Feasibility of a phased acoustic array for monitoring acoustic signatures from meshing gear teeth

This paper investigates the feasibility of sensing damage emanating from rotating drivetrain elements such as bearings, gear teeth, and drive shafts via airborne paths. A planar phased acoustic array is evaluated as a potential fault detection scheme for detecting spatially filtered acoustic signatures radiating from gearbox components. Specifically, the use of beam focusing and steering to monitor individual tooth mesh dynamics is analyzed taking into consideration the constraints of the array/gearbox geometry and the spectral content of typical gear noise. Experimental results for a linear array are presented to illustrate the concepts of adaptive beam steering and spatial acoustic filtering. This feasibility study indicates that the planar array can be used to track the acoustic signatures at higher harmonics of the gear mesh frequency.     

A Simplified Formulation to Estimate Influence of Gearbox Parameters on the Rattle Noise

Occurrence of gear rattle in transmission systems can result in severe vibration and noise, which in applications such as automobiles is an important source of user discomfort. As a result , the reduction of the rattling noise has attracted lot of concerns. The rattling noise level is affected by several gearbox parameters, an understanding of which is essential to prevent the expensive design modifications at later stages of product development. To develop such understanding at the gearbox design stage, this paper analytically evaluates the gear parameters’ effect on the root mean square of the wheel gear acceleration under idling condition, which is known to be linearly correlated to the rattling noise level. Therefore, this evaluation allows for an investigation of the gear parameters’ influence on the rattling noise as well. This method is then verified by comparing the analytical results with the simulation results from a dynamic model built in SIMPACK as well as previously published experimental results. Thus, the proposed analytical evaluation method can optimize the gearbox specifications at the design stage to reduce the gear rattle noise level.     

Measuring,modelling and optimising an embedded rail track

A finite element (FE) model and a boundary element (BE) model have been developed to predict the decay rate, vibration and noise responses of an embedded rail track. These models are validated using measured results. The optimisation of the embedded rail track is conducted using these calculated models. The results indicate that the optimised cross-section of the gutter for the embedding rail can significantly reduce the radiated noise of the embedded rail track. The embedded rail track using the I-shaped cross-section gutter reduces the radiated noise of the track by at least by 3 dB(A). Furthermore, combining the material parameter optimisation with the gutter cross-section optimisation can further reduce the radiated noise of the embedded rail track. Increasing the Young’s modulus of the rail pad in the embedded rail track with the I-shaped cross-section gutter can result in a radiated noise reduction of 4 dB(A).     

用于汽车压缩机振动噪声控制的声子晶体设计与试验*

针对汽车压缩机低频振动噪声控制难的问题,基于局域共振机理在压缩机外壳设计一种声子晶体结构。借助有限元法,计算声子晶体带隙范围,阐明声子晶体结构参数与在压缩机外壳布置方式选取原因,分析其具备的优势。而后,定制各部分材料组装声子晶体实体并布置于压缩机外壳后端面,搭建压缩机振动噪声台架试验台,选取4个声学场点采集辐射噪声,并记录压缩机本体振动变化情况。进一步,选取某型号汽车搭建压缩机整车振动噪声试验台,在驾驶员座椅右侧靠近人耳处设置声学麦克风采集驾驶室内辐射噪声,并记录压缩机本体振动变化情况。试验结果表明,压缩机外壳安装声子晶体后,在声子晶体带隙频率范围对应转速内,台架与整车试验测得总辐射噪声与压缩机本体各向振动加速度RMS值基本存在改善,且部分转速范围效果显著。本文为汽车压缩机低频振动噪声控制研究提供了新的参考。     

