An adaptive temperature compensation type worm and gear reduction system

Abstract

The present application relates to worm gear reduction technical field, especially to a kind of adaptive temperature compensation formula worm gear reduction system, including box, reduction module, cooling module, monitoring module, compensation analysis module and excitation response module, compensation analysis module is based on the determination of the temperature rising tendency of reduction module based on vulnerable representation value, and under the condition of determining that reduction module is strong temperature rising tendency, control cooling module operates and based on micro-bubble formation factor determines whether to correct the speed of vacuum pump in defoaming device;Excitation response module is based on the determination of whether to correct the operating power of oil pump under the condition that cooling module operates based on the number of hetero change ratio. Through the adaptive compensation mechanism of oil circuit circulating water cooling, defoaming control correction, the thermal stability and reliability of worm gear under complex working conditions are improved.

Description

Technical Field

[0001] This invention relates to the field of worm gear reduction technology, and more particularly to an adaptive temperature-compensated worm gear reduction system. Background Technology

[0002] Worm gear reducers are widely used in metallurgical conveyor lines, mining and building materials equipment, automated warehousing and lifting mechanisms, valve and gate actuators, port and crane equipment, food and packaging production lines, and various automated workstations for attitude adjustment and positioning transmission due to their large transmission ratio, compact structure, good self-locking, and relatively convenient installation and maintenance. Worm gear drives are a typical sliding friction meshing type, generating significant frictional heat during operation. Under conditions of continuous operation, heavy load impact, frequent start-stop, or significant fluctuations in ambient temperature and humidity, the temperature and gas content of the lubricating oil inside the gearbox can easily change, affecting transmission efficiency, tooth surface wear, bearing life, and sealing reliability.

[0003] In heavy-load continuous operation scenarios, high temperature and humidity environments, and scenarios sensitive to stability and lifespan, reduction systems are more prone to problems such as rapid temperature rise, easy oil foaming, and fluctuating cooling load with operating conditions.

[0004] Chinese Patent Publication No. CN115370714A discloses a worm gear reducer, including a reducer with a condensing assembly fixedly installed externally and extending into the reducer. A drainage assembly is fixedly installed on the condensing assembly. The condensing assembly includes a temperature-conducting plate fixedly installed externally to the reducer, with multiple semiconductor cooling chips fixedly installed on one side of the temperature-conducting plate, and the cooling side of the multiple semiconductor cooling chips fixedly installed on the temperature-conducting plate. By setting the condensing assembly on one side of the reducer, water vapor inside the reducer can be collected in advance. However, the above technical solution has the following problems: it does not consider an adaptive compensation mechanism through oil-circulated water cooling and defoaming control correction, affecting thermal stability and reliability under complex operating conditions. Summary of the Invention

[0005] To address this issue, the present invention provides an adaptive temperature-compensated worm gear reduction system to overcome the problem in the prior art that the adaptive compensation mechanism, which does not take into account the correction through oil circuit circulating water cooling and defoaming control, affects the thermal stability and reliability under complex working conditions.

[0006] To achieve the above objectives, the present invention provides an adaptive temperature-compensated worm gear reduction system, comprising:

[0007] The reduction module includes a reduction worm gear, a reduction worm, and a control motor;

[0008] The cooling module includes oil pipes connected to both sides of the housing, a cooling plate installed on one side of the oil pipes for water cooling, an oil pump installed inside the oil pipes to control the circulation of lubricating oil in the housing, and a defoamer connected to the oil pipes to defoam the circulating lubricating oil.

[0009] The monitoring module includes a first temperature sensor installed inside the chamber, a second temperature sensor installed on the side wall of the cooling plate, and a humidity sensor installed outside the chamber.

[0010] The compensation analysis module is connected to the cooling module, the deceleration module and the monitoring module respectively. It is used to determine the heating tendency of the deceleration module based on the vulnerability characterization value, and under the condition that the deceleration module has a strong heating tendency, control the operation of the cooling module and determine whether to correct the speed of the vacuum pump in the defoamer based on the microbubble formation factor.

[0011] An excitation response module, which is connected to the cooling module, is used to determine whether to correct the operating power of the oil pump based on the anomaly ratio when the cooling module is operating.

[0012] Furthermore, the compensation analysis module is used to determine the vulnerability characterization value based on the concern factor, temperature variation factor, and friction variation factor. The concern factor is determined based on the thermal expansion coefficient of the worm gear and the thermal expansion coefficient of the housing. The temperature variation factor is determined based on the continuous running time of the control motor. The friction variation factor is determined based on the current humidity obtained by the humidity sensor.

[0013] Furthermore, the compensation analysis module is used to determine the temperature rise tendency of the deceleration module based on the vulnerability characterization value, including:

[0014] If the vulnerability index value is greater than the preset vulnerability index value, the deceleration module is determined to have a strong tendency to heat up.

[0015] Furthermore, the compensation analysis module is used to control the operation of the cooling module and determine the operating power of the oil pump based on the vulnerability characterization value, under the condition that the deceleration module has a strong tendency to heat up.

[0016] The operating power of the oil pump is positively correlated with its wear-prone characteristics.

[0017] Furthermore, the compensation analysis module is used to determine the microbubble formation factor, including:

[0018] Used to determine the molding tendency value based on the current viscosity of the lubricating oil;

[0019] Used to determine the mixing tendency value based on the current operating power of the oil pump;

[0020] Used to determine the microbubble formation factor based on the forming tendency value and the mixing tendency value.

[0021] Furthermore, the compensation analysis module is used to determine whether to correct the speed of the vacuum pump in the defoamer based on the microbubble formation factor, after adjusting the operating power of the oil pump.

