Gearbox abnormal sound judgment method based on transmission and working condition coupling

Abstract

The invention discloses a gearbox abnormal sound judgment method based on transmission and working condition coupling, and relates to the technical field of gearbox fault judgment. The method comprises the steps that when abnormal sound occurs, gearbox working condition parameters are collected; identifying a working condition operation type according to the gearbox working condition parameters; determining an abnormal sound source area by combining the gearbox working condition parameters and the working condition operation type; and according to the transmission route map of the gearbox, positioning the abnormal sound component in combination with the abnormal sound source area. According to the invention, through a dual positioning mechanism automatically executed by a machine, the diagnosis precision is improved from a system level to a component level, the problems that a traditional method depends on experience and is fuzzy in positioning and existing abnormal sound diagnosis methods such as a vibration spectrum analysis method and an acoustic imaging method are high in cost and complex in installation are solved, the troubleshooting efficiency and the diagnosis precision are improved, and the cost is reduced. The device is suitable for gearbox factory running-in testing, installation debugging and other scenes.

Description

Technical Field

[0001] This invention relates to a method for judging abnormal noises in a transmission based on the coupling of transmission and operating conditions, belonging to the technical field of transmission fault diagnosis. Background Technology

[0002] As a core transmission component of construction machinery, the reliability of the gearbox directly affects the overall performance and service life of the machine. In gearbox failures, abnormal noises are often extremely difficult to diagnose due to variations in testing methods and the difficulty in pinpointing the location and pattern of the noise. However, since abnormal noises often indicate potential mechanical damage such as abnormal gear pitting, torque converter damage, pump spline wear, or system cavitation, failure to accurately locate the fault source in a timely manner can lead to a chain reaction of damage (e.g., metal debris contaminating the oil circuit causing valve jamming), and in severe cases, sudden shutdowns and safety hazards.

[0003] Traditional methods for diagnosing abnormal noises mainly rely on the experience of maintenance personnel to locate the noise through auscultation, which is highly subjective, has low accuracy, and is time-consuming. Existing equipment diagnostic methods (such as vibration spectrum analysis and acoustic imaging) often only establish abnormal noise spectrum analysis models for components such as bearings and gears based on simple operating conditions or single signals. These methods still have problems such as narrow operating condition coverage, unclear identification of abnormal noise locations or components, and high costs associated with multiple installation and measurement.

[0004] Therefore, the industry urgently needs a systematic, efficient, and multi-condition-covering method for diagnosing abnormal noises that can accurately pinpoint the source of the noise or specific components. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a method for judging abnormal noises in a transmission based on the coupling of transmission and operating conditions. Through a dual positioning mechanism automatically executed by the machine, the diagnostic accuracy is improved from the system level to the component level. This solves the problems of traditional methods relying on experience and having ambiguous positioning, as well as the high cost and complex installation of existing sensor diagnostic methods. It improves the efficiency of troubleshooting and the accuracy of diagnosis, and is applicable to scenarios such as transmission factory break-in testing and installation debugging.

[0006] To achieve the above objectives, the present invention is implemented using the following technical solution: This invention provides a method for judging abnormal noises in a transmission based on the coupling of transmission and operating conditions, including: When abnormal noise occurs, collect transmission operating parameters; Identify the operating condition type based on the transmission operating parameters; Determine the source area of ​​abnormal noise by combining transmission operating parameters and operating conditions; Based on the transmission route diagram of the gearbox, locate the abnormal noise components in the area where the abnormal noise originates.

[0007] Furthermore, the transmission operating parameters include the working gear, engine speed, lifting arm operating lever displacement, shift operating lever displacement, steering angle, and throttle opening change rate.

[0008] Furthermore, the working gear position is monitored by a Hall sensor located at the gear shift lever; the engine speed is monitored by a magnetoelectric speed sensor located at the front end of the engine flywheel housing or crankshaft; the displacement of the lifting arm operating lever is monitored by a cable-operated lever displacement sensor located at the lifting arm operating lever; the displacement of the shift operating lever is monitored by a cable-operated lever displacement sensor located at the shift operating lever; the steering angle is monitored by a photoelectric steering wheel angle sensor located on the steering column; and the throttle opening change rate is monitored by a Hall-type throttle pedal position sensor located at the throttle pedal.

[0009] Furthermore, the operating conditions include boom lifting, steering, gear shifting, and speed increase / decrease in the same gear.

