Influence of manufacturing errors on dynamic floating characteristics for herringbone planetary gears

Owing to the present of manufacturing errors, the dynamic floating characteristics of herringbone planetary gear train (HPGT) can be changed in comparison with the original ideal design. In this research, based on the actual structure of herringbone gears, taking into consideration manufacturing eccentric errors and tooth profile errors, bearing deformation, time-varying meshing stiffness, gyroscopic effect, and so on, a novel and generalized bending–torsional–axial coupled dynamic model of a herringbone planetary gear train is presented to investigate the dynamic floating performances applying the lumped-parameter approach. The model is capable of being employed for the vibration behavior analysis of the HPGT with different types of manufacturing errors and arbitrary number of planets. The variable step Runge–Kutta algorithm is utilized to compute the dynamic responses of the HPGT system. In combination with the proposed computational approach of the component floating displacement amount, the relationship among manufacturing errors, component floating displacements, and different floating forms is obtained, and the effects of manufacturing errors on the HPGT dynamic floating performances are discussed. Meanwhile, sun gear radial floating trajectories in two cases of sun gear float and non-float are compared and analyzed. Results indicate that the manufacturing error and component float prominently affect the dynamic floating characteristics in the HPGT system.     

The mathematical phenomenological mapping in non-linear dynamics of spur gear pair and radial ball bearing due to the variable stiffness

In this paper the philosophy of mathematical phenomenological mapping has been applied to the non-linear dynamics of spur gears and radial ball bearings. The spur gear pair dynamics and rolling element bearing dynamics are analyzed separately, but with a tendency to reduce the both of the systems to the same mathematical model. The different reasonable assumptions are taken in every of these analyzes, but they do not have significant influence to the accuracy of the results. The systems are reduced to the single degree of freedom dynamics model. The total gear stiffness and ball bearing stiffness are recognized as the main influent factor of vibration behavior of these machine elements. Therefore, the special attention was paid to the new approach and procedure for stiffness solving and related problems. A single spur gear pair dynamics is solved and the results for total gear stiffness and vibration are shown. The conclusions emphasize the importance of described parallel analyzes in order to reduce the calculation time in solving different phenomena with usage of the principle of mathematical phenomenology.     

双联行星轮角度偏差对系统均载特性的影响

为了研究双联行星齿轮在实际设计参数下,其相对角度偏差对复合行星传动系统动力学特性的影响,采用集中参数法建立了3K-I型行星齿轮动力学模型,模型中将双联行星齿轮的相对角度偏差转化为啮合副齿侧间隙的变化,考虑了双联齿轮角度偏差、轮齿侧隙和时变啮合刚度等非线性因素,采用龙格库塔法求解了系统的时域响应并计算其均载系数。分析了不同工况、偏差下系统的动态特性。结果表明,存在双联行星轮角度偏差时,轻载下更容易发生齿轮的脱齿与冲击,系统的均载系数随着双联行星轮角度偏差差值及系统的负载降低而增大,各组行星轮角度偏差分布越集中,角度偏差对系统均载特性的影响越小;角度偏差分布同号时,对系统中某一对齿轮的承载影响明显;角度偏差分布异号时,对系统均载特性的影响最大。     

The Application of Advanced Signal Processing Techniques to Induction Motor Bearing Condition Diagnosis

Four approaches based on bispectral and wavelet analysis of vibration signals are investigated as signal processing techniques for application in the diagnosis of a number of induction motor rolling element bearing faults. The bearing conditions considered are a normal bearing and bearings with cage and inner and outer race faults. The vibration analysis methods investigated are based on the bispectrum, the bispectrum diagonal slice, the summed bispectrum and wavelets. Singular value decomposition (SVD) is used to extract the most significant features from the vibration signatures and the features are used as inputs to an artificial neural network trained to identify the bearing faults. The results obtained show that the diagnostic system using a supervised multi-layer perceptron type neural network is capable of classifying bearing condition with high success rate, particularly when applied to summed bispectrum signatures.     