Acoustic noise simulation and measurement of a gradient insert in a 4 T MRI

High speed switching of current in gradient coils within high magnetic field strength magnetic resonance imaging (MRI) scanners results in high acoustic sound pressure levels (SPL) in and around these machines. Many studies have already been conducted to characterize the sound field in and around MRIs and various methods have been investigated to attenuate the noise generated. In the work presented here a computational vibro-acoustic model was developed based on an iteratively modified and validated finite element (FE) model to characterize the acoustic noise properties of the gradient coil. The simulation results from the computational model were verified through experimental noise measurement for the gradient coil insert in a 4 T MRI scanner by using swept sinusoidal time waveform inputs. Comparisons show that the computational model predicts the noise characteristic properties extremely accurately. There are three dominant frequency bands where the SPL is much higher than those at other frequencies. The SPL in the horizontal direction is much higher than that in the vertical direction due to the excitation to the horizontally placed X coil. The SPL to the inner surface of the coil is higher than far from the inner surface, which proves that the acoustic noise is radiated from the inner surface and primarily caused by the normal vibration of the inner surface. Further verification was conducted by using two types of trapezoidal sequence inputs usually used, which is to simulate real scanning sequences for small animals. Again the accuracy of the developed model is verified. The validated acoustic computational model could be used as an effective method to predict the noise that would be produced by a coil in the design stage. Modification of the structural design or the excitation pulse could be performed to reduce the acoustic noise when the gradient coil is in scanning.     

基于流固耦合的油底壳振动噪声预测分析

为了对油底壳的改进方案进行噪声预测,首先建立油底壳的流固耦合有限元模型,进行耦合模态计算,获得其固有频率和振型,通过模态试验验证了耦合有限元模型的准确性;其次,在发动机工作过程中,通过试验测得油底壳各螺栓固定处的振动加速度;再次,基于模态结果,在油底壳各螺栓固定处施加测试的振动加速度,采用有限元的分析方法对油底壳进行了强迫振动计算和辐射噪声计算,并进行了试验对比,结果表明该方法可用于发动机开发试验确认阶段,对油底壳改进方案进行振动噪声的预测,减小开发风险;最后,对含油量多少对辐射噪声的影响进行了对比分析。     

ARX model-based gearbox fault detection and localization under varying load conditions

The development of the fault detection schemes for gearbox systems has received considerable attention in recent years. Both time series modeling and feature extraction based on wavelet methods have been considered, mostly under constant load. Constant load assumption implies that changes in vibration data are caused only by deterioration of the gearbox. However, most real gearbox systems operate under varying load and speed which affect the vibration signature of the system and in general make it difficult to recognize the occurrence of an impending fault.This paper presents a novel approach to detect and localize the gear failure occurrence for a gearbox operating under varying load conditions. First, residual signal is calculated using an autoregressive model with exogenous variables (ARX) fitted to the time-synchronously averaged (TSA) vibration data and filtered TSA envelopes when the gearbox operated under various load conditions in the healthy state. The gear of interest is divided into several sections so that each section includes the same number of adjacent teeth. Then, the fault detection and localization indicator is calculated by applying F-test to the residual signal of the ARX model. The proposed fault detection scheme indicates not only when the gear fault occurs, but also in which section of the gear. Finally, the performance of the fault detection scheme is checked using full lifetime vibration data obtained from the gearbox operating from a new condition to a breakdown under varying load.     

Complex signal analysis for wind turbine planetary gearbox fault diagnosis via iterative atomic decomposition thresholding

The vibration signals from complex structures such as wind turbine (WT) planetary gearboxes are intricate. Reliable analysis of such signals is the key to success in fault detection and diagnosis for complex structures. The recently proposed iterative atomic decomposition thresholding (IADT) method has shown to be effective in extracting true constituent components of complicated signals and in suppressing background noise interferences. In this study, such properties of the IADT are exploited to analyze and extract the target signal components from complex signals with a focus on WT planetary gearboxes under constant running conditions. Fault diagnosis for WT planetary gearboxes has been a very important yet challenging issue due to their harsh working conditions and complex structures. Planetary gearbox fault diagnosis relies on detecting the presence of gear characteristic frequencies or monitoring their magnitude changes. However, a planetary gearbox vibration signal is a mixture of multiple complex components due to the unique structure, complex kinetics and background noise. As such, the IADT is applied to enhance the gear characteristic frequencies of interest, and thereby diagnose gear faults. Considering the spectral properties of planetary gearbox vibration signals, we propose to use Fourier dictionary in the IADT so as to match the harmonic waves in frequency domain and pinpoint the gear fault characteristic frequency. To reduce computing time and better target at more relevant signal components, we also suggest a criterion to estimate the number of sparse components to be used by the IADT. The performance of the proposed approach in planetary gearbox fault diagnosis has been evaluated through analyzing the numerically simulated, lab experimental and on-site collected signals. The results show that both localized and distributed gear faults, both the sun and planet gear faults, can be diagnosed successfully.     

