摘要:ObjectiveAs a key component of the round pipe belt conveyor, the contact force of the roller directly determines the service life, and the arrangement of the roller spacing is equally very important for the stable operation and transmission efficiency of the conveyor.MethodsAbaqus software was used to carry out DEM-FEM coupling simulation analysis on straight section and convex and concave arc sections of round pipe belt conveyor, the distribution of roller contact force along different lines was obtained, and the feasibility of the model was verified through theoretical analysis. By changing the roller spacing, the influence of this factor on the contact force distribution of each roller in the same roller group on the curve section was studied, and by comparing with the straight section, the difference of the roller spacing on different conveyor lines was obtained.ResultsThe study provides valuable reference and guidance for the adjustment and optimization of the roller selection and spacing in practical engineering.
关键词:Roller contact force;Round pipe belt conveyor;Convex and concave arcs;Roller spacing;Simulation
摘要:ObjectiveThe gear contact fatigue failure mechanism has become an important bottleneck problem to be solved in the industrial circles. A key method for the effective prediction of gear contact fatigue failure is the correlation mechanism between the strength gradient load capacity characteristics of the carburized gear modification layer and the mechanical response of the meshing contact stress-strain.MethodsBased on the modified layer gradient bearing effect of carburized and quenched spur gears, a coupled mathematical model for the risk prediction of contact fatigue of gears with gradient loading was developed. By employing the explicit analytical solution of rectangular microelements and the discrete numerical efficient calculation method, the singular integral contact problem of the mathematical equations of elastic half-plane contact stress components was resolved. The objective was to investigate the characteristic parameters associated with the fatigue risk failure.ResultsThis study demonstrates that the stress risk domain caused by the friction tangential load increment of the characteristic parameter is a consequence of near-surface-to-surface movement. This indicates that cracks may form on the near surface and extend to the pitting failure under conditions of good lubrication. In contrast, under the poor lubrication, the surface stresses may increase, resulting in the formation of cracks and extension to the micro-pitting. The material load parameters are enhanced through the application of surface hardness increments, thereby improving the load capacity of the gear contact. The shear resistance along the depth is enhanced by the gradient increment of the residual compressive stress, and the initiation rate of tear-type cracks caused by the shear stresses is slowed down at the subsurface. And gear contact fatigue failure is easily accelerated by normal load increments. The pitting and micro-pitting crack initiation mechanisms and failure life characteristics demonstrated in the predictive model is in perfect agreement with these in actual gear running class loading tests.
关键词:Gear transmission;Contact fatigue;Carburizing and quenching;Multiaxial stress;Load capacity
摘要:ObjectiveTo effectively design shape-changing mechanisms and improve design efficiency, the comprehensive design method for such mechanisms was studied, and a solution region optimization method suitable for these mechanisms was proposed.MethodsFirstly, for different deformation tasks, three types of rigid-body chains were determined. To reduce the difficulty of controlling mechanism deformation, two-link bars were added to the rigid-body chains to obtain single-degree-of-freedom shape-changing mechanisms. Based on the motion generation theory of hinged two-bar groups, an analytical synthesis model of shape-changing mechanisms was established, which could theoretically yield an infinite number of mechanisms capable of completing specified deformation tasks. Then, the motion feasibility of the mechanisms was analyzed, a defect identification method for shape-changing mechanisms was proposed, and the transmission performance of these mechanisms was evaluated. Finally, combined with the solution region optimization method, the optimal mechanism meeting design requirements was quickly screened out from numerous design schemes, thereby shortening the design cycle of such mechanisms. A morphing wing was designed according to the proposed method, and motion simulation was performed on the optimal mechanism.ResultsThe simulation results show that the mechanism can complete the specified deformation tasks, verifying the feasibility and effectiveness of the proposed method.