[0022] Under the condition that the microbubble forming factor is greater than the preset forming factor, the rotation speed of the vacuum pump in the defoamer is corrected based on the microbubble forming factor.

[0023] The increase in the speed of the vacuum pump in the defoamer is positively correlated with the microbubble formation factor.

[0024] Furthermore, the excitation response module is used to determine whether to correct the operating power of the oil pump based on the anomaly ratio under the condition that the cooling module is operating, including:

[0025] Used to plot temperature time-domain curves based on the temperatures at each time point obtained by the first temperature sensor;

[0026] The average slope of each time node in the temperature time domain curve is calculated. Time nodes with a slope greater than the average slope are identified as anomalous nodes. The ratio of the total number of anomalous nodes to the preset number of monitoring nodes is calculated to obtain the anomalous number ratio.

[0027] When the temperature variation ratio is greater than the preset temperature variation ratio, the operating power of the oil pump is adjusted based on the variation ratio.

[0028] Furthermore, the excitation response module is used to determine the operating power of the corrected oil pump based on the anomaly ratio, wherein,

[0029] The increase in the operating power of the oil pump is positively correlated with the ratio of the number of abnormalities.

[0030] Furthermore, the excitation response module is used to determine whether to correct the maximum operating time of the control motor based on the temperature of the cooling plate, after completing the correction of the operating power of the oil pump, including:

[0031] When the temperature of the cooling plate is greater than the preset critical temperature of the cooling plate, the maximum running time of the control motor is adjusted based on the temperature difference.

[0032] Furthermore, the excitation response module is used to correct the maximum operating time of the control motor based on the temperature difference, wherein,

[0033] Calculate the temperature difference between the inside of the chamber and the side wall of the cooling plate to obtain the temperature difference value;

[0034] The maximum operating time of the control motor is positively correlated with the temperature difference.

[0035] Compared with existing technologies, the beneficial effects of this invention are that worm gear meshing is a type of strong sliding friction transmission, and the meshing clearance is highly sensitive to thermal expansion. The different materials and structures of the worm gear and the housing lead to inconsistent dimensional changes at the same temperature rise due to differences in their coefficients of thermal expansion, thereby altering the meshing backlash, contact line position, and local load distribution. The absolute difference in expansion represents the degree of inconsistency in the dimensional response of the worm gear and the housing to temperature changes. A concern factor normalizes this difference. Inconsistent thermal expansion causes increased local contact stress on the tooth surface, thinning of the lubricating film, and an increased proportion of boundary lubrication, leading to an increased coefficient of friction and further exacerbating heat generation, creating a cycle of temperature rise, contact deterioration, and even higher temperature rise. The larger the concern factor, the greater the difference, the more drastic the change in meshing geometry with temperature, the more likely local friction and wear will suddenly increase, and the stronger the tendency to heat up. By quantifying the thermal adaptation risk of materials and structures through the concern factor, cooling and power correction can be triggered in advance. Determining the temperature anomaly factor, the temperature rise characteristic of worm gears is that the initial temperature rise is absorbed by the heat capacity of the housing, but after continuous operation for a certain period, it enters the heat accumulation stage. Therefore, the continuous operating time and the critical temperature rise time are direct indicators for judging whether it has entered the thermal instability region. The critical temperature rise time can be understood as the time limit at which the oil temperature begins to rise significantly under the current structural heat dissipation capacity and typical load. Longer operating time will lead to increased oil temperature, decreased viscosity, reduced oil film thickness, increased probability of metal contact, and increased frictional heat generation; at the same time, oil oxidation will accelerate, further reducing lubrication performance. The longer the operation, the closer it is to the upper limit of thermal equilibrium or the entry into the thermal instability stage, and the risk of temperature rise increases monotonically. The larger the temperature anomaly factor, the higher the risk. By capturing the heat accumulation trend in the time dimension, earlier warnings can be given than single-point temperature thresholds, reducing overheating and oil deterioration. Determining the friction anomaly factor, high humidity environments will increase the water content of the oil through the breathing effect or micro-permeation of the seal; high humidity environments will form micro-electrolytic corrosion and rust products on the metal surface. The humidity ratio is used to characterize the intensity of environmental corrosion promotion and water content promotion. Rust products and contaminant particles alter the micro-roughness peak distribution of the tooth surface, exacerbating abrasive wear. Trace amounts of water in the oil reduce oil film load, induce additive failure, and increase foaming tendency, leading to instability in the friction coefficient and heat generation. Higher humidity strengthens the corrosion, water content, and contamination chain, making friction more prone to variation and increasing the tendency to heat up. Incorporating environmental factors into thermal risk assessment enhances the reliability of worm gears in humid, coastal, and decontamination environments. Vulnerability characterization values ​​are determined by combining factors of concern, temperature variation factors, and friction variation factors. Based on these vulnerability characterization values, the strength of the heat rise tendency is determined, and with limited control resources, a distinction is made between normal thermal fluctuations and potential thermal instability. Complex factors are compressed into strong / weak categories, reducing control complexity and improving real-time performance. Unnecessary cooling energy consumption is avoided during weak tendencies; during strong tendencies, timely initiation of cooling and defoaming reduces the probability of failure. By predicting risks in advance through vulnerability characterization values, the cooling module is controlled to perform targeted cooling tasks, improving the thermal stability and reliability of worm gears under complex operating conditions.

