Wide helical gear tooth surface contact state analysis and evaluation method based on tooth root stress ratio

Abstract

The invention relates to a wide helical gear tooth surface contact state analysis and evaluation method based on a tooth root stress ratio. The method comprises the following steps: establishing a wide helical gear tooth surface contact stress simulation model considering axis deflection; tooth surface contact stress simulation is carried out under the condition of different axis deflection amounts, and a stress ratio and a corresponding tooth surface contact impression area are obtained; establishing a mapping relation between the stress ratio and the tooth surface contact impression area by adopting a neural network algorithm; arranging a strain gauge at the tooth root of the actual gear pair, and collecting the actual ratio of stress; the actual ratio is input into the established mapping relation, and tooth surface contact impression area prediction is obtained; and analysis and evaluation of the tooth surface contact state of the wide helical teeth are realized. According to the method, the contact mark area of the tooth surface of the gear is mapped based on the tooth root stress ratio, and the tooth surface contact state of the wide bevel gear is analyzed quickly and accurately.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of gear tooth surface contact state representation, and particularly relates to a wide helical gear tooth surface contact state analysis and evaluation method based on a dedendum stress ratio, which realizes accurate analysis of the tooth surface contact state through measurement and analysis of the dedendum stress of the wide helical gear pair. BACKGROUND

[0002] In a gear transmission system, the shaft alignment accuracy is a key factor determining the transmission efficiency. Generally, a helical gear with a width-to-diameter ratio greater than 1.5 is defined as a wide helical gear. The wide helical gear pair is widely used in heavy load transmission occasions such as ship propulsion, wind power speed-up, and metallurgical rolling mill due to its high load-carrying capacity and smooth running characteristics. However, in the manufacturing and assembly process, due to the limitations of machining tolerances and installation errors, the center axes of the gear shaft, bearing and bearing seat hole are often difficult to be completely aligned, resulting in axial deviation between the two gear shafts. This misalignment can cause abnormal load distribution in the tooth width direction and generate a partial load phenomenon.

[0003] Once the partial load occurs, the actual contact area of the gear pair decreases, the local load sharply rises, and pitting corrosion of the tooth surface is easily caused, and uneven wear occurs along the tooth width direction. At the same time, the noise and vibration of the transmission system increase, and the smoothness decreases, and in severe cases, even destructive damage to the gear teeth can occur. Since the tooth width of the wide helical gear is large, it is particularly sensitive to the partial load effect.

[0004] At present, there is still a lack of a fast and efficient analysis method for the tooth surface contact state of the wide helical gear under the partial load condition. The existing technology mostly uses the coloring method, that is, red paint or blue oil is applied on the tooth surface, and the contact situation is judged by observing the contact marks. However, this method needs to be stopped and disassembled to be implemented, and cannot realize online monitoring of the contact state, and is difficult to meet the requirements of modern equipment predictive maintenance. SUMMARY

[0005] In view of the deficiencies of the prior art, the present application provides a wide helical gear tooth surface contact state analysis and evaluation method based on a dedendum stress ratio, which solves the problem that the traditional tooth surface contact state analysis technology needs to be stopped and disassembled, cannot realize online monitoring of the contact state, and is difficult to meet the requirements of modern equipment predictive maintenance.

[0006] To achieve the above technical purpose, the present application provides the following technical scheme: a wide helical gear tooth surface contact state analysis and evaluation method based on a dedendum stress ratio, comprising the following steps: establishing a wide helical gear tooth surface contact stress simulation model considering the axial skew; Based on the established wide helical gear tooth surface contact stress simulation model, tooth surface contact stress simulation is carried out under different axial deflection conditions, a plurality of groups of stress data at the tooth root are obtained, the ratio of the maximum stress to the average stress is calculated, and the corresponding tooth surface contact mark area is recorded; The neural network algorithm is used to establish the mapping relationship between the ratio of the maximum stress to the average stress at the tooth root and the corresponding tooth surface contact mark area; Strain gauges are arranged at the tooth root of the actual gear pair, and stress data at the tooth root of the actual gear pair are synchronously collected during actual operation; Based on the collected stress data at the tooth root of the actual gear pair, the actual ratio of the maximum stress to the average stress at the tooth root of the actual gear pair is calculated; The actual ratio is input into the established mapping relationship, and the corresponding tooth surface contact mark area is predicted; According to the predicted tooth surface contact mark area, the ideal contact area or the contact area threshold is set to analyze and evaluate the contact state of the wide helical gear tooth surface.

