Abstract: Low gear noise is an important sound quality feature in modern passenger cars. Annoying gear noise from the gearbox is influenced by the gear design, gearbox shaft layout, manufacturing deviations in the components, assembly errors and the mounting arrangement of the complete gearbox. Geometrical deviations in the form of profile and lead errors are often present on the flanks of the inspected gears. Ghost frequencies of a gear are very challenging to identify in standard gear measurement and analysis process due to small wavelengths involved. In this paper, gear whine noise occurring at non-integral multiples of gear mesh frequency of passenger car gearbox is investigated and the root cause is identified using the displacement deviation analysis (DDA) method. DDA method is applied to identify ghost frequency excitations on the flanks of gears arising out of generation grinding. Frequency identified through DDA correlated with the frequency of vibration and noise on the end-of-line machine as well as vehicle level measurements. With the application of DDA method along with standard lead profile measurement, gears with ghost frequency geometry deviations were identified on the production line to eliminate defective parts and thereby eliminate ghost frequency noise from a vehicle. Further, displacement deviation analysis can be used in conjunction with the manufacturing process simulation to arrive at suitable countermeasures for arresting the ghost frequency.
Abstract: This paper presents modeling and control strategy for the grid connected wind turbine system based on Permanent Magnet Synchronous Generator (PMSG). The considered system is based on back-to-back converter topology. The Grid Side Converter (GSC) achieves the DC bus voltage control and unity power factor. The Machine Side Converter (MSC) assures the PMSG speed control. The PMSG is used as a variable speed generator and connected directly to the turbine without gearbox. The pitch angle control is not either considered in this study. Further, Optimal Tip Speed Ratio (OTSR) based MPPT control strategy is used to ensure the most energy efficiency whatever the wind speed variations. A filter (L) is put between the GSC and the grid to reduce current ripple and to improve the injected power quality. The proposed grid connected wind system is built under MATLAB/Simulink environment. The simulation results show the feasibility of the proposed topology and performance of its control strategies.
Abstract: Proposing an appropriate control strategy is an effective and practical way to address the overheat problems of the wet multi-plate clutch in Direct Shift Gearbox under the long-time creeping condition. To do so, the temperature variation of the wet multi-plate clutch is investigated firstly by establishing a thermal resistance model for the gearbox cooling system. To calculate the generated heat flux and predict the clutch temperature precisely, the friction torque model is optimized by introducing an improved friction coefficient, which is related to the pressure, the relative speed and the temperature. After that, the heat transfer model and the reasonable friction torque model are employed by the vehicle powertrain model to construct a comprehensive co-simulation model for the Direct Shift Gearbox (DSG) vehicle. A creeping control strategy is then proposed and, to evaluate the vehicle performance, the safety temperature (250 ℃) is particularly adopted as an important metric. During the creeping process, the temperature of two clutches is always under the safety value (250 ℃), which demonstrates the effectiveness of the proposed control strategy in avoiding the thermal failures of clutches.
Abstract: Power transmitted from the engine to the final drive where useful work is applied through a system consisting of a gearbox, clutch, drive shaft and a differential in the rear-wheel-drive automobiles. It is well-known that the steel drive shaft is usually manufactured in two pieces to increase the fundamental bending natural frequency to ensure safe operation conditions. In this work, hybrid one-piece propeller shafts composed of carbon/epoxy and glass/epoxy composites have been designed for a rear wheel drive automobile satisfying three design specifications, such as static torque transmission capability, torsional buckling and the fundamental natural bending frequency. Hybridization of carbon and glass fibers is being studied to optimize the cost/performance requirements. Composites shaft materials with various fiber orientation angles and stacking sequences are being fabricated and analyzed using finite element analysis (FEA).
