Multi-sensor integrated intelligent gear

Abstract

The invention discloses a multi-sensor integrated intelligent gear. The multi-sensor integrated intelligent gear comprises a gear body, a PCB integrated with a plurality of functional modules and a sealing cover plate. According to the multi-sensor integrated intelligent gear, the sensing function, the wireless communication function and the gear body are integrated, real-time sensing, wireless transmission, display and storage of stress, acceleration, temperature and noise information in the working state of the gear are achieved, and an intelligent gear part is achieved. According to the multi-sensor integrated intelligent gear, a groove is formed in the end face of a gear body or a radial plate, an annular or fan-shaped PCB designed according to the sizes of different gears is embedded into the groove, and the annular or fan-shaped PCB is fixed through screws or bonding and sealed through a sealing cover plate, so that the sensing function, the wireless communication function and the gear are integrated. The multi-sensor integrated intelligent gear has real-time sensing and wireless communication functions, does not need additional sensors and communication devices, is compact in structure and high in integration level, considers dynamic balance and realizes intellectualization of gear parts.

Description

Technical Field

[0001] This invention belongs to the field of intelligent mechanical components technology, specifically a multi-sensor integrated intelligent gear. Background Technology

[0002] In recent years, with the continuous development of intelligent equipment and products, the demand for intelligent components with sensing capabilities has been increasing. Integrating functions such as sensing, communication, data processing, and even power supply into the component itself, and realizing multi-information sensing capabilities at the component level, can greatly improve the intelligence level of equipment and products and simplify system design. As a core component of the transmission system, gear components operate under extremely complex conditions, and their intelligentization faces both urgent needs and significant technical challenges. For example, multi-information sensing and reliable data transmission under the constraints of complex system structures and operating conditions are key technical challenges for intelligent gear components.

[0003] The challenges of structural integration lie in the fact that gear teeth bear the main alternating loads, and opening holes or slots in their bodies would severely weaken their mechanical properties. Furthermore, the tooth surface is the working surface, making component installation difficult. The space available for integration is extremely limited, and integration must not affect its dynamic balance. The challenges of energy sustainability are also significant. Gears are typically sealed within a housing and operate continuously for extended periods, unlike tool holders which receive charging opportunities during tool changes, or bearings which allow for convenient placement of external induction coils. Providing long-term, stable, and maintenance-free energy to the integrated electronic systems is one of the biggest challenges. The challenges of signal transmission reliability are further compounded by the fact that gearboxes are typically enclosed metal environments, severely shielding radio signals. Achieving highly reliable, low-latency wireless transmission of monitoring data in continuous rotation and complex oil mist environments is a major technical hurdle.

[0004] Publication number CN 115541224 A discloses "A Gear Intelligent Monitoring System and Method Including Multi-dimensional Information Fusion," in which the sensing module is directly fixed to the end face of the gear and installed coaxially with the gear, representing a solution based on an auxiliary component. Publication number CN 117213839 A discloses "A WIFI-based Embedded Gear Monitoring System and Method," which employs an additional embedding solution, disrupting the dynamic balance of the shaft system. These two representative sensing solutions involve modifications to existing mechanical systems and gear component structures, significantly impacting the system's structural design, dynamic balance, and reliability.

[0005] Therefore, existing technologies lack a design scheme for intelligent gear parts that can integrate sensing, power supply, and communication functions into the gear part body without disrupting the existing system structure, thereby achieving real-time perception. Summary of the Invention