关键词:Shape-changing mechanism;Mechanism synthesis;Solution region optimization;Mechanism defect
摘要:ObjectiveAlthough abundant achievements have been made in the dynamic characteristics research of planetary gear transmission systems, existing studies mostly focus on straight-tooth structures, leaving a theoretical gap in the dynamic research of helical planetary gear systems used in electronic continuously variable transmissions (ECVT) for hybrid commercial vehicles. To address the vibration issues of the planetary gear transmission system in ECVT, in-depth research was conducted.MethodsTaking the engine direct-drive mode as the research condition, a 24-degree-of-freedom (24-DOF) lumped parameter analytical model was constructed by comprehensively considering nonlinear factors such as meshing phase difference, time-varying meshing stiffness, and tooth side clearance. The Runge-Kutta numerical solution method was used to obtain the time-domain responses of dynamic parameters such as vibration displacements in the x, y, z directions and dynamic meshing forces of each component in the system. The frequency-domain characteristics were analyzed combined with fast Fourier transform.ResultsThe study shows that in the planetary gear transmission system, the mean value of the axial vibration displacement of the sun gear is the most prominent, and the vibration characteristics of the remaining components show regular distribution. The values of internal and external dynamic meshing forces in the system are significant, reflecting high tooth surface bearing loads. By building an ECVT test bench platform to simulate actual working conditions and collect vibration signals, the effectiveness and reliability of the theoretical analysis model are verified. The research results can provide reference for the structural optimization design and vibration characteristic improvement of the planetary gear transmission system in ECVT for hybrid commercial vehicles.
摘要:ObjectiveThe two-translation-one-rotation (2T1R) parallel mechanism shows good engineering application potential due to its simple structure and low cost, but the current research on new 2T1R mechanism configurations lags behind, contrasting sharply with the research enthusiasm for 1T2R mechanisms. To fill the research gap of 2T1R parallel mechanisms, a pure lower-pair constructed 2T1R parallel mechanism was designed based on the theory of position and orientation characteristic (POC) set to meet the diversified requirements of engineering applications for mechanism performance.MethodsFirstly, the topological structure of the mechanism was systematically analyzed using topological analysis methods, and key topological features were extracted. Then, a kinematic model was constructed based on topological features, and symbolic forward and inverse position solutions of the mechanism were derived, followed by solving the velocity and acceleration of the moving platform. On this basis, the geometric parameters of the workspace and singular configurations of the mechanism were determined through theoretical analysis. The driving force variation law of the mechanism was solved by means of dynamic modeling. Finally, the conceptual design of the mechanism was completed in combination with practical application scenarios.ResultsThe study shows that the pure lower-pair 2T1R parallel mechanism not only has the characteristic of symbolic forward position solution, but also can realize partial motion decoupling with excellent dynamic performance. Meanwhile, its advantages of low cost and large operation space are significant, providing reference and practical guidance for subsequent mechanism optimization design and engineering application.
摘要:ObjectiveLittle research has been conducted on the rational parameter setting of micro harmonic reducers. To improve the force condition and transmission performance of micro harmonic flexsplines, a neural network-based parameter optimization method was proposed.MethodsFirstly, a flexspline simulation model was established, and optimization parameters were screened using local sensitivity analysis method. Then, the artificial neural network was optimized by the genetic algorithm, and a mapping model between the optimization parameters and flexspline stress as well as flexspline stiffness was constructed. Finally, through model analysis, the global sensitivity of the optimization parameters was obtained, and the relation between the optimization parameters and flexspline stress as well as flexspline stiffness was revealed.ResultsThe calculation results show that the optimization of flexspline structural parameters based on neural network-based global sensitivity analysis can effectively alleviate the stress concentration of the flexspline, the stiffness of the flexspline is improved, and the transmission performance of the harmonic reducer is enhanced.
