Ultrasonic guided wave inspection device for gear on-line monitoring

Abstract

The application relates to an ultrasonic guided wave flaw detection device for online monitoring of a gear, which comprises a box shell, a plurality of rotating shafts are arranged in the box shell, a gear is arranged on the outer wall of the rotating shaft, a clamping part is arranged on the rotating shaft, a supporting part is arranged on the top of the clamping part, an ultrasonic guided wave probe is arranged in the supporting part, the supporting part comprises a shell, two mounting shafts are slidably arranged in the inner cavity of the shell, a roller shaft is rotatably arranged on the mounting shaft, springs are arranged between the top of the mounting shaft and the inner cavity, the gear block of the gear is located between the two roller shafts, the clamping part which can be clamped and fixed on the rotating shaft of the transmission is matched with the supporting part which can be adjusted in height and can rotate in the circumferential direction, the ultrasonic guided wave probe is accurately positioned in front of the gear block, the gear is subjected to online ultrasonic guided wave flaw detection without disassembly and disintegration, and thus the problems of gear detection in the prior art, such as the need of disassembly, complicated procedures, easy damage of parts and low detection efficiency, are solved.

Description

Technical Field

[0001] This invention relates to the field of gear monitoring technology, and more specifically, to an ultrasonic guided wave flaw detection device for online gear monitoring. Background Technology

[0002] Gears, as the most fundamental and core component in mechanical transmission, are widely used in various power transmission mechanisms such as gearboxes, reducers, and engines. They are primarily used for speed regulation, torque transmission, and power reversal, and are key components ensuring the stable operation of mechanical equipment. For example, inside a gearbox (… Figure 1 As shown in the figure, power transmission and speed switching at different gears are usually achieved by meshing multiple sets of gears with different numbers of teeth and different modules.

[0003] Under long-term high-load, high-speed, and alternating load operating conditions, the gears and teeth of the transmission are repeatedly subjected to impact, compression, and alternating stress. This makes them highly susceptible to internal defects such as microcracks, porosity, and inclusions in the tooth root and tooth surface. These defects are difficult to detect from the outside in the early stages, but they will continue to expand under continuous load, eventually leading to serious faults such as broken teeth, chipped corners, and failure of the gears, directly causing damage to the transmission or even the shutdown of the entire machine. Therefore, in the daily maintenance, upkeep, and fault detection of the transmission, it is necessary to perform internal defect detection on the gears.

[0004] The current conventional testing method requires disassembling the transmission, removing the gears from the shaft, and then using an ultrasonic guided wave flaw detector to scan each gear block one by one to determine whether there is internal damage. However, the disassembly and reassembly process is cumbersome and time-consuming, which greatly increases maintenance time and labor costs. Summary of the Invention

[0005] This invention provides an ultrasonic guided wave flaw detection device for online gear monitoring. It uses a clamping part that can be clamped and fixed on the gearbox shaft and a support part that can be adjusted in height and rotated circumferentially to accurately position the ultrasonic guided wave probe in front of the gear teeth, so as to realize online ultrasonic guided wave flaw detection without disassembly or disassembly of the gear. This solves the problems of disassembly, complicated procedures, easy damage to parts, and low detection efficiency in the prior art.

[0006] To achieve the above objectives, the ultrasonic guided wave flaw detection device for online gear monitoring includes a gearbox, the gearbox including a housing, the housing having multiple rotating shafts installed inside, and gears fixedly mounted on the outer wall of the rotating shafts.

[0007] The rotating shaft is provided with a clamping part, and an adjustable and rotatable support part is provided on the top of the clamping part. The ultrasonic guided wave probe is fixedly installed inside the support part, and the probe detection end is always aligned with the front of the gear teeth, so as to realize online flaw detection without disassembling the machine.