Abstract: This paper presents an innovative method to control the rotational speed of a satellite solar panel during its deployment phase. A brushed DC motor has been utilized in the passive spring driven deployment mechanism to reduce the deployment speed. In order to use the DC motor as a damper, its connector terminals have been connected with an external resistance in a closed circuit. It means that, in this approach, there is no external power supply in the circuit. The working principle of this method is based on the back electromotive force (or back EMF) of the DC motor when an external torque (here the torque produced by the torsional springs) is coupled to the DC motor’s shaft. In fact, the DC motor converts to an electric generator and the current flows into the circuit and then produces the back EMF. Based on Lenz’s law, the generated current produced a torque which acts opposite to the applied external torque, and as a result, the deployment speed of the solar panel decreases. The main advantage of this method is to set an intended damping coefficient to the system via changing the external resistance. To produce the sufficient current, a gearbox has been assembled to the DC motor which magnifies the number of turns experienced by the DC motor. The coupled electro-mechanical equations of the system have been derived and solved, then, the obtained results have been presented. A full-scale prototype of the deployment mechanism has been built and tested. The potential application of brushed DC motors as a rotational speed damper has been successfully demonstrated.
Abstract: Singular value decomposition based optimisation of
geometric design parameters of a 5-speed gearbox is studied. During
the optimisation, a four-degree-of freedom torsional vibration model
of the pinion gear-wheel gear system is obtained and the minimum
singular value of the transfer matrix is considered as the objective
functions. The computational cost of the associated singular value
problems is quite low for the objective function, because it is only
necessary to compute the largest and smallest singular values (μmax
and μmin) that can be achieved by using selective eigenvalue solvers;
the other singular values are not needed. The design parameters are
optimised under several constraints that include bending stress,
contact stress and constant distance between gear centres. Thus, by
optimising the geometric parameters of the gearbox such as, the
module, number of teeth and face width it is possible to obtain a
light-weight-gearbox structure. It is concluded that the all optimised
geometric design parameters also satisfy all constraints.
Abstract: In more complex systems, such as automotive
gearbox, a rigorous treatment of the data is necessary because there
are several moving parts (gears, bearings, shafts, etc.), and in this
way, there are several possible sources of errors and also noise. The
basic objective of this work is the detection of damage in automotive
gearbox. The detection methods used are the wavelet method, the
bispectrum; advanced filtering techniques (selective filtering) of
vibrational signals and mathematical morphology. Gearbox vibration
tests were performed (gearboxes in good condition and with defects)
of a production line of a large vehicle assembler. The vibration
signals are obtained using five accelerometers in different positions
of the sample. The results obtained using the kurtosis, bispectrum,
wavelet and mathematical morphology showed that it is possible to
identify the existence of defects in automotive gearboxes.
Abstract: Flanges are widely used for connecting valves, pipes and other industrial devices such as gearboxes. Method of producing a flange has a considerable impact on the manner of their involvement with the industrial engines and gearboxes. By Using die casting instead of sand casting and machining for manufacturing flanges, production speed and dimensional accuracy of the parts increases. Also, in die casting, obtained dimensions are close to final dimensions and hence the need for machining flanges after die casting process decreases which makes a significant savings in raw materials and improves the mechanical properties of flanges. In this paper, a typical die of an industrial helical gearbox flange (size ISO 50) was designed and die casting process for producing this type of flange was simulated using ProCAST software. The results of simulation were used for optimizing die design. Finally, using the results of the analysis, optimized die was built.
Abstract: Large rotating systems, especially gear drives and gearboxes, occur as parts of many mechanical devices transmitting the torque with relatively small loss of power. With the increased demand for high speed machinery, mathematical modeling and
dynamic analysis of gear drives gained importance. Mathematical description of such mechanical systems is a complex task evolving for several decades. In gear drive dynamic models, which include flexible shafts, bearings and gearing and use the finite elements, nonlinear effects due to gear mesh and bearings are usually ignored, for such models have large number of degrees of freedom (DOF) and it is computationally expensive to analyze nonlinear systems with large number of DOF. Therefore, these models are not suitable for simulation of nonlinear behavior with amplitude jumps in frequency response. The contribution uses a methodology of nonlinear large rotating system modeling which is based on degrees of freedom (DOF) number reduction using modal synthesis method (MSM).
The MSM enables significant DOF number reduction while keeping
the nonlinear behavior of the system in a specific frequency range.
Further, the MSM with DOF number reduction is suitable for
including detail models of nonlinear couplings (mainly gear and
bearing couplings) into the complete gear drive models. Since each
subsystem is modeled separately using different FEM systems, it
is advantageous to parameterize models of subsystems and to use
the parameterization for optimization of chosen design parameters.