[0007] Optionally, the wide helical gear tooth surface contact stress simulation model is set by adjusting the position of only one end of the bearing to realize the setting of different axial deflection amounts.

[0008] Optionally, the neural network algorithm can use a BP neural network algorithm or a CNN neural network algorithm.

[0009] Optionally, the strain gauges are arranged at the tooth root along the tooth width direction.

[0010] Optionally, the strain gauges are arranged at the tooth root along the tooth width direction, comprising: A vertical bisector of the addendum is made on one side surface of the tooth root; A straight line is made at an angle of 30° with the vertical bisector and tangent to the tooth root transition curve, and the tangent point is marked as A; The above operation is repeated on the other side surface of the tooth root to obtain a tangent point B; The strain gauges are uniformly arranged on the line connecting the tangent points A and B.

[0011] Optionally, the number of the strain gauges is determined according to the width of the actual gear pair, and is not less than 4.

[0012] The application also provides a wide helical gear tooth surface contact state analysis and evaluation device based on tooth root stress ratio, which is used for applying the wide helical gear tooth surface contact state analysis and evaluation method based on tooth root stress ratio, and comprises: A simulation model establishing unit is used for establishing a wide helical gear tooth surface contact stress simulation model considering axial deflection; a stress data acquisition unit, configured to perform tooth surface contact stress simulation, calculate the ratio of the maximum stress to the average stress at the tooth root of a plurality of simulation sample groups, and the corresponding tooth surface contact patch area; The stress data acquisition unit is further configured to acquire stress data at the tooth root of an actual gear pair, and calculate the actual ratio of the maximum stress to the average stress at the tooth root of the actual gear pair; a neural network single-loop unit, configured to establish a mapping relationship between the ratio of the maximum stress to the average stress at the tooth root and the corresponding tooth surface contact patch area by using a neural network algorithm; The neural network single-loop unit is further configured to receive the acquired actual ratio, and predict the corresponding tooth surface contact patch area based on the mapping relationship; an analysis and evaluation unit, configured to analyze and evaluate the contact state of the wide helical tooth surface according to the predicted tooth surface contact patch area.

[0013] The application further provides an electronic device, which comprises at least one processor and a memory connected with the at least one processor in communication; the memory stores a computer program executable by the at least one processor; the computer program is executed by the at least one processor, so that the at least one processor can execute the wide helical gear tooth surface contact state analysis and evaluation method based on the tooth root stress ratio.

[0014] The application further provides a computer readable storage medium, which stores computer instructions for enabling a processor to execute the wide helical gear tooth surface contact state analysis and evaluation method based on the tooth root stress ratio.

[0015] The application further provides a computer program product, which comprises a computer program; the computer program enables a processor to execute the wide helical gear tooth surface contact state analysis and evaluation method based on the tooth root stress ratio when executed by the processor.

[0016] By the above technical solution, the application provides a wide helical gear tooth surface contact state analysis and evaluation method based on the tooth root stress ratio, which has at least the following beneficial effects: (1) The application establishes the corresponding relationship between the tooth root stress ratio and the tooth surface contact patch area, can effectively predict the tooth surface contact state, and provides a feasible technical means for realizing online monitoring of the tooth surface contact state; compared with the traditional method, the application can significantly reduce the gear load imbalance problem caused by the axis skew; (2) The prior art mainly relies on passive modification and static detection mode, and cannot realize online dynamic adjustment, and needs to stop operation in the detection process, so the efficiency is low, compared with the present application, which supports dynamic real-time monitoring, and does not need to interrupt the operation of the equipment, has higher engineering applicability and detection efficiency, and provides an effective way for realizing online state evaluation and early warning of the gear transmission system; (3) The present application constructs the mapping relationship by calculating the ratio of the maximum stress and the average stress at the tooth root, avoids the limitation of using the maximum stress or the average stress alone, can more sensitively reflect the degree of partial load, and thus improves the accuracy and reliability of the contact state representation; (4) The present application determines the uniform arrangement of strain gauges through the tangent line, ensures that the strain gauges cover all key areas of the tooth root dangerous section along the tooth width direction, can accurately capture the distribution characteristics of the maximum stress and the average stress, compared with the conventional single-point measurement, this uniform arrangement can obtain more comprehensive stress data, avoids missing local stress concentration, and thus improves the representativeness and accuracy of the stress ratio calculation, and further optimizes the precision of the contact state prediction. BRIEF DESCRIPTION OF DRAWINGS