[0006] To address the problems of indirect signal transmission, inaccurate positioning, complex and unreliable wired slip ring systems, and low integration and significant structural modifications required by wireless solutions in existing gear state information sensing technologies, this invention aims to provide an integrated, modular, self-powered, multi-sensor integrated intelligent gear and its manufacturing method. This solution aims to solve the challenge of high-density, non-destructive integration of sensing units onto the gear body, achieving wireless power supply and communication. This endows the gear with long-term, in-situ, maintenance-free real-time wireless sensing capabilities without compromising the strength, dynamic balance, or gearbox structure of the gear body, thus enabling intelligent gear design.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: A multi-sensor integrated smart gear includes: a gear body, a printed circuit board (PCB), and a sealing cover. The gear body has an annular embedding groove on its end face spokes; the PCB shape matches the embedding groove, and is designed to be annular or fan-shaped to accommodate gears of different sizes, and is fixed in the embedding groove by adhesive or screws; the sealing cover is adapted to the size of the embedding groove and is used to seal and protect the PCB, preventing corrosion from liquids inside the gearbox; the sealing cover is made of radio frequency transparent materials, including but not limited to plastics, to ensure that the signal output by the wireless communication module can penetrate the sealing cover and be output from the gear to the outside while maintaining a seal; the PCB, the sealing cover, and the gear body are integrated into a single structure and rotate synchronously with the gear.

[0008] The embedding groove is located in the low-stress region of the gear end face spoke, and its position is determined based on finite element load analysis. The groove is an annular recess that matches the shape of the printed circuit board (PCB), with rounded edges at the bottom to reduce stress concentration. The groove contains threaded holes or snap-fit ​​structures for fixing the PCB and includes vias for wires or wireless transmission windows. CNC milling or electrical discharge machining (EDM) is preferred for machining the embedding groove. For high-hardness gears that have undergone heat treatment, EDM is used to avoid damage to material properties. Metal additive manufacturing can also be used to integrally form a structure with cavities and internal features during gear manufacturing. The core technology for creating the embedding groove is ensuring the integrity of the gear's main structure and the reliability of its functional integration. The depth (H) of the embedding groove is no more than 60% of the spoke thickness (T) at its location. The specific depth is determined by the total thickness of the PCB assembly plus the encapsulation layer thickness plus a safety margin, typically only a few millimeters. For example, if a printed circuit board and microchip are used, the total thickness can be controlled to 4-5 mm. If the embedding groove is too deep, it will severely weaken the load-bearing section, making it prone to low-cycle fatigue failure or static fracture. At the same time, excessive material removal makes dynamic balancing more difficult to correct. If it is too shallow, it will not be able to accommodate the complete electronic module, affecting gear installation or operation.

[0009] The PCB integrates: (1) A multi-sensor sensing module is used to sense the gear running status data in real time during the gear working process. The multi-sensor includes, but is not limited to, strain sensor, temperature sensor and acceleration sensor, and is used to measure the strain, temperature and acceleration signals in real time during the gear working process.

[0010] (2) Signal conditioning module, used to amplify, filter, convert A / D and other processes the signals collected by the sensor, and to preprocess the signals for wireless transmission; (3) Wireless communication module, used to accurately output gear status signals from the rotating gear to realize real-time monitoring of gear running status; (4) Power management module, used to regulate the power supply of the multi-sensor sensing module and the wireless communication module, and to manage the charging and discharging of the battery; (5) Battery, which serves as a power supply for the multi-sensor sensing module and the wireless communication module; it can also serve as a counterweight to adjust the dynamic balance of the gear.

[0011] The battery is a rechargeable micro lithium battery or a custom-shaped pouch battery. Its mounting base is located in a pre-defined mounting area within the gear end face groove, or directly fixed to a printed circuit board (PCB). By installing the battery at different angular positions within this circumference, the mass distribution of the system can be changed, thereby achieving dynamic balance adjustment. The specific position and weight are determined using a systematic method. During the design phase, the imbalance is estimated based on the system's three-dimensional model, and the allowable imbalance according to national standards (such as ISO 1940) is referenced. The required mass moment range for the counterweight is calculated using the mass moment balance equation, and the nominal weight of the battery is selected accordingly. During the actual calibration phase, for precise fine-tuning, the battery can be paired with a miniature detachable counterweight. Its final precise position is objectively determined by dynamic balance measurement and calculation: first, the components without the battery are dynamically balanced to measure the phase angle and magnitude of the initial imbalance; then, through dynamic balance calculation, the polar coordinate angle (θ) at which the battery needs to be installed within the annular region is determined, and finally, it is fixed at that position. The entire process is based on preliminary calculations and subsequent precise measurements. It is a deterministic engineering method that can efficiently achieve the preset balance accuracy level and avoid repeated trial and error.

