experiment, the voltage loading mechanism 40 could monitor the current flowing through the gear samples, and the load loading mechanism 30 could monitor the torque and speed of the gear samples. The data acquisition mechanism collected the experimental data, and the experimenters compiled the collected experimental data into a gear electrical breakdown experimental data table. Based on the gear electrical breakdown experimental data table, the minimum breakdown voltage of gear samples of the same specifications under different torque, voltage frequency, and speed was obtained.

[0065] Because the gears in a real-world generator gearbox integrated system are lubricated by oil and the load they bear is mainly torque, the gear testing device of this application, by setting up a gear testing mechanical mechanism 10 that enables gear sample replacement, a power mechanism 20 that drives the gear sample to rotate, an oil supply mechanism 50 that enables the formation of an oil film layer on the meshing surface of the gear sample, a load loading mechanism 30 that applies torque to the gear sample, a voltage loading mechanism 40 that applies voltage to the gear sample of the gear testing mechanical mechanism 10, and a data acquisition mechanism for collecting experimental data, can accurately simulate the actual operating conditions of the gears in a generator gearbox integrated system, thereby enabling high-precision electrical breakdown tests on the gear samples.

[0066] In one embodiment of this application, such as Figures 4 to 6As shown, the gearbox 11 includes an upper cover 111, a lower cover 113 located below the upper cover 111, and a middle housing 112 detachably connecting the lower cover 113 and the upper cover 111; the inner cavities of the upper cover 111, the middle housing 112, and the lower cover 113 together form a mounting cavity 118; the gearbox 11 is provided with a first hole group and a second hole group, the first hole group including a first mounting hole 114 and a second mounting hole 115 arranged opposite to each other; the second hole group includes a third mounting hole 116 and a fourth mounting hole 117 arranged opposite to each other; the first mounting hole 114 and the second mounting hole 115 are both formed by a first semicircle on the upper cover 111. The first mounting hole 1111 is formed by combining the second semicircular hole 1121 on the middle box 112. The third mounting hole 116 and the fourth mounting hole 117 are both formed by combining the third semicircular hole 1122 on the middle box 112 and the fourth semicircular hole 1131 on the lower box cover 113. One end of the first rotating shaft 121 is rotatably installed in the first mounting hole 114, and the other end of the first rotating shaft 121 passes through the second mounting hole 115 and connects to the power mechanism 20. One end of the second rotating shaft 131 is rotatably installed in the third mounting hole 116, and the other end of the second rotating shaft 131 passes through the fourth mounting hole 117 and connects to the load loading mechanism 30. The gearbox 11 is configured to be detachably assembled from an upper cover 111, a lower cover 113, and a middle housing 112, facilitating quick assembly and disassembly of the first rotating shaft 121 and the second rotating shaft 131 within the gearbox 11. When it is necessary to install the first rotating shaft 121 and the second rotating shaft 131 into the gearbox 11, the middle housing 112 can be removed from the lower cover 113 first, then the upper cover 111 can be removed from the middle housing 112, and then the second rotating shaft 131 and the first rotating shaft 121 can be installed onto the gearbox 11 in sequence. When installing the second rotating shaft 131 onto the gearbox 11, the second rotating shaft 131 should first be placed on the lower cover. The first shaft 121 is installed on the gearbox 11 by aligning the second shaft 121 with the second semicircular holes 1121 of the middle housing 112, then aligning the first semicircular holes 1111 and 1121, and finally detachably installing the upper housing 111 onto the middle housing 112. To remove the entire gear assembly from the gearbox 11, follow the reverse steps.

[0067] To ensure the stability of the rotation of the first rotating shaft 121 and the second rotating shaft 131, in one embodiment of this application, such as... Figure 2As shown, the gear assembly also includes a first bearing 14, a second bearing 15, a third bearing 16, and a fourth bearing 17. The first bearing 14 and the second bearing 15 are detachably mounted on the first rotating shaft 121 and respectively installed in the first mounting hole 114 and the second mounting hole 115, so that the first rotating shaft 121 is rotatably connected to the gearbox 11 via the first bearing 14 and the second bearing 15. The third bearing 16 and the fourth bearing 17 are detachably mounted on the second rotating shaft 131 and respectively installed in the third mounting hole 116 and the fourth mounting hole 117, so that the second rotating shaft 131 is rotatably connected to the gearbox 11 via the third bearing 16 and the fourth bearing 17. To ensure that after the voltage loading mechanism 40 supplies power to the gear assembly, the first bearing 14, the second bearing 15, the third bearing 16, and the fourth bearing 17 will not transmit electricity to the gearbox 11 and affect the experimental results, all three bearings are insulated bearings.