[0010] Furthermore, the step of identifying the operating condition type based on the transmission operating condition parameters includes: When the transmission operating parameters exceed the preset threshold, it is determined to be the corresponding operating condition operation type. Among them, the displacement of the lifting arm operating lever corresponds to the lifting arm operation, the displacement of the shift operating lever corresponds to the shift operation, the steering angle corresponds to the steering operation, and the throttle opening change rate corresponds to the same gear acceleration / deceleration operation.

[0011] Furthermore, determining the abnormal noise source area by combining transmission operating parameters and operating mode types includes: When the operating condition is boom lifting operation and abnormal noise occurs in each working position, it is determined to be the working pump area. When the operating condition is steering, and abnormal noise occurs in all working gears, it is determined to be the steering pump area. When the operating condition is gear shifting, and abnormal noise occurs in each working gear, and the frequency difference of the abnormal noise in different working gears is >200Hz, it is judged to be the torque converter area. When the operating condition is the same gear speed increase / decrease operation, and abnormal noise occurs in each working gear and the engine speed is >2000r / min, it is judged to be the transmission pump area; When the operating condition is the same gear speed increase / decrease operation, and abnormal noise occurs in each working gear within the preset engine speed range, it is determined to be the oil suction device area. If abnormal noise occurs in non-all working gears when the current operating condition is not being performed, it is determined to be in the clutch area.

[0012] Furthermore, the preset engine speed range is 850~2200 r / min.

[0013] Furthermore, the step of locating the abnormal noise component based on the transmission route diagram and the abnormal noise source area includes: The transmission route for each working gear is obtained from the transmission route diagram of the gearbox when performing this type of operation. The transmission route includes the power transmission path and the force state of the components. The components in the power transmission state or the load-bearing state are determined according to the transmission route; The abnormal noise components are selected from those that are in a power transmission state or a load-bearing state.

[0014] Furthermore, the components in the power transmission state or load-bearing state include components directly connected to the transmission input shaft or transmission output shaft, components with theoretically calculated torque greater than the set value, and the driving and driven components of the current gear meshing gear pair.

[0015] Furthermore, the abnormal noise components identified from components in a power transmission state or a load-bearing state include: When the abnormal noise source area includes the clutch area, the abnormal noise components are the components in the clutch area that are not shared in the abnormal noise working gear and the non-abnormal noise working gear, as well as the components in the other abnormal noise source areas. When the abnormal noise source area does not include the clutch area, the abnormal noise component is the component within the abnormal noise source area.

[0016] Compared with the prior art, the beneficial effects achieved by the present invention are as follows: This invention utilizes a dual positioning mechanism of machine-automated functional area and specific component, combined with transmission route analysis of loaded components, to improve diagnostic accuracy from the system level to the component level. Furthermore, the entire process is based on quantitative parameters collected by sensors and fixed rule judgments, solving the problems of traditional methods relying on experience, ambiguous positioning, and the narrow coverage of existing abnormal noise diagnosis methods such as vibration spectrum analysis and acoustic imaging. This improves the efficiency of troubleshooting and the accuracy and objectivity of diagnosis. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall process of a gearbox abnormal noise judgment method based on transmission and operating condition coupling in one embodiment of the present invention. Figure 2 This is a schematic diagram of the specific judgment process of the gearbox abnormal noise judgment method based on transmission and working condition coupling in one embodiment of the present invention. Figure 3 This is a schematic diagram of the sensor installation position in Embodiment 2 of the present invention; Figure 4 This is a schematic diagram showing the classification of the functional areas of the gearbox in Embodiment 2 of the present invention; Figure 5This is a transmission route diagram of the gearbox in Embodiment 2 of the present invention; In the diagram: 1-Hall effect gear position sensor, 2-magnetic speed sensor, 3-first cable-operated lever displacement sensor, 4-second cable-operated lever displacement sensor, 5-photoelectric steering wheel angle sensor, 6-Hall effect accelerator pedal position sensor; D1 - Working pump area, D2 - Steering pump area, D3 - Variable speed pump area, D4 - Torque converter area, D5 - Oil suction device area, D6 - Clutch area; F1-Working pump shaft gear, F2-Working pump bearing, F3-Steering pump shaft gear, F4-Steering pump bearing, F5-Transmission pump, F6-Torque converter, F7-Oil suction pipe, F8-Overrunning clutch, F9-Reverse gear system, F10-First gear system, F11-Second gear clutch, z1~z9-Gear positions. Detailed Implementation