[0036] Furthermore, determining the forming tendency value reveals that lubricating oil viscosity is closely related to the generation, collapse, and buoyancy dynamics of microbubbles. Changes in viscosity alter the ease with which bubbles shear, break up, merge, and escape in the oil. The viscosity ratio is determined to characterize the degree of deviation of the current oil from its ideal viscosity state. In actual transmission, tooth surface shearing and pump impeller agitation entrain air into the oil. Within certain viscosity ranges, bubbles are more easily sheared into stable microbubbles and carried by the oil film, forming a foam layer, leading to a decrease in effective lubrication volume fraction and an increase in compressibility. Determining the mixing tendency value shows that higher pump power results in stronger circulation, and simultaneously stronger agitation, shearing, and return oil impact, leading to a greater ability to entrain air and break up bubbles, which is equivalent to a greater excitation for the mixing and generation of microbubbles. A larger power ratio indicates higher flow velocity, stronger shearing, and an increased probability of microbubble generation. The microbubble formation factor is determined. Microbubble problems are caused by a combination of oil properties and flow excitation conditions. Abnormal viscosity alone, coupled with weak circulation, may not lead to significant bubble formation; conversely, strong circulation with suitable oil properties may result in rapid bubble escape. Multiplication is used to reflect the synergistic effect of these two factors, capturing high-risk situations where bubbles are easily formed but also strongly agitated. This allows for more precise defoamer adjustment. The microbubble formation factor is used to determine whether to adjust the speed of the vacuum pump in the defoamer. Foaming increases the equivalent compressibility of lubricating oil, reduces oil film load, and causes meshing noise, temperature fluctuations, and localized abrasion. The defoamer's role is to promote bubble breakage and separation, restoring the stability of the continuous oil phase. A higher microbubble formation factor indicates stronger bubble generation and stabilization, requiring higher defoaming intensity to offset the generation rate; therefore, the increase in power is positively correlated. This reduces lubrication failure and temperature fluctuations caused by foaming, improves transmission smoothness, and reduces wear. It also improves the thermal stability and reliability of worm gears under complex operating conditions.

[0037] Furthermore, by plotting temperature-time curves and identifying anomalous nodes, many overheating events are not simply due to high temperatures, but rather abnormal heating rates. When tooth surface contact suddenly deteriorates, the oil film is momentarily destroyed, or foaming leads to a decrease in effective heat transfer, the temperature curve will exhibit a sudden increase in slope. The slope represents the rate of temperature rise per unit time, equivalent to the degree to which net heat generation exceeds heat dissipation. The average slope serves as an adaptive baseline, used to eliminate overall differences under different ambient temperatures and loads. Once boundary lubrication or localized scratches occur, frictional heat will surge, manifested as a significant increase in the local slope of the temperature curve; this phenomenon appears earlier than absolute temperature. Determining the anomaly ratio is crucial. A single anomaly may be noise or an occasional disturbance, while continuous anomalies indicate that the worm gear is in an unstable state. The anomaly ratio measures the density and persistence of anomalies, improving the reliability of control triggering. If the anomaly ratio exceeds a threshold, the oil pump power is adjusted, and the increase is positively correlated with the threshold. The preceding oil pump power adjustment is based on feedforward adjustment of vulnerable characteristic values, which is predictive. Temperature slope anomalies, however, provide feedback evidence, indicating that the prediction may have underestimated actual heat generation or heat transfer obstruction, requiring stronger circulation to suppress the temperature rise rate. A higher anomaly ratio indicates more frequent and difficult-to-stabilize temperature surges, necessitating stronger heat transfer and faster oil temperature equalization; therefore, the oil pump power increase is positively correlated with this. This process pulls temperature fluctuations back from continuous increases to controllable small fluctuations, improving thermal stability and preventing overheating shutdowns. It also enhances the thermal stability and reliability of the worm gear under complex operating conditions. Attached Figure Description

[0038] Figure 1 This is a block diagram of the adaptive temperature-compensated worm gear reduction system according to an embodiment of the present invention;

[0039] Figure 2 This is a schematic diagram of the cooling module according to an embodiment of the present invention;

[0040] Figure 3 This is a logic diagram of the compensation analysis module in an embodiment of the present invention determining the heating tendency of the deceleration module based on the vulnerable characterization value;

[0041] Figure 4 This is a logic diagram for the compensation analysis module of this invention to determine whether to correct the speed of the vacuum pump in the defoamer based on the microbubble formation factor.

[0042] Figure 5 This is a logic diagram of the excitation response module in an embodiment of the present invention, which determines whether to correct the operating power of the oil pump based on the ratio of the number of variations.

[0043] In the diagram: 11. Housing; 31. Oil pipeline; 32. Oil pump; 33. Cooling plate. Detailed Implementation

[0044] To make the objectives and advantages of the present invention clearer, the present invention will be further described below with reference to embodiments; it should be understood that the specific embodiments described herein are merely for explaining the present invention and are not intended to limit the present invention.

[0045] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely illustrative of the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0046] It should be noted that in the description of this invention, the terms "upper", "lower", "left", "right", "inner", "outer", etc., which indicate directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings. This is only for the convenience of description and is not intended to indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation of this invention.

[0047] Furthermore, it should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0048] Please refer to the following documents separately. Figure 1 and Figure 2 The diagram shows a block diagram of the adaptive temperature-compensated worm gear reduction system and a structural schematic diagram of the cooling module, respectively, according to embodiments of the present invention. An embodiment of the present invention provides an adaptive temperature-compensated worm gear reduction system, comprising:

[0049] Box 11,

[0050] The reduction module (not shown in the figure) includes a reduction worm gear, a reduction worm, and a control motor;

[0051] The cooling module includes an oil pipe 31 connected to both sides of the housing 11, a cooling plate 33 installed on one side of the oil pipe 31 for water cooling, an oil pump 32 installed inside the oil pipe 31 for controlling the circulation of lubricating oil in the housing 11, and a defoamer (not shown in the figure) connected to the oil pipe 31 for defoaming the circulating lubricating oil.