Final complex model of gear drive is assembled in MATLAB and
MATLAB tools are used for dynamical analysis of the nonlinear
system. The contribution is further focused on developing of a
methodology for investigation of behavior of the system by Nonlinear
Normal Modes with combination of the MSM using numerical
continuation method. The proposed methodology will be tested using
a two-stage gearbox including its housing.
Abstract: In this study, a field testing has been carried out to assess the power characteristics of some small scale wind turbines fabricated by one native technician from Tanzania. Two Horizontal Axis Wind Turbines (HAWTs), one with five and other with sixteen blades were installed at a height of 2.4m above the ground. The rotation speed of the rotor blade and wind speed approaching the turbines were measured simultaneously. The data obtained were used to determine how the power coefficient varies as a function of tip speed ratio and also the way in which the output power compares with available power in the wind for each turbine. For the sixteen-bladed wind turbine the maximum value of power coefficient of about 0.14 was found to occur at a tip speed ratio of around 0.65 while for the five bladed, these extreme values were respectively attained at approximately 0.2 and 1.7. The five bladed-wind turbine was found to have a higher power efficiency of about 37.5% which is higher compared to the sixteen bladed wind turbine whose corresponding value was 14.37%. This is what would be expected, as the smaller the number of blades of a wind turbine, the higher the electric power efficiency and vice versa. Some of the main reasons for the low efficiency of these machines may be due to the low aerodynamic efficiency of the turbine or low efficiency of the transmission mechanisms such as gearbox and generator which were not examined in this study. It is recommended that some other researches be done to investigate the power efficiency of such machines from different manufacturers in the country. The manufacturers should also be encouraged to use fewer blades in their designs so as to improve the efficiency and at the same time reduce materials used to fabricate the blades. The power efficiency of the electric generators used in the locally fabricated wind turbines should also be examined.
Abstract: This paper presents a new study on the applications of
optimization and regression analysis techniques for optimal
calculation of partial ratios of four-step helical gearboxes for getting
minimal gearbox length. In the paper, basing on the moment
equilibrium condition of a mechanic system including four gear units
and their regular resistance condition, models for determination of the
partial ratios of the gearboxes are proposed. In particular, explicit
models for calculation of the partial ratios are proposed by using
regression analysis. Using these models, the determination of the
partial ratios is accurate and simple.
Abstract: This research deals with investigations on the “Active
Generator" under rotor speed variations and output frequency
control. It runs at turbine speed and it is connected to a three phase
electrical power grid which has its own frequency different from
turbine frequency. In this regard the set composed of a four phase
synchronous generator and a natural commutated matrix converter
(NCMC) made with thyristors, is called active generator. It replaces a
classical mechanical gearbox which introduces many drawbacks. The
main idea in this article is the presentation of frequency control at
grid side when turbine runs at variable speed. Frequency control has
been done by linear and step variations of the turbine speed. Relation
between turbine speed (frequency) and main grid zero sequence
voltage frequency is presented.
Abstract: A mathematical model for determining the overall efficiency
of a multistage tractor gearbox including all gear, lubricant,
surface finish related parameters and operating conditions is
presented. Sliding friction, rolling friction and windage losses were
considered as the main sources of power loss in the gearing system. A
computer code in FORTRAN was developed to simulate the model.
Sliding friction contributes about 98% of the total power loss for
gear trains operating at relatively low speeds (less than 2000 rpm
input speed). Rolling frictional losses decrease with increased load
while windage losses are only significant for gears running at very
high speeds (greater than 3000 rpm). The results also showed that the
overall efficiency varies over the path of contact of the gear meshes
ranging between 94% to 99.5%.
Abstract: In this paper, some common gearboxes vibration analysis methods and condition monitoring systems are explained. In addition, an experimental gearbox vibration analysis is discussed through a critical case history for a mixer gearbox related to Iran oil industry. The case history also consists of gear manufacturing (machining) recommendations, lubrication condition of gearbox and machinery maintenance activities that caused reduction in noise and vibration of the gearbox. Besides some of the recent patents and innovations in gearboxes, lubrication and vibration monitoring systems explained. Finally micro pitting and surface fatigue in pinion and bevel of mentioned horizontal to vertical gearbox discussed in details.