Ventilation duct with concurrent acoustic feed-forward and decentralised structural feedback active control

This paper presents theoretical and experimental work on concurrent active noise and vibration control for a ventilation duct. The active noise control system is used to reduce the air-borne noise radiated via the duct outlet whereas the active vibration control system is used to both reduce the structure-borne noise radiated by the duct wall and to minimise the structural feed-through effect that reduces the effectiveness of the active noise control system. An elemental model based on structural mobility functions and acoustic impedance functions has been developed to investigate the principal effects and limitations of feed-forward active noise control and decentralised velocity feedback vibration control. The principal simulation results have been contrasted and validated with measurements taken on a laboratory duct set-up, equipped with an active noise control system and a decentralised vibration control system. Both simulations and experimental results show that the air-borne noise radiated from the duct outlet can be significantly attenuated using the feed-forward active noise control. In the presence of structure-borne noise the performance of the active noise control system is impaired by a structure-borne feed-through effect. Also the sound radiation from the duct wall is increased. In this case, if the active noise control is combined with a concurrent active vibration control system, the sound radiation by the duct outlet is further reduced and the sound radiation from the duct wall at low frequencies reduces noticeably.     

Prediction of airborne radiated noise from lightly loaded lubricated meshing gear teeth

This paper introduces a novel analytical method for determination of gear airborne noise under lightly loaded conditions, often promoting gear rattle of loose unengaged gear pairs. The system examined comprises a single gear pair, modelled through integrated contact tribology and inertial transient dynamics. Lubricant film thickness, structural vibration and airborne gear noise are predicted and correlated with experimental measurements undertaken in a semi-anechoic environment. Good agreement is noticed between the numerical predictions and the experimental measurements. The presented model is capable of estimating the airborne radiated gear noise levels and the dynamic behaviour of gear pairs under different operating conditions, with superimposed impulsive input speed harmonics.     

某型振动轮噪声数值模拟及优化分析

空中声源的辐射噪声谱包括宽带连续谱和窄带线谱,线谱能量高于连续谱。与水下声源相比,空中声源的运动速度普遍较高,线谱多普勒频移明显,可用于进行水下对空中声源的运动参数估计。首先通过时频分析提取接收信号的瞬时频率,而后利用非线性最小二乘法将瞬时频率提取值与预测值相拟合,进而估计声源的运动参数(声源的运动速度、静止频率、与接收器最小水平距离及经过最近点时刻)。仿真与实验均能较为准确地估计出声源运动参数,同时在实验中实现了水下对空中运动声源的测距和定位,测距误差小于15.8%。在满足一定信噪比和保证足够多普勒信息的情况下,该参数估计方法具有很好的适用性。     

基于激光自混合传感器的齿轮局部故障振动信号分析

建立了齿圈局部故障调频现象模型,分析了故障轮齿啮合频率及其倍频两侧边频带的产生机理,给出了齿圈局部故障特征频率的计算公式,建立了倒频谱分析模型。采用激光自混合传感器,分别从径向和轴向两个方向采集齿轮箱振动信号波形。在齿轮箱1Hz和2Hz两种不同输出转频下,分别研究了无故障齿轮箱和故障齿轮箱的振动信号特征。通过实验研究验证了理论推导结果。     

Dynamic modelling of spur gear pair and application of empirical mode decomposition-based statistical analysis for early detection of localized tooth defect

