Large-scale road maintenance machinery gear box dynamic reliability detection device

Abstract

The utility model discloses a large-scale road maintenance machinery gear box dynamic reliability detection device comprising a driving module used for providing dynamic power input for a detected gear box; the load simulation module is connected with an output shaft of the tested gearbox and is used for applying a variable load; the sensor module comprises a three-axis vibration sensor, a temperature sensor and a rotating speed sensor which are respectively arranged at different positions of the tested gearbox and are used for respectively and simultaneously acquiring a vibration signal, a temperature signal and a rotating speed signal; the data acquisition and analysis module is connected with the sensor module and is used for acquiring and processing the vibration signal, the temperature signal and the rotating speed signal; the rack comprises a fixed platform and a base, and the fixed platform is connected with the base through a vibration isolation device and used for bearing the tested gearbox and reducing external vibration interference; a tested gear box is fixed on the fixed platform, the vibration sensor is installed on a gear box bearing seat, and the temperature sensor is attached to the outer surface of a box body of the tested gear box.

Description

TECHNICAL FIELD

[0001] The utility model relates to the field of large road maintenance machinery intelligent operation and maintenance and state monitoring, especially relates to a large road maintenance machinery gear box dynamic reliability detection device for simulating the dynamic load under the actual working condition of gear box, real -time collection vibration, temperature and rotating speed data, and comprehensive evaluation its reliability. BACKGROUND

[0002] As the core transmission component of railway maintenance equipment, the large road maintenance machinery gear box bears complex alternating load for a long time, and is prone to failure due to fatigue, wear or poor lubrication. The traditional detection method is mostly based on static test or single parameter analysis, and cannot truly reflect the performance degradation trend under dynamic working condition. In the prior art, factors such as insufficient load simulation accuracy, unreasonable sensor arrangement and external vibration interference will cause deviation of the detection result. Therefore, there is an urgent need for a detection device that can accurately simulate dynamic load, synchronously collect multiple parameters and has strong anti-interference ability. UTILITY MODEL CONTENT

[0003] The utility model is used for providing a dynamic reliability detection device that can simulate the real working condition of gear box, multi-dimension data fusion analysis and has vibration isolation and noise reduction function, to solve the problems of inaccurate dynamic load simulation, incomplete data collection and vibration noise interference of traditional detection method. The main structure includes:

[0004] Drive module: servo motor and planetary reducer combination, provide dynamic power input;

[0005] Load simulation module: magnetic powder brake cooperates with torque controller, realizes accurate load adjustment;

[0006] Sensor module: vibration, temperature, rotating speed sensor multi-dimension arrangement, covers the key monitoring point of gear box;

[0007] Data acquisition and analysis module: multi-channel data acquisition card and edge computing unit are combined, and time domain, frequency domain and temperature data are processed in real time;

[0008] Rack: vibration isolation device and counterweight block design, suppress external vibration interference;

[0009] Protective cover: sound-absorbing material covers, reduces the influence of noise on detection accuracy.

[0010] The utility model aims at providing a large road maintenance machinery gear box dynamic reliability detection device, which comprises:

[0011] Drive module, used for providing dynamic power input to the measured gear box (10);

[0012] Load simulation module (20) connected with the output shaft of the measured gear box (10), used for applying variable load;

[0013] a sensor module (30) comprising a three-axis vibration sensor (31), a temperature sensor (32) and a rotation speed sensor (33) respectively installed at different positions of the measured gearbox (10) for simultaneously collecting vibration signals, temperature signals and rotation speed signals respectively;

[0014] a data acquisition and analysis module (40) connected with the sensor module (30) for collecting and processing the vibration signals, temperature signals and rotation speed signals;

[0015] a rack (50) comprising a fixed platform (51) and a base (52), the fixed platform (51) being connected with the base (52) through a vibration isolation device (53) for carrying the measured gearbox (10) and reducing external vibration interference; the measured gearbox (10) is fixed on the fixed platform (51), the vibration sensor (31) is installed on the gearbox bearing seat (101), and the temperature sensor (32) is attached to the outer surface of the measured gearbox (10).