[0017] The drawings described herein are used to provide further understanding of the present application, constitute a part of the present application, the illustrative embodiments of the present application and the description thereof are used to explain the present application, and do not constitute improper limitation on the present application. In the drawings: Figure 1 A flow chart of a wide helical gear tooth surface contact state analysis and evaluation method based on tooth root stress ratio of the present application; Figure 2 A schematic diagram of a wide helical gear tooth surface contact stress simulation model established by the present application; Figure 3 A tooth root stress ratio and tooth surface contact mark area mapping relationship diagram provided by the embodiment of the present application; Figure 4 A strain gauge patch position diagram provided by the embodiment of the present application. DETAILED DESCRIPTION

[0018] In order to make the above-mentioned purposes, features and advantages of the present application more obvious and easy to understand, the present application will be further described in detail below in combination with the drawings and specific embodiments. The realization process of how to apply technical means to solve technical problems and achieve technical effects of the present application can be fully understood and implemented.

[0019] Those skilled in the art can understand that all or part of the steps in the embodiment method can be completed by programs instructing relevant hardware, therefore, the present application can adopt a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware aspects. Moreover, the present application can adopt a computer program product in the form of being implemented on one or more computer usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer usable program codes.

[0020] Please refer to Figures 1-4 , a specific embodiment of the present embodiment is shown, the present embodiment establishes a wide helical gear tooth surface contact stress simulation model, obtains simulation data to calculate the stress ratio at the tooth root, uses a neural network algorithm to establish a mapping relationship between the stress ratio and the corresponding tooth surface contact mark area, arranges stress sheets, collects stress data at the tooth root during actual operation, calculates the actual ratio, inputs the established mapping relationship, and obtains the tooth surface contact mark area prediction, thereby quickly and accurately realizing the analysis of the tooth surface contact state of the wide helical gear.

[0021] Please refer to Figure 1 , the present embodiment proposes a wide helical gear tooth surface contact state analysis and evaluation method based on the stress ratio at the tooth root, which comprises the following steps: S1, a wide helical gear tooth surface contact stress simulation model considering axis deflection is established.

[0022] As a preferred embodiment of step S1, the wide helical gear tooth surface contact stress simulation model is achieved by adjusting the position of only one end of the bearing to set different axis deflection amounts. The established wide helical gear tooth surface contact stress simulation model can refer to Figure 2 .

[0023] S2, based on the established wide helical gear tooth surface contact stress simulation model, tooth surface contact stress simulation is carried out under different axis deflection amounts, tooth surface contact stress simulation analysis under different axis deflection amounts is carried out, stress data at the tooth root of multiple simulation samples are obtained, the ratio of the maximum stress to the average stress is calculated, and the corresponding tooth surface contact mark area is recorded.

[0024] The present application constructs a mapping relationship by calculating the ratio of the maximum stress to the average stress at the tooth root, which is a special design for the uneven stress distribution of the wide helical gear under the condition of axis deflection. This ratio can effectively quantify the uniformity of stress distribution: the larger the ratio, the more serious the stress concentration, and the worse the tooth surface contact state; the closer the ratio to 1, the more uniform the stress distribution, and the better the contact state. This ratio-based method avoids the limitations of using the maximum stress or the average stress alone, and can more sensitively reflect the degree of eccentric load, thereby improving the accuracy and reliability of the contact state representation.

[0025] S3, a neural network algorithm is used to establish a mapping relationship between the ratio of the maximum stress at the tooth root to the average stress and the corresponding contact patch area of the tooth surface.