[0052] The monitoring module (not shown in the figure) includes a first temperature sensor installed inside the housing 11, a second temperature sensor installed on the side wall of the cooling plate 33, and a humidity sensor installed outside the housing 11.

[0053] The compensation analysis module (not shown in the figure) is connected to the cooling module, the deceleration module and the monitoring module respectively. It is used to determine the heating tendency of the deceleration module based on the vulnerability characterization value, and under the condition that the deceleration module has a strong heating tendency, control the operation of the cooling module and determine whether to correct the speed of the vacuum pump in the defoamer based on the microbubble formation factor.

[0054] The excitation response module (not shown in the figure) is connected to the cooling module and is used to determine whether to correct the operating power of the oil pump 32 based on the anomaly ratio when the cooling module is running.

[0055] Specifically, the defoamer can be a vacuum degassing defoamer. Circulating lubricating oil from oil line 31 is introduced into the degassing tank. A vacuum pump establishes a negative pressure environment within the degassing tank, reducing external pressure and causing dissolved gases in the oil to precipitate out. Simultaneously, the bubbles expand and rise. The gas is then removed by the vacuum pump, and the degassed lubricating oil returns to oil line 31. The bubble elimination intensity can be adjusted by regulating the speed of the vacuum pump.

[0056] Specifically, the compensation analysis module is used to determine the vulnerability characterization value, including:

[0057] The absolute value of the difference between the thermal expansion coefficient of the worm gear and the thermal expansion coefficient of the housing 11 is used to obtain the absolute expansion difference. The ratio of the absolute expansion difference to the preset allowable thermal expansion difference is calculated to obtain the attention factor.

[0058] The ratio of the continuous running time of the control motor to the critical heating time is used to obtain the temperature variation factor;

[0059] It is used to calculate the ratio of the current humidity to the preset humidity to obtain the friction anomaly factor;

[0060] The corresponding weight coefficients are assigned to the factors of concern, temperature variation factors, and friction variation factors, and the summation is used to obtain the vulnerability characterization value.

[0061] Specifically, the preset allowable thermal expansion difference is jointly determined by the allowable fit clearance between the worm gear and housing 11 materials and the operating temperature range. The larger the factor of concern, the worse the thermal compatibility of the material and the higher the tendency to heat up. The preset allowable thermal expansion difference is a design parameter that can be obtained through finite element analysis or actual testing. It is the maximum geometric deformation that can be allowed to prevent the worm gear pair from jamming or the lubricating film from rupturing at the highest operating temperature. The corresponding difference in the coefficient of thermal expansion is then deduced, which is the preset allowable thermal expansion difference.

[0062] Specifically, the preset humidity represents the highest permissible ambient humidity at which the worm gear can operate normally. The humidity point at which the worm gear material begins to show significant electrochemical corrosion under specific humidity conditions can be experimentally determined, and this corresponding humidity point is defined as the preset humidity. In a single embodiment, when the relative humidity exceeds 60%RH, the corrosion rate of the worm gear material increases significantly, and 60%RH is set as the preset humidity.

[0063] Specifically, the weighting coefficients can be determined using the analytic hierarchy process (AHP) or regression analysis of experimental data. The weighting coefficient for the most important factor is 0.5. The mismatch in the thermal expansion coefficients of the materials is the fundamental structural factor leading to changes in the meshing clearance of the worm gear pair and the generation of abnormal frictional heat. The greater the difference, the higher the risk of overheating; therefore, it is given the highest weight. The weighting coefficient for the temperature variation factor is 0.3. Continuous operating time is a direct external cause of heat accumulation. Although important, if the materials are well-matched, short-term overheating will not immediately lead to overheating; therefore, its weighting is second highest. The weighting coefficient for the friction variation factor is 0.2. Increased humidity exacerbates corrosion and friction, but its effect is relatively slow, representing a gradual deterioration factor. In the short term, its direct impact on temperature rise is less than the previous two factors; therefore, it is given the lowest weight.

[0064] Please see Figure 3 As shown, this is a logic diagram of the compensation analysis module in an embodiment of the present invention determining the temperature rise tendency of the deceleration module based on the vulnerability characterization value. The compensation analysis module of the present invention is used to determine the temperature rise tendency of the deceleration module based on the vulnerability characterization value, including:

[0065] Under the condition that the vulnerability index value is greater than the preset vulnerability index value, the deceleration module is determined to have a strong tendency to heat up;

[0066] Under the condition that the vulnerability characterization value is less than or equal to the preset vulnerability characterization value, the deceleration module is determined to have a weak tendency to heat up.

[0067] Specifically, the preset vulnerability characterization value is selected within the range [0.45, 0.52]. Those skilled in the art can select and determine this value themselves. Multiple reducers of the same model can be selected and operated under different loads, operating times, and humidity levels. The values ​​of the concern factor, temperature variation factor, and friction variation factor are recorded when the lubricating oil temperature rises by more than 10°C within one hour. The vulnerability characterization values ​​under these critical states are calculated, and the safe lower limit value is taken as the preset vulnerability characterization value. In this embodiment, preferably, the preset vulnerability characterization value is 0.52.