[0008] The clamping part includes a connecting block 1, and a mounting frame 1 is fixedly connected to the bottom of the connecting block 1. The connecting block 1 and the mounting frame 1 are distributed perpendicularly to each other. A mounting frame 2 is provided below the mounting frame 1. Two rollers are rotatably mounted on the bottom of the mounting frame 1, and one roller is rotatably mounted on the top of the mounting frame 2. The three rollers are arranged in a triangle and can stably hug the outer wall of the rotating shaft. A bolt 1 is installed between the mounting frame 1 and the mounting frame 2 to realize the quick clamping and locking of the clamping part on the rotating shaft.

[0009] Specifically, mounting bracket one and mounting bracket two are placed on the upper and lower sides of the rotating shaft, respectively, so that the three rollers are in a triangular embrace and tightly attached to the outer wall of the rotating shaft. Then, bolt one is tightened to tighten mounting bracket one and mounting bracket two inward, thus fixing the clamping part on the rotating shaft. Since the rollers and the rotating shaft are in rolling contact, the clamping part can still rotate circumferentially along the outer wall of the rotating shaft in the locked state, which not only ensures a firm clamping, but also allows for flexible adjustment of the circumferential position of the probe, providing a basis for subsequent tooth-by-tooth testing.

[0010] Connecting block 2 is slidably installed inside connecting block 1, and mounting block 1 is fixedly connected to the top of connecting block 2. A vertical sliding groove is provided on the inner wall of connecting block 1, and a slider is fixedly provided on the outer wall of connecting block 2. The sliding groove and the slider slide together, so that connecting block 2 can be freely raised and lowered in the vertical direction to adapt to gears of different diameters and thicknesses.

[0011] The first connecting block has a guide groove inside, and the second connecting block has a screw hole inside. A bolt is installed between the guide groove and the screw hole. When the second connecting block is raised or lowered to a suitable height so that the ultrasonic guided wave probe is aligned with the tooth block detection area, the bolt is tightened to lock the first connecting block and the second connecting block in place, thereby achieving precise positioning in the height direction.

[0012] Mounting block one is bolted to mounting block two, and mounting block two is bolted to a housing. Both mounting blocks one and two have coaxial through holes. The ultrasonic guided wave probe is fixed inside the through hole, and the probe's detection end extends downward into the housing to ensure that the ultrasonic guided wave can directly act on the gear teeth, achieving high sensitivity and high accuracy in detecting internal defects.

[0013] Two mounting shafts are slidably installed in the inner cavity of the housing. Rollers are rotatably mounted on the mounting shafts. A spring is installed between the top of the mounting shaft and the inner cavity of the housing. The spring always provides downward elastic pressure to the mounting shaft and the roller. Supporting horizontal plates are formed on both sides of the housing and straddle the top of the gear. When the housing is placed above the gear, the gear teeth can automatically engage between the two rollers to achieve automatic positioning and automatic centering.

[0014] When the toothed block is inserted between the two rollers, the probe end of the ultrasonic guided wave probe is precisely aligned with the front of the toothed block, ensuring accurate detection position, stable signal, and high repeatability. The assembled device is shown in the figure. Online flaw detection can be performed directly without disassembling the gears or the gearbox.

[0015] By connecting the ultrasonic guided wave probe to an external ultrasonic guided wave flaw detector, internal defects of the current tooth block can be detected. After the detection of a single tooth block is completed, the operator can slowly rotate the support part to drive the housing and ultrasonic guided wave probe to move around the gear circumferentially, since the clamping part can rotate circumferentially along the rotating shaft.