[0018] The present invention will be further described below with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and should not be used to limit the scope of protection of the present invention. Example 1

[0019] like Figure 1 As shown, this embodiment of the invention provides a method for judging abnormal noises in a transmission based on the coupling of transmission and operating conditions, combined with... Figure 2 Specifically, it includes the following steps: S1. Gearbox operating condition parameter acquisition When the abnormal noise occurs, combine Figure 3 The working gear is obtained by Hall effect gear position sensor 1 installed at the gear shift lever of the gearbox, and the engine speed is monitored by magnetoelectric speed sensor 2 installed at the front end of the engine flywheel housing or crankshaft. The working gear can be increased or decreased according to the actual gear of the gearbox under test. In this embodiment, the working gear includes forward first gear, forward second gear, and reverse first gear.

[0020] The abnormal noise in all gears refers to the abnormal noise occurring in all working gears: first gear, second gear, and third gear. The abnormal noise in all gears refers to at least one gear (first gear, second gear, and first reverse gear) that makes abnormal noise, and at least one gear among all working gears that does not make abnormal noise.

[0021] In addition to the aforementioned gear position and engine speed, the transmission operating parameters also include the displacement of the lifting arm operating lever, the displacement of the shift operating lever, the steering angle, and the rate of change of throttle opening. These transmission operating parameters are used to identify the type of operation.

[0022] The displacement of the boom control lever is monitored by a cable-operated control lever displacement sensor 3 installed at the boom control lever; the displacement of the shift control lever is monitored by a cable-operated control lever displacement sensor 4 installed at the shift control lever; the steering angle and angular velocity are monitored by a photoelectric steering wheel angle sensor 5 installed on the steering column; and the throttle opening and rate of change are monitored by a Hall effect throttle pedal position sensor 6 installed at the throttle pedal.

[0023] The signals collected by each sensor are transmitted to the edge computing unit in real time for processing and storage.

[0024] S2, Identify operating conditions and types In this embodiment, the operating conditions include boom lifting, steering, gear shifting, and speed increase / decrease in the same gear.

[0025] When a certain transmission operating parameter exceeds a preset threshold, it is determined that the transmission is currently in the operating condition type corresponding to that transmission operating parameter.

[0026] In this embodiment, a lifting arm operation is determined when the displacement of the lifting arm operating lever is greater than 50mm; A steering operation is determined when the steering angle is greater than 30°. A shift operation is determined when the displacement of the shift lever is greater than 30mm. When the rate of change of throttle opening is greater than 5% / s, it is determined to be a speed increase or decrease operation in the same gear.

[0027] S3. Identify the area of ​​the abnormal noise source. When the operating condition is boom lifting operation and abnormal noise occurs in all gears, it is determined to be the working pump area D1; When the operating condition is steering and abnormal noise occurs in all gears, it is determined to be the steering pump area D2. When the operating condition is a gear shifting operation, and abnormal noise occurs in all gears, and the frequency difference of the abnormal noise in different working gears is >200Hz, it is determined to be torque converter region D4. In this embodiment, the abnormal noise frequency can be obtained by acoustic sensor. When the operating condition is the same gear speed increase / decrease operation, and abnormal noise occurs in all gears and the engine speed is >2000r / min, it is judged to be the transmission pump area D3; When the operating condition is the same gear speed increase / decrease operation, and abnormal noise occurs in all gears within the range of 850~2200r / min, it is determined to be the oil suction device area D5; When abnormal noise occurs in non-all working gears when the current operating condition is not being performed, it is determined to be in the clutch area D6.

[0028] S4, Locating abnormal noise components The edge computing unit, based on the pre-stored digital twin model of the gearbox, retrieves the transmission route map within the determined abnormal noise source area. From the transmission route map, it filters out the components that are in the power transmission state or the load-bearing state, and the components that are in the power transmission state or the load-bearing state are the abnormal noise components.

[0029] Components in a power transmission or load-bearing state include those directly connected to the transmission input or output shaft, components with a theoretically calculated torque greater than the machine's starting torque, and the driving and driven components of the currently engaged gear pair. For example... Figure 3 As shown, in this embodiment, depending on the different structural forms of the gearbox, the components in the power transmission state or the load-bearing state include, but are not limited to, the working pump shaft gear F1, the steering pump shaft gear F3, the transmission pump F5, the torque converter F6, the oil suction pipe F7, and the gear position gears z1-zn. Example 2

[0030] Based on Example 1, this example combines the following: Figure 4 The transmission route of the gearbox, which shows two gears before and one gear after, will be explained in detail below: Current transmission operating status: After the transmission was installed, the sensor detected that when the engine speed was 1500 rpm, abnormal noises occurred in all gears during steering. When not steering, only the first gear caused abnormal noises, while other gears operated normally.