[0068] Specifically, worm gear meshing is a type of strong sliding friction transmission, and the meshing clearance is highly sensitive to thermal expansion. The worm gear and housing 11 have different materials and structures, and the difference in their coefficients of thermal expansion leads to inconsistent dimensional changes at the same temperature rise, thus altering the meshing backlash, contact line position, and local load distribution. The absolute difference in expansion represents the degree of inconsistency in the dimensional response of the worm gear and housing 11 to temperature changes. A concern factor normalizes this difference. Inconsistent thermal expansion causes increased local contact stress on the tooth surface, thinner lubricating film, increased boundary lubrication ratio, and a higher coefficient of friction, further exacerbating heat generation and creating a cycle of temperature rise, contact deterioration, and even higher temperature rise. A larger concern factor indicates a greater difference, more drastic changes in meshing geometry with temperature, and a greater likelihood of sudden increases in local friction and wear, resulting in a stronger tendency for temperature rise. The concern factor quantifies the thermal adaptation risk of materials and structures, triggering cooling and power correction in advance. Determining the temperature anomaly factor, the temperature rise characteristic of worm gears is that the temperature rise is absorbed by the heat capacity of the housing 11 in a short period of time, but after continuous operation for more than a certain period of time, it enters the heat accumulation stage. Therefore, the continuous operation time and the critical temperature rise time are direct indicators for judging whether it has entered the thermal instability region. The critical temperature rise time can be understood as the time limit at which the oil temperature begins to rise significantly under the current structure's heat dissipation capacity and typical load. Longer operation time will lead to increased oil temperature, decreased viscosity, reduced oil film thickness, increased probability of metal contact, and increased frictional heat generation; at the same time, oil oxidation will accelerate, and lubrication performance will further decline. The longer the operation, the closer it is to the upper limit of thermal equilibrium or the entry into the thermal instability stage, and the risk of temperature rise increases monotonically. The larger the temperature anomaly factor, the higher the risk. By capturing the heat accumulation trend in the time dimension, we can provide early warnings than single-point temperature thresholds, reducing overheating and oil deterioration. Determining the friction anomaly factor, high humidity environments will increase the water content of the oil through the breathing effect or micro-permeation of the seal; high humidity environments will form micro-electrolytic corrosion and rust products on the metal surface. The humidity ratio is used to characterize the intensity of environmental factors promoting corrosion and water content. Rust products and contaminant particles alter the distribution of micro-roughness peaks on the tooth surface, leading to increased abrasive wear. Trace amounts of water in the oil reduce oil film load, induce additive failure, and increase foaming tendency, resulting in unstable friction coefficients and heat generation. Higher humidity strengthens the corrosion, water content, and contamination chain, making friction more prone to variation and increasing the tendency to rise in temperature. Incorporating environmental factors into thermal risk assessment makes worm gears more reliable in humid, coastal, and decontamination environments. Vulnerability characterization values ​​are determined by combining factors of concern, temperature variation factors, and friction variation factors. Based on these vulnerability characterization values, the strength of the temperature rise tendency is determined, and with limited control resources, a distinction is made between normal thermal fluctuations and states that may lead to thermal instability. Complex factors are compressed into strong / weak categories, reducing control complexity and improving real-time performance. Unnecessary cooling energy consumption is avoided during weak tendencies; during strong tendencies, cooling and defoaming are initiated promptly to reduce the probability of failure. By identifying risks in advance through vulnerable characterization values, the cooling module can be controlled to perform cooling tasks in a targeted manner, thereby improving the thermal stability and reliability of worm gears under complex working conditions.

[0069] Specifically, the compensation analysis module is used to control the operation of the cooling module and determine the operating power of the oil pump 32 based on the vulnerability characterization value when the deceleration module is determined to have a strong tendency to heat up.

[0070] The operating power of oil pump 32 is positively correlated with its wear-prone characterization value.

[0071] In this embodiment, optionally,

[0072] After determining that the deceleration module has a strong tendency to heat up and activating the cooling module, the compensation analysis module adjusts the operating power of the oil pump 32 based on the vulnerability characterization values. The initial operating power of the oil pump 32 refers to the power required to maintain the basic circulation of lubricating oil under standard operating conditions.

[0073] The vulnerability characterization value is compared with the first preset vulnerability comparison value and the second preset vulnerability comparison value;

[0074] If the vulnerability index value is less than or equal to the first preset vulnerability comparison value, the operating power of the oil pump 32 will be adjusted to 1.11 times the initial operating power of the oil pump 32.

[0075] If the vulnerability index value is less than or equal to the second preset vulnerability comparison value and greater than the first preset vulnerability comparison value, then the operating power of the oil pump 32 will be adjusted to 1.19 times the initial operating power of the oil pump 32.

[0076] If the vulnerability index value is greater than the second preset vulnerability comparison value, the operating power of the oil pump 32 will be adjusted to 1.25 times the initial operating power of the oil pump 32.

[0077] The first preset vulnerability comparison value is 0.7, and the second preset vulnerability comparison value is 0.8.

[0078] Specifically, activating the cooling module indicates a strong tendency to heat up, meaning that if heat is not actively removed, the oil temperature will quickly exceed the oil's applicable range, leading to lubrication film damage and tooth surface abrasion. The hot oil within the housing 11 is guided to the cooling plate 33 for heat exchange through oil circuit circulation, reducing oil temperature, restoring oil film thickness, and suppressing frictional heat generation at its source. The power of the oil pump 32 is positively correlated with its vulnerability index. The oil pump 32 determines the lubricating oil circulation flow rate and heat exchange. When the flow rate is insufficient, the heat exchange potential of the cooling plate 33 cannot be fully utilized, and localized heat accumulation in the housing 11 will still occur. A higher vulnerability index indicates a higher thermal risk and a greater need for heat transfer capacity. Increasing the power of the oil pump 32, increasing the flow rate and oil velocity, improving the convective heat transfer coefficient, leveling the oil temperature gradient more quickly, and increasing the heat removed per unit time. By reducing hot spots in the housing 11 and suppressing oil temperature surges, while simultaneously ensuring more thorough lubrication, boundary lubrication and wear are reduced. This improves the thermal stability and reliability of the worm gear under complex operating conditions.