Nonlinear behavior analysis of geared rotor bearing system featuring confluence transmission

In this paper, the nonlinear vibration characteristics of geared rotor bearing system and the interactions among gears, shafts, and plain journal bearings were studied. First, with the consideration of backlash, transmission error, time-varying mesh stiffness, and layout parameters, the dynamic model of geared rotor bearing system featuring confluence transmission was proposed. The nonlinear oil-film forces were computed with the Reynolds equation for finite-length journal bearings. Second, the responses of meshing vibration and bearing vibration were discussed. The numerical results revealed that the system exhibited a diverse range of periodic, sub-harmonic, and chaotic behaviors. Under different ranges of rolling frequency, the system got into chaos state through different roads. Moreover, in lower frequency, meshing vibration showed coexist of different periodic motions. Lastly, couplings of nonlinear oil-film force and nonlinear gear mesh force were discussed through a range of rolling frequencies. Gear-bearing dynamic interactions were demonstrated through the analysis of dynamic gear loads and dynamic bearing loads, and the coupling effect behaved different when rolling frequency changed.     

Nonlinear response and nonsmooth bifurcations of an unbalanced machine-tool spindle-bearing system

In this effort, a six-degree-of-freedom (DOF) model is presented for the study of a machine-tool spindle-bearing system. The dynamics of machine-tool spindle system supported by ball bearings can be described by a set of second order nonlinear differential equations with piecewise stiffness and damping due to the bearing clearance. To investigate the effect of bearing clearance, bifurcations and routes to chaos of this nonsmooth system, numerical simulation is carried out. Numerical results show when the inner race touches the bearing ball with a low speed, grazing bifurcation occurs. The solutions of this system evolve from quasi-periodic to chaotic orbit, from period doubled orbit to periodic orbit, and from periodic orbit to quasi-periodic orbit through grazing bifurcations. In addition, the tori doubling process to chaos which usually occurs in the impact system is also observed in this spindle-bearing system.     

3D Dynamic Modelling of Spatial Geared Systems

In this paper, a nonlinearly dynamic model for a spatial geared systemwith intersecting-axes, which consists of bevel gears, bearings, andshafts, is proposed based on a specific finite element theory. A newtype of spatial gear element which is consistent with the specific finiteelement theory is developed and completely describes all thedeformations that exist for the spatial motions of a pair of bevel gears,the time-variant meshing stiffness, and various types of gear errors inmanufacturing and assembly. The 3D motions of the spatial geared systemin axial, lateral, and torsional directions are coupled in the model. Theproposed approach has been coded into a software system and a dynamicanalysis for the spatial geared system is carried out. The nonlinearinfluences of axial, lateral and torsional stiffnesses of the shaft onthe vibration of the spatial geared system are especially investigated.The lateral stiffness changes the resonance peak frequencies of thespatial geared system and the torsional stiffness greatly affects thesize of the dynamic load and vibration amplitude.     

Nonlinear dynamics of a spur gear pair with force-dependent mesh stiffness

Time-varying mesh stiffness is one of the main excitation sources of a gear system, and it is also considered as an important factor for the vibration and noise of gears. Thus, this excitation is usually taken as an input into the gear dynamic model to obtain the system dynamic responses. However, the mesh stiffness of a gear pair is actually nonlinear with respect to the dynamic mesh force (DMF) that fluctuates during the operation of gears. Therefore, the dynamic model of gears with the quasi-static mesh stiffness calculated under a constant load is not accurate sufficiently. In this paper, a dynamic model of spur gear is established with considering the effect of the force-dependent time-varying mesh stiffness, backlash and profile deviation. Due to the nonlinear relationship between the mesh stiffness and the load for each tooth pair, it needs first to determine the load sharing among tooth pairs and then calculate the overall mesh stiffness of the gear pair. As the mesh stiffness and DMF are related, the mesh stiffness is no longer directly taken into the gear dynamic model as an input, but is jointly solved with the numerical integration process using the gear dynamic model. Finally, the dynamic responses predicted from the established gear dynamic model are compared with the experimental results for validation and compared with the traditional models to reveal their differences. The results indicate that the established dynamic model of spur gear transmission has a wider application range than the traditional models.     

Dynamics of a Gear System with Faults in Meshing Stiffness

Gear box dynamics is characterised by a periodically changing stiffness. In real gear systems, a backlash also exists that can lead to a loss in contact between the teeth. Due to this loss of contact the gear has piecewise linear stiffness characteristics, and the gears can vibrate regularly and chaotically. In this paper we examine the effect of tooth shape imperfections and defects. Using standard methods for nonlinear systems we examine the dynamics of gear systems with various faults in meshing stiffness.     