[0031] S1 operating condition parameter acquisition: The Hall effect sensor detects the working gear, including first gear, second gear, and reverse gear. The magnetoelectric speed sensor detected an engine speed of 1500 rpm; Table 1 shows the data for the lifting arm lever displacement detected by the cable-operated lever displacement sensor, the shift lever displacement detected by the cable-operated lever displacement sensor, the steering angle detected by the photoelectric steering wheel angle sensor, and the throttle opening change rate detected by the Hall effect accelerator pedal position sensor. Table 1: Operating Parameter Data

[0032] S2 identifies operating conditions and types: Based on the data in Table 1, a total of 2 operation steps were performed. In operation step 1, the steering angle exceeding 30° was determined to be a steering operation; the displacement of the forward first gear, forward second gear, and reverse gear shift levers exceeding 30mm was determined to be a gear shift operation; and the displacement of the lifting arm shift lever and the throttle opening change rate being 0 were determined to be no lifting arm or same-gear speed increase / decrease operation. If the displacement of the shift lever for first gear, second gear, and reverse gear in operation step 2 is greater than 30mm, it is determined that all gear shifting operations have been performed; if the change rate of steering angle, lifting arm shift lever displacement, and throttle opening is 0, it is determined that lifting arm and speed adjustment operations in the same gear have not been performed.

[0033] S3 Identify the area of ​​the abnormal noise source: Based on the transmission operating parameters and the type of operation, the current transmission operating status is as follows: 1. Abnormal noise occurs in all gears when steering; 2. Abnormal noise occurs only in first gear when not steering, and other gears operate normally.

[0034] Therefore, based on the operating condition being a reversing operation and the abnormal noise occurring in all gears, the source of the abnormal noise is determined to include the steering pump area D2. Since the abnormal noise does not occur in all gears, the source of the abnormal noise is also determined to include the clutch area D6.

[0035] S4 locates the noisy component: The edge computing unit retrieves the transmission routes for each gear during steering operations and combines them with... Figure 5 The details are as follows: The transmission route corresponding to the steering operation is that power is transmitted from the torque converter F6 to the steering pump shaft gear F3; When shifting to first gear, the first gear planetary gear set F10 engages, and power is transmitted from the torque converter F6 to the overrunning clutch F8 gears z1 and z2, then through the sun gear z3 to the first gear planetary gear z6. Since the first gear internal gear ring gear z7 is braked, power is transmitted through the first gear planetary carrier z5 to the second gear clutch F11 gear z8, and then to the output shaft gear z9 for power output. Therefore, the transmission route for shifting to first gear is z1→z2→z3→z6→z5→z8→z9. When in second gear, the second gear clutch F11 engages, and power is transmitted from the torque converter F6 to the gears z1 and z2 of the overrunning clutch F8, then directly to the z8 of the second gear clutch F11 via the sun gear z3, and finally to the output shaft gear z9 for power output. Therefore, the transmission route for second gear is z1→z2→z3→z8→z9; In reverse gear, the reverse planetary gear set F9 engages, and power is transmitted from the torque converter F6 to the overrunning clutch F8 via gears z1 and z2, then through the sun gear z3 to the reverse planetary gear set z4. Because the reverse planetary carrier is braked, power is transmitted through the first gear planetary carrier z5 to the second gear clutch F11 via gear z8, and finally to the output shaft gear z9 for power output. Therefore, the reverse gear transmission route is z1→z2→z3→z4→z5→z8→z9; The edge computing unit, combining the above transmission route analysis with the fault phenomenon of abnormal noise in first gear but not in other gears, eliminated the gear teeth z1, z2, z3, z5, z8, and z9 that are shared by the transmission routes of first gear and other gears; it determined that the abnormal noise source in clutch area D6 was the first gear planetary gear z6 tooth. Based on the transmission route during steering, it confirmed that the abnormal noise source in steering pump area D2 was the steering pump shaft gear F3.

[0036] The abnormal noise was ultimately identified as the F3 and Z6 teeth of the steering pump shaft gear.