Gears are one of the most common and important machine components in many advanced machines. An improved understanding of vibration signal is required for the early detection of incipient gear failure to achieve high reliability. This paper mainly consists of two parts: in the first part, a 6-degree-of-freedom gear dynamic model including localized tooth defect has been developed. The model consists of a spur gear pair, two shafts, two inertias representing load and prime mover and bearings. The model incorporates the effects of time-varying mesh stiffness and damping, backlash, excitation due to gear errors and profile modifications. The second part consists of signal processing of simulated and experimental signals. Empirical mode decomposition (EMD) is a method of breaking down a signal without leaving a time domain. The process is useful for analysing non-stationary and nonlinear signals. EMD decomposes a signal into some individual, nearly monocomponent signals, named as intrinsic mode function (IMF). Crest factor and kurtosis have been calculated of these IMFs. EMD pre-processed kurtosis and crest factor give early detection of pitting as compared to raw signal.     

A flexible multi-body approach for frictional contact in spur gears

In the present paper, a large rotational approach for dynamic contact problems with friction is proposed. The approach is used for modelling a spur gear pair with shafts and bearings. The model is obtained by superposing small displacement elasticity on rigid-body motions, and postulating tribological laws on the gear flanks. The finite element method is used to model the elastic properties of the gear pair. Shafts and bearings are represented by linear springs. The tribological laws of the contact interface are Signorini's contact law and Coulomb's law of friction. An important feature of the approach is that the difficulties of impacting mass nodes are avoided. The governing equations of the model are numerically treated by use of the augmented Lagrangian approach. In such manner the geometry of the gear flanks are well represented in the numerical simulations. It is possible to study accurately the consequences of different types of profile modifications as well as flank errors. In this work, the dynamic transmission error is studied. For instance, it turns out that the effect from profile modification is less significant for the transmission error when frictional effects are included.     

A time domain approach to diagnose gearbox fault based on measured vibration signals

Spectral analysis techniques to process vibration measurements have been widely studied to characterize the state of gearboxes. However, in practice, the modulated sidebands resulting from the local gear fault are often difficult to extract accurately from an ambiguous/blurred measured vibration spectrum due to the limited frequency resolution and small fluctuations in the operating speed of the machine that often occurs in an industrial environment. To address this issue, a new time-domain diagnostic algorithm is developed and presented herein for monitoring of gear faults, which shows an improved fault extraction capability from such measured vibration signals. This new time-domain fault detection method combines the fast dynamic time warping (Fast DTW) as well as the correlated kurtosis (CK) techniques to characterize the local gear fault, and identify the corresponding faulty gear and its position. Fast DTW is employed to extract the periodic impulse excitations caused from the faulty gear tooth using an estimated reference signal that has the same frequency as the nominal gear mesh harmonic and is built using vibration characteristics of the gearbox operation under presumed healthy conditions. This technique is beneficial in practical analysis to highlight sideband patterns in situations where data is often contaminated by process/measurement noises and small fluctuations in operating speeds that occur even at otherwise presumed steady-state conditions. The extracted signal is then resampled for subsequent diagnostic analysis using CK technique. CK takes advantages of the periodicity of the geared faults; it is used to identify the position of the local gear fault in the gearbox. Based on simulated gear vibration signals, the Fast DTW and CK based approach is shown to be useful for condition monitoring in both fixed axis as well as epicyclic gearboxes. Finally the effectiveness of the proposed method in fault detection of gears is validated using experimental signals from a planetary gearbox test rig. For fault detection in planetary gear-sets, a window function is introduced to account for the planet motion with respect to the fixed sensor, which is experimentally determined and is later employed for the estimation of reference signal used in Fast DTW algorithm.     