Abstract: In this paper, a study on the applications of the
optimization and regression techniques for optimal calculation of
partial ratios of helical gearboxes with second-step double gear-sets
for minimal cross section dimension is introduced. From the condition
of the moment equilibrium of a mechanic system including three gear
units and their regular resistance condition, models for calculation of
the partial ratios of helical gearboxes with second-step double
gear-sets were given. Especially, by regression analysis, explicit
models for calculation of the partial ratios are introduced. These
models allow determining the partial ratios accurately and simply.
Abstract: Research on damage of gears and gear pairs using
vibration signals remains very attractive, because vibration signals
from a gear pair are complex in nature and not easy to interpret.
Predicting gear pair defects by analyzing changes in vibration signal
of gears pairs in operation is a very reliable method. Therefore, a
suitable vibration signal processing technique is necessary to extract
defect information generally obscured by the noise from dynamic
factors of other gear pairs.This article presents the value of cepstrum
analysis in vehicle gearbox fault diagnosis. Cepstrum represents the
overall power content of a whole family of harmonics and sidebands
when more than one family of sidebands is present at the same time.
The concept for the measurement and analysis involved in using the
technique are briefly outlined. Cepstrum analysis is used for detection
of an artificial pitting defect in a vehicle gearbox loaded with
different speeds and torques. The test stand is equipped with three
dynamometers; the input dynamometer serves asthe internal
combustion engine, the output dynamometers introduce the load on
the flanges of the output joint shafts. The pitting defect is
manufactured on the tooth side of a gear of the fifth speed on the
secondary shaft. Also, a method for fault diagnosis of gear faults is
presented based on order Cepstrum. The procedure is illustrated with
the experimental vibration data of the vehicle gearbox. The results
show the effectiveness of Cepstrum analysis in detection and
diagnosis of the gear condition.
Abstract: This paper presents modern vibration signalprocessing
techniques for vehicle gearbox fault diagnosis, via the
wavelet analysis and the Squared Envelope (SE) technique. The
wavelet analysis is regarded as a powerful tool for the detection of
sudden changes in non-stationary signals. The Squared Envelope
(SE) technique has been extensively used for rolling bearing
diagnostics. In the present work a scheme of using the Squared
Envelope technique for early detection of gear tooth pit. The pitting
defect is manufactured on the tooth side of a fifth speed gear on the
intermediate shaft of a vehicle gearbox. The objective is to
supplement the current techniques of gearbox fault diagnosis based
on using the raw vibration and ordered signals. The test stand is
equipped with three dynamometers; the input dynamometer serves as
the internal combustion engine, the output dynamometers introduce
the load on the flanges of output joint shafts. The gearbox used for
experimental measurements is the type most commonly used in
modern small to mid-sized passenger cars with transversely mounted
powertrain and front wheel drive; a five-speed gearbox with final
drive gear and front wheel differential. The results show that the
approaches methods are effective for detecting and diagnosing
localized gear faults in early stage under different operation
conditions, and are more sensitive and robust than current gear
diagnostic techniques.
Abstract: This work presents a numerical model developed to
simulate the dynamics and vibrations of a multistage tractor gearbox.
The effect of time varying mesh stiffness, time varying frictional
torque on the gear teeth, lateral and torsional flexibility of the shafts
and flexibility of the bearings were included in the model. The model
was developed by using the Lagrangian method, and it was applied to
study the effect of three design variables on the vibration and stress
levels on the gears. The first design variable, module, had little effect
on the vibration levels but a higher module resulted to higher bending
stress levels. The second design variable, pressure angle, had little
effect on the vibration levels, but had a strong effect on the stress
levels on the pinion of a high reduction ratio gear pair. A pressure
angle of 25o resulted to lower stress levels for a pinion with 14 teeth
than a pressure angle of 20o. The third design variable, contact ratio,
had a very strong effect on both the vibration levels and bending
stress levels. Increasing the contact ratio to 2.0 reduced both the
vibration levels and bending stress levels significantly. For the gear
train design used in this study, a module of 2.5 and contact ratio of
2.0 for the various meshes was found to yield the best combination
of low vibration levels and low bending stresses. The model can
therefore be used as a tool for obtaining the optimum gear design
parameters for a given multistage spur gear train.