摘要:ObjectiveTo address the issue that achieving curved translation in two-translation one-rotation (2T1R) parallel mechanisms requires complex curve-fitting algorithms, a novel mechanism capable of realizing curved translation by leveraging its inherent characteristics was designed.MethodsFirstly, based on the parallel mechanism design theory of the position and orientation characteristic (POC) set equation, a 2T1R parallel mechanism with a symbolic forward position solution was designed. The topological properties of this mechanism, including its POC set, degree of freedom, and coupling degree, were analyzed. Secondly, following the kinematic modeling principles of topological structures, the symbolic forward and inverse position solution equations of the mechanism were derived, and their correctness was verified through numerical calculations. Finally, the curved translation and straight-line motion characteristics of the mechanism were validated using Matlab software.ResultsTest results demonstrate that the designed mechanism exhibits both straight-line and curved translation capabilities within its workspace, significantly simplifying the complexity of achieving curved translation and reducing the difficulty of control algorithms.
摘要:ObjectiveTo address the deficiencies in non-quick return and cyclic load adaptation of the reversing device for extended-range pumping units, a high-efficiency and reliable non-circular gear crank slider reversing device was developed.MethodsThe calculation of push and pull forces on the slider was conducted, along with motion analysis, and the optimal fastening angle between the crank and driven non-circular gear was determined. By employing dynamic simulation methods, the impact of the fastening angle between the crank and the driven eccentric non-circular gear as well as the eccentricity of the ellipse on the motion law of the reversing device was examined. Furthermore, finite element simulation methods were utilized to conduct the comprehensive analysis of contact stress on the tooth surface of the non-circular gear.ResultsThe findings indicate that the upstroke movement of this reversing device is stable, and the downstroke time is relatively short, which is conducive to enhancing the stability and oil extraction efficiency of the pumping unit. In the meshing area where single tooth and double teeth of the non-circular gear pair alternate, the contact stress undergoes significant variations. The eccentricity and tooth width of the non-circular gear pair have a considerable influence on the distribution of the tooth surface contact stress and must be restricted. The research results can provide reference for the work efficiency and reliability improvement of extended-range pumping units.
摘要:ObjectiveThe calibration of carbon-free vehicles typically necessitates repeated adjustments to mitigate trajectory deviations, resulting in low operational efficiency. Conducting an error analysis on the vehicle enables tracing the sources of trajectory deviations, thereby facilitating the structural optimization through the error source identification. This approach transforms conventional trial-and-error calibration into a data-driven design methodology.MethodsSobol sensitivity analysis was implemented to evaluate structural parameters of the cam steering mechanism. Based on analytical outcomes, the vehicle’s structure was optimized, manufacturing methods were adjusted, and the fabrication precision of critical components was enhanced. The optimization effectiveness was subsequently validated through both simulation models and physical prototypes.ResultsThe results demonstrate that the optimized vehicle’s target acquisition performance is improved significantly, with scoring points increasing from a maximum of 6 to a stable range of 8 to 9. It provides a foundation and engineering insights for performance optimization of both new energy vehicles and carbon-free vehicles.
摘要:ObjectiveSlipping failure of the wind power coupling torque limiter could cause damage to the transmission system of wind turbines. The coupling torque limiter of a 5 MW unit was taken as the research object, and the key causes of its slipping failure were explored to provide support for improving reliability and unit stability.MethodsA multi-dimensional analysis was adopted, combined with fault data, on-site disassembly results, and calibration test data. End torque was calculated, and speed matching and torque fluctuation were analyzed; the failure limiter was disassembled to inspect friction plate wear and structural defects; and calibration tests were conducted to study the influence of torque fluctuation and calibration methods.ResultsThe main causes of failure include: unstable converter signals leading to excessive impact torque; the two-lobe cantilever structure causing uneven wear of friction plates; and inadequate torque control accuracy due to the calibration method. After optimization, the slipping problem can be effectively solved, and the service life and operational reliability were improved.