[0016] During the movement, the top surface of the tooth block presses upward against the roller, pushing the mounting axis to compress the spring upward, providing clearance for the probe movement. When the probe moves directly above the next tooth block, the tooth block automatically engages between the two rollers, and the spring quickly pushes the roller downward to reset, pressing it against both sides of the tooth block, accompanied by a noticeable sound and slight vibration, providing the operator with a clear indication that the ultrasonic guided wave probe has been accurately aligned with the current tooth block.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows: By installing an ultrasonic guided wave probe with a clamping part that can be held around the rotating shaft and a support part that can be height-adjusted and rotated circumferentially, and by using the guiding and positioning structure of rollers and roller shaft, the probe can be quickly aligned, accurately positioned and continuously scanned with different gear blocks. Online flaw detection of internal defects in transmission gears can be completed without disassembling the gears, solving the technical problems of traditional detection that require disassembling the transmission, which is cumbersome, easily damages parts and has low detection efficiency. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the transmission structure; Figure 2 This is an enlarged structural schematic diagram of the clamping part of the present invention; Figure 3 This is a schematic diagram of the installation of the clamping part of the present invention; Figure 4 This is an exploded structural diagram of the support portion of the present invention; Figure 5 This is a schematic diagram of the internal structure of the housing of the present invention; Figure 6 This is a schematic diagram showing the positions of the roller and the toothed block in this invention; Figure 7 This is a schematic diagram showing the positions of the ultrasonic guided wave probe and the toothed block in this invention; Figure 8 for Figure 7 Another perspective illustration; Figure 9 This is a schematic diagram of the assembled structure of the present invention; Figure 10 This is a schematic diagram illustrating the use of the present invention; Figure 11 This is a schematic diagram of the ultrasonic guided wave probe from another angle during the use of the present invention.

[0019] The meanings of the labels in the diagram are as follows: 1. Gearbox; 11. Housing; 12. Shaft; 13. Gear; 2. Clamping part; 21. Connecting block one; 22. Mounting bracket one; 23. Mounting bracket two; 24. Roller; 25. Bolt one; 3. Support part; 31. Mounting block one; 32. Connecting block two; 33. Bolt two; 34. Mounting block two; 35. Housing; 36. Mounting shaft; 37. Roller; 38. Spring; 4. Ultrasonic guided wave probe; 5. Ultrasonic guided wave flaw detector. Detailed Implementation

[0020] The technical solutions of this invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0021] refer to Figure 1 As shown, the transmission 1 includes a housing 11, and a plurality of rotating shafts 12 are installed inside the housing 11. Gears 13 are fixedly installed on the outer wall of the rotating shafts 12.

[0022] Traditional testing methods require completely disassembling gear 13 from shaft 12, then scanning each tooth with an ultrasonic guided wave flaw detector 5 and ultrasonic guided wave probe 4, and reassembling after testing. This process is complex, inefficient, and can easily damage the fit between gear 13 and shaft 12.

[0023] Therefore, in view of the above-mentioned problems, the present invention provides an ultrasonic guided wave flaw detection device for online monitoring of gears. In order to realize online detection of gear 13 without disassembly, the present invention provides a clamping part 2 on the rotating shaft 12, and an adjustable and rotatable support part 3 is provided on the top of the clamping part 2. The ultrasonic guided wave probe 4 is fixedly installed inside the support part 3, and the probe detection end is always aligned with the front of the tooth block of gear 13, so as to realize online flaw detection without disassembly.

[0024] Next, the structure of clamping part 2 will be disclosed first, see reference. Figure 2As shown, the clamping part 2 includes a connecting block 21. A mounting bracket 22 is fixedly connected to the bottom of the connecting block 21. The connecting block 21 and the mounting bracket 22 are perpendicular to each other. A mounting bracket 23 is provided below the mounting bracket 22. Two rollers 24 are rotatably mounted on the bottom of the mounting bracket 22, and one roller 24 is rotatably mounted on the top of the mounting bracket 23. The three rollers 24 are arranged in a triangle and can stably hug the outer wall of the rotating shaft 12. A bolt 25 is installed between the mounting bracket 22 and the mounting bracket 23 to realize the quick clamping and locking of the clamping part 2 on the rotating shaft 12.