[0012] Furthermore, based on the different gear dimensions and the space of the end face spokes, two optimized implementation methods are specifically provided: (1) Integrated ring PCB solution for pinion gear When the gear body is a small gear, the PCB is ring-shaped and is embedded in the groove at the spoke end of the gear around the gear axis. The multi-sensor sensing module is calibrated and distributed to the accurate position along the circumference. By precisely installing the battery at the polar coordinate position (angle θ) determined by dynamic balance calculation as a movable / positionable counterweight unit, the high-speed dynamic balance correction of the gear system is achieved by mass moment compensation. It also includes an annular sealing cover plate that is detachably connected to the end face of the gear, and the sealing cover plate is fixed to the pinion body by adhesive. During assembly, the ring-shaped PCB integrating various functional modules is first placed into the embedding groove of the gear body, and then the sealing cover is fastened to the gear body. Finally, the PCB is encapsulated between the sealing cover and the gear body, resulting in a compact structure and good protection.

[0013] (2) Combined sector PCB solution for large gears: When the gear body is a large gear, the PCB is fan-shaped. Multiple fan-shaped PCBs surround the gear axis and are spliced ​​together along the circumference of the gear to form a complete ring spliced ​​PCB, or they are symmetrically distributed along the axis of the gear end face. The gear dynamic balance is achieved by the circumferential or symmetrical distribution of PCBs. It also includes an annular sealing cover plate that is detachably connected to the end face of the gear, and the cover plate is fixed to the large gear body by adhesive. During assembly, the multiple annular PCBs are arranged in a multi-segmented manner within the embedding grooves of the gear body along the circumference of the gear. The sealing cover is then securely connected to the gear body. Ultimately, the PCBs are encapsulated between the sealing cover and the gear body, resulting in a compact structure and good protection.

[0014] Furthermore, the sensors include, but are not limited to, strain sensors, acceleration sensors, temperature sensors, etc., used to sense strain signals, acceleration signals, temperature signals, etc. during the gear's operation.

[0015] Furthermore, the signal conditioning module includes, but is not limited to, a signal amplification circuit, a filtering circuit, and an ADC acquisition circuit, which are used to amplify, filter, and perform A / D conversion on the signals acquired by the sensor, and to preprocess the signals for wireless transmission. Furthermore, the wireless communication module employs communication protocols including but not limited to Bluetooth and WIFI to enable wireless output of gear status signals from the rotating gear body.

[0016] Furthermore, a sealing cover plate is provided at the opening of the embedding groove, which is adapted to the size of the annular embedding groove, to seal and protect the PCB, thereby forming a waterproof and dustproof structure. The sealing cover plate is made of radio frequency transparent materials, including but not limited to plastics, to ensure that the signal output by the wireless communication module can penetrate the sealing cover plate and be output from the gear body to the outside while ensuring a seal. The present invention also provides manufacturing methods for the two types of intelligent gears mentioned above.

[0017] (1) A smart gear manufacturing method integrating multiple sensors for pinions mainly includes the following steps: An annular embedding groove is machined on the end face of the pinion body; A ring-shaped PCB is fabricated, and a multi-sensor sensing module, a signal preprocessing module, a wireless communication module, a power management module, and a battery are integrated on it; The PCB is first placed into the embedding groove and fixed to the gear body by adhesive or screws. Then, the sealing cover is assembled and fixed to the gear body by adhesive, so that the cover covers and seals the embedding groove.