[0068] To facilitate the installation of the first gear sample 12, the first bearing 14, and the second bearing 15 on the first rotating shaft 121, and to facilitate the assembly and disassembly of the second gear sample 13, the third bearing 16, and the fourth bearing 17 on the second rotating shaft 131, the first gear sample 12, the second gear sample 13, the first bearing 14, the second bearing 15, the third bearing 16, and the fourth bearing 17 are all clamped and fixed to the rotating shaft by a locking ring fitted with the stepped surface of the rotating shaft. Specifically, as shown... Figure 2 and Figure 3As shown, the first gear sample 12 is locked to the first rotating shaft 121 by the first locking ring 101 and the first step surface 1211 of the first rotating shaft 121. The first bearing 14 is locked to the first rotating shaft 121 by the second locking ring 102 and the second step surface 1212 of the first rotating shaft 121. The second bearing 15 is locked to the first rotating shaft 121 by the third locking ring 103 and the third step surface 1213 of the first rotating shaft 121. In order to prevent the first locking ring 101 and the second locking ring 102 from causing the current to be diverted from the first rotating shaft 121 to the gearbox 11, the current flow path is ensured to be voltage loading mechanism 40 → first rotating shaft 121 → first gear sample 12 → second gear sample 13 → second rotating shaft 131 → voltage loading mechanism 40. The outer surfaces of the first locking ring 101, the second locking ring 102 and the third locking ring 103 are all spaced apart from the gearbox 11. Similarly, the second gear sample 13 is locked to the second rotating shaft 131 by the fourth locking ring 104 in conjunction with the fourth step surface 1311 on the second rotating shaft 131, the third bearing 16 is locked to the second rotating shaft 131 by the fifth locking ring 105 in conjunction with the fifth step surface 1312 on the second rotating shaft 131, and the fourth bearing 17 is locked to the second rotating shaft 131 by the sixth locking ring 106 in conjunction with the sixth step surface 1313 on the second rotating shaft 131. In order to prevent the fifth locking ring 105 and the sixth locking ring 106 from diverting the current flowing through the second rotating shaft 131 to the gearbox 11, and to ensure that the current flow path can only be voltage loading mechanism 40 → first rotating shaft 121 → first gear sample 12 → second gear sample 13 → second rotating shaft 131 → voltage loading mechanism 40, the outer surfaces of the fourth locking ring 104, the fifth locking ring 105 and the sixth locking ring 106 are all spaced apart from the gearbox 11.

[0069] Optionally, the gear experimental mechanical mechanism 10 also includes a first dust-blocking component 18 and a second dust-blocking component 19, such as... Figure 4 As shown, the first dust-blocking component 18 is detachably installed on the gearbox 11 and covers the first mounting hole 114 to prevent external dust from accumulating on the first bearing 14 and to avoid dust affecting the operation of the first bearing 14; Figure 5 As shown, the second dust baffle 19 is detachably mounted on the gearbox 11 and covers the third mounting hole 116 to prevent external dust from accumulating on the third bearing 16 and affecting its operation. This is to ensure that after the voltage loading mechanism 40 supplies power to the gear assembly, the gear assembly will not conduct electricity to the gearbox 11 through the first dust baffle 18 and the second dust baffle 19, thus preventing any impact on the experimental results.

[0070] Furthermore, such as Figure 4As shown, the first dust-blocking member 18 is plate-shaped. One end of the first dust-blocking member 18 is inserted into the first mounting hole 114, forming a first clearance cavity for the insertion of the first rotating shaft 121. The other end of the first dust-blocking member 18 is located outside the gearbox 11 and forms a first fixing protrusion 181. The first fixing protrusion 181 is formed on the side of the first dust-blocking member 18 and is detachably connected to the gearbox 11 by screws; similarly, as Figure 5 As shown, the second dustproof member 19 is also plate-shaped. One end of the second dustproof member 19 is inserted into the third mounting hole 116 and forms a second clearance cavity for the insertion of the second rotating shaft 131. The other end of the second dustproof member 19 is located outside the gearbox 11 and forms a second fixing protrusion 191. The second fixing protrusion 191 is formed on the side of the second dustproof member 19 and is detachably connected to the gearbox 11 by screws.

[0071] Furthermore, sealing rings are provided between the first dust baffle 18 portion located in the first mounting hole 114 and the gearbox 11, and between the second dust baffle 19 portion located in the third mounting hole 116 and the gearbox 11, to prevent the lubricating oil in the mounting cavity 118 from leaking out of the gearbox 11 from the first mounting hole 114 and the third mounting hole 116.

[0072] Furthermore, such as Figure 4 As shown, there are two first fixing protrusions 181. These two protrusions 181 are detachably connected to the upper cover 111 and the middle box body 112 via screws. This allows the upper cover 111 and the middle box body 112 to be reinforced by the first dustproof component 18, thus giving the first dustproof component 18 a multi-functional role. It not only prevents dust and oil leakage but also strengthens the connection between the upper cover 111 and the middle box body 112. Figure 5 As shown, there are also two second fixing protrusions 191. The two second fixing protrusions 191 are detachably connected to the middle box 112 and the lower box cover 113 by screws. This allows the lower box cover 113 and the middle box 112 to be strengthened by the second dustproof component 19, so that the second dustproof component 19 also has multiple functions. It not only plays the role of preventing dust and oil leakage, but also plays the role of strengthening the connection strength between the lower box cover 113 and the middle box 112.

[0073] In this application, the gear specimens are involute helical gears or involute cylindrical gears. In one embodiment of this application, to facilitate the calculation of experimental results, the two gear specimens are chosen to be of the same size, and both are preferably involute cylindrical gears. In other feasible embodiments, the two gear specimens may also be of different sizes. Based on the different sizes of the two gear specimens, the gear specimens may be involute helical gears or involute cylindrical gears. Although choosing these combinations will make the calculation of experimental results more difficult, they are necessary in some experiments.

[0074] Optionally, the gear experimental mechanism 10 also includes an insulating seat 110 mounted below the gearbox 11, which is used to prevent the gearbox 11 from transmitting electricity to external objects.

[0075] In one embodiment of this application, such as Figure 1 As shown, the power mechanism 20 includes an adjustable speed motor 21 and a power insulated coupling 22. The adjustable speed motor 21 is connected to the first rotating shaft 121 through the power insulated coupling 22.