Influences of wear on dynamic characteristics of angular contact ball bearings

Wear between balls and races has significant effects on the dynamic characteristics of bearing, which is the main reason to cause bearing failure. Some existing contact stiffness models were established to study the dynamic characteristics of bearing. However, the wear of bearing has been rarely investigated due to the complexities of contact load and wear mechanism. This paper presents a new dynamic wear simulation model of angular contact ball bearings mounted in pairs to solve this problem. A final contact stiffness model is established based on the wear model. The effects of running distance, horizontal load, preload, initial contact angle, number and diameter of balls on wear performances are analyzed. A generalized time-varying and piecewise-nonlinear dynamic model of angular contact ball bearings is established to perform an accurate investigation on its dynamic characteristics, especially considering the coupling effects of wear and rolling contact. The effects of wear on the contact stiffness and nonlinear dynamic characteristics are analyzed according to the dynamic model. Additionally, the variations of the contact stiffnesses and frequency responses with different preloads are discussed and the results indicate that parameter selection has significant effects on the wear and nonlinear response.

     

Dynamics and stability of turbocharger rotors

The paper discusses the bifurcation and stability behavior of (automotive) turbochargers with full-floating ring bearings. Turbocharger rotors exhibit a highly nonlinear behavior due to the nonlinearities introduced by the floating ring bearings. A flexible multibody model of the rotor/bearing system is presented. Numerical run-up simulations are compared with corresponding test rig measurements. The nonlinear oscillation effects are thoroughly investigated by means of simulated and measured rotor vibrations. The influence of various system parameters on the bifurcation behavior of the rotor/bearing system is analyzed. The article examines rotors supported in full-floating ring bearings with plain circular bearing geometry in the inner and outer oil gap. By recapitulating the well-known oil whirl and oil whip phenomena for single and double oil film bearings, the paper gives an overview on the fundamental dynamic effects occurring in turbocharger systems.     

Bifurcation and chaos analysis of multistage planetary gear train

A nonlinear time-varying dynamic model for a multistage planetary gear train, considering time-varying meshing stiffness, nonlinear error excitation, and piece-wise backlash nonlinearities, is formulated. Varying dynamic motions are obtained by solving the dimensionless equations of motion in general coordinates by using the varying-step Gill numerical integration method. The influences of damping coefficient, excitation frequency, and backlash on bifurcation and chaos properties of the system are analyzed through dynamic bifurcation diagram, time history, phase trajectory, Poincaré map, and power spectrum. It shows that the multi-stage planetary gear train system has various inner nonlinear dynamic behaviors because of the coupling of gear backlash and time-varying meshing stiffness. As the damping coefficient increases, the dynamic behavior of the system transits to an increasingly stable periodic motion, which demonstrates that a higher damping coefficient can suppress a nonperiodic motion and thereby improve its dynamic response. The motion state of the system changes into chaos in different ways of period doubling bifurcation, and Hopf bifurcation.     

Dynamic modeling and analysis of a spur planetary gear involving tooth wedging and bearing clearance nonlinearity

Tooth wedging, also known as tight mesh, occurs when a gear tooth comes into contact on the drive-side and back-side simultaneously. Tooth wedging risks bearing failures from elevated forces. This work studies the nonlinear tooth wedging behavior and its correlation with planet bearing forces by analyzing the dynamic response of an example planetary gear. This planetary gear is representative of a wind turbine geartrain. A two-dimensional lumped-parameter model is extended to include tooth separation, back-side contact, tooth wedging, and bearing clearances. The results show significant impact of tooth wedging on planet bearing forces for a wide range of operating speeds. To develop a physical understanding of the tooth wedging mechanism, connections between planet bearing forces and tooth forces are studied by investigating physical forces and displacements acting throughout the planetary gear. A method to predict tooth wedging based on geometric interactions is developed and verified. The major causes of tooth wedging relate directly to translational vibrations caused by gravity forces and the presence of clearance-type nonlinearities in the form of backlash and bearing clearance.     

磨损与动力学耦合的行星传动齿轮动力学研究

行星齿轮磨损会导致齿轮齿侧间隙非线性增大、传动精度下降、齿面冲击力增大, 进而会导致齿轮传动系统振动加剧, 因此需要对行星齿轮的齿面磨损与动力学耦合特性进行研究. 本文构建了齿轮非线性磨损与考虑齿轮齿侧间隙的非线性动力学耦合计算模型, 对行星传动齿轮磨损动力学特性进行了研究. 首先建立齿轮啮合非线性动力学模型, 获得齿轮运行过程中的非线性啮合力; 进一步将非线性啮合力与齿轮齿面磨损模型相结合, 研究齿轮齿面磨损分布规律; 并根据齿轮磨损后的齿侧间隙对齿面重构, 同时对齿轮动力学模型进行更新; 进而得到行星齿轮传动中动态啮合力和磨损特性的变化趋势, 并获得齿轮传动系统齿轮齿向振动响应. 数值计算结果表明, 行星齿轮磨损导致齿轮在单?双齿交替啮合时产生的冲击增大, 同时太阳轮?行星轮啮合齿对对磨损较为敏感, 齿面啮合条件剧烈恶化, 是造成行星齿轮传动性能退化的主要原因, 本文研究结果为行星齿轮传动系统运行状态评估与可靠性预测提供了理论基础.      