[0016] Preferably, the driving module comprises a servo motor (11) and a planetary reducer (12), the servo motor (11) drives the measured gearbox (10) through the planetary reducer (12); the output shaft of the servo motor (11) is connected with the planetary reducer (12) through a flange, the input shaft of the planetary reducer (12) is coaxially installed with the output shaft of the servo motor (11), and the output shaft of the planetary reducer (12) is connected with the input shaft of the measured gearbox (10) through an elastic coupling (13).

[0017] Preferably, the load simulation module (20) comprises a magnetic powder brake (21) and a torque controller (22), the magnetic powder brake (21) is connected with the output shaft of the measured gearbox (10) through a coupling, and the torque controller (22) is located on one side of the magnetic powder brake (21) for adjusting the loading torque of the magnetic powder brake (21).

[0018] Preferably, the three-axis vibration sensor (31) is a three-axis acceleration sensor, which is symmetrically installed on both sides of the gearbox bearing seat (101) of the measured gearbox (10).

[0019] Preferably, the temperature sensor (32) is an infrared temperature measurement probe, which is installed on the outer surface of the measured gearbox (10).

[0020] Preferably, the rotation speed sensor (33) is an optical encoder, which is installed at the end of the output shaft of the measured gearbox (10) through a coupling, and the output pulse signal is transmitted to the multi-channel data acquisition card (41) of the data acquisition and analysis module (40) through a differential circuit.

[0021] Preferably, the data acquisition and analysis module (40) includes a multi-channel data acquisition card (41), an edge computing unit (42), and a display terminal (43); wherein the multi-channel data acquisition card (41) is connected to the sensor module (30) by signal, the edge computing unit (42) integrates time domain analysis, frequency domain analysis and temperature trend prediction algorithms, and the display terminal (43) is used to display the detection results in real time.

[0022] Preferably, the vibration isolation device (53) includes a rubber damper (531) and a counterweight (532). The rubber damper (531) is symmetrically distributed at the four corners of the fixed platform (51). The counterweight (532) is embedded and fixed at the bottom of the base (52). The base (52) supports the fixed platform (51) through the rubber damper (531) and the counterweight (532).

[0023] Preferably, it also includes a protective cover (60) that covers the gearbox under test (10) and the load simulation module (20).

[0024] Preferably, the inner wall of the protective cover (60) is attached with a honeycomb sound-absorbing material (61).

[0025] The beneficial effects of the method and system of this utility model are as follows:

[0026] 1. Capable of high-precision dynamic load simulation: Through the combination of magnetic powder brake 21 and torque controller 22, the load at the output end of the gearbox can be precisely adjusted. The loading torque resolution of the magnetic powder brake reaches ±1% FS, which meets the requirements of transient impact testing of the gearbox.

[0027] 2. Capable of multi-parameter collaborative synchronous analysis: Integrating vibration, temperature, and speed sensors, combined with multi-channel data acquisition and analysis algorithms, it comprehensively evaluates the dynamic reliability of the gearbox, and integrates vibration, temperature, and speed data to support early identification of fault characteristics (such as tooth surface spalling and bearing loosening).

[0028] 3. It features vibration isolation and noise reduction design, making the operating environment more friendly and reducing detection noise interference: The combination of rubber damper (531) and sound-absorbing protective cover (60) ensures that the detection process is free from external vibration and noise interference. The vibration isolation device reduces the vibration transmission rate to below 10%, and the noise reduction of the protective cover is ≥20dB(A). Attached Figure Description

[0029] In order to more clearly illustrate the technical solutions in the specific embodiments or related art of the present application, the drawings needed to be used in the specific embodiments or related art description will be briefly introduced as follows. Obviously, the drawings in the following description are some embodiments of the present application, and other drawings can also be obtained by those skilled in the art without creative labor on the basis of these drawings.

[0030] Figure 1 The overall structure of the device provided by the embodiment of the present application is shown in an axonometric view.