[0076] In one embodiment of this application, such as Figure 1 As shown, the load loading mechanism 30 includes a magnetic powder brake 31, a brake coupling 32, a torque-speed sensor 33, a torque measuring insulated coupling 34, and a brake controller 35. The magnetic powder brake 31 is connected to the torque-speed sensor 33 via the brake coupling 32. The torque-speed sensor 33 is connected to the second rotating shaft 131 via the torque measuring insulated coupling 34. Both the torque-speed sensor 33 and the magnetic powder brake 31 are electrically connected to a data acquisition mechanism. The torque-speed sensor 33 is used to measure the torque and speed of the gear sample in real time and transmit the measured torque and speed information to the data acquisition mechanism in real time. The brake controller 35 is electrically connected to the magnetic powder brake 31 and is used to regulate the torque applied to the gear sample by the magnetic powder brake 31. During operation, the magnetic powder brake 31 applies torque to the gear sample, and the torque and speed sensor 33 measures the torque on the gear sample and the speed of the first gear sample 12 and the second gear sample 13. When it is necessary to change the torque applied to the gear sample by the magnetic powder brake 31, the brake controller 35 controls the magnetic powder brake 31 to achieve this. The torque and speed sensor 33 uses existing instruments capable of measuring speed and torque.

[0077] Furthermore, the load loading mechanism 30 also includes a water chiller 36, which is connected to the magnetic powder brake 31 and is used to cool the magnetic powder brake 31 with water to ensure the performance and service life of the magnetic powder brake 31.

[0078] In one embodiment of this application, such as Figure 7 As shown, the voltage loading mechanism 40 includes a power supply measurement component, a first carbon brush assembly, and a second carbon brush assembly. The power supply measurement component, the first carbon brush assembly, the gear pair, and the second carbon brush assembly are sequentially electrically connected to form a closed experimental circuit. The first carbon brush assembly is electrically connected to a first rotating shaft 121, and the second carbon brush assembly is electrically connected to a second rotating shaft 131. Further, the power supply measurement component includes a power amplifier 42 electrically connected to the first and second carbon brush assemblies, and a signal generator 41 electrically connected to the power amplifier 42. The signal generator 41 is used to connect to an external power source and send a power signal to the power amplifier. The power amplifier 42 is used to amplify the power supply voltage as needed.

[0079] In order to prevent the first carbon brush assembly and the second carbon brush assembly from obstructing the rotation of the first rotating shaft 121 and the second rotating shaft 131, the first carbon brush assembly and the second carbon brush assembly are respectively electrically connected to the first rotating shaft 121 and the second rotating shaft 131 in contact. For example, the first carbon brush assembly includes a first bracket 43, a first carbon brush 44, and a first wire 45. One end of the first carbon brush 44 is mounted on the first bracket 43 and connected to the power amplifier 42 of the power supply measurement assembly via the first wire 45. The other end of the first carbon brush 44 forms a first carbon brush semicircular hole that matches the first rotating shaft 121. The wall of the first carbon brush semicircular hole contacts the outer surface of the first rotating shaft 121. The second carbon brush assembly includes a second bracket 46, a second carbon brush 47, and a second wire 48. One end of the second carbon brush 47 is mounted on the second bracket 46 and connected to the power amplifier 42 of the power supply measurement assembly via the second wire 48. The other end of the second carbon brush 47 forms a second carbon brush semicircular hole that matches the second rotating shaft 131. The wall of the second carbon brush semicircular hole contacts the outer surface of the second rotating shaft 131.

[0080] In one embodiment of this application, such as Figure 8 As shown, the oil supply mechanism 50 includes an oil tank 51, an oil inlet pipe assembly, an oil outlet pipe assembly, an oil inlet pump 571, an oil outlet pump 572, an oil temperature measurement module, an oil pressure measurement module 58, and a heat exchanger 510; the oil tank 51, the oil inlet pipe assembly, the oil outlet pipe assembly, and the gearbox 11 are connected in series to form a closed oil supply circuit; the oil tank 51 is selected as an existing oil storage structure with oil heating and oil pressure regulation; the oil inlet pipe assembly includes a first oil pipe 52 and an oil injection pipe 54, the oil injection pipe 54 is located in the mounting cavity 118, the oil injection pipe 54 extends along the axial direction of the first gear sample 12 and the second gear sample 13, and is connected to the first gear sample 12 and the second gear sample 13. The meshing parts of the first gear sample 12 and the second gear sample 13 are located at the same height. The oil injection pipe 54 is provided with oil injection holes 541 facing the meshing parts of the first gear sample 12 and the second gear sample 13, so that the lubricating oil sprayed from the oil injection pipe 54 can be directly sprayed onto the meshing tooth surfaces of the first gear sample 12 and the second gear sample 13, ensuring that an oil film layer can be well formed on the meshing tooth surfaces of the first gear sample 12 and the second gear sample 13. One end of the first oil pipe 52 is connected to the oil tank 51, and the other end is connected to the oil injection pipe 54. The oil outlet pipe assembly includes a second oil pipe 55, and the two ends of the second oil pipe 55 are respectively connected to the oil tank 51 and the bottom end of the mounting cavity 118. After the lubricating oil is sprayed from the oil injection pipe 54, part of it adheres to the first gear sample 12 and the second gear sample 13, and the other part falls to the bottom of the mounting cavity 118 and is discharged back into the oil tank 51 through the second oil pipe 55. The oil pressure measurement module 58, the inlet oil pump 571, the outlet oil pump 572, the oil temperature measurement module, and the heat exchanger 510 are all located in the oil supply circuit.

[0081] Furthermore, the inlet pipe assembly also includes a first flange 53, through which the first oil pipe 52 is fixed to the gearbox 11. The first flange 53 is located outside the gearbox 11 and is detachably connected to the gearbox 11 by screws. The outlet pipe assembly also includes a second flange 56, through which the second oil pipe 55 is fixed to the gearbox 11. The second flange 56 is located outside the gearbox 11 and is detachably connected to the gearbox 11 by screws.