[0037] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A method for judging abnormal noise in a transmission based on the coupling of transmission and operating conditions, characterized in that, include: When abnormal noise occurs, collect transmission operating parameters; Identify the operating condition type based on the transmission operating parameters; Determine the source area of ​​abnormal noise by combining transmission operating parameters and operating conditions; Based on the transmission route diagram of the gearbox, locate the abnormal noise components in the area where the abnormal noise originates.

2. The method for judging abnormal noise of a gearbox based on transmission and operating condition coupling according to claim 1, characterized in that, The transmission operating parameters include the working gear, engine speed, lifting arm operating lever displacement, shift operating lever displacement, steering angle, and throttle opening change rate.

3. The method for judging abnormal noise of a gearbox based on transmission and operating condition coupling according to claim 2, characterized in that, The working gear position is monitored by a Hall sensor located at the gear shift lever; the engine speed is monitored by a magnetoelectric speed sensor located at the front end of the engine flywheel housing or crankshaft; the displacement of the lifting arm operating lever is monitored by a cable-operated operating lever displacement sensor located at the lifting arm operating lever; the displacement of the shift operating lever is monitored by a cable-operated operating lever displacement sensor located at the shift operating lever; the steering angle is monitored by a photoelectric steering wheel angle sensor located on the steering column; and the throttle opening change rate is monitored by a Hall-type throttle pedal position sensor located at the throttle pedal.

4. The method for judging abnormal noise of a gearbox based on transmission and operating condition coupling according to claim 1, characterized in that, The operating conditions include boom lifting, steering, gear shifting, and speed increase / decrease in the same gear.

5. The method for judging abnormal noise of a gearbox based on transmission and operating condition coupling according to claim 1, characterized in that, The process of identifying the operating condition type based on the transmission operating condition parameters includes: When the transmission operating parameters exceed the preset threshold, it is determined to be the corresponding operating condition operation type. Among them, the displacement of the lifting arm operating lever corresponds to the lifting arm operation, the displacement of the shift operating lever corresponds to the shift operation, the steering angle corresponds to the steering operation, and the throttle opening change rate corresponds to the same gear acceleration / deceleration operation.

6. The method for judging abnormal noise of a gearbox based on transmission and operating condition coupling according to claim 1, characterized in that, The process of determining the abnormal noise source area by combining transmission operating parameters and operating mode types includes: When the operating condition is boom lifting operation and abnormal noise occurs in each working position, it is determined to be the working pump area. When the operating condition is steering, and abnormal noise occurs in all working gears, it is determined to be the steering pump area. When the operating condition is gear shifting, and abnormal noise occurs in each working gear, and the frequency difference of the abnormal noise in different working gears is >200Hz, it is judged to be the torque converter area. When the operating condition is the same gear speed increase / decrease operation, and abnormal noise occurs in each working gear and the engine speed is >2000r / min, it is judged to be the transmission pump area; When the operating condition is the same gear speed increase / decrease operation, and abnormal noise occurs in each working gear within the preset engine speed range, it is determined to be the oil suction device area. If abnormal noise occurs in non-all working gears when the current operating condition is not being performed, it is determined to be in the clutch area.

7. The method for judging abnormal noise of a gearbox based on transmission and operating condition coupling according to claim 6, characterized in that, The preset engine speed range is 850~2200 r / min.

8. The method for judging abnormal noise of a gearbox based on transmission and operating condition coupling according to claim 1, characterized in that, The method of locating the abnormal noise component based on the transmission route diagram and the abnormal noise source area includes: The transmission route for each working gear is obtained from the transmission route diagram of the gearbox when performing this type of operation. The transmission route includes the power transmission path and the force state of the components. The components in the power transmission state or the load-bearing state are determined according to the transmission route; The abnormal noise components are selected from those that are in a power transmission state or a load-bearing state.

9. The method for judging abnormal noise of a gearbox based on transmission and operating condition coupling according to claim 8, characterized in that, The components in the power transmission state or load-bearing state include components directly connected to the transmission input shaft or transmission output shaft, components with theoretically calculated torque greater than the set value, and the driving and driven components of the current gear meshing gear pair.

10. The method for judging abnormal noise of a gearbox based on transmission and operating condition coupling according to claim 9, characterized in that, The abnormal noise components identified from components in a power transmission state or a load-bearing state include: When the abnormal noise source area includes the clutch area, the abnormal noise components are the components in the clutch area that are not shared in the abnormal noise working gear and the non-abnormal noise working gear, as well as the components in the other abnormal noise source areas. When the abnormal noise source area does not include the clutch area, the abnormal noise component is the component within the abnormal noise source area.

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