Gearbox In-Situ Monitoring Using Piezoelectric Transducer Arrays
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Solution Overview
Problem
Conventional gearbox inspection methods require disassembly, leading to costly downtime, potential failure due to disrupted alignments and contamination, and increased risk of corrosion, as well as inefficiencies in monitoring fatigue, crack growth, and other conditions.
Innovation Solution
An in-situ monitoring system integrated within the gearbox using a transducer array of piezoelectric transducers arranged in a circular pattern, which ultrasonically obtains diagnostic information without disassembly, utilizing wireless or wired communication to transmit data externally for analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional disassembly inspection methods are used, then diagnostic information can be obtained, but gearbox downtime increases and failure risk increases
Solution Approach 1:
The system performs preliminary ultrasonic inspection actions before disassembly is required, continuously monitoring gearbox components during operation to detect wear, cracks, and fatigue conditions early, thereby obtaining diagnostic information without causing downtime
Solution Approach 2:
The patent replaces the mechanical disassembly inspection system with an ultrasonic wave-based non-contact detection system. Piezoelectric transducers generate ultrasonic waves that propagate through gearbox components to detect internal conditions without mechanical contact or disassembly, eliminating downtime while maintaining diagnostic precision
2Measurement precision
If conventional disassembly inspection methods are used, then diagnostic information can be obtained, but gearbox integrity deteriorates due to disrupted alignments and contamination
Solution Approach 1:
The patent replaces mechanical disassembly with ultrasonic wave propagation through the gearbox components. The piezoelectric transducers generate ultrasonic waves that travel through the gear teeth and other components, allowing diagnostic information to be obtained without physical contact that would disrupt alignments or introduce contamination
Solution Approach 2:
The ultrasonic waves serve as an intermediary medium between the inspection system and the gearbox components. The waves propagate through the components to carry diagnostic information without requiring physical access or contact that would compromise gearbox integrity, avoiding disruption of alignments and preventing contamination
3Measurement precision
If conventional disassembly inspection methods are used, then diagnostic information can be obtained, but operational costs increase
Solution Approach 1:
The system performs preliminary continuous monitoring during normal operation, detecting wear, cracks, and fatigue conditions before they lead to failure. This prevents costly emergency repairs and extends component life, reducing overall operational costs while maintaining diagnostic precision
Solution Approach 2:
The ultrasonic monitoring system operates continuously during gearbox operation, providing ongoing diagnostic information without interrupting productivity. This continuous monitoring enables proactive maintenance scheduling, optimizing resource allocation and reducing operational costs compared to periodic disassembly inspections
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 continuous monitoring of gearbox conditions without disassembly, reducing failure risks, costs, and downtime, while maintaining gearbox integrity and efficiency.
Implementation Method 1
a transducer array having a plurality of piezoelectric transducers disposed on the mounting plate
Implementation Method 2
direct a response received from one or more of the plurality of piezoelectric transducers in proximity to the selected piezoelectric transducer toward a processor
Implementation Method 3
The transducer array is in contact with a surface of one or more mechanical components within the gearbox to ultrasonically obtain diagnostic information
Data Source
AI summary
Systems and methods for in-situ monitoring of gearbox are provided. An example system includes a mounting plate coupled to a component within the gearbox and a transducer array having a plurality of piezoelectric transducers disposed thereon to ultrasonically obtain diagnostic information about one or more components in the gearbox. The plurality of piezoelectric transducers are in contact with a surface of one or more mechanical components within the gearbox. The system includes circuitry, at least a portion of which is mounted inside the gearbox, electrically couplable to the transducer array, the circuitry configured to direct an excitation signal to a selected piezoelectric transducer of the plurality of piezoelectric transducers, and direct a response received from one or more of the plurality of piezoelectric transducers in proximity to the selected piezoelectric transducer toward a processor programmed or configured to determine gearbox diagnostic information therefrom.