A new model for spall-rolling-element interaction

Evaluation of the spall size of a radially loaded rolling-element bearing is required for the assessment of the bearing damage severity and estimation of its remaining useful life. A new multi-body, nonlinear dynamic model of the interaction between the rolling-element and a spalled outer race is presented. The study focuses on the physics of rolling-element contact in a broader range of spall sizes than has been investigated to date, with intermittent contact between rolling-element and the outer race, which is a relevant defect size for diagnostics and prognosticsquery. The analysis is performed in several time intervals according to periods of rolling-element/race contact and periods when the rolling-element is not connected with the outer race. An explicit expression of the spall size as function of the time-to-impact has been developed by considering radial load, shaft speed, and gravity. The expression of the spall size was used in a sensitivity study of the effect of parameters such as geometry and radial load. The results obtained from the new model are in good agreement with a well-established general bearing model. The acceleration of the outer ring during the rolling-element/spall interaction with intermittent rolling-element race connection is a novel contribution, which allows verification of the model from direct observations using vibration sensors mounted on the structure     

Study for ball bearing outer race characteristic defect frequency based on nonlinear dynamics analysis

The characteristic defect frequencies are widely used for diagnosing the local defect of the ball bearing. The varying compliance (VC) frequency of a fault-free rotor–bearing system equals to the BPFO (ball bearing outer race defect frequency) due to the internal kinematic relationship of a bearing assembly. In order to indicate this issue, a semi-analytical method—the harmonic balance method with alternating frequency/time domain technique—is exploited to obtain the solutions of rotor–ball bearing systems with /without an outer race defect. The solutions and the features of a rotor–ball bearing system with essentially nonlinear parametric excitation are analyzed. We prove the VC frequency equals the BPFO and explain the reasons that the harmonics of the characteristic defect frequency generally appear in the frequency domain. The VC, BPFO as well as their harmonics affected by the primary and super-harmonic resonance of the system are found out. Finally, a test rig of a rigid rotor–bearing system is established to verify the theoretical analysis qualitatively by presenting the performance of VC, BPFO and their harmonics in the frequency domain. In addition, the tests are accomplished in a cycle of running up and down to reveal the primary and super-harmonic resonance characteristics. On the basis of the theoretical and experimental results, the basic BPFO is not enough to judge an outer race defect. The discussion on frequency spectrum, the primary and super-harmonic resonance provides a more reliable way to elucidate the characteristic defect frequencies.     

圆锥滚子轴承润滑与动力学耦合研究

为准确分析圆锥滚子轴承润滑和动力学耦合性能,建立了基于油膜刚度与阻尼的圆锥滚子轴承动力学耦合方程,并对方程进行了验证和数值求解. 数值结果表明:与不考虑润滑相比,考虑润滑后轴承内圈轴向运动更加稳定,轴向位移变小;在不同的滚子端面球半径和挡边倾角下,润滑效应能够使内圈径向振动加速度级减小1.71到2.07 dB;同时滚子个数的增加会使轴承内圈滚道和内圈挡边的平均最小油膜厚度分别增加7.97%和4.43%.      

Evolutive and nonlinear vibrations of rotor on aerodynamic bearings

The use of air as a lubricant in aerodynamic bearings is advantageous, particularly in the food industry. Aerodynamic bearings with tilting pads have complicated stiffness and damping properties and need a very detailed theoretical and experimental research. Response curves of rigid rotor supported on aerodynamic bearings are presented for a linear but evolutive mathematical model. Due to non-monotone properties of stiffness and damping matrices at variable revolutions, a new resonance appears. The mathematical model of rotor vibrations in the whole area of bearing clearance is also developed in the consideration of strongly nonlinear properties of aerodynamic bearing.     

A general method for impact dynamic analysis of a planar multi-body system with a rolling ball bearing joint

Impact affects the dynamic characteristics of mechanical multi-body systems and damages those rotating parts, such as the joint rolling element bearings, which are high-precision, defