Gearbox Monitoring for Zero-Torque Load Change Wear
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Solution Overview
Problem
Existing drive systems with electric motors and gear units face premature failure due to wear caused by load changes, particularly during zero-crossing torque events, leading to increased stress and backlash, which can result in costly repairs and production losses.
Innovation Solution
Monitoring load changes with zero-crossing torque to detect critical operating states, allowing for signaling of potential issues and implementing a more gentle operation mode, logging wear data for maintenance planning, and enabling automated interventions such as emergency shutdowns or adaptive control strategies to mitigate wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gearbox operates with normal gear backlash during load changes with zero torque crossing, then the tooth flanks disengage and reengage causing impact forces, but this leads to increased wear and premature failure of the transmission
Solution Approach 1:
The system performs preliminary detection of load changes with zero torque crossing through monitoring operating parameters. By identifying these critical conditions before they cause damage, the system can take preventive action such as signaling warnings or activating gentler operation modes to avoid tooth flank impact and wear
Solution Approach 2:
The system continuously monitors operating parameters including torque, speed, and power to detect load changes. This feedback mechanism allows real-time identification of zero-crossing events and enables adaptive control responses to mitigate wear during such conditions
2Reliability
If the motor is controlled to avoid zero-crossing load changes, then wear is reduced, but this requires complex monitoring and control systems
Solution Approach 1:
The monitoring system utilizes existing multi-functional operating parameters (torque, speed, power) that are already measured for motor control purposes. By evaluating these existing parameters for wear detection, the system avoids adding dedicated sensors while achieving comprehensive monitoring capability
Solution Approach 2:
The system uses the motor's own operating parameters and control infrastructure to perform wear detection and protection functions. The motor controller itself evaluates its operating data to identify critical conditions, making the system self-monitoring without requiring external complex monitoring equipment
Data Source
AI summary
The invention relates to a method for monitoring a transmission driven by an electric motor with a motor control, in which load changes with zero crossing of the motor torque in the transmission are monitored, wherein at least one operating parameter of the electric motor and/or the motor control is measured and evaluated for monitoring the load change.