[0079] Specifically, the compensation analysis module is used to determine the microbubble formation factor, including:

[0080] Calculate the ratio of the current viscosity of the lubricating oil to the preset viscosity to obtain the molding tendency value;

[0081] The ratio of the current operating power of oil pump 32 to the initial operating power of oil pump 32 is calculated to obtain the mixing tendency value;

[0082] The microbubble formation factor is obtained by calculating the product of the forming tendency value and the mixing tendency value.

[0083] Specifically, the monitoring module also includes a linear viscometer installed in the oil pipeline 31 to monitor the dynamic viscosity of the lubricating oil in real time.

[0084] Specifically, the preset viscosity is the optimal viscosity value required to ensure good lubrication at this operating temperature. The optimal viscosity value can be calculated based on the oil viscosity-temperature characteristic curve and the current oil temperature T. The optimal viscosity value can be obtained by querying the oil viscosity-temperature characteristic curve stored in the compensation analysis module.

[0085] Please see Figure 4 As shown, this is a logic diagram of the compensation analysis module of this invention determining whether to correct the speed of the vacuum pump in the defoamer based on the microbubble formation factor. The compensation analysis module of this invention is used to determine whether to correct the speed of the vacuum pump in the defoamer based on the microbubble formation factor, after adjusting the operating power of the oil pump 32.

[0086] Under the condition that the microbubble forming factor is greater than the preset forming factor, the rotation speed of the vacuum pump in the defoamer is corrected based on the microbubble forming factor.

[0087] Under the condition that the microbubble forming factor is less than or equal to the preset forming factor, the vacuum pump in the defoamer is controlled to continue to operate at the current speed.

[0088] The increase in the speed of the vacuum pump in the defoamer is positively correlated with the microbubble formation factor.

[0089] In this embodiment, optionally, the operating power of the defoamer is adjusted according to the microbubble forming factor:

[0090] If the microbubble formation factor is less than or equal to the preset comparison factor, then the speed of the vacuum pump in the defoamer will be adjusted to 1.2 times the initial speed.

[0091] If the microbubble formation factor is greater than the preset comparison factor, the speed of the vacuum pump in the defoamer will be adjusted to 1.3 times the initial speed. The preset comparison factor is 0.9.

[0092] Specifically, the preset formation factor is selected within the range [0.7, 0.8], which can be determined by those skilled in the art through experimentation. The bubble content in the lubricating oil is observed under different oil pump power (32) and oil temperature conditions. When the microbubble formation factor exceeds a critical value, the bubble content increases sharply, leading to lubrication failure. This critical value can be defined as the preset formation factor. In a single embodiment, when the microbubble formation factor is greater than 0.8, the air content in the oil exceeds 5% (by volume); in this case, 0.8 is set as the preset formation factor.

[0093] Specifically, determining the forming tendency value is crucial because lubricating oil viscosity is closely related to the generation, collapse, and buoyancy dynamics of microbubbles. Changes in viscosity alter the ease with which bubbles shear, break up, merge, and escape in the oil. Determining the viscosity ratio characterizes the deviation of the current oil from its ideal viscosity state. In actual transmission, tooth surface shearing and the agitation of the oil pump 32 impeller entrain air into the oil. When the viscosity is within certain ranges, bubbles are more easily sheared into stable microbubbles and carried by the oil film, forming a foam layer, leading to a decrease in the effective lubrication volume fraction and an increase in compressibility. Determining the mixing tendency value is also important; higher oil pump 32 power results in stronger circulation, stronger agitation, shearing, and return oil impact, and a greater ability to entrain air and break up bubbles, equivalent to a greater excitation for the mixing and generation of microbubbles. A larger power ratio indicates higher flow velocity, stronger shearing, and an increased probability of microbubble generation. The microbubble formation factor is determined. Microbubble problems are caused by a combination of oil properties and flow excitation conditions. Abnormal viscosity alone, coupled with weak circulation, may not lead to significant bubble formation; conversely, strong circulation with suitable oil properties may result in rapid bubble escape. Multiplication is used to reflect the synergistic effect of these two factors, capturing high-risk situations where bubbles are easily formed but also strongly agitated. This allows for more precise defoamer adjustment. The microbubble formation factor is used to determine whether to adjust the speed of the vacuum pump in the defoamer. Foaming increases the equivalent compressibility of lubricating oil, reduces oil film load, and causes meshing noise, temperature fluctuations, and localized abrasion. The defoamer's role is to promote bubble breakage and separation, restoring the stability of the continuous oil phase. A higher microbubble formation factor indicates stronger bubble generation and stabilization, requiring higher defoaming intensity to offset the generation rate; therefore, the increase in power is positively correlated. This reduces lubrication failure and temperature fluctuations caused by foaming, improves transmission smoothness, and reduces wear. It also improves the thermal stability and reliability of worm gears under complex operating conditions.

[0094] Please see Figure 5 The diagram shown illustrates the logic decision of the excitation response module in this embodiment of the invention, which determines whether to correct the operating power of the oil pump 32 based on the variation ratio. The excitation response module of this invention is used to determine whether to correct the operating power of the oil pump 32 based on the variation ratio under the condition that the cooling module is operating, including:

[0095] Based on the temperatures acquired by the first temperature sensor at each time point, a temperature time-domain curve is plotted.

[0096] The average slope of each time node in the temperature time domain curve is calculated. Time nodes with a slope greater than the average slope are identified as anomalous nodes. The ratio of the total number of anomalous nodes to the preset number of monitoring nodes is calculated to obtain the anomalous number ratio.

[0097] When the temperature variation ratio is greater than the preset temperature variation ratio, the operating power of oil pump 32 is adjusted based on the variation ratio.

[0098] Under the condition that the ratio of temperature variation is less than or equal to the preset temperature variation ratio, the control oil pump 32 continues to operate at the current operating power.

