Gear Fatigue Estimation from Lubricant Debris Accumulation
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Solution Overview
Problem
In power transmission devices, foreign matter such as metal powders and broken pieces mixed in lubricating oil due to gear wear can lead to vehicle on-road failures, necessitating an effective estimation of gear breakage time based on the foreign matter mixed amount to prevent such failures.
Innovation Solution
A device comprising a foreign matter mixed amount acquisition means, fatigue damage degree estimation means, and cumulative fatigue damage degree estimation means, which includes a collection member to detect the foreign matter in the lubricating oil, estimate the fatigue damage per unit travel, and calculate the cumulative damage based on travel distance and time, with a warning system for impending breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foreign matter mixed amount is monitored to estimate gear breakage time, then vehicle reliability is improved, but device complexity increases due to additional sensors and estimation systems
Solution Approach 1:
The patent introduces a strainer as an intermediary component that physically collects foreign matter from the lubricating oil. This strainer serves as a mediator between the gear system and the estimation system, allowing indirect measurement of wear through foreign matter accumulation rather than direct monitoring of gear condition
Solution Approach 2:
The patent replaces complex direct mechanical monitoring of gear condition with a simpler system that measures foreign matter accumulation in the lubricating oil. Instead of installing sensors on the gears themselves, the system uses a strainer to collect wear particles and estimates breakage time based on the accumulated foreign matter amount
2Measurement precision
If real-time foreign matter detection is implemented, then breakage time estimation accuracy is improved, but manufacturing cost increases due to additional components
Solution Approach 1:
The strainer automatically collects foreign matter from the lubricating oil during normal system operation without requiring additional active components. The accumulation of foreign matter on the strainer itself serves as the measurement indicator, eliminating the need for complex sensors or detection devices
Solution Approach 2:
The system monitors the change in foreign matter accumulation over time and travel distance to estimate breakage time. By tracking the rate of foreign matter accumulation and projecting it to a threshold value representing gear failure, the system achieves accurate breakage time estimation using simple measurement of a single parameter (foreign matter amount)
Data Source
AI summary
An estimation device includes mixed amount acquisition part 110, 201 configured to acquire a foreign matter mixed amount in a fluid that lubricates meshing elements G1 to G4, a fatigue damage degree estimation unit 202 configured to estimate fatigue damage degrees received by the meshing elements G1 to G4 per unit traveling of a vehicle based on the acquired foreign matter mixed amount, and a cumulative fatigue damage degree estimation unit 203 configured to estimate cumulative fatigue damage degrees of the meshing elements G1 to G4 based on the estimated fatigue damage degrees and at least one of a traveling distance and traveling time of the vehicle.