[0018] (2) The intelligent gear manufacturing method for large gears with multi-sensor integration mainly includes the following steps: An annular embedding groove is machined on the end face of the large gear body; A fan-shaped PCB is fabricated, and a multi-sensor sensing module, a signal preprocessing module, a wireless communication module, a power management module, and a battery are integrated on it; Multiple sector-shaped PCBs are spliced ​​together along the circumference of the gear to form a complete ring spliced ​​PCB, or they are symmetrically distributed along the axis of the gear end face in a multi-segment distribution. At the same time, the gear dynamic balance is achieved through the circumferential or symmetrical PCB distribution. Multiple fan-shaped PCBs are distributed in the embedding groove along the circumference of the gear and are fixed to the gear body by adhesive or screws. Then, the sealing cover plate is assembled and fixed to the gear body by adhesive, so that the cover plate covers and seals the embedding groove. By adopting the technical solution described above, the present invention has the following beneficial effects: 1. High Integration and Non-Destructive Embedding: By creating embedding slots in the non-primarily load-bearing end face plates of the original gear, the entire electronic system is embedded in PCB form, achieving maximum space saving and structural integration. This design has minimal impact on the original strength and dynamic balance of the gear body, realizing the "invisible" integration of the sensing system.

[0019] 2. Direct sensing and precise positioning: The sensor is directly mounted on the gear body, which can obtain the most real and direct physical signals such as strain, vibration and temperature, avoiding the attenuation and interference caused by the signal transmission path, and can realize early warning and precise positioning of faults.

[0020] 3. Energy Independence and Wireless Communication: The built-in battery, combined with a power management module, provides the system with an independent power source. Coupled with optional charging (achieved through the power management module), energy self-sufficiency and sustainability are achieved. Wireless communication completely eliminates the physical contact components found in wired communication solutions such as slip rings, greatly improving the reliability and accuracy of the output signal under high-speed rotation conditions.

[0021] 4. Modular Design and Strong Adaptability: The innovative design of both ring-shaped and fan-shaped PCB layouts, along with the multi-PCB splicing structure, endows the solution with strong modularity. This allows the invention to flexibly adapt to gears of different diameters, tooth widths, and structures, achieving standardized design and personalized adaptation, thus reducing manufacturing costs and complexity.

[0022] 5. Strong protection and convenient maintenance: The sealed cover and sealing treatment ensure the long-term stable operation of the embedded electronic system in the harsh environment of the gearbox. At the same time, the detachable cover design or the fan-shaped modular design makes battery replacement or single module repair possible without replacing the entire gear or complex disassembly, greatly reducing the later maintenance costs. Attached Figure Description

[0023] Figure 1 This is a structural diagram of an integral ring-shaped PCB assembly scheme for a small gear.

[0024] Figure 2 This is a structural diagram of a combined sector PCB assembly scheme for large gears.

[0025] Figure 3 This is a top view of a combined sector-shaped PCB for a large gear, distributed circumferentially.

[0026] Figure 4 This is a top view of a symmetrically distributed sector-shaped PCB for a large gear.

[0027] Figure 5 This is a schematic diagram of the various functional modules on a ring-shaped PCB.

[0028] Figure 6 This is a schematic diagram of the various functional modules on a sector-shaped PCB.

[0029] Figure 7 This is a schematic diagram of the circuit system.

[0030] The labels in the diagram are explained as follows: 1. Small gear body; 2. Ring PCB; 3. Sealing cover; 4. Large gear body; 5. Sector PCB; 6. Strain signal sensing module; 7. Temperature signal sensing module; 8. Acceleration signal sensing module; 9. Signal preprocessing module; 10. Main control module; 11. Power management module; 12. Battery. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. The described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] like Figures 1 to 7 As shown, this embodiment of the invention provides a multi-sensor integrated intelligent gear, including: a small gear body 1, an annular PCB 2, a sealing cover plate 3, a large gear body 4, and a sector-shaped PCB 5.

[0033] Two specific embodiments are given below, depending on the gear size and the space of the end face spokes.

[0034] 1. An example of a smart gear with multi-sensor integration for pinions. See attached document Figure 1 This embodiment provides a smart gear implementation scheme for multi-sensor integration suitable for small-sized, high-speed gears. The pinion is a small-sized gear with a module Mn=3mm and a tooth tip circle diameter Da=150mm. Due to the extremely limited space of the pinion, high integration is required. The embedding groove is designed as a single complete annular embedding groove located on the end face of the gear shaft hole. The printed circuit board (PCB) is designed as a complete annular printed circuit board PCB 2.