摘要:ObjectiveTo investigate the windage power loss of the driving gear in a helical cylindrical gearbox under the working conditions of 1 500-2 500 r/min without a shroud and with different shroud parameters at 2 000 r/min, the nephograms of velocity and turbulent kinetic energy inside the gearbox were analyzed.MethodsBased on computational fluid dynamics (CFD) method, a simplified model of a high-speed helical cylindrical gearbox was established. The RNG k-ε turbulence model was adopted, and the gear boundary was driven by a user-defined function (UDF) to control the rotational speed and direction of the gear pair. The dynamic mesh model was used to dynamically modify the mesh structure in the computational domain for simulating actual working conditions.ResultsThe results show that the gear rotational speed has a significant impact on windage power loss. The gear shroud can effectively reduce the windage power loss of high-speed helical cylindrical gears, and the smaller the radial and axial clearances, the more remarkable the optimisation effect. However, for helical cylindrical gear pairs, excessively small clearances may aggravate the flow field motion in the meshing area, thereby increasing the windage power loss. This study provides reference for the design of shrouds in engineering applications.
关键词:Windage power loss;Cylindrical helical gear pair;Computational fluid dynamics;Windshield
摘要:ObjectiveAiming at the problem of insufficient adaptability of existing lower limb rehabilitation exoskeleton robots, a multi-part dimension adjustable exoskeleton robot was designed. Its kinematic and dynamic characteristics were explored to provide a basis for structural optimization and motor selection.MethodsBased on the structural characteristics of the human lower limbs, a kinematic model was established using the D-H parameter method, and a dynamic model was constructed via the Lagrange’s equation. Theoretical calculations and simulation verification were conducted by combining Matlab and Adams software, and no-load and loaded simulation analyses were carried out.ResultsThe movements of the left and right sides of the robot show periodic changes with a half-gait cycle difference, which is consistent with the law of human walking. During the swing phase, the driving torque of the hip joint does not exceed 60 N·m, and that of the knee joint does not exceed 40 N·m. The movement is stable, meeting the design requirements, which provides reference for the development of the control system and the development of physical prototypes.
摘要:ObjectiveIn the locomotive transmission system, the gear-shaft interference fit is prone to plastic hole expansion under long-term meshing impact and residual stress relaxation, leading to a reduction in interference magnitude and potential safety hazards. Therefore, it is crucial to reveal the plastic hole expansion mechanism of gear interference fits.MethodsAiming at the plastic hole expansion phenomenon of gears, based on the established shaft-hole interference fit model, the allowable interference magnitude for shaft-hole interference fit was calculated. A mathematical model describing the variation of plastic deformation with cyclic load was established, the influence law of shaft-hole force on interference magnitude under interference fit was analyzed, and the effect of residual stress on the stress distribution of gear inner hole was investigated. On this basis, test pieces were designed, and gear plastic hole expansion tests were carried out.ResultsThe results show that the maximum force is borne on the interference fit surface, and the forces on the gear and shaft increase with the increase of interference magnitude. Residual stress causes significant changes in the radial and axial distribution of stress inside the gear. The principle-based tests conducted verify the accuracy of the theoretical prediction model for plastic hole expansion under shaft-hole interference fit.
摘要:ObjectiveWith the explosive growth of demand for high-precision internal helical gears in the electric vehicle industry, traditional machining technologies such as shaping, honing, and form grinding face bottlenecks including severe tool wear, insufficient tooth surface error correction capability, and low processing efficiency, which are difficult to meet the development requirements of short production cycles and high-performance transmissions for electric vehicles. Therefore, a new machining method for internal helical gears based on generating grinding with a spherical worm grinding wheel was proposed.MethodsBased on the conjugate surface envelopment theory and spatial meshing principle, the mapping relationships among the equivalent helical gear tooth surface, spherical worm grinding wheel tooth surface, and internal helical gear tooth surface were systematically constructed. Through rigorous mathematical derivation, the profile equation and spiral angle of the spherical worm grinding wheel were solved to achieve precise digital characterization of the double tooth surfaces. Simulation analysis was carried out using Vericut software to quantify the deviation between the theoretical tooth surface and the simulated tooth surface.ResultsThe research confirms that the generating grinding technology with a spherical worm grinding wheel can effectively achieve high-precision machining of internal helical gears, providing a new path and reference for breaking through the manufacturing technology bottlenecks of core transmission components in electric vehicles.