[0031] Figure 2 The arrangement of the sensor and the data acquisition module is shown in a partial enlarged view, in which the mounting details of the three-axis vibration, temperature and rotation speed sensors are shown.

[0032] Figure 3 The cross-sectional view of the vibration isolation device provided by the embodiment of the present application is shown, in which the internal structure of the rubber damper and the counterweight block is shown.

[0033] Figure 4 The arrangement of the protective cover provided by the embodiment of the present application is shown in a schematic view. DETAILED DESCRIPTION

[0034] The technical solutions of the present application will be described clearly and completely in conjunction with the drawings. Obviously, the described embodiments are some embodiments of the present application, not all embodiments. Based on the embodiments of the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0035] In the description of the present application, it should be pointed out that the orientation or position relationship indicated by the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and the like is based on the orientation or position relationship shown in the drawings, and is only for the convenience of describing the present application and simplifying the description, and therefore cannot be understood as indicating or implying that the device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present application. In addition, the terms "first", "second", "third" are only for the purpose of description, and cannot be understood as indicating or implying relative importance.

[0036] In the description of the utility model, it is necessary to explain, unless another explicit provision and limitation, term "installation", "link", "connection" should do broad sense understanding, for example, can be fixed connection, also can be detachable connection, or integrally connected;Can be mechanical connection, also can be electrical connection;Can be directly connected, also can be indirectly connected through intermediate medium, can be two elements inside the communication.For ordinary skilled in the art, the above-mentioned terms can be understood in the utility model with the specific meaning of the specific situation.

[0037] As Figure 1 The utility model discloses a large road maintenance machinery gear box dynamic reliability detection device, including:

[0038] Drive module is used to provide dynamic power input to the gear box 10 of being measured, including servo motor 11 and planetary reducer 12, and servo motor 11 drives the gear box 10 of being measured through planetary reducer 12;

[0039] Load simulation module 20 is connected with the output shaft of the gear box 10 of being measured, for applying variable load;

[0040] As Figure 2 Sensor module 30, including three-axis vibration sensor 31, temperature sensor 32 and tachometer 33, is installed at different positions of the gear box 10 of being measured respectively, for collecting vibration signal, temperature signal and tachometer signal respectively;

[0041] Data acquisition and analysis module 40 are connected with the sensor module 30, for collecting and processing vibration signal, temperature signal and tachometer signal;

[0042] As Figure 3 Rack 50, including fixed platform 51 and base 52, the fixed platform 51 is connected with base 52 through vibration isolation device 53, for bearing the gear box 10 of being measured and reducing external vibration interference, the gear box 10 of being measured is fixed on fixed platform 51, and the vibration sensor 31 is installed on gear box bearing seat 101, and temperature sensor 32 is attached to the outer surface of the gear box of being measured.

[0043] As a preferred embodiment, the drive module includes servo motor 11 and planetary reducer 12, the output shaft of servo motor 11 is connected with the input shaft of the gear box 10 of being measured coaxially through the planetary reducer 12.

[0044] As a preferred embodiment, the load simulation module 20 comprises a magnetic powder brake 21 connected with the output shaft of the measured gearbox 10 through a shaft coupling and a torque controller 22 located on one side of the magnetic powder brake 21 for adjusting the loading torque of the magnetic powder brake 21.

[0045] As a preferred embodiment, the triaxial vibration sensor 31 is a triaxial acceleration sensor symmetrically installed on both sides of the gearbox bearing seat 101 of the measured gearbox 10.

[0046] As a preferred embodiment, the temperature sensor 32 is an infrared temperature measurement probe installed on the outer surface of the housing of the measured gearbox 10.

[0047] As a preferred embodiment, the rotational speed sensor 33 is an optical encoder installed at the end of the output shaft of the measured gearbox 10, and the output pulse signal is transmitted to the multi-channel data acquisition card 41 of the data acquisition and analysis module 40 through a differential circuit.

[0048] As a preferred embodiment, the data acquisition and analysis module 40 comprises a multi-channel data acquisition card 41, an edge computing unit 42 and a display terminal 43; wherein the multi-channel data acquisition card 41 is signal connected with the sensor module 30, the edge computing unit 42 integrates time domain analysis, frequency domain analysis and temperature trend prediction algorithms, and the display terminal 43 is used for real-time display of detection results.

