Gearbox Torque Signal Analysis for Early Wear Detection
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Solution Overview
Problem
Existing methods for detecting gear damage in motor-gearbox units are inadequate in terms of resource efficiency and early detection, especially under varying environmental and operating conditions, and fail to provide reliable results.
Innovation Solution
A method that analyzes torque signal curves to identify regions indicative of gearbox damage, using a detection module to measure input and output torque, and employs histogram analysis to detect deviations from expected distributions, allowing for early warning of damage without requiring precise identification of damage location or type.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If motor current analysis is performed to detect wear and damage, then damage detection capability is provided, but reliability under varying environmental influences and operating conditions is insufficient
Solution Approach 1:
The patent introduces torque signal curves as an intermediary measurement that correlates directly with gearbox loading conditions. By measuring torque (directly or via motor current) and analyzing it as a function of gearbox position, the method creates a mediator signal that is independent of environmental influences while still reflecting damage conditions. This resolves the contradiction by providing reliable damage detection that adapts to varying operating conditions through position-correlated torque analysis.
2Reliability
If comprehensive signal processing is performed to detect damage, then detection capability is improved, but resource consumption increases
Solution Approach 1:
The patent extracts only the essential information needed for damage detection by analyzing torque signal curves in relation to gearbox position. Instead of performing comprehensive spectrum analysis on entire motor current signals, the method extracts torque values at specific positions and compares them across different operating conditions. This extraction approach maintains high detection accuracy while significantly reducing computational resource consumption.
Solution Approach 2:
The patent performs preliminary grouping of torque signal curves according to gearbox position before detailed analysis. By pre-organizing data into position-based groups and identifying characteristic positions where damage effects are most prominent, the method reduces the scope of subsequent analysis. This preliminary action enables accurate damage detection with minimal computational resources by focusing only on critical positions.
3Loss of information
If detailed damage location identification is performed, then diagnostic information is improved, but complexity of the method increases
Solution Approach 1:
The patent applies partial action by focusing analysis only on specific gearbox positions where damage effects are most likely to manifest. Instead of analyzing the entire gearbox uniformly, the method identifies characteristic positions (such as those where damaged teeth engage) and concentrates analysis there. This provides sufficient diagnostic information for damage detection without the excessive complexity of comprehensive location identification.
Data Source
AI summary
A method for detecting wear and/or damage to a motor-gearbox unit with a motor and a gearbox coupled to the motor on the output side includes a detection module determining an input and/or output torque either directly or indirectly as a measured variable that can be unambiguously correlated with the input and/or output torque when the gearbox is moved by the motor. A signal curve is respectively generated for such movements, which signal curve reflects the input and/or output torque respectively determined directly or indirectly as a function of a variable correlated with the position of the gearbox. At least some of these signal curves are analyzed automatically, wherein a region of the variable correlated with the position of the gearbox is identified, to which a feature characteristic of gearbox damage can be assigned for the respective signal curve.