摘要:ObjectiveTo address the issue of harmonic interference affecting local fault feature in gearbox fault diagnosis, a harmonic separation and impact feature extraction method based on a deep convolutional binary decomposition network (DCBDN) was proposed.MethodsFirstly, by improving the feature transmission and output patterns of the stacked autoencoder network, a separation constraint for harmonic components was introduced to achieve harmonic separation and impact fault feature extraction during the network's feature propagation process. Subsequently, a binary output network training approach grounded in a fault mechanism model was developed for the proposed network. A simulated dataset was constructed based on the fault mechanism model, and the parameters of both harmonic and impact feature extractors within the model were dynamically updated via effect compensation, thereby completing network training.ResultsSimulation and test analyses demonstrate that compared with existing convolutional autoencoder models and fast spectral kurtosis methods, the proposed method effectively separates coupled harmonic and fault impact components, exhibiting superior anti-interference capability and enhanced local fault feature extraction performance.
摘要:ObjectiveAiming at the problems of cumbersome operation and strong subjectivity of the traditional detection method for the transmission accuracy of spiral bevel gears, an acoustic signal-assisted detection method for judging the transmission accuracy of spiral bevel gears was proposed.MethodsCombining the gear rolling inspection machine with the developed acoustic signal acquisition system, a real-time acoustic signal acquisition experiment was designed for detecting the quality of the contact marks on the tooth surface of the spiral bevel gear. Combined with the particle swarm optimization (PSO) algorithm and the maximum correlated kurtosis deconvolution (MCKD) based signal processing methods, the effect of different axial deviations on the gear mesh acoustic signals was investigated.ResultsIt is found that the increase of the axial deviation leads to the increase of the amplitude corresponding to the mesh frequency and its octave frequency, which seriously affects the transmission accuracy of the gear. Meanwhile, the feasibility of the proposed method is verified by using practical examples, which provides an effective auxiliary mean for the detection of the meshing performance of spiral bevel gears.
关键词:Spiral bevel gear;Acoustic signal detection;Transmission accuracy;Contact mark;Signal processing
摘要:ObjectiveIn order to improve the accuracy of small-module gears, small-module gears are prepared by using 420 stainless steel powder as raw material and metal powder injection molding (MIM) process at a sintering temperature of 1 330-1 360 ℃. The injection blank with the best micro-morphology was taken as a prerequisite to study the effect of sintering temperature on the accuracy of small-module gears.MethodsMLA650F field emission scanning electron microscope was used to observe the microscopic morphology of the gear injection blanks; JE 20 gear measuring center, Image J software, and Rockwell hardness tester were used to measure the accuracy, porosity, and hardness of the sintered gears, respectively.ResultsThe results show that under 110 MPa injection pressure, when the sintering temperature is increased from 1 330 ℃ to 1 350 ℃, the porosity of the gear surface decreases by 48.28%, the density increases by 5%, the hardness increases by 8.22%, the shrinkage continues to increase, and the accuracy is gradually improved; when the temperature is more than 1 350 ℃, the porosity decreases by 20%, the density decreases by 0.26%, the hardness decreases by 0.51%, the shrinkage rate increases slowly, and the accuracy of the gear gradually decreases; when the sintering temperature is 1 350 ℃, the gear has the best comprehensive performance, with a porosity of 1.5%, a density of 7.56 g/cm3, a hardness of 39.5 HRC, a shrinkage rate of 14.1%, and the highest accuracy level of grade 7 in the GB/T 2363—1990 testing standard.