[0099] Specifically, the preset temperature variation ratio is selected within the range [0.11, 0.16]. Those skilled in the art can determine this selection themselves. It can be achieved by collecting historical temperature data of the reducer under stable operating conditions, calculating the slope range of its temperature time-domain curve, and taking a statistical upper limit as a benchmark. In a single embodiment, it is statistically determined that under stable operating conditions, the number of variation nodes typically does not exceed 5% of the total number of monitored nodes. To ensure system stability, a slightly higher tolerance threshold is set, and the preset temperature variation ratio is determined to be 15%. Once this value is exceeded, it is considered to be in an abnormal fluctuation state, requiring intervention.

[0100] Specifically, a temperature time-domain curve is plotted based on the temperature at each time point sampled at a fixed frequency by the first temperature sensor. The preset number of monitoring nodes is the total number of nodes within the current monitoring period.

[0101] Specifically, in situations such as sudden increases in load, shocks during startup and shutdown, momentary air resistance in the oil circuit causing poor oil supply, or fluctuations in the control motor current, these disturbances can cause an abnormally rapid rise in temperature within a short period, resulting in a point of instability. Even if the average temperature is not high, this fluctuation indicates that the worm gear is in an unstable state and requires timely compensation.

[0102] Specifically, the excitation response module is used to determine the operating power of the corrected oil pump 32 based on the anomaly ratio, wherein,

[0103] The increase in the operating power of oil pump 32 is positively correlated with the ratio of the number of anomalies.

[0104] In this embodiment, optionally,

[0105] Compare the mutation count ratio with the preset mutation comparison value;

[0106] If the ratio of abnormal quantities is less than or equal to the preset abnormal quantity comparison value, the operating power of oil pump 32 will be adjusted to 1.1 times the current operating power of oil pump 32.

[0107] If the anomaly ratio is greater than the preset anomaly ratio value, the operating power of oil pump 32 will be adjusted to 1.2 times the current operating power of oil pump 32. The preset anomaly ratio value is 0.3.

[0108] Specifically, by plotting the temperature-time domain curve and identifying anomalous nodes, many overheating issues are not simply due to high temperatures, but rather abnormal heating rates. When tooth surface contact suddenly deteriorates, the oil film is instantly destroyed, or foaming reduces effective heat transfer, the temperature curve will show a sudden increase in slope. The slope represents the rate of temperature rise per unit time, equivalent to the degree to which net heat generation exceeds heat dissipation. The average slope serves as an adaptive baseline, used to eliminate overall differences under different ambient temperatures and loads. Once boundary lubrication or localized scratches occur, frictional heat will surge, manifesting as a significant increase in the local slope of the temperature curve; this phenomenon appears earlier than absolute temperature. Determining the anomaly ratio is crucial. A single anomaly might be noise or an occasional disturbance, while continuous anomalies indicate an unstable state for the worm gear. The anomaly ratio measures the density and persistence of anomalies, improving the reliability of control triggering. If the anomaly ratio exceeds a threshold, the oil pump power is adjusted by 32, with the increase being positively correlated with the threshold. The power adjustment of oil pump 32, based on the vulnerability characteristic value, is predictive. Temperature slope anomalies, however, provide feedback evidence, indicating that the prediction may have underestimated actual heat generation or heat transfer obstruction, requiring stronger circulation to suppress the temperature rise rate. A higher anomaly ratio indicates more frequent and difficult-to-stabilize temperature surges, necessitating stronger heat transfer and faster oil temperature equalization; therefore, the power increase of oil pump 32 is positively correlated with this. This reduces continuous temperature increases to controllable small fluctuations, improving thermal stability and preventing overheating shutdown. It also enhances the thermal stability and reliability of the worm gear under complex operating conditions.

[0109] Specifically, the excitation response module is used to determine whether to adjust the maximum operating time of the control motor based on the temperature of the cooling plate 33, after adjusting the operating power of the oil pump 32, including:

[0110] When the temperature of the cooling plate 33 is greater than the preset critical temperature of the cooling plate 33, the maximum running time of the control motor is corrected based on the temperature difference.

[0111] Specifically, the excitation response module is used to correct the maximum operating time of the control motor based on the temperature difference, wherein,

[0112] Calculate the temperature difference between the inside of the chamber 11 and the side wall temperature of the cooling plate 33 to obtain the temperature difference value;

[0113] The maximum operating time of the control motor is positively correlated with the temperature difference.

[0114] In this embodiment, optionally,

[0115] Compare the temperature difference value with the first preset temperature difference comparison value and the second preset temperature difference comparison value;

[0116] If the temperature difference is less than or equal to the first preset temperature difference comparison value, the maximum running time of the control motor will be adjusted to 0.85 times the initial standard running time.

[0117] If the temperature difference is less than or equal to the second preset temperature difference comparison value and greater than the first preset temperature difference comparison value, then the maximum running time of the control motor will be adjusted to 0.89 times the initial standard running time.

[0118] If the temperature difference is greater than the second preset temperature difference comparison value, the maximum running time of the control motor will be adjusted to 0.95 times the initial standard running time.

[0119] The first preset temperature difference comparison value is 6℃, and the second preset temperature difference comparison value is 13℃.

[0120] The maximum runtime is the rated continuous running time.

