Research on Vibroactivity of Toothed Gears with Highly Flexible Metal Clutch under Variable Load Conditions
Abstract
:1. Introduction
- Structural factors, including nominal rotational speed, nominal gear mesh frequency, nominal gear load, damping properties of lubricants, fit and stiffness of bearings, structural form of the gear housing, and free vibrations of the entire system; for this group of factors, it is possible to make sure that various causes of damage and malfunction can be significantly reduced at the design stage, for instance by increasing dimensions or reducing breaking stresses.
- Technological factors, including pitch deviations, tooth line direction deviations, radial runout, and surface irregularities; a common solution to this group of problems, one which reduces the potential damage, is increasing the gear teeth manufacture accuracy, for instance by using advanced machining equipment or highly accurate assembly.
- Disruptive factors interfering with the motion of gears, including change of meshing stiffness and damping in the mesh within the engagement section, tooth deformation due to loading, dynamic imbalance of wheels and shafts, change in wheel interaction conditions attributable to wear of tooth surfaces, inter-tooth play; it is relatively difficult to curb the negative effects of the aforementioned constituent factors, and it often requires reference profile alterations, adequate outline modifications or even gear overhaul.
2. Materials and Methods
- torsional stiffness—135 Nm/deg,
- dimensionless damping coefficient ψ—0.52,
- nominal torque transferred—600 Nm,
- safety factor—3.
- long-term power transmitted (at 1470 rpm)—22 kW,
- three-stage gear (1 conical and 2 cylindrical stages),
- total gear ratio i = 12.962,
- splash lubrication with a VG 220 grade mineral oil.
- Torque measurement using torque meters M1, M2, M4 (No. 3, 9, 15—Figure 6) (MT-750, Pracownia Elektroniki R. Pomianowski, Poznań, Poland) set up- and downstream the flexible clutch as well as at the output of the gear performing the multiplier function; the measurement signal from the torque meter sensor was conditioned in a matching circuit, transmitted to a three-channel measuring system, and recorded in parallel with the other signals recorded;
- Torsional angle measurement—this measurement was taken using a magnetic sensor which generated a signal related to the rotation of a measuring disc featuring a wound bipolar magnetic tape (add designation, Pracownia Elektroniki R. Pomianowski, Poznań, Poland); the measurement signal received from this sensor was conditioned in the matching circuit, transmitted to a single-channel measuring system, and recorded in parallel with the other signals recorded;
- Measurement of vibration accelerations on the gear housing by contact methods using four Endevco 44A10 3-axis accelerometer sensors (measuring points: 14519, 14553, 10244, 14448—Figure 7) and one Dytran 3093 3-axis accelerometer sensor;
- Non-contact laser measurement of the instantaneous changes in the torsional vibration velocity of the flexible clutch’s input shaft using the Polytec RLV-5500 Rotational Laser Vibrometer (Waldbronn, Germany);
- Determination of the impulses associated with the shaft rotation using two ROLS (tacho) laser sensors with a power of <1 mW and a measuring frequency of 1–250,000 rpm.
3. Results and Discussion
- meshing frequency,
- pinion and gear frequency,
- frequencies characteristic of the operation of rolling bearings, including the following:
- BPFO (Ball Pass Frequency Outer) or outer race failing frequency;
- BPFI (Ball Pass Frequency Inner) or inner race failing frequency;
- BSF (Ball Spin Frequency) or rolling element failing frequency;
- FTF (Fundamental Train Frequency) or cage failing frequency.
4. Conclusions
- Using the methodology proposed by the authors of this article for testing of power transmission systems featuring the innovative and patented highly torsionally flexible metal clutch in question—a methodology which takes into account the sensing systems based on diverse phenomena: piezoelectric, magnetic, the Doppler effect, etc., as well as the amplitude and frequency analyses discussed in the paper, it can be concluded that, since the time-varying forces emerging between the mating gear teeth (including those induced by time-varying external loads) are transmitted through the shafts and bearings to the gear housing, the reduction of the vibration acceleration values of the bearing housings of both the input and output shaft in the gear owing to the use of the innovative flexible clutch in the power transmission system implies that the dynamic forces affecting the gear meshing as well as the shaft bearing have decreased, which is particularly desirable with respect to the service life of the power transmission system.
- With reference to the complex power transmission system and based on the established instantaneous changes in the velocity of the torsional vibrations of the shaft between the clutch and the multi-stage reduction gear, illustrated in Figure 11 and recorded using a rotational laser vibrometer relatively seldom used for testing purposes, the studies addressed in this article made it possible to establish the relationships between the processes at work, i.e., the decline of the linear vibrations of the gear housing (which is undoubtedly positive in power transmission systems) at the expense of increasing torsional vibrations of the innovative clutch, the latter not to be considered unfavourable to users in the case analysed.