摘要:ObjectiveAiming at the problems of low signal-to-noise ratio and difficulty in extracting fault features from acoustic emission signals of rolling bearing early faults, a fault feature extraction method combining improved Teager energy envelope and empirical wavelet transform (EWT) was proposed.MethodsIn this method, the impact characteristics of bearing fault acoustic emission signals were highlighted through improved Teager energy envelope processing. The empirical wavelet transform was applied to decompose the improved Teager energy envelope sequence. Components were screened and reconstructed using the empirical wavelet kurtosis index, and then the envelope analysis was performed on the reconstructed acoustic emission signals.ResultsSimulation and test results show that this method can effectively suppress noise, enhance fault elastic waves, and accurately extract the frequency characteristics of bearing fault acoustic emission signals.
摘要:ObjectiveThe Fourier decomposition method (FDM) is a method that adaptively determines modal components based on signal spectral characteristics. However, when extracting modal components from non-stationary signals, this method tends to generate numerous invalid narrow-band components, which hinders the precise identification of fault features. To address this issue, a frequency band optimization Fourier decomposition method (FBO-FDM) was proposed.MethodsFirstly, based on Fourier transform, the original Fourier spectrum was scanned and segmented in the order from high frequency to low frequency to obtain initial segmentation boundaries. Secondly, a frequency band reconstruction strategy was established.The partial mean of multi-scale permutation entropy (PMMPE) was used to quantify the frequency band information within each segmentation boundary, and bands with PMMPE values greater than the mean were retained to remove invalid narrow-band components. Finally, adaptive multi-scale morphological filtering was applied to the reconstructed components to eliminate the influence of noise and irrelevant components. The proposed method was analyzed using rolling bearing simulation signals and compared with FDM, empirical wavelet transform (EWT), and variational mode decomposition (VMD).ResultsThe results show that FBO-FDM can more effectively identify fault characteristic frequencies with a higher signal-to-noise ratio (SNR), and exhibites better noise reduction performance for colored noise. When applied to the analysis of measured vibration signals, the comparative results further validate the superiority of FBO-FDM in frequency band division and fault diagnosis capability.
关键词:Fourier decomposition method;Partial mean of multi-scale permutation entropy;Adaptive multi-scale morphological filtering;Rolling bearing;Fault diagnosis
摘要:SignificanceThe jumping function of quadruped robots is an important ability to achieve high maneuverability and adaptability in complex environments. [Analysis] The current research status of the jumping function of quadruped robots was reviewed, including the latest progress in the structural design, the control model design, and the control algorithm design. In terms of the structural design based on the jumping function, the skeleton structure, joint design, and material selection of quadruped robots were optimized to improve the jumping ability and the stability. In the design of control models based on the jumping function, various dynamic models were proposed to describe the jumping behavior of quadruped robots. These models can be used to predict and optimize the jumping performance, and provide a foundation for the subsequent control algorithm design. An accurate control model can ensure the stable and precise control, thereby improving the jumping performance and adaptability of robots. In the design of control algorithms based on the jumping function, traditional control methods such as PID control, fuzzy control, and adaptive control were widely used in the control of jumping function. In addition, advanced control methods such as reinforcement learning, neural networks, and genetic algorithms also were explored and applied. These methods can improve the jumping performance, the stability, and the adaptability, enabling robots to achieve efficient jumping in dynamic and complex environments.
摘要:SignificancePipeline robots are efficient and intelligent devices specifically designed for mobility within pipelines to perform tasks such as inspection and cleaning. The application of this technology can significantly reduce the risks and costs associated with manual pipeline operations while improving operational efficiency and safety. [Analysis] The application prospects of pipeline robots in the fields of pipeline inspection and cleaning, as well as the development trends of their technologies, were analyzed in depth. An overview of the current research status of pipeline robots was provided, with classifications from multiple perspectives including their movement modes, functions, and application fields. Through the review of the development history of pipeline robots, the key technical points in this field have been further refined. Insights into technical challenges and future development trends have been put forward, aiming to provide references and guidance for the further research and application of pipeline robot technology.
关键词:Pipeline robot;State of research;Mode of movement;Key technology