[0049] As a preferred embodiment, the vibration isolation device 53 comprises rubber dampers 531 and counterweights 532, the rubber dampers 531 are symmetrically distributed at the four corners of the fixed platform 51, and the counterweights 532 are embedded and fixed at the bottom of the base 52, and the base 52 supports the fixed platform 51 through the rubber dampers 531 and the counterweights 532.

[0050] As shown in Figure 4 As a preferred embodiment, it further comprises a protective cover 60 covering the measured gearbox 10 and the load simulation module 20.

[0051] As a preferred embodiment, the inner wall of the protective cover 60 is attached with honeycomb sound-absorbing material 61.

[0052] Referring to Figure 1 , the overall layout of the large road maintenance machinery gearbox dynamic reliability detection device:

[0053] Left: The servo motor 11 drives the measured gearbox 10 through the planetary reducer 12.

[0054] Middle: The gearbox 10 under test is fixed on the fixed platform 51, the vibration sensor 31 is installed on the bearing seat 101, and the temperature sensor 32 is attached to the outer surface of the box body.

[0055] Right: The magnetic powder brake 21 is connected to the gearbox output shaft through a shaft coupling, and the torque controller 22 is located beside the magnetic powder brake.

[0056] Bottom: The base 52 supports the fixed platform 51 through the rubber damper 531 and the counterweight 532.

[0057] See Figure 2 for details of the arrangement of sensors and data acquisition modules:

[0058] Details of the arrangement of sensors:

[0059] The three-axis vibration sensor 31 is symmetrically installed on both sides of the gearbox bearing seat 101.

[0060] The photoelectric encoder 33 is installed at the end of the gearbox output shaft to detect the rotational speed signal.

[0061] Details of the arrangement of data acquisition modules:

[0062] The multi-channel data acquisition card 41 is integrated on the side of the rack 50 and connected to the sensor module 30 through a cable.

[0063] The display terminal 43 is placed separately and displays the vibration spectrum, temperature curve, and reliability evaluation results in real time.

[0064] See Figure 3 for vibration isolation and protection design:

[0065] The rubber damper 531 is distributed on the four corners of the fixed platform, and the counterweight 532 is embedded in the base 52.

[0066] The detachable protective cover 60 covers the gearbox and load module, and the inner wall is attached to the honeycomb sound-absorbing material 61.

[0067] Example 1: Device structure and function implementation

[0068] 1. Drive module

[0069] (1) Servo motor 11: Choose permanent magnet synchronous servo motor (model: SIMOTICS S-1FL6, rated power 30kW, peak torque 600N·m), output shaft connected to planetary reducer 12 through flange.

[0070] (2) Planetary reducer 12: reduction ratio 1:10, input shaft coaxially installed with servo motor output shaft, output shaft connected with input shaft of gearbox 10 under test through elastic coupling 13, coaxiality error ≤0.02mm.

[0071] 2. Load simulation module 20

[0072] Magnetic powder brake 21: Choose water-cooled magnetic powder brake (maximum torque 2000 N·m, response time ≤ 50 ms), installed on the output shaft end of the gear box 10 through the flange, the internal magnetic powder filling amount is dynamically adjusted according to the load curve.

[0073] Torque controller 22: Adopt PID closed-loop control algorithm, current regulation accuracy ±0.5%, receive host computer instructions through CAN bus, real-time adjust magnetic powder brake excitation current, simulate the actual working condition load spectrum of the gear box.

[0074] 3. Sensor module 30

[0075] Three-axis vibration sensor 31: Choose three-axis piezoelectric acceleration sensor (range ±500g, frequency response range 0.5Hz-10kHz), symmetrically installed on both sides of the gear box bearing seat 101 through the magnetic base, X / Y / Z three-axis orthogonal aligns the sensitive direction of the gear box vibration.