[0082] The oil pump 571, oil pressure measuring module 58, and heat exchanger 510 are all located on the first oil pipe 52. The oil pump 571 is used to drive the lubricating oil in the oil tank 51 to flow to the gear sample. The oil pressure measuring module 58 uses a pressure gauge. During the experiment, the operator observes the pressure data of the pressure gauge and controls the oil pressure regulating structure of the oil tank 51 to adjust the output oil pressure of the oil tank 51 to the oil pressure required for the experiment. The heat exchanger 510 is used to regulate the oil temperature in the first oil pipe 51 and is preferably located near the gearbox 11. When regulating the temperature, the oil tank 61 first heats the oil to a specified temperature through its own oil heating structure. This specified temperature is higher than the lubricating oil temperature required for the gear sample. Then, the heat exchanger 66 precisely cools the lubricating oil to the lubricating oil temperature required for the gear sample.

[0083] The oil temperature measurement module measures the lubricating oil temperature at the outlet of the first oil pipe and the inlet of the second oil pipe, ensuring that the temperature of the lubricating oil delivered to the gear sample is very close to the required experimental temperature, thus guaranteeing the accuracy of the experiment. Specifically, the oil temperature measurement module includes an inlet temperature sensor 591 and an outlet temperature sensor 592. The inlet temperature sensor 591 is located at one end of the first oil pipe 52 connected to the injection pipe 54, and the outlet temperature sensor 592 is located at one end of the second oil pipe 55 connected to the mounting cavity 118. During the experiment, the inlet temperature measured by the inlet temperature sensor 591 and the outlet temperature measured by the outlet temperature sensor 592 are used to control the heating mode of the heat exchanger 510 and the oil tank 51, so that the temperature of the lubricating oil delivered to the gear sample is the required temperature.

[0084] The oil pump 572 is located on the second oil pipe 55 and is used to drive the lubricating oil from the mounting cavity back into the oil tank.

[0085] Furthermore, such as Figure 9 As shown, there are at least two oil injection holes 541, which are arranged sequentially at intervals along the axial direction of the first gear sample 12. This arrangement allows the lubricating oil to be sprayed in a fine jet onto the meshing tooth surfaces of the first gear sample 12 and the second gear sample 13, thereby enabling the lubricating oil to cover the meshing surfaces of the gear samples more evenly and providing a good lubrication effect on the meshing surfaces of the first gear sample 12 and the second gear sample 13.

[0086] In one embodiment of this application, the data acquisition mechanism is a split structure, such as... Figure 1 As shown, the data acquisition mechanism includes a torque and speed information acquisition display 61 electrically connected to the torque and speed sensor 33, a digital oscilloscope 62 electrically connected to the power amplifier 42, and a temperature acquisition display (not shown) electrically connected to the inlet oil temperature sensor 591 and the outlet oil temperature sensor 592. The torque and speed information acquisition display 61 acquires and displays the torque and speed of the gear sample; the digital oscilloscope 62 acquires and displays the voltage applied to the gear sample and the current flowing through it during the experiment; and the temperature acquisition display acquires and displays the lubricating oil temperature information acquired by the inlet oil temperature sensor 591 and the outlet oil temperature sensor 592. The acquired data is recorded, and the minimum oil film thickness required for electrical breakdown of the gear sample under different torques, speeds, and simulated voltage frequencies is calculated based on the recorded data. In other feasible embodiments, the torque and speed information acquisition display 61, the digital oscilloscope 62, and the temperature acquisition display can be integrated into one unit, making the data acquisition mechanism an all-in-one machine, such as an industrial all-in-one machine or a multi-functional industrial control device.

[0087] The present invention also provides a method for testing the electrical breakdown of gears, comprising the following steps:

[0088] S10. Provide the gear test apparatus for the gear electrical breakdown test as described above, and perform pre-test preparation work on the gear test apparatus.

[0089] Specifically, when providing the gear test apparatus for the gear electrical breakdown test, the gear test apparatus is already in the state where the gear sample is installed inside the gearbox 11.

[0090] S20, Start the oil supply mechanism 50 to lubricate the gear sample.

[0091] Specifically, during the start-up of the oil supply mechanism 50, the parameters such as oil temperature and oil pressure are first adjusted. The oil temperature and oil pressure are achieved through the temperature control structure and oil pressure regulation structure of the oil tank 51. Then, the oil supply mechanism 50 is driven to deliver lubricating oil to the meshing part of the first gear sample 12 and the second gear sample 13, so that an oil film layer can be formed on the meshing tooth surface of the first gear sample 12 and the second gear sample 13.

[0092] S30. Determine the working parameters for the electrical breakdown test. The working parameters for the electrical breakdown test include the rotational speed of the gear sample, the torque of the gear sample, and the frequency and magnitude of the simulated voltage applied to the gear sample. According to the working parameters for the electrical breakdown test, start and adjust the power mechanism 20, the load loading mechanism 30, and the voltage loading mechanism 40, and continue for a specified time. Then, while keeping the frequency of the simulated voltage, the rotational speed of the gear sample, and the torque of the gear sample constant, gradually increase the simulated voltage and monitor the change in the current flowing through the gear sample. Each time the simulated voltage is increased, continue for a specified time. When a sudden increase in current is detected, stop the experiment. Record the experimental data during the test.