[0035] See attached document Figure 5 In this embodiment, the annular printed circuit board PCB 2 integrates, but is not limited to, a strain signal sensing module 6, a temperature signal sensing module 7, an acceleration signal sensing module 8, a signal preprocessing module 9, a main control module 10, a power management module 11, and a battery 12. The annular PCB 2 is inserted into an embedding groove and fixed to the pinion body 1 by adhesive or screws. The sealing cover plate 3 is then glued to the pinion body 1, covering and sealing the embedding groove. The annular PCB 2, integrating the functional modules, is integrated with the pinion body 1 as a single unit, rotating simultaneously with the gear.

[0036] The intelligent gear integrating multiple sensors was tested on a test bench, including but not limited to gear strain signal sensing tests, gear temperature signal sensing tests, and gear acceleration signal sensing tests. These tests were used to determine the tooth root strength limit state, tooth surface wear and precursors to surface failure, tooth surface scuffing failure, and vibration characteristics during gear operation.

[0037] Specifically, the strain sensing module uses a strain gauge half-bridge circuit to collect strain signals. When the gear rotates, the strain at the tooth root changes. The strain gauge converts the strain change into a resistance change, and the output voltage of the bridge circuit changes accordingly, converting the strain signal at the gear tooth root into an electrical signal. The signal output from the bridge circuit is then amplified, filtered, and converted to an A / D value by the signal conditioning module. The acceleration sensing module uses a MEMS velocitiesmeter to collect vibration signals from the gear during operation. The vibration signals are pre-processed by the signal conditioning module, including amplification, filtering, and A / D conversion. The temperature sensing module uses a three-wire RTD bridge circuit to collect temperature signals. The RTD converts the temperature change of the gear during operation into a resistance change, and the output voltage of the bridge circuit changes accordingly, converting the gear temperature signal into an electrical signal. The signal output from the bridge circuit is amplified, filtered, and converted to an A / D value by the signal conditioning module. The processed signals are then transmitted to the main control module for storage. The signals are wirelessly transmitted to the outside of the gear body via a wireless communication module. The entire circuit is powered by a rechargeable battery, and the power management module manages power conditioning and battery charging / discharging control. The signal is then received via an external wireless communication module or a host computer.

[0038] 2. An example of a smart gear with multi-sensor integration for large gears. See attached document Figure 2 This embodiment provides a multi-sensor integrated intelligent gear implementation scheme suitable for large-sized, medium-to-low-speed heavy-duty gears. The large gear is a large-sized gear with a module Mn=5mm and a tooth tip circle diameter Da=300mm. Considering the ample space on the large gear spokes and the high load-bearing requirements, the embedding groove is designed as a single complete annular embedding groove located on one end face spoke of the large gear body 4. The printed circuit board (PCB) is designed as multiple fan-shaped PCBs 5 arranged in a multi-segment distributed manner within the embedding groove.

[0039] Specifically, refer to the appendix Figure 3 Multiple fan-shaped PCBs 5 are distributed in the embedded groove along the circumference of the gear and are fixed to the large gear body 4 by adhesive or screws, splicing them into a complete ring. The fan-shaped PCBs 5 are distributed in multiple segments.

[0040] Specifically, refer to the appendix Figure 4 Multiple fan-shaped PCBs 5 are symmetrically distributed in the embedded groove along the gear axis and are fixed to the large gear body 4 by adhesive or screws. The fan-shaped PCBs 5 are distributed in a multi-segment manner.

[0041] See attached document Figure 6In this embodiment, the fan-shaped printed circuit board (PCB) 5 integrates, but is not limited to, a strain signal sensing module 6, a temperature signal sensing module 7, an acceleration signal sensing module 8, a signal preprocessing module 9, a main control module 10, a power management module 11, and a battery 12. The fan-shaped PCB 5 is distributed in the embedded slot and is fixed to the large gear body 4 by adhesive or screws. The sealing cover plate 3 is assembled and fixed to the large gear body 4 by adhesive, so that the cover plate covers and seals the embedded slot. The fan-shaped PCB 5, integrating the functional modules, is integrated with the large gear body 4 as a single unit and rotates simultaneously with the gear.