[0025] For detailed installation steps of clamping part 2, please refer to [link / reference]. Figure 3 As shown, mounting bracket 1 22 and mounting bracket 23 are placed on the upper and lower sides of the rotating shaft 12 respectively, so that the three rollers 24 are in a triangular embrace and tightly attached to the outer wall of the rotating shaft 12. Then, tighten bolt 1 25 to tighten mounting bracket 1 22 and mounting bracket 2 23 inward, thus completing the fixation of clamping part 2 on the rotating shaft 12. Since the rollers 24 and the rotating shaft 12 are in rolling contact, clamping part 2 can still rotate circumferentially along the outer wall of the rotating shaft 12 in the locked state, which not only ensures the clamping is firm, but also allows for flexible adjustment of the circumferential position of the probe, providing a basis for subsequent tooth-by-tooth inspection 13.

[0026] Then the structure of support part 3 is disclosed, for reference. Figure 4 As shown, a second connecting block 32 is slidably installed inside the first connecting block 21. The top of the second connecting block 32 is fixedly connected to the first mounting block 31. A vertical sliding groove is provided on the inner wall of the first connecting block 21. A slider is fixedly provided on the outer wall of the second connecting block 32. The sliding groove and the slider slide together, so that the second connecting block 32 can be freely raised and lowered in the vertical direction to adapt to gears 13 of different diameters and thicknesses.

[0027] Connecting block 21 has a guide groove inside, and connecting block 32 has a screw hole inside. Bolt 33 is installed between the guide groove and the screw hole. When connecting block 32 is raised to a suitable height so that the ultrasonic guided wave probe 4 is aligned with the tooth block detection area, tightening bolt 33 can lock connecting block 21 and connecting block 32 together, achieving precise positioning in the height direction.

[0028] Mounting block 1 31 is bolted to the outer wall of mounting block 2 34. Mounting block 2 34 is bolted to the inside of housing 35. Both mounting block 1 31 and mounting block 2 34 have coaxial through holes. Ultrasonic guided wave probe 4 is fixedly installed inside the through hole. The probe's detection end extends downward into the housing 35 to ensure that the ultrasonic guided wave can directly act on the gear 13 tooth block, achieving high sensitivity and high accuracy of internal defect detection.

[0029] Next, refer to Figure 5 and Figure 6As shown, two mounting shafts 36 are slidably installed in the inner cavity of the housing 35. Rollers 37 are rotatably mounted on the mounting shafts 36. A spring 38 is installed between the top of the mounting shaft 36 and the inner cavity of the housing 35. The spring 38 always provides downward elastic pressure to the mounting shaft 36 and the roller 37. Supporting horizontal plates are formed on both sides of the housing 35 and span the top of the gear 13. When the housing 35 is placed above the gear 13, the gear 13 teeth can automatically engage between the two rollers 37 to achieve automatic positioning and automatic centering.

[0030] Combination Figure 7 and Figure 8 As shown, when the toothed block is inserted between the two rollers 37, the detection end of the ultrasonic guided wave probe 4 is precisely aligned with the front of the toothed block, ensuring accurate detection position, stable signal, and high repeatability. The entire device, once assembled, is as follows: Figure 9 As shown, online flaw detection can be performed directly without disassembling gear 13 or disassembling transmission 1.

[0031] For details on the monitoring process, please refer to... Figure 10 and Figure 11 As shown, by connecting the ultrasonic guided wave probe 4 to the external ultrasonic guided wave flaw detector 5, the internal defects of the current tooth block can be detected. After the detection of a single tooth block is completed, since the clamping part 2 can rotate around the rotating shaft 12, the operator can slowly rotate the support part 3 to drive the housing 35 and the ultrasonic guided wave probe 4 to move around the gear 13.

[0032] During the movement, the top surface of the tooth block presses upward against the roller 37, pushing the mounting shaft 36 upward to compress the spring 38, providing clearance for the probe movement. When the probe moves to the top of the next tooth block, the tooth block automatically engages between the two rollers 37, and the spring 38 quickly pushes the roller 37 downward to reset, pressing against the two sides of the tooth block, accompanied by a noticeable sound and slight vibration, providing the operator with a clear indication that the ultrasonic guided wave probe 4 has been accurately aligned with the current tooth block.