[0093] Specifically, based on the determined electrical breakdown test parameters, the power mechanism 20 and the load loading mechanism 30 are first started and adjusted so that the speed and torque values ​​of the gear sample reach the determined values ​​in the electrical breakdown test parameters. After the operation is stable, the external power supply is turned on, and a voltage of a specified frequency is applied to the gear sample through the voltage loading mechanism 40 for a specified duration. The magnitude of the current flowing through the gear sample is monitored by the digital oscilloscope 62 in the voltage loading mechanism 40. Then, while keeping the speed, torque, and frequency of the simulated voltage of the gear sample constant, the simulated voltage is increased step by step, and each increase is maintained for a specified duration. When a sudden increase in current is detected, it indicates that the oil film layer of the gear sample has been broken down. The experiment is stopped, and the voltage, current, oil temperature, and other data are recorded. The gear sample is retained for subsequent inspection and analysis.

[0094] For example, as shown in Table 1, initially, the speed of the adjustable motor 21 was adjusted to 40 rpm, and the torque of the magnetic powder brake 31 was adjusted to 20 Nm. After the operation stabilized, the external power supply was turned on, and a simulated voltage of 0.1V with a frequency of 20Hz was applied to the gear sample through the voltage loading mechanism 40 for 3-5 minutes. Subsequently, the simulated voltage was gradually increased by 0.1V at a time through the power amplifier 42 in the voltage loading mechanism 40, with each increase lasting 3-5 minutes. The current and oil temperature data were recorded each time the simulated voltage was increased. When a sudden increase in current was detected, the experiment was stopped. The relevant data obtained from the experiment are recorded in Table 1 below.

[0095] Table 1. Recording Table of Electrical Breakdown Experiment Data

[0096]

[0097] S40. Replace the gear sample with one of the same specifications and repeat steps S20 and S30 continuously. Adjust the electrical breakdown test parameters of the replaced gear sample according to the electrical breakdown test plan during the experiment.

[0098] Specifically, when replacing the gear sample, the entire gear assembly is not replaced. Since the first gear sample 12 and the second gear sample 13 are detachably mounted on the first rotating shaft 121 and the second rotating shaft 131, respectively, only the first gear sample 12 and the second gear sample 13 need to be replaced. To shorten the replacement time, two shaft assemblies consisting of the first rotating shaft 121 and the second rotating shaft 131 are provided. While one shaft assembly is being tested inside the gearbox 11 with the gear sample installed, the other shaft assembly can simultaneously complete the installation of the gear sample outside the gearbox 11. The assembly is switched immediately after the gear electrical breakdown test, thus achieving seamless connection between gear sample replacement and the gear sample test. Please refer to Table 2, which is the gear electrical breakdown test scheme. During the experiment, the replaced gear sample is adjusted according to the gear sample rotation speed, gear sample torque, and the magnitude and frequency of the simulated voltage in the electrical breakdown test operating parameters as shown in Table 2.

[0099] Table 2 Electrical Breakdown Test Procedure

[0100]

[0101] S50. Based on the recorded experimental data, calculate the minimum oil film thickness of the gear sample when it is electrically broken down under different electrical breakdown test parameters, and mark the minimum breakdown voltage of the gear sample under different electrical breakdown test operating parameters.

[0102] Specifically, based on the experimental data recorded in Table 1 above, the minimum oil film thickness of each gear sample of the same specification was calculated, and the minimum breakdown voltage of each gear sample was marked. The minimum breakdown voltage is the voltage that causes a sudden current surge during the simulated voltage process of each gear sample. Finally, using the data in Table 1, the minimum oil film thickness and minimum breakdown voltage values ​​of gear samples of the same specification under different speeds, torques, and simulated voltage frequencies were obtained.

[0103] In existing generator gearbox integrated systems, the transmission gear type is mainly involute helical gears. Considering the similarity of oil film thickness properties between involute helical gear transmission and involute spur gear transmission, and to simplify the experiment and minimize experimental interference, in one embodiment of this application, both the first gear sample 12 and the second gear sample 13 are selected as involute cylindrical gears of the same size. Therefore, the basic parameters of the two gear samples are also the same. For example, the basic parameters of the two gear samples are selected as: i = 1; z = 30, α n =20°, c=0.25.

[0104] Based on the fact that both the first gear sample 12 and the second gear sample 13 are selected as involute cylindrical gears and are of equal size, the minimum oil film thickness value of each gear sample can be calculated according to the following formula:

[0105]

[0106] In equation (1), α is the viscosity coefficient, with units of Pa. -1 η0 is the dynamic viscosity of lubricating oil under normal pressure, in Pa·s; V m R is the average tangential velocity of the gear pair meshing point surface, in m / s; W is the radius of curvature, in m; E is the load per unit contact width, in N / m; and E is the overall elastic modulus of the gear pair, in Pa.

[0107] The formula for calculating W is:

[0108]

[0109] V m The formula for calculation is:

[0110]

[0111] In equations (2) and (3), b is the tooth width of the gear sample, in meters (m); T is the torque applied to the gear sample, in Nm; n is the rotational speed, in m / s; i represents the transmission ratio; a is the center distance between the first gear sample 12 and the second gear sample 13, in meters; α n Represents the normal pressure angle, in degrees.

[0112] In equations (1), (2), and (3), α and η0 can be obtained based on the relevant parameters of the selected lubricating oil, and R, E, b, a, and α... n The parameters n and T can be obtained from the relevant parameters of the selected gear sample, and are obtained through experiments using a gear testing device.

[0113] In one embodiment of this application, step S10 includes pre-assembly preparation and post-assembly preparation of the gear experimental device.

[0114] The preparations before device assembly include the following steps:

[0115] S11. Re-inspect the dimensions of the gear sample and its corresponding assembly to ensure they meet the design requirements.

[0116] S12. Perform individual debugging on the voltage loading mechanism 40, load loading mechanism 30, oil supply mechanism 50 and power mechanism 20 to ensure that each mechanism is in normal working condition.

