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Warm press forming technology is a new method for manufacturing high-density, high-performance iron-based powder metallurgy materials at low cost. It has unique advantages in manufacturing high-density complex structural parts, and is particularly suitable for manufacturing gears. Powder metallurgy temperature-pressure helical gears have low manufacturing costs and require no cutting. It has excellent mechanical properties and good wear resistance, high temperature resistance and corrosion resistance. The study of its vibration characteristics, that is, in reducing vibration and reducing noise, has not been reported at home and abroad.
Based on the Labview integrated development environment, the virtual instrument system for gear vibration signal acquisition, analysis and processing was designed. The vibration signal of the powder metallurgy temperature-pressure helical gear system was measured and analyzed. The 38CrMoAl rigid helical gear system was compared. The test results were The application and promotion of powder metallurgy temperature-pressure helical gears is of great significance.
2 Characteristics of gear vibration signal The vibration of the gear is self-excited vibration, and the vibration exists even in the "ideal" condition. Gear vibration mainly comes from two parts: one is the vibration caused by the normal alternating load, including the natural vibration and meshing vibration of the gear; the other is the vibration related to the error and failure of the gear, such as the vibration caused by the wear and local abnormality. The vibration frequency of the gear can be basically classified into three categories: the rotational frequency of the shaft and its harmonic frequency; the meshing frequency of the gear and its harmonic frequency; the natural frequencies of the gears themselves. The actual vibration of the gear is often some combination of the above various types of vibration.
The spectrogram of the vibration of the gear is very complicated. In addition to the apparent spectral lines representing the meshing frequency and the spectral lines of the harmonics, there are many small spectral lines that are distributed according to a certain regularity. This is the sideband common in the vibration spectrum of the gear. The sideband is generated because several kinds of dynamic loads act on the gear at the same time, causing several vibrations to be generated at the same time, and they are superimposed on each other to produce a modulation result. The gear vibration signal has both amplitude modulation and frequency modulation. Both modulations are represented in the spectrogram as having a cluster sideband on both sides of the meshing frequency and its harmonic frequency. The interval of each sideband is the modulated signal. frequency. Usually, the carrier frequency is the meshing frequency and its high-order harmonics or other high-frequency components, and the rotational frequency of the axis and its high-order harmonics are modulated signals.
3 Gear vibration signal test hardware system research shows that the circumferential vibration is the main form of vibration in gear transmission, which is closely related to the noise of gear transmission. The working principle of the whole test system is shown in Figure 1. The gear speed in the test bench is regulated by the inverter (0~1500r/min), and the load torque is controlled by the magnetic powder brake (0~50N?
m). The circumferential vibration acceleration signal is picked up by the acceleration sensor B&K4373, and then the signal from the sensor is amplified by the charge amplifier B&K2635 and input to the A/D capture card. The A/D converted signal is sent to the computer, and the Labview virtual instrument system is used in the computer. Analyze and process the gear vibration signal.
The vibration test bench of the dynamic performance test bench of the gear adopts the JCY mechanical transmission performance comprehensive test bench of Xiang Instrument. I modified it and placed the acceleration sensor on the gear box developed by myself. See Figure 2. It can test the acceleration measurement of the gear transmission vibration response and the test modal analysis of the gear box.
Acceleration Sensor Arrangement Position 4 Gear Vibration Signal Analysis and Processing System Developed and designed a virtual instrument system based on Labview for analyzing and processing the acquired signals.
The Labview platform has two development windows. The first window is the front panel development window. The design of the virtual instrument front panel is completed and completed in this window. It is equivalent to the front panel of the operation and display of the traditional test instrument. The second window is the flow chart programming window, the flow chart is the graphical source code, and Labview uses the graphical programming method to realize the virtual instrument test function, which is equivalent to the software and hardware circuit associated with the front panel in the traditional instrument.
In the Labview development environment, the gear vibration signal acquisition and analysis processing system was designed and developed by itself. Figure 3 is the front panel of the gear vibration signal processing system composed of the relevant controls in the Labview control template. The related icons and connections in the Labview function template are connected. The composition of the instrument flow chart is omitted.
Gear vibration signal processing system front panel The gear vibration signal processing system can control the work of the acquisition card. Set the acquisition parameters on the front panel and start sampling, then the vibration analog signal can be converted into a computer-processable digital signal, and the collected signal is The real-time display in the time domain of the virtual oscilloscope, by calling the data processing function, can perform digital filtering, noise reduction, frequency domain analysis and the like on the vibration signal to extract the signal characteristic value.