[0033] Based on the above-mentioned working principle of automatic positioning, automatic centering, and positioning reminder, the operator can continuously rotate the support part 3 or slowly rotate the rotating shaft 12 to drive the gear 13 to rotate, so that the ultrasonic guided wave probe 4 is aligned with each tooth block in turn, and completes online ultrasonic guided wave flaw detection with full coverage of the gear ring without omission.

[0034] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. An ultrasonic guided wave flaw detection device for online gear monitoring, comprising a housing (11), wherein a plurality of rotating shafts (12) are installed inside the housing (11), and gears (13) are installed on the outer wall of the rotating shafts (12), characterized in that: A clamping part (2) is installed on the rotating shaft (12), and a support part (3) is installed on the top of the clamping part (2). An ultrasonic waveguide probe (4) is installed inside the support part (3). The support (3) includes a housing (35), in which two mounting shafts (36) are slidably mounted, and rollers (37) are rotatably mounted on the mounting shafts (36). A spring (38) is installed between the top of the mounting shafts (36) and the inner cavity. The gear (13) has its teeth located between two rollers (37), and the probe end of the ultrasonic waveguide (4) faces the front of the teeth.

2. The ultrasonic guided wave flaw detection device for online gear monitoring according to claim 1, characterized in that: The clamping part (2) includes a connecting block (21), the bottom of the connecting block (21) is fixedly connected to a mounting bracket (22), the bottom of the mounting bracket (22) is provided with a mounting bracket (23), the bottom of the mounting bracket (22) has two rollers (24) rotatably mounted, and the top of the mounting bracket (23) has one roller (24) rotatably mounted.

3. The ultrasonic guided wave flaw detection device for online gear monitoring according to claim 2, characterized in that: Bolt 1 (25) is installed between mounting bracket 1 (22) and mounting bracket 2 (23), and the three rollers (24) are distributed in a triangle and attached to the outer wall of the rotating shaft (12).

4. The ultrasonic guided wave flaw detection device for online gear monitoring according to claim 2, characterized in that: The support part (3) includes a connecting block two (32) that is slidably installed inside the connecting block one (21). The top of the connecting block two (32) is connected to the mounting block one (31). The mounting block two (34) is installed on the outer wall of the mounting block one (31). The housing (35) is installed inside the mounting block two (34).

5. The ultrasonic guided wave flaw detection device for online gear monitoring according to claim 4, characterized in that: The inner wall of the first connecting block (21) is provided with a sliding groove, and the outer wall of the second connecting block (32) is fixedly connected with a slider. The first connecting block (21) and the second connecting block (32) are slidably connected through the sliding groove and the slider.

6. The ultrasonic guided wave flaw detection device for online gear monitoring according to claim 4, characterized in that: Both mounting block one (31) and mounting block two (34) have coaxial through holes. The ultrasonic waveguide probe (4) is installed in the through hole, and the detection end of the ultrasonic waveguide probe (4) is located below the housing (35).

7. The ultrasonic guided wave flaw detection device for online gear monitoring according to claim 4, characterized in that: The first connecting block (21) has a guide groove, and the second connecting block (32) has a screw hole inside. A second bolt (33) is installed between the guide groove and the screw hole, and the second bolt (33) passes through the guide groove and the screw hole to connect the second connecting block (32).

8. The ultrasonic guided wave flaw detection device for online gear monitoring according to claim 1, characterized in that: The housing (35) is provided with support plates on both sides. When the housing (35) is located on top of the gear (13), the gear block is stuck between the two rollers (37).

9. The ultrasonic guided wave flaw detection device for online gear monitoring according to claim 1, characterized in that: When the toothed block moves between the two rollers (37), the spring (38) drives the rollers (37) to reset and press against both sides of the toothed block, producing a prompting sound and vibration.

10. The ultrasonic guided wave flaw detection device for online gear monitoring according to claim 1, characterized in that: The ultrasonic guided wave probe (4) is electrically connected to the ultrasonic guided wave flaw detector (5) via a wire. The wire is used to transmit the monitoring signal.

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