[0076] Temperature sensor 32: Infrared temperature measurement probe (model: FLIR A40, temperature measurement range -20℃~650℃, accuracy ±1℃) is installed in the hot spot area of the gear box shell (such as above the bearing seat), the focal length is adjusted to 50mm, the sampling rate is 1Hz.

[0077] Rotational speed sensor 33: Photoelectric encoder (resolution 1000PPR) is connected with the gear box output shaft through the shaft coupling, and the output pulse signal is transmitted to the data acquisition card 41 through the differential circuit.

[0078] 4. Data acquisition and analysis module 40

[0079] Multi-channel data acquisition card 41: Choose NI PXIe-4499 (24-bit ADC, synchronous sampling rate 200kS / s), the channel configuration is as follows:

[0080] Channel 1-6: Vibration sensor signal (three-axis x 2);

[0081] Channel 7: Temperature sensor analog voltage signal;

[0082] Channel 8: Encoder pulse signal.

[0083] Edge computing unit 42: Embedded industrial computer (Intel i7 processor) runs LabVIEW real-time system, integrates the following algorithms:

[0084] Time domain analysis: Calculate vibration effective value (RMS), peak factor (Crest Factor);

[0085] Frequency domain analysis: FFT spectrum analysis (frequency resolution 0.5 Hz), extract gear meshing frequency harmonic components;

[0086] Temperature trend prediction: predict temperature rise rate based on ARIMA model, trigger overheating warning.

[0087] Display terminal 43: industrial touch screen real-time display of detection parameters, interface partition shows vibration spectrum, temperature curve and reliability score.

[0088] 5, rack 50

[0089] Fixed platform 51: Q345B steel plate welded frame (size 2000x1200x200mm), surface milling (flatness ≤0.1mm), measured gear box 10 is fixed by bolts.

[0090] Vibration isolation device 53: four rubber dampers 531 are installed (stiffness 50kN / m, damping ratio 0.15), counterweight block 532 is embedded in base 52 (total mass 500kg, gravity center coincides with gear box axis), external vibration transmission is suppressed.

[0091] 6, protective cover (60)

[0092] Cover the gear box and load module, use transparent acrylic plate (thickness 10mm) and steel skeleton splicing, inner wall attached honeycomb aluminum sound absorption panel 61 (thickness 20mm, noise reduction coefficient NRC 0.8), hinge door is set in front side for easy operation.

[0093] Example 2: detection process

[0094] Install the measured gear box: hoist the gear box 10 to the fixed platform 51, calibrate the coaxiality of the input / output shaft with the drive module and the load module.

[0095] Load spectrum setting: import the preset load curve (such as sine sweep, step load) in the torque controller 22.

[0096] Data acquisition start: drive the servo motor 11 to the target speed (such as 1500rpm), start the data acquisition card (41) and the edge computing unit 42 synchronously.

[0097] Dynamic reliability evaluation:

[0098] Vibration data warning threshold: bearing seat vibration velocity effective value ≥4.5mm / s;

[0099] Temperature warning threshold: gear box shell temperature ≥85℃;

[0100] Comprehensive score formula:

[0101]

[0102] wherein V is the vibration effective value, V max is the vibration maximum value, T is the temperature, T max is the temperature maximum value, N is the actual speed and rated speed ratio, N nom is the normalized value of the speed.

[0103] The result output is to generate a detection report, mark the abnormal frequency band (such as the 2 times meshing frequency corresponding to the gear eccentricity) and maintenance suggestion.

[0104] The detection device has been applied to the railway maintenance machinery section, successfully identified multiple gear box early failures (such as bearing inner ring crack, gear surface pitting), the detection efficiency is improved by 40% compared with the traditional method, and the false positive rate is reduced to below 5%.

[0105] Finally, it should be noted that: the above embodiments are only used to illustrate the technical solutions of the present application, and not to limit them; although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that: it can still modify the technical solutions recorded in the foregoing embodiments, or make equivalent replacement for part or all of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present application.