[0026] As a preferred embodiment of step S3, the neural network algorithm can use a BP neural network algorithm or a CNN neural network algorithm. The established mapping relationship can refer to Figure 3 , and the red curve in the figure is the fitting curve of the mapping relationship.

[0027] S4, strain gauges are arranged at the tooth root of the actual gear pair, and stress data at the tooth root of the actual gear pair are synchronously collected during actual operation.

[0028] As a preferred embodiment of step S4, the strain gauges arranged at the tooth root of the actual gear pair include that the strain gauges are uniformly arranged at the tooth root along the tooth width direction.

[0029] More specifically, the number of strain gauges arranged is determined according to the width of the actual gear pair, and is not less than 4.

[0030] The strain gauge patch position confirmation method can refer to Figure 4 . Specifically: First, a vertical bisector I of the tooth top is drawn on one side surface of the tooth root, and a straight line II is drawn which is 30° to the vertical bisector I and tangent to the tooth root transition curve. The tangent point of the straight line II and the tooth root transition curve is marked as A; A vertical line III of the straight line I is drawn through the tangent point A, and a plane perpendicular to the vertical bisector I through the vertical line III is the dangerous cross section.

[0031] The above operation is repeated on the other side surface of the tooth root to obtain a tangent point B; Connecting the tangent point A and the tangent point B obtains a line segment AB as the center alignment reference line of the strain gauges. The arrangement range of the strain gauges along the tooth length is determined by shifting 4mm inward from both tooth sides, and four vertical lines of the line segment AB are uniformly drawn in the range. The intersection points of the vertical lines and the line segment AB are marked as O 1、 O 2、 O 3、 O4, the four points are the positioning reference of the center points of the strain gauges.

[0032] In the present application, the process of determining the tangent line and uniformly arranging the strain gauges on the tangent line is a special method designed for the characteristics of wide helical gear with large tooth width and stress distribution changing along the tooth width direction. The design ensures that the strain gauges cover all the key areas of the dangerous cross section of the tooth root along the tooth width direction, and can accurately capture the distribution characteristics of the maximum stress and the average stress. Compared with conventional single-point measurement, this uniform arrangement can obtain more comprehensive stress data, avoid missing local stress concentration, and thus improve the representativeness and accuracy of the stress ratio calculation, further optimize the precision of the contact state prediction.

[0033] S5, based on the collected stress data at the tooth root of the actual gear pair, calculating the actual ratio of the maximum stress to the average stress at the tooth root of the actual gear pair.

[0034] Specifically, a plurality of strain gauges are arranged at the tooth root of the actual gear pair The collected stress data is , wherein represents the stress value of the measurement point of the th strain gauge . The stress value is converted from the strain signal collected by the strain gauge according to Hooke's law, that is , wherein is the elastic modulus of the gear material, is the strain value measured by the strain gauge.

[0035] The maximum stress and the average stress are calculated as follows: ; ; The calculation formula of the actual ratio of the two is: ; , wherein is the actual ratio, is the maximum stress value among all measurement points at the tooth root of the actual gear pair, is the average stress value of all measurement points at the tooth root of the actual gear pair.

[0036] The ratio reflects the uniformity of the stress distribution at the tooth root, that is The larger the value is, the more uneven the stress distribution is, and there is local stress concentration; The closer the value is to 1, the more uniform the stress distribution is.

[0037] S6, inputting the actual ratio into the established mapping relationship to predict the corresponding tooth surface contact mark area; ​​S7, according to the predicted tooth surface contact area, set the ideal contact area or contact area threshold, the contact state of the wide helical gear tooth surface is analyzed and evaluated.

[0038] Specifically, by comparing the ratio of the predicted tooth surface contact area and the ideal contact area, or the contact area threshold, it is judged whether the contact state is good. If the area is too small (the ratio is close to 0 or the area is much smaller than the contact area threshold), it indicates that the load is seriously unbalanced; if the area is close to the ideal value (the ratio is close to 1 or the area is close to the contact area threshold), it indicates that the contact state is good.