基于电磁力近似算法的驱动电机NVH快速仿真方法

电动汽车驱动电机产生的电磁噪声是汽车NVH关注的重点问题,对其进行全转速段多工况NVH仿真通常需要耗费大量时间和计算资源。该文通过有限单元分析揭示了电机气隙电磁力随转速变化的规律,并根据这一规律提出了基于外特性曲线的电磁力时间缩放及插值的近似算法。文章采用电磁力到结构网格的映射算法对结构振动有限元模型进行激励力加载,使用声场有限元方法计算电机的辐射噪声,最终实现了车用驱动电机的电磁振动及噪声的快速仿真。使用该方法对车用电机进行全转速段振动噪声仿真,可大大压缩多工况电磁场有限元分析所需的计算时间,提升仿真效率。     

Reduction of radiated exterior noise from the flexible vibrating plate of a rectangular enclosure using multi-channel active control

This study attempted to control the radiated exterior noise from a rectangular enclosure in which an internal plate vibrates by acoustic excitation and noise is thus radiated from that plate. Multi-channel active control was applied to reduce the vibration and external radiation of this enclosed plate. A piezoelectric ceramic was used as a distributed actuator for multiple mode control of the vibration and radiated noise in the acoustically excited plate. To maximize the effective control, an approach was proposed for attachment the piezoelectric actuator in the optimal location. The plate and internal acoustic space in the enclosure are coupled with each other. This will change dominant frequency characteristics of the plate and, thus, those of the externally radiated noise. Active noise control was accomplished using an accelerometer attached to the plate and a microphone placed adjacent to that plate as an error sensor under acoustic excitation of sine wave and white noise. It was found that the control of radiated external radiation noise requires a microphone as an error sensor, a sound pressure sensor due to vibration of the plate, differences in the dominant frequency of externally radiated noise, and complex vibration modes of the plate.     

A method to determine dynamic loads on spur gear teeth and on bearings

A method is described which can be used to calculate dynamic gear tooth force and bearing forces. The model includes elastic bearings. The gear mesh stiffness and the path of contact are determined using the deformations of the gears and the bearings. This gives contact outside the plane-of-action and a time-varying working pressure angle. In a numerical example it is found that the only important vibration mode for the gear contact is the one where the gear tooth deformation is dominant. The bearing force variation, however, will be much more affected by the other vibration modes. The influence of the friction force is also studied. The friction has no dynamic influence on the gear contact force or on the bearing force in the gear mesh line-of-action direction. On the other hand, the changing of sliding directions in the pitch point is a source for critical oscillations of the bearings in the gear tooth frictional direction. These bearing force oscillations in the frictional direction appear unaffected by the dynamic response along the gear mesh line-of-action direction.     

Research on dynamics and fault mechanism of spur gear pair with spalling defect

This study focuses on the nonlinear dynamic and vibration characteristics of spur gear pair with local spalling defect to explore the spalling mechanism. The dynamic model of the gear pair with spalling defect and time-variant mesh stiffness is established to investigate the effect of spalling defect on mesh stiffness and dynamic response. The analytical solutions of the system which is deduced into four different stages of the gear with the time-variant stiffness in a mesh period are obtained. The dynamic responses with the evolvement of sapll are analyzed by using time history, phase contrail, Poincaré section and spectrum analysis. The spalling characteristics are also evaluated by employing statistical techniques, which shows that the spalling failure is suitable to be detected under low velocity and small excitation. The gearbox with spalling defect is designed and the experiments are carried out to get the dynamic characteristics of the spalling vibration signals. The results obtained herein show the good agreement qualitatively with the theoretical analysis, which provides a theoretical basis to spalling fault diagnosis of gearbox.     

Identification of multiple transient faults based on the adaptive spectral kurtosis method

This paper proposes a multi-fault detection method based on the adaptive spectral kurtosis (ASK) analysis of the vibration signal from single sensor. A theoretical model of multiple bearing faults is established in this paper. Compared with the kurtogram and protrugram techniques, the proposed method can more effectively extract signatures of multiple bearing faults even in the presence of strong background noise. The performance of the proposed method in fault detection of the rolling element bearings is validated using simulation data and experimental signals from a bearing with multiple faults and two faulty bearings.