[0042] The intelligent gear integrating multiple sensors was tested on a test bench, including but not limited to gear strain signal sensing tests, gear temperature signal sensing tests, and gear acceleration signal sensing tests. These tests were used to determine the tooth root strength limit state, tooth surface wear and precursors to surface failure, tooth surface scuffing failure, and vibration characteristics during gear operation.

[0043] Specifically, the strain sensing module uses a strain gauge half-bridge circuit to collect strain signals. When the gear rotates, the strain at the tooth root changes. The strain gauge converts the strain change into a resistance change, and the output voltage of the bridge circuit changes accordingly, converting the strain signal at the gear tooth root into an electrical signal. The signal output from the bridge circuit is then amplified, filtered, and converted to an A / D value by the signal conditioning module. The acceleration sensing module uses a MEMS velocitiesmeter to collect vibration signals from the gear during operation. The vibration signals are pre-processed by the signal conditioning module, including amplification, filtering, and A / D conversion. The temperature sensing module uses a three-wire RTD bridge circuit to collect temperature signals. The RTD converts the temperature change of the gear during operation into a resistance change, and the output voltage of the bridge circuit changes accordingly, converting the gear temperature signal into an electrical signal. The signal output from the bridge circuit is amplified, filtered, and converted to an A / D value by the signal conditioning module. The processed signals are then transmitted to the main control module for storage. The signals are wirelessly transmitted to the outside of the gear body via a wireless communication module. The entire circuit is powered by a rechargeable battery, and the power management module manages power conditioning and battery charging / discharging control. The signal is then received via an external wireless communication module or a host computer.

[0044] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A smart gear integrating multiple sensors, characterized in that: include: The gear body comprises a printed circuit board (PCB) and a sealing cover. The gear body has an annular insert groove on its end face. The PCB, with a shape matching the insert groove, is either annular or fan-shaped and is fixed within the groove by adhesive or screws. The sealing cover, adapted to the size of the insert groove, seals and protects the PCB, preventing corrosion from liquids inside the gearbox. The sealing cover is made of radio frequency transparent material, ensuring that the signal output from the wireless communication module penetrates the sealing cover and is output from the gear to the outside while maintaining a tight seal. The PCB, sealing cover, and gear body are integrated into a single structure and rotate synchronously with the gear.

2. The intelligent gear integrating multiple sensors according to claim 1, characterized in that: The embedded groove is located in the low-stress area of ​​the gear end face spoke, and its position is determined based on finite element load analysis. The groove body is an annular recess that matches the shape of the printed circuit board (PCB). The bottom edge of the groove is rounded to reduce stress concentration. The groove is provided with threaded holes or snap-fit ​​structures for fixing the PCB, and wire through holes or wireless transmission windows are reserved.

3. A multi-sensor integrated intelligent gear according to claim 1 or 2, characterized in that: The machining of the insert groove is carried out by CNC milling or electrical discharge machining. For high-hardness gears that have been heat-treated, electrical discharge machining is used to avoid damage to material properties. Alternatively, metal additive manufacturing technology can be used to integrally form a structure with cavities and internal features during the gear manufacturing process. The purpose of setting the insert groove is to ensure the integrity of the gear body structure and the reliability of functional integration.

4. The intelligent gear integrating multiple sensors according to claim 1, characterized in that: The PCB integrates: The multi-sensor sensing module is used to sense the gear running status data in real time during the gear working process. The multi-sensor includes a strain sensor, a temperature sensor, and an acceleration sensor, which are used to measure the strain, temperature, and acceleration signals of the gear in real time during the working process. The signal conditioning module is used to amplify, filter, and perform A / D conversion on the signals collected by the sensor, providing preprocessing for wireless signal transmission. The wireless communication module is used to accurately output gear status signals from the rotating gear, enabling real-time monitoring of the gear's operating status. The power management module is used to regulate the power supply of the multi-sensor sensing module and the wireless communication module, and at the same time to manage the charging and discharging of the battery. The battery serves as a power source for the multi-sensor sensing module and the wireless communication module; it also acts as a counterweight for adjusting the dynamic balance of the gears.