Claims

1. A dynamic reliability testing device for gearboxes of large-scale road maintenance machinery, characterized in that, include: The drive module is used to provide dynamic power input to the gearbox (10) under test; The load simulation module (20) is connected to the output shaft of the gearbox (10) under test and is used to apply a variable load; The sensor module (30) includes a triaxial vibration sensor (31), a temperature sensor (32) and a speed sensor (33), which are installed at different positions in the gearbox (10) under test, respectively, to collect vibration signals, temperature signals and speed signals simultaneously. The data acquisition and analysis module (40) is connected to the sensor module (30) and is used to acquire and process the vibration signal, temperature signal and rotation speed signal; The frame (50) includes a fixed platform (51) and a base (52). The fixed platform (51) is connected to the base (52) through a vibration isolation device (53) to support the gearbox (10) under test and reduce external vibration interference. The gearbox (10) under test is fixed on the fixed platform (51). The vibration sensor (31) is installed on the gearbox bearing seat (101). The temperature sensor (32) is attached to the outer surface of the gearbox (10) under test.

2. The dynamic reliability testing device for a large-scale road maintenance machinery gearbox according to claim 1, characterized in that, The drive module includes a servo motor (11) and a planetary reducer (12). The servo motor (11) drives the gearbox under test (10) through the planetary reducer (12). The output shaft of the servo motor (11) is connected to the planetary reducer (12) through a flange. The input shaft of the planetary reducer (12) is coaxially mounted with the output shaft of the servo motor (11). The output shaft of the planetary reducer (12) is connected to the input shaft of the gearbox under test (10) through a flexible coupling (13).

3. The dynamic reliability testing device for a large-scale road maintenance machinery gearbox according to claim 2, characterized in that, The load simulation module (20) includes a magnetic powder brake (21) and a torque controller (22). The magnetic powder brake (21) is connected to the output shaft of the gearbox (10) under test via a coupling. The torque controller (22) is located on one side of the magnetic powder brake (21) and is used to adjust the loading torque of the magnetic powder brake (21).

4. The dynamic reliability testing device for a large-scale road maintenance machinery gearbox according to claim 3, characterized in that, The triaxial vibration sensor (31) is a triaxial acceleration sensor, which is symmetrically installed on both sides of the gearbox bearing seat (101) of the gearbox under test (10).

5. The dynamic reliability testing device for a large-scale road maintenance machinery gearbox according to claim 4, characterized in that, The temperature sensor (32) is an infrared temperature probe, which is installed on the outer surface of the gearbox (10) being tested.

6. The dynamic reliability testing device for a large-scale road maintenance machinery gearbox according to claim 5, characterized in that, The speed sensor (33) is a photoelectric encoder, which is installed at the end of the output shaft of the gearbox (10) under test via a coupling. The output pulse signal is transmitted to the multi-channel data acquisition card (41) of the data acquisition and analysis module (40) via a differential circuit.

7. The dynamic reliability testing device for a large-scale road maintenance machinery gearbox according to claim 6, characterized in that, The data acquisition and analysis module (40) includes a multi-channel data acquisition card (41), an edge computing unit (42), and a display terminal (43); wherein, the multi-channel data acquisition card (41) is connected to the sensor module (30) by signal, the edge computing unit (42) integrates time domain analysis, frequency domain analysis and temperature trend prediction algorithms, and the display terminal (43) is used to display the detection results in real time.

8. The dynamic reliability testing device for a large-scale road maintenance machinery gearbox according to claim 7, characterized in that, The vibration isolation device (53) includes a rubber damper (531) and a counterweight (532). The rubber damper (531) is symmetrically distributed at the four corners of the fixed platform (51). The counterweight (532) is embedded and fixed at the bottom of the base (52). The base (52) supports the fixed platform (51) through the rubber damper (531) and the counterweight (532).

9. The dynamic reliability testing device for a large-scale road maintenance machinery gearbox according to claim 8, characterized in that, It also includes a protective cover (60) that covers the gearbox under test (10) and the load simulation module (20).

10. A dynamic reliability testing device for a large-scale road maintenance machinery gearbox according to claim 9, characterized in that, The inner wall of the protective cover (60) is covered with honeycomb sound-absorbing material (61).

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