[0039] Next, taking setting the ideal contact area as an example, a specific evaluation method is given: The predicted tooth surface contact area is compared with the ideal contact area , and the ideal contact area is the full tooth width contact area obtained by simulation or theoretical calculation under the condition of no axis skew. The contact state evaluation index is defined: According to the value of , the contact state is evaluated: If ≥0.9, it is considered that the contact state is good, and the load distribution is uniform; If 0.7≤ ≤0.9, it is considered that the contact state is general, there is light unbalance, and it is recommended to monitor; If ≤0.7, it is considered that the contact state is poor, and there is serious unbalance, which needs to be adjusted or repaired in time.

[0040] In addition, combined with the predicted contact area, the contact offset situation can be further analyzed to provide a basis for gear modification or axis adjustment.

[0041] The embodiment of the application also provides a wide helical gear tooth surface contact state analysis and evaluation device based on the tooth root stress ratio, which is used for applying the wide helical gear tooth surface contact state analysis and evaluation method based on the tooth root stress ratio, and comprises: A simulation model establishing unit is configured to establish a wide helical gear tooth surface contact stress simulation model considering axis skew; A stress data acquisition unit is configured to perform tooth surface contact stress simulation, calculate the ratio of the maximum stress to the average stress at the tooth root of a plurality of simulation samples, and the corresponding tooth surface contact area; The stress data acquisition unit is also configured to acquire stress data at the tooth root of an actual gear pair, and calculate the actual ratio of the maximum stress to the average stress at the tooth root of the actual gear pair; ​The neural network single-ring unit is configured to establish a mapping relationship between a ratio of a maximum stress to an average stress at a tooth root and a corresponding tooth surface contact patch area by using a neural network algorithm. The neural network single-ring unit is further configured to receive the obtained actual ratio, and predict the corresponding tooth surface contact patch area based on the mapping relationship. The analysis and evaluation unit is configured to analyze and evaluate a contact state of the wide helical gear tooth surface according to the predicted tooth surface contact patch area.

[0042] The embodiments of the present application further provide an electronic device, which comprises at least one processor and a memory connected with the at least one processor in communication; wherein the memory stores a computer program executable by the at least one processor, and the computer program is executed by the at least one processor to enable the at least one processor to execute the wide helical gear tooth surface contact state analysis and evaluation method based on the tooth root stress ratio.

[0043] The embodiments of the present application further provide a computer readable storage medium, which stores computer instructions for enabling a processor to execute the wide helical gear tooth surface contact state analysis and evaluation method based on the tooth root stress ratio.

[0044] The embodiments of the present application further provide a computer program product, which comprises a computer program for enabling a processor to execute the wide helical gear tooth surface contact state analysis and evaluation method based on the tooth root stress ratio.

[0045] In the description of the present application, the description of the terms “one embodiment”, “some embodiments”, “an example”, “a specific example”, or “some examples” means that the specific features, structures, materials or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present application. Moreover, the specific features, structures, materials or characteristics described can be combined in any appropriate manner in any one or more embodiments or examples. In addition, the person skilled in the art can combine and combine the different embodiments or examples described in the present application and the features of the different embodiments or examples without contradiction.

[0046] The logic and / or steps represented in the flowcharts or otherwise described herein, for example, can be considered as a list of executable instructions for implementing logic functions, which can be embodied in any computer-readable medium for use by an instruction execution system, apparatus or device, such as a computer-based system, a system including a processor, or other system that can fetch and execute instructions from the instruction execution system, apparatus or device, or in conjunction with these instructions execution systems, apparatus or devices.

[0047] The above embodiments provide a detailed description of the present invention. Specific examples have been used to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of the present invention. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A method for analyzing and evaluating the contact state of wide helical gear tooth surfaces based on the tooth root stress ratio, characterized in that, include: Establish a simulation model of the contact stress on the tooth surface of a wide helical gear that takes into account the axial deviation; Based on the established simulation model of tooth surface contact stress of wide helical gears, tooth surface contact stress simulation was carried out under different axial misalignment conditions. Stress data at the tooth root of multiple simulation samples were obtained, the ratio of maximum stress to average stress was calculated, and the corresponding tooth surface contact imprint area was recorded. A neural network algorithm was used to establish the mapping relationship between the ratio of the maximum stress to the average stress at the tooth root and the corresponding contact imprint area on the tooth surface. Strain gauges are placed at the root of the actual gear pair, and stress data at the root of the actual gear pair are collected synchronously during actual operation. Based on the collected stress data at the actual gear tooth root, the actual ratio of the maximum stress to the average stress at the actual gear tooth root is calculated. By inputting the actual ratio into the established mapping relationship, the corresponding tooth surface contact imprint area is predicted. Based on the predicted contact imprint area on the tooth surface, the contact state of the wide helical tooth surface is analyzed and evaluated by setting an ideal contact area or a contact area threshold.

2. The method for analyzing and evaluating the contact state of a wide helical gear tooth surface based on the tooth root stress ratio according to claim 1, characterized in that: The simulation model of contact stress on the tooth surface of the wide helical gear achieves different axial misalignment by adjusting only the position of one end of the bearing.

3. The method for analyzing and evaluating the contact state of a wide helical gear tooth surface based on the tooth root stress ratio according to claim 1, characterized in that: The neural network algorithm can be either a BP neural network algorithm or a CNN neural network algorithm.

4. The method for analyzing and evaluating the contact state of a wide helical gear tooth surface based on the tooth root stress ratio as described in claim 1, characterized in that: The arrangement of strain gauges at the root of the actual gear pair includes: the strain gauges are uniformly arranged at the root of the gear along the tooth width direction.

5. The method for analyzing and evaluating the contact state of a wide helical gear tooth surface based on the tooth root stress ratio according to claim 4, characterized in that: The strain gauges are uniformly arranged at the tooth root along the tooth width direction, specifically including: Draw the perpendicular bisector of the tooth tip on one side of the tooth root; Draw a straight line that forms a 30° angle with the perpendicular bisector and is tangent to the tooth root transition curve. The point of tangency is denoted as A. Repeat the above operation on the other side of the tooth root to obtain the tangent point B; The strain gauges are evenly arranged on the line connecting the tangent points A and B.

6. The method for analyzing and evaluating the contact state of a wide helical gear tooth surface based on the tooth root stress ratio according to claim 1, characterized in that: The number of strain gauges is determined based on the actual width of the gear pair, and shall not be less than four.

7. A device for analyzing and evaluating the contact state of a wide helical gear tooth surface based on the tooth root stress ratio, used to apply the method for analyzing and evaluating the contact state of a wide helical gear tooth surface based on the tooth root stress ratio as described in any one of claims 1-6, characterized in that, include: The simulation model building unit is used to build a simulation model of the contact stress on the tooth surface of a wide helical gear considering the axial deviation. The stress data acquisition unit is used to perform tooth surface contact stress simulation, calculate the ratio of the maximum stress to the average stress at the tooth root of multiple simulation samples, and the corresponding tooth surface contact imprint area. The stress data acquisition unit is also used to acquire stress data at the root of the actual gear pair and calculate the actual ratio of the maximum stress to the average stress at the root of the actual gear pair. A single-loop neural network unit is used to establish a mapping relationship between the ratio of the maximum stress to the average stress at the tooth root and the corresponding contact imprint area on the tooth surface using a neural network algorithm. The single-loop unit of the neural network is also used to receive the actual ratio obtained and predict the corresponding tooth surface contact imprint area based on the mapping relationship. The analysis and evaluation unit is used to analyze and evaluate the contact state of the wide-beveled tooth surface based on the predicted tooth surface contact imprint area.

8. An electronic device, characterized in that, The electronic device includes: at least one processor; and a memory communicatively connected to the at least one processor; wherein the memory stores a computer program executable by the at least one processor, the computer program being executed by the at least one processor to enable the at least one processor to perform the wide helical gear tooth surface contact state analysis and evaluation method based on tooth root stress ratio as described in any one of claims 1-6.

9. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores computer instructions that cause a processor to execute the method for analyzing and evaluating the contact state of a wide helical gear tooth surface based on the tooth root stress ratio as described in any one of claims 1-6.

10. A computer program product, characterized in that, The computer program product includes a computer program that, when executed by a processor, implements the method for analyzing and evaluating the contact state of wide helical gear tooth surfaces based on the tooth root stress ratio according to any one of claims 1-6.

Images