-120-10th Xie Haidong et al.: Experimental study on vibration characteristics of powder metallurgy helical gears. Study on vibration signal of high power engine oil pump helical gears. Compare vibration characteristics of powder metallurgy temperature and pressure helical gears and 38CrMoAl helical gears. Parameters: number of teeth z1=z2= 10; normal modulus mn = 5.5; helix angle = 8.1 °; pressure angle "= 25 °; tooth width b = 37 mm, 7-level machining accuracy. Set the driving gear speed = 600r / min, calculated by its meshing The frequency fz = (nz) / 60 = 100 Hz, the input power is 0.2 kW; in order to improve the accuracy of the analysis, the sampling frequency is set to 10 kHz, and the number of samples is 102,400.
The vibration signal of the powder metallurgy helical gear is measured on the modified JCY mechanical transmission performance comprehensive test bench. The acceleration sensor is arranged above the box near the bearing, perpendicular to the vibration direction (Fig. 3), which is convenient for measuring the circumferential vibration of the gear. The measurement was started after the motor was raised to 600 r/min and stabilized for a certain period of time. Since the comparison test is performed, the collected voltage signals can be directly compared, and the amplitude is displayed as a voltage value.
The collected original signal is subjected to wavelet denoising by Labview virtual instrument system, and self-power spectrum analysis is performed, as shown in FIG. 4 .
Powder metallurgical helical gear acceleration self-power spectrum 638CrMoAl helical gear vibration signal test analysis Dismantled transmission gearbox, installed 38CrMoAl helical gear, gear parameters in addition to material parameters, other conditions and powder metallurgy temperature pressure helical gear. The accelerometer is placed above the casing near the bearing, and is the same as the vibration test position of the powder metallurgical temperature-pressure helical gear for comparative study. The measurement was started after the motor was raised to 600 r/min, the input power was 0.2 kW, and the operation was stable for a certain period of time. The collected original signal is subjected to wavelet denoising by Labview virtual instrument system, and self-power spectrum analysis is performed, as shown in Fig. 5.
38CrMoAl helical gear acceleration self-power spectrumFig.7 Performance comparison between powder metallurgy helical gear and 38CrMoAl helical gear transmission As can be seen from Fig. 4 and Fig. 5, the powder metallurgy temperature and pressure helical gear has smaller acceleration amplitude than the 38CrMoAl helical gear under the same conditions, and the transmission is more smooth. The peak value of the gear vibration appears at the meshing gear frequency and its multiplier, and the modulation of the axial frequency occurs, and there is uniform wear phenomenon, which is in good agreement with the previous theoretical analysis. In order to further compare the transmission performance, the normal vibration accelerations of 10 different measuring points (distributed on the top of the box) of powder metallurgy helical gear and 38CrMoAl helical gear under 1000r/min rotating speed and input power of 0.2kW were tested. Square root value and peak-to-peak value.
The acceleration peak-peak value of each measuring point at 1000r/min is a graph for comparing the peak-to-peak value of each measuring point acceleration. Figure 6 shows the graph of the test speed of 1000r/min, in the figure "â—" And "â–²"
The test points of the powder metallurgical temperature-pressure helical gear and the 38CrMoAl helical gear are respectively shown, and the fitting spline is a curve representing the representative change trend according to the test point. It can be seen from the figure that the amplitude of the powder metallurgy temperature-pressure helical gears at each measuring point is lower than that of the 38Cr-MoAl helical gear, and the powder metallurgy temperature-pressure helical gear transmission is more stable and the dynamic performance is good.
8 Conclusions (1) The Labview-based gear vibration signal acquisition and analysis processing system can collect and analyze the vibration signals generated by the gear meshing process in real time, and can reduce noise, filter, time-frequency analysis, etc. Signal processing requirements.
(2) Test analysis shows that under the same working conditions, the powder metallurgical temperature-pressure helical gear has smaller vibration peak than the 38CrMoAl helical gear, the vibration attenuation is faster, the material absorbs more energy, and the operation is more stable.
(3) The results of the test analysis show that the powder metallurgy material has the function of buffering vibration absorption, good lubrication performance and low wear, so the transmission system using the powder metallurgy helical gear is more reliable. Powder metallurgy temperature-pressure helical gears have broad application prospects.