5. The intelligent gear integrating multiple sensors according to claim 4, characterized in that: The battery is a rechargeable micro lithium battery or a custom-shaped pouch battery; the mounting base is located in a pre-set mounting area within the groove embedded in the gear end face, or is directly fixed to the printed circuit board (PCB); by installing the battery at different angular positions within the circumference range, the mass distribution of the system is changed, thereby achieving dynamic balance adjustment.

6. A multi-sensor integrated intelligent gear according to claim 4 or 5, characterized in that: During the design phase, the unbalance is estimated based on the three-dimensional model of the system, and the allowable unbalance is referenced. The range of mass moments required for the counterweight is calculated through the mass moment balance equation, and the nominal weight of the battery is selected. In the actual calibration stage, for precise fine-tuning, the battery is equipped with a miniature detachable counterweight; the final precise position is determined by dynamic balance measurement and calculation: first, the component without the battery is subjected to dynamic balance test to measure the phase angle and magnitude of the initial imbalance, then the polar coordinate angle at which the battery needs to be installed in the annular area is determined through dynamic balance calculation, and finally fixed.

7. The intelligent gear integrating multiple sensors according to claim 1, characterized in that: Based on the different gear sizes and end face spoke space, the following is an integral ring PCB solution for the pinion; When the gear body is a small gear, the PCB is ring-shaped and is embedded in the groove at the spoke end of the gear around the gear axis. The multi-sensor sensing module is distributed to the accurate position along the circumference after calibration. By installing the battery at the polar coordinate position determined by dynamic balance calculation, it serves as a movable or positionable counterweight unit, and high-speed dynamic balance correction of the gear system is achieved by mass moment compensation. It also includes an annular sealing cover that is detachably connected to the end face of the gear, and the sealing cover is fixed to the pinion body by adhesive.

8. The intelligent gear integrating multiple sensors according to claim 1, characterized in that: Based on the different gear sizes and end face spoke space, the combined sector PCB solution for the large gear is as follows; When the gear body is a large gear, the PCB is fan-shaped. Multiple fan-shaped PCBs surround the gear axis and are spliced ​​together along the circumference of the gear to form a complete ring spliced ​​PCB, or they are symmetrically distributed along the axis of the gear end face. The gear dynamic balance is achieved by the circumferential or symmetrical distribution of PCBs. It also includes an annular sealing cover that is detachably connected to the end face of the gear, and the cover is fixed to the large gear body by adhesive.

9. A method for manufacturing an intelligent gear based on the multi-sensor integration described in claim 1, characterized in that: The intelligent gear with multi-sensor integration for small gears includes the following steps: Step 1: Machining an annular embedding groove on the end face of the pinion body; Step 2: Fabricate a ring-shaped PCB and integrate a multi-sensor sensing module, a signal preprocessing module, a wireless communication module, a power management module, and a battery on it; Step 3: First, place the PCB into the embedding groove and fix it to the gear body with adhesive or screws. Then, assemble and fix the sealing cover plate to the gear body with adhesive so that the cover plate covers and seals the embedding groove.

10. A method for manufacturing an intelligent gear based on the multi-sensor integration described in claim 1, characterized in that: For a smart gear with multi-sensor integration for large gears, the following steps are included: Step 1: Machining an annular embedding groove on the end face of the large gear body; Step 2: Prepare a fan-shaped PCB and integrate a multi-sensor sensing module, a signal preprocessing module, a wireless communication module, a power management module, and a battery on it; Step 3: Multiple sector-shaped PCBs are spliced ​​together along the circumference of the gear to form a complete ring spliced ​​PCB, or they are symmetrically distributed along the axis of the gear end face in a multi-segment distribution. At the same time, the gear dynamic balance is achieved through the circumferential or symmetrical PCB distribution. Step 4: Multiple fan-shaped PCBs are distributed in the embedding groove along the circumference of the gear and fixed to the gear body by adhesive or screws. Then, the sealing cover plate is assembled and fixed to the gear body by adhesive, so that the cover plate covers and seals the embedding groove.

Images