[0117] Specifically, before assembly, the power supply measurement component of the voltage loading mechanism 40, the adjustable speed motor 21 of the power mechanism 20, the magnetic powder brake 31 and torque and speed sensor 33 of the load loading mechanism 30, and the oil pump 57 of the oil supply mechanism 50 are individually tested to ensure that each mechanism can work normally.

[0118] S13. Replace the lubricating oil in the oil supply mechanism 50 with a suitable lubricating oil according to the model of the selected gear sample.

[0119] S14. Inspect the gear samples and keep inspection records.

[0120] Specifically, the inspection records include the serial number, appearance quality, dimensional accuracy, surface morphology, etc., and photos are taken as evidence.

[0121] S15. Mark the rotation direction of the gear sample for comparative analysis before and after the experiment.

[0122] In step S10, the preparation after assembly includes the following steps:

[0123] Debug the gear experimental device, check whether all connections of the gear experimental device are properly connected, and ensure that the experimental device operates without abnormality.

[0124] In summary, the gear electrical breakdown test method of the present invention, by employing the above-mentioned gear test apparatus, can perform high-precision electrical breakdown tests on gear samples under oil lubrication conditions, thereby significantly improving the reliability of the electrical breakdown test data.

[0125] like Figure 10 As shown, the present invention also provides a gear testing apparatus for electro-erosion experiments. The structure of this apparatus is very similar to that of the gear testing apparatus for gear electrical breakdown experiments described above. The difference lies in that this gear testing apparatus further includes a vibration sensor 70 for measuring the vibration of the gear sample. In some embodiments, the vibration sensor 70 may be as follows: Figure 10 The accelerometer shown is mounted on the outer wall of the gearbox 11. Since the vibration of the gear sample is transmitted to the gearbox 11, this arrangement effectively captures the vibration signal of the gear sample. In other feasible embodiments, the vibration sensor 70 can also be a laser vibrometer located on one side of the gearbox 11, acquiring the vibration velocity / displacement of the gear sample through the Doppler effect or interferometry to obtain the vibration information of the gear sample. The vibration sensor 70 is electrically connected to the data acquisition mechanism to transmit the measured vibration information to the data acquisition mechanism. When the corrosion of the gear sample is severe, the vibration data will suddenly increase. During operation, while keeping the torque, rotational speed, and the magnitude and frequency of the analog voltage applied to the gear sample constant, the experiment continues. The vibration sensor 70 monitors the vibration changes of the gear sample to monitor the electrolytic corrosion of the gear sample.

[0126] The aforementioned gear experimental device with vibration sensor 70 can accurately simulate the actual operating conditions of gears in a generator gearbox integrated system, enabling precise electro-erosion experiments on gear samples.

[0127] It should be noted that the gear test apparatus with vibration sensor described above can be used not only for gear erosion tests but also for gear electrical breakdown tests. When used for gear electrical breakdown tests, the operation of vibration sensor 70 is ignored.

[0128] In one embodiment of the application, in addition to the gear experimental apparatus equipped with a vibration sensor 70, the data acquisition mechanism further includes a vibration display 63 electrically connected to the vibration sensor 70. The vibration display 63 acquires and displays the vibration information monitored by the vibration sensor 70.

[0129] The present invention also provides a method for testing gear electro-erosion, comprising the following steps:

[0130] S10. Provide the gear test apparatus with vibration sensor 70 as described above, and perform pre-experiment preparation work on the gear test apparatus.

[0131] S20. Determine the working parameters of the electro-erosion test for the gear sample. The working parameters of the electro-erosion test include the rotational speed of the gear sample, the torque of the gear sample, and the frequency of the simulated voltage applied to the gear sample. Based on the initial working parameters of the electro-erosion test and the experimental results obtained by the gear electrical breakdown test method as described above, determine the minimum breakdown voltage of the gear sample. Set the magnitude of the simulated voltage applied to the gear sample based on the minimum breakdown voltage.

[0132] Specifically, after determining the working parameters of the gear sample, find the corresponding minimum breakdown voltage value from Table 1 above based on the gear sample rotation speed and gear sample torque in the determined working parameters. Then, set the magnitude of the simulated voltage applied to the gear sample according to the minimum breakdown voltage. The simulated voltage must be greater than the minimum breakdown voltage. Generally, the simulated voltage is set to 5 times, 10 times, 20 times, etc. of the minimum breakdown voltage to ensure that the gear sample directly enters the electro-erosion stage.

[0133] S30, Start the oil supply mechanism 50 to lubricate the gear sample.

[0134] Specifically, during the start-up of the oil supply mechanism 50, the parameters such as oil temperature and oil pressure are first adjusted. The oil temperature and oil pressure are achieved through the temperature control structure and oil pressure regulation structure of the oil tank 51. Then, the oil supply mechanism 50 is driven to deliver lubricating oil to the meshing part of the first gear sample 12 and the second gear sample 13, so that an oil film layer can be formed on the meshing tooth surface of the first gear sample 12 and the second gear sample 13.

[0135] S40, start the power mechanism 20, voltage loading mechanism 40 and load loading mechanism 30, adjust the torque and speed of the gear sample, as well as the magnitude and frequency of the simulated voltage applied to the gear sample, according to the working parameters of the electro-erosion experiment determined in step S20, keep the working parameters of the electro-erosion experiment unchanged and continue the experiment, monitor the vibration change of the gear sample in real time through the vibration sensor 70, stop the experiment when a sudden increase in vibration is detected, observe the macro and micro morphology of the surface of the gear sample after the experiment, and record the relevant experimental data.