[0121] Specifically, the temperature of cooling plate 33 is used as a state quantity of cooling capacity. The temperature of cooling plate 33 can reflect whether the heat exchange capacity of the water-cooled end is sufficient: if the temperature of cooling plate 33 itself is too high, it means that the cooling water temperature is high, the flow rate is insufficient, or the heat exchange surface is contaminated, and the heat dissipation limit is reduced. Looking only at the temperature of the cabinet 11 is lagging behind, while looking at the temperature of cooling plate 33 can determine whether the cooling end is under strain. When the cooling end capacity is insufficient, the time limit is set in advance to avoid irreversible temperature rise. The temperature difference reflects the driving force and thermal resistance state of the temperature difference between the heat source end and the cooling end. When the temperature of cooling plate 33 exceeds the critical value, the maximum running time of the motor is adjusted according to the temperature difference. The temperature difference is an indicator of the thermal driving force between the heat source end of cabinet 11 and the cooling end of cooling plate 33. The larger the difference, the more sufficient the gradient of heat removal by cooling plate 33 is and the greater the cooling margin. Therefore, the maximum running time of the motor is set to be positively correlated with the temperature difference value, so that the time limit is reduced when the cooling capacity is stronger, and the thermal recovery window is entered earlier when the cooling capacity is weaker. It reduces the coupling risks of overheating, blistering, and wear, improves thermal stability, and balances energy consumption and production line continuity. It enhances the thermal stability and reliability of worm gears under complex operating conditions.

[0122] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the scope of protection of the present invention.

[0123] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An adaptive temperature compensated worm and gear reduction system, characterized by, include: The reduction module includes a reduction worm gear, a reduction worm, and a control motor; The cooling module includes oil pipes connected to both sides of the housing, a cooling plate installed on one side of the oil pipes for water cooling, an oil pump installed inside the oil pipes to control the circulation of lubricating oil in the housing, and a defoamer connected to the oil pipes to defoam the circulating lubricating oil. The monitoring module includes a first temperature sensor installed inside the chamber, a second temperature sensor installed on the side wall of the cooling plate, and a humidity sensor installed outside the chamber. The compensation analysis module is connected to the cooling module, the deceleration module and the monitoring module respectively. It is used to determine the heating tendency of the deceleration module based on the vulnerability characterization value, and under the condition that the deceleration module has a strong heating tendency, control the operation of the cooling module and determine whether to correct the speed of the vacuum pump in the defoamer based on the microbubble formation factor. An excitation response module, connected to the cooling module, is used to plot a temperature time-domain curve based on the temperature at each time point obtained by the first temperature sensor under the condition that the cooling module is running, and to calculate the average slope of each time point in the temperature time-domain curve, identify time points in the temperature time-domain curve whose slope is greater than the average slope as abnormal nodes, calculate the ratio of the total number of abnormal nodes to the preset number of monitoring nodes to obtain the abnormal number ratio, and determine whether to correct the operating power of the oil pump based on the abnormal number ratio. The compensation analysis module is used to determine the vulnerability characterization value based on the attention factor, temperature variation factor, and friction variation factor. The concern factor is determined based on the thermal expansion coefficients of the worm gear and the housing; the temperature variation factor is determined based on the continuous running time of the control motor; and the friction variation factor is determined based on the current humidity obtained by the humidity sensor. The concern factor, temperature variation factor, and friction variation factor are assigned corresponding weight coefficients and summed to obtain the vulnerability characterization value. The compensation analysis module is also used to determine the microbubble formation factor, including: Used to determine the molding tendency value based on the current viscosity of the lubricating oil; Used to determine the mixing tendency value based on the current operating power of the oil pump; The microbubble formation factor is determined based on the forming tendency value and the mixing tendency value.

2. The adaptive temperature compensated worm and gear reduction system of claim 1, wherein, The compensation analysis module is used to determine the temperature rise tendency of the deceleration module based on the vulnerability characterization value, including: If the vulnerability index value is greater than the preset vulnerability index value, the deceleration module is determined to have a strong tendency to heat up.

3. The adaptive temperature compensated worm and gear reduction system of claim 2, wherein, The compensation analysis module is used to control the operation of the cooling module and determine the operating power of the oil pump based on the vulnerability characterization value when the deceleration module is determined to have a strong tendency to heat up. The operating power of the oil pump is positively correlated with the vulnerability characterization value.

4. The adaptive temperature-compensated worm gear reduction system according to claim 1, characterized in that, The compensation analysis module is used to determine whether to correct the speed of the vacuum pump in the defoamer based on the microbubble formation factor, under the condition that the operating power of the oil pump has been adjusted. Specifically, when the microbubble formation factor is greater than the preset formation factor, the speed of the vacuum pump in the defoamer is corrected based on the microbubble formation factor. The increase in the speed of the vacuum pump in the defoamer is positively correlated with the microbubble formation factor.

5. The adaptive temperature-compensated worm gear reduction system according to claim 4, characterized in that, The excitation response module is used to determine whether to correct the operating power of the oil pump based on the anomaly ratio under the condition that the cooling module is operating, including: When the temperature variation ratio is greater than the preset temperature variation ratio, the operating power of the oil pump is adjusted based on the variation ratio.

6. The adaptive temperature-compensated worm gear reduction system according to claim 5, characterized in that, The excitation response module is used to determine the operating power of the corrected oil pump based on the anomaly ratio, wherein, The increase in the operating power of the oil pump is positively correlated with the ratio of the number of abnormalities.

7. The adaptive temperature-compensated worm gear reduction system according to claim 6, characterized in that, The excitation response module is used to determine whether to adjust the maximum operating time of the control motor based on the temperature of the cooling plate, after adjusting the operating power of the oil pump, including: When the temperature of the cooling plate is greater than the preset critical temperature of the cooling plate, the maximum running time of the control motor is adjusted based on the temperature difference.

8. The adaptive temperature-compensated worm gear reduction system according to claim 7, characterized in that, The excitation response module is used to correct the maximum operating time of the control motor based on the temperature difference, wherein... Calculate the temperature difference between the inside of the chamber and the side wall of the cooling plate to obtain the temperature difference value; The maximum operating time of the control motor is positively correlated with the temperature difference.

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