Gear Damage Detection Using Acoustic Emission Signals
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Solution Overview
Problem
Existing inspection techniques for detecting damage in the meshing state of gears in electric vehicles are challenging due to the instability of the vehicle during traveling, making it difficult to perform reliable inspections while the motor is mounted.
Innovation Solution
An inspection apparatus equipped with a sensor to detect Acoustic Emission (AE) signals during gear meshing and a processor to determine the presence or absence of damage based on the AE signals, allowing for inspections to be performed when the vehicle is stopped.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If inspection is performed during vehicle traveling with motor mounted, then inspection can be conducted in operational state, but vehicle stability deteriorates and inspection reliability decreases
Solution Approach 1:
The inspection apparatus performs preliminary actions by detecting AE signals during vehicle operation, then uses these pre-collected data to conduct reliable inspections when the vehicle is stopped. This allows the system to gather operational data without compromising inspection reliability, as the actual damage assessment is performed in a stable, controlled environment.
Solution Approach 2:
The AE signal detection acts as an intermediary mechanism that bridges the gap between operational inspection needs and reliable inspection conditions. By using AE signals as an intermediate measurement method, the system can assess gear damage without requiring the vehicle to be in a stable stopped state during the actual damage detection process.
2Productivity
If inspection is performed during vehicle traveling, then inspection can be conducted without stopping, but vibration stability deteriorates making damage detection difficult
Solution Approach 1:
The system performs preliminary AE signal detection during vehicle operation to capture operational characteristics, then uses these pre-collected signals for precise damage assessment when the vehicle is stopped. This separates the continuity function from the precision function, allowing both to be optimized independently.
Solution Approach 2:
The inspection apparatus operates in periodic cycles, collecting AE signals during operational phases and then performing analysis during stopped phases. This periodic operation pattern allows the system to maintain inspection continuity while ensuring measurement precision during stable periods.
3Adaptability or versatility
If motor is mounted on vehicle for inspection, then gear inspection becomes possible, but vehicle stability decreases during inspection
Solution Approach 1:
The motor is mounted on the vehicle in advance to enable gear inspection capability, but the actual inspection is performed after the motor is removed or during a state where it does not affect stability. The AE signals are collected during the operational phase with the motor mounted, then analysis is performed when the motor is removed, ensuring stability during the critical measurement phase.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables reliable inspection of gear damage in a stable condition, reducing variations in inspection conditions and allowing for early detection of gear degradation, thus ensuring the reliability and safety of the vehicle's transmission system.
Implementation Method 1
a sensor configured to detect an AE signal in a meshing state of the gears
Data Source
AI summary
An inspection apparatus is configured to inspect damage on gears in a transmission that transmits a torque generated by a motor mounted as a drive source of a vehicle. The inspection apparatus comprising: a sensor configured to detect an AE signal in a meshing state of the gears; and a processor configured to determine presence or absence of occurrence of damage in the meshing state of the gears based on the AE signal.