[0136] Specifically, an electro-erosion experiment data table is prepared. First, the initially determined electro-erosion experiment working parameters are recorded in Table 3 below. Then, the power mechanism 20 and the load loading mechanism 30 are started, followed by the voltage loading mechanism 40. According to the determined electro-erosion experiment working parameters and the magnitude of the simulated voltage, the rotational speed and torque of the gear sample, as well as the magnitude and frequency of the simulated voltage applied to the gear sample, are adjusted and the experiment is continued. When a sudden increase in vibration of the gear sample is detected, it indicates that the corrosion degree of the gear sample surface has reached or exceeded the expected corrosion degree. The experiment is stopped, and the voltage, current, oil temperature, vibration acceleration of the gear sample, and experiment duration are recorded in the electro-erosion experiment data table. Subsequently, the gear sample is removed from the gearbox 11, and the macro- and micro-morphological morphology of the gear sample surface after the experiment is observed and analyzed. The relevant data of the gear sample surface morphology analysis are recorded in the electro-erosion experiment data table for subsequent analysis.

[0137] For example, the experimental data is recorded using the electro-erosion test data table shown in Table 3 below. Initially, the adjustable speed motor speed in the working parameters of the gear sample is set to 40 rpm, the torque of the gear sample is set to 20 Nm, and the simulated voltage applied to the gear sample is set to a frequency of 20 Hz. Based on the set working parameters of the gear sample and the electrical breakdown test data, the magnitude of the simulated voltage is set to 5 V. Based on the set working parameters of the electro-erosion test and the magnitude of the simulated voltage, the speed of the adjustable speed motor 21 of the power mechanism 20 is adjusted to 40 rpm, and the torque of the magnetic powder brake 31 of the load loading mechanism 30 is adjusted to 20 Nm. After the operation is stable, the external power supply is turned on, and a simulated voltage of 5 V with a frequency of 20 Hz is applied to the gear sample through the voltage loading mechanism 40. Then, the speed and torque of the gear sample, as well as the magnitude and frequency of the simulated voltage, are kept constant and the experiment continues. The vibration change of the gear sample is observed through the vibration sensor 70. When a sudden increase in the vibration of the gear sample is detected, the experiment is stopped, the gear sample is taken out of the gearbox 11, and the macro- and micro-morphology of the surface of the gear sample after the experiment is observed and analyzed. Throughout the experiment, the relevant data obtained were recorded in Table 3 below.

[0138] Table 3. Record of Electrolytic Erosion Experiment Data

[0139]

[0140] S50. Replace the gear sample and repeat steps S20 to S40 continuously. Adjust the working parameters of the electro-erosion test according to the electro-erosion test plan for the replaced gear sample during the experiment.

[0141] Specifically, when replacing the gear sample, it is not necessary to replace the entire gear assembly. Since the first gear sample 12 and the second gear sample 13 are detachably mounted on the first rotating shaft 121 and the second rotating shaft 131, respectively, only the first gear sample 12 and the second gear sample 13 need to be replaced. During the replacement process, in order to shorten the replacement time, two shaft combinations consisting of the first rotating shaft 121 and the second rotating shaft 131 are provided. When one shaft combination is used to install the gear sample and conduct the experiment inside the gearbox 11, the other shaft combination can simultaneously complete the installation of the gear sample outside the gearbox 11. After the electrical breakdown test is completed, the two shafts are switched immediately, thus achieving a seamless connection between the gear sample replacement and the gear sample experiment. Please refer to Table 4, which is the electrical erosion test scheme table. The rotation speed, torque, and frequency of the replaced gear sample are adjusted according to Table 4. After each adjustment, the experimental data are recorded in Table 3 above.

[0142] Table 4 Electro-erosion test scheme

[0143]

[0144] S60. Analyze the experimental data.

[0145] Specifically, the effects of different voltages, torques, and rotational speeds on the electro-erosion of gear samples were analyzed using experimental data.

[0146] The gear electrolytic corrosion test method of the present invention, by using the above-mentioned gear test device with vibration sensor, can perform high-precision electrical breakdown test on gear samples, thereby significantly improving the reliability of electrolytic corrosion test data.

[0147] The above description is merely an example and illustration of the structure of the present invention. Those skilled in the art can make various modifications or additions to the specific embodiments described, or use similar methods to replace them, as long as they do not deviate from the structure of the invention or exceed the scope defined in the claims, all of which should fall within the protection scope of the present invention.

Claims

1. A gear experimental apparatus, characterized in that, include: A gear experimental mechanical mechanism includes a gearbox and a gear assembly. The gearbox has a mounting cavity, and the gear assembly is detachably installed in the mounting cavity and is insulated from the gearbox. The gear assembly includes a first rotating shaft, a second rotating shaft, and two gear samples, which are detachably installed on the first rotating shaft and the second rotating shaft, respectively. A power mechanism, insulated from the first rotating shaft, is used to drive the gear sample to rotate; A load loading mechanism, insulated from the second rotating shaft, is used to apply torque to the gear sample and monitor the torque and rotational speed of the gear sample in real time. A voltage loading mechanism, electrically connected to the first rotating shaft and the second rotating shaft, is used to drive the gear assembly to generate a current flowing through the gear sample; An oil supply mechanism, connected to the mounting cavity, is used to supply lubricating oil to the contact surfaces of the two gear samples; and The data acquisition mechanism is electrically connected to the load loading mechanism and the voltage loading mechanism, and is used to acquire experimental data.

2. The gear experimental apparatus according to claim 1, characterized in that, The gear samples were all involute helical gears or involute cylindrical gears.

3. The gear experimental apparatus according to claim 1, characterized in that, The two gear samples are the same size.

4. The gear experimental apparatus according to claim 1, characterized in that, The power mechanism includes an adjustable speed motor and a power insulated coupling, wherein the adjustable speed motor is connected to the first rotating shaft through the power insulated coupling.

