Gear Meshing Frequency Determination for Unknown Design Specs
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Solution Overview
Problem
In gear devices, particularly in wind power generators and large-scale plants, diagnosing gear abnormalities is challenging when design specifications are unknown, as characteristic vibration frequencies cannot be determined, making it difficult to identify abnormal states and schedule maintenance effectively.
Innovation Solution
A state monitoring system that includes a meshing frequency determination device, which uses sensors to detect meshing vibrations, sets harmonic regions, and calculates maximum peak amplitudes across estimated frequency ranges to determine the meshing frequency and tooth surface speed, allowing for accurate diagnosis of gear abnormalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If design specifications of gear are unknown, then general vibration monitoring can be performed, but characteristic meshing frequency cannot be determined for accurate abnormality diagnosis
Solution Approach 1:
The system performs self-diagnosis by automatically determining meshing frequency from vibration data without requiring external design specification information. The meshing frequency determination device analyzes the vibration signal itself to extract characteristic frequencies, enabling the system to serve itself in identifying abnormal portions and estimating abnormal states.
Solution Approach 2:
The system changes the approach from using design specification parameters to using vibration signal parameters. By analyzing frequency components, amplitude distributions, and temporal patterns in the vibration data, the system determines meshing frequency and identifies abnormalities without relying on manufacturer-provided design specifications.
2Ease of operation
If only general feature values (effective value, maximum value) are used for monitoring, then simple monitoring can be performed, but specific abnormal portions cannot be identified
Solution Approach 1:
The vibration signal is segmented into frequency components through spectral analysis. The system divides the frequency spectrum into regions and identifies specific frequency components corresponding to meshing frequency and its harmonics, allowing localization of abnormal portions within specific gear pairs rather than treating the entire vibration signal as a whole.
Solution Approach 2:
The system transitions from time-domain analysis (effective value, maximum value) to frequency-domain analysis. By examining the frequency dimension of vibration signals, the system can identify characteristic meshing frequencies and distinguish between normal and abnormal vibration patterns, enabling specific abnormal portion identification while maintaining operational simplicity.
3Measurement precision
If meshing frequency is determined from design specifications, then accurate characteristic frequency can be obtained, but manufacturer specifications must be public and available
Solution Approach 1:
The system creates a universal monitoring method that can be applied to any gear device regardless of manufacturer or design specification availability. The meshing frequency determination device extracts characteristic frequencies directly from vibration signals, making the system adaptable to diverse gear configurations without requiring manufacturer-specific information.
Solution Approach 2:
The vibration signal serves as an intermediary between the gear device and the monitoring system. Instead of requiring direct access to design specifications, the system uses the vibration signal as a mediator to indirectly determine meshing frequency and identify abnormalities, enabling monitoring of gear devices with unknown design specifications.
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
This system enables the determination of meshing frequencies and tooth counts in gear devices with unknown design specifications, facilitating precise gear abnormality diagnosis and maintenance planning by distinguishing between self-induced and forced vibrations.
Implementation Method 1
a sensor configured to detect a meshing vibration occurring in each gear pair
Data Source
AI summary
A state monitoring system for monitoring state of a gear device having a plurality of gear pairs has a meshing frequency determination device. The meshing frequency determination device includes a maximum-peak-amplitude calculation unit that calculates a maximum peak amplitude from a detected meshing vibration, in estimated frequency ranges and a set harmonic region, and selects such estimated frequencies that a difference in maximum peak amplitude between a plurality of estimated frequency ranges, is less than or equal to a predetermined multiple, and a meshing frequency determination unit that determines an estimated frequency having a total value of maximum peak amplitudes calculated in the plurality of estimated frequency ranges, within a predetermined time, being the k-th (k is a natural number) greatest among the selected estimated frequencies, as a meshing frequency of a gear pair having the k-th highest tooth surface speed.