- Having analysed the vibration accelerations signals observed, one can clearly conclude that, for the housing of the bearing of both the input and output shaft in the multi-stage reduction gear, and for all the three loads and all the three measurement directions analysed, the peak-to-peak values of vibration accelerations obtained for the clutch in the flexible operation mode were significantly lower than those obtained when the clutch was torsionally locked in operation. The fact that the results discussed in the paper could be obtained precisely for all three loads, two measurement points, at the input and output of the multi-stage toothed gear, and three measurement directions prior to the actual studies and analyses was actually neither obvious nor certain, but was ultimately proved, which surely is a valuable outcome.
- The signals of the RMS values of the vibration accelerations calculated within a time window explicitly imply that, for the housing of the bearing of both the input and output shaft in the multi-stage reduction gear, and for all the three loads and all the three measurement directions analysed, the root mean square values of vibration accelerations obtained for the clutch in the flexible operation mode were significantly lower than those obtained when the clutch was torsionally locked; the foregoing proves the clutch proposed as the means to reduce the effect of external loads on the load and vibrations in the toothed gear to be highly useful.
- Based on the results of the frequency analysis of the vibration acceleration signals for both the gear output shaft bearing housing and for that of the gear input shaft, it was established that:
- Within the frequency bands where the vibration acceleration amplitudes showed the highest values, the vibration acceleration amplitudes were reduced multiple (at least three) times where the clutch was locked in operation as a result of the application of the patented innovative flexible clutch, this being a very beneficial effect;
- The fact that the innovative and patented highly flexible clutch was introduced into the power transmission system did not cause that within the spectrum of the signals any amplitude emerged with a value higher than that of the amplitude dominant in the case of the locked operation of the clutch, yet associated with a frequency different than the frequency corresponding to the amplitude dominant in the case of the locked operation of the clutch.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Mean Load Torque ± Amplitude of Load Torque Changes for Flexible Clutch Operation Mode [Nm] | Rotational Speed [rpm] | Clutch Operation Mode |
---|---|---|
41.8 ± 27.9 | 1480 | flexible (red colour) |
locked (green colour) | ||
79.2 ± 55 | flexible (red colour) | |
locked (green colour) | ||
114.8 ± 75.9 | flexible (red colour) | |
locked (green colour) |
Rotations per Minute | ||||||||
---|---|---|---|---|---|---|---|---|
RLV-500 Sensor Head | 7.5 mm beam separation | 24 mm beam separation | ||||||
Measurement range | –8000 RPM–+20,000 RPM | –2500 RPM–+6500 RPM | ||||||
Analogue output | –4 V–10 V | –2.5 V–+6.5 V | ||||||
Calibration error 1 | <0.6% of RPM reading ±2 RPM | <0.3% of RPM reading ±2 RPM | ||||||
Angular Velocity (Δω) | ||||||||
RLV-500 Sensor | Head 7.5 mm beam separation | 24 mm beam separation | ||||||
Peak analogue output (Vpeak) | 10 | 100 | 1000 | 12,000 | 10 | 100 | 1000 | 6000 |
Measurement ranges (°/s/V) | ±10 | ±10 | ±10 | +10/−4 | ±10 | ±10 | ±10 | +6.5/−2.5 |
Frequency range (kHz) | 0.001–10 | 0–10 | 0.001–10 | 0–10 | ||||
Measurement error <1% (at f = 1 kHz) |
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Kuczaj, M.; Wieczorek, A.N.; Konieczny, Ł.; Burdzik, R.; Wojnar, G.; Filipowicz, K.; Głuszek, G. Research on Vibroactivity of Toothed Gears with Highly Flexible Metal Clutch under Variable Load Conditions. Sensors 2023, 23, 287. https://doi.org/10.3390/s23010287
Kuczaj M, Wieczorek AN, Konieczny Ł, Burdzik R, Wojnar G, Filipowicz K, Głuszek G. Research on Vibroactivity of Toothed Gears with Highly Flexible Metal Clutch under Variable Load Conditions. Sensors. 2023; 23(1):287. https://doi.org/10.3390/s23010287
Chicago/Turabian StyleKuczaj, Mariusz, Andrzej N. Wieczorek, Łukasz Konieczny, Rafał Burdzik, Grzegorz Wojnar, Krzysztof Filipowicz, and Grzegorz Głuszek. 2023. "Research on Vibroactivity of Toothed Gears with Highly Flexible Metal Clutch under Variable Load Conditions" Sensors 23, no. 1: 287. https://doi.org/10.3390/s23010287
APA StyleKuczaj, M., Wieczorek, A. N., Konieczny, Ł., Burdzik, R., Wojnar, G., Filipowicz, K., & Głuszek, G. (2023). Research on Vibroactivity of Toothed Gears with Highly Flexible Metal Clutch under Variable Load Conditions. Sensors, 23(1), 287. https://doi.org/10.3390/s23010287