5. The gear experimental apparatus according to claim 1, characterized in that, The load loading mechanism includes a magnetic powder brake, a brake coupling, a torque and speed sensor, a torque measuring insulated coupling, and a brake controller; the magnetic powder brake is connected to the torque and speed sensor via the brake coupling; the torque and speed sensor is connected to the second rotating shaft via the torque measuring insulated coupling; both the torque and speed sensor and the magnetic powder brake are electrically connected to the data acquisition mechanism; the brake controller is electrically connected to the magnetic powder brake.

6. The gear experimental apparatus according to claim 1, characterized in that, The voltage loading mechanism includes a power supply measurement component, a first carbon brush assembly, and a second carbon brush assembly. The power supply measurement component, the first carbon brush assembly, the gear assembly, and the second carbon brush assembly are sequentially electrically connected to form a closed experimental circuit. The first carbon brush assembly is electrically connected to the first rotating shaft through contact, and the second carbon brush assembly is electrically connected to the second rotating shaft through contact.

7. The gear experimental apparatus according to claim 1, characterized in that, The oil supply mechanism includes an oil tank, an oil inlet pipe assembly, an oil outlet pipe assembly, an oil inlet pump, an oil outlet pump, an oil temperature measurement module, an oil pressure measurement module, and a heat exchanger; the oil tank, the oil inlet pipe assembly, the oil outlet pipe assembly, and the gearbox are connected in series to form a closed oil supply circuit; the oil tank is an oil storage structure with oil heating and oil pressure regulation; the oil inlet pipe assembly includes a first oil pipe and an oil injection pipe, the oil injection pipe is located in the mounting cavity, the oil injection pipe extends along the axial direction of the gear sample, and the parts that mesh with the two gear samples are located at the same height; the oil injection pipe... The first oil pipe is provided with an oil injection hole facing the meshing part of the two gear samples; both ends of the first oil pipe are connected to the oil tank and the oil injection pipe; the oil outlet pipe assembly includes a second oil pipe, the two ends of the second oil pipe are respectively connected to the oil tank and the bottom end of the mounting cavity; the oil inlet pump, the oil pressure measuring module and the heat exchanger are all located on the first oil pipe; the oil outlet pump is located on the second oil pipe; the oil temperature measuring module is located in the oil supply circuit and is used to measure the lubricating oil temperature at the oil outlet end of the first oil pipe and the lubricating oil temperature at the oil inlet end of the second oil pipe.

8. The gear experimental apparatus according to any one of claims 1 to 7, characterized in that, It also includes a vibration sensor electrically connected to the data acquisition mechanism, the vibration sensor being used to measure the vibration of the gear sample.

9. A method for testing the electrical breakdown of gears, characterized in that, Includes the following steps: S10. Provide a gear testing apparatus as described in any one of claims 1 to 7, and perform pre-experiment preparation work on the gear testing apparatus; S20. Start the oil supply mechanism to lubricate the gear sample; S30. Determine the working parameters of the electrical breakdown test. The working parameters of the electrical breakdown test include the rotational speed of the gear sample, the torque of the gear sample, and the frequency and magnitude of the simulated voltage applied to the gear sample. According to the working parameters of the electrical breakdown test, start and adjust the power mechanism, the load loading mechanism, and the voltage loading mechanism, and continue for a specified time. Then, while keeping the frequency of the simulated voltage, the rotational speed of the gear sample, and the torque of the gear sample constant, gradually increase the simulated voltage and monitor the change in the current flowing through the gear sample. Each time the simulated voltage is increased, continue for a specified time. When a sudden increase in current is detected, stop the experiment. Record the experimental data during the test. S40. Replace the gear sample and repeat steps S20 to S30 continuously. The working parameters of the electrical breakdown test are adjusted according to the electrical breakdown test scheme for the replaced gear sample during the experiment. S50. Based on the recorded experimental data, calculate the minimum oil film thickness of the gear sample when it is electrically broken down under different electrical breakdown test parameters, and mark the minimum breakdown voltage of the gear sample under different electrical breakdown test parameters.

10. A method for testing the electro-erosion of gears, characterized in that, Includes the following steps: S10. Provide the gear testing apparatus as described in claim 8, and perform pre-experiment preparation work on the gear testing apparatus; S20. Determine the working parameters of the electro-erosion test of the gear sample. The working parameters of the electro-erosion test include the rotational speed of the gear sample, the torque of the gear sample, and the frequency of the simulated voltage applied to the gear sample. Based on the working parameters of the electro-erosion test and the experimental results obtained by the gear electrical breakdown test method as described in claim 9, determine the minimum breakdown voltage of the gear sample. Set the magnitude of the simulated voltage based on the minimum breakdown voltage. S30. Start the oil supply mechanism to lubricate the gear sample; S40. Start the power mechanism, the voltage loading mechanism and the load loading mechanism. According to the working parameters of the electro-erosion experiment determined in step S20, adjust the torque and speed of the gear sample, as well as the magnitude and frequency of the simulated voltage applied to the gear sample. Keep the working parameters of the electro-erosion experiment unchanged and continue the experiment. Monitor the vibration changes of the gear sample in real time through the vibration sensor. When a sudden increase in vibration is detected, stop the experiment, observe the macro- and micro-morphology of the surface of the gear sample after the experiment, and record the relevant experimental data. S50. Replace the gear sample and repeat steps S20 to S40 continuously. The working parameters of the electro-erosion test are adjusted according to the electro-erosion test plan for the replaced gear sample during the experiment. S60. Analyze the experimental data.

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