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Volume 25
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10.3390/s25185810
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

Research on Shape–Performance Integrated Monitoring Technology for Planetary Gearboxes Based on the Integration of Artificial Intelligence, Finite Element Analysis, and Multibody Dynamics Simulation

by
Yanping Cui
,
Boshuo An
,
Zhe Wu
*,
Ziao Shang
and
Xuanrui Zhang
School of Mechanical Engineering, Hebei University of Science and Technology, Shijiazhuang 050018, China
*
Author to whom correspondence should be addressed.
Sensors 2025, 25(18), 5810; https://doi.org/10.3390/s25185810
Submission received: 11 July 2025 / Revised: 4 September 2025 / Accepted: 15 September 2025 / Published: 17 September 2025
(This article belongs to the Section Physical Sensors)
Versions Notes

Abstract

To address gear tooth damage and the difficulty of acquiring performance data under high-speed and high-load operating conditions of planetary gearboxes, a digital twin-based system for operational state recognition and performance prediction is proposed, integrating morphological and functional characteristics. Driven by experimental data, the system incorporates finite element analysis, multibody dynamics simulation, artificial intelligence algorithms, and 3D visualization to achieve a virtual mapping of the gearbox’s geometric configuration, structural properties, and dynamic behavior. Structural performance is represented using finite element and dynamic simulation techniques combined with texture mapping, visualized through color gradients; dynamic performance is captured through multibody dynamics simulations and stored in a time-series database, presented as sequential images. The integrated system is constructed by combining a structural performance surrogate model, a system-driven model, and a dynamic performance database, enabling comprehensive functionality. Results demonstrate that the maximum error of the structural performance model is 3%, occurring only under specific working conditions, with negligible impact on the overall meshing performance evaluation of the sun gear. The maximum error in dynamic performance prediction is 1.68%, showing strong consistency with experimental data.
Keywords: planetary gearbox; morphology–performance integration; artificial intelligence; structural performance analysis; multibody dynamics analysis planetary gearbox; morphology–performance integration; artificial intelligence; structural performance analysis; multibody dynamics analysis

Share and Cite

MDPI and ACS Style

Cui, Y.; An, B.; Wu, Z.; Shang, Z.; Zhang, X. Research on Shape–Performance Integrated Monitoring Technology for Planetary Gearboxes Based on the Integration of Artificial Intelligence, Finite Element Analysis, and Multibody Dynamics Simulation. Sensors 2025, 25, 5810. https://doi.org/10.3390/s25185810

AMA Style

Cui Y, An B, Wu Z, Shang Z, Zhang X. Research on Shape–Performance Integrated Monitoring Technology for Planetary Gearboxes Based on the Integration of Artificial Intelligence, Finite Element Analysis, and Multibody Dynamics Simulation. Sensors. 2025; 25(18):5810. https://doi.org/10.3390/s25185810

Chicago/Turabian Style

Cui, Yanping, Boshuo An, Zhe Wu, Ziao Shang, and Xuanrui Zhang. 2025. "Research on Shape–Performance Integrated Monitoring Technology for Planetary Gearboxes Based on the Integration of Artificial Intelligence, Finite Element Analysis, and Multibody Dynamics Simulation" Sensors 25, no. 18: 5810. https://doi.org/10.3390/s25185810

APA Style

Cui, Y., An, B., Wu, Z., Shang, Z., & Zhang, X. (2025). Research on Shape–Performance Integrated Monitoring Technology for Planetary Gearboxes Based on the Integration of Artificial Intelligence, Finite Element Analysis, and Multibody Dynamics Simulation. Sensors, 25(18), 5810. https://doi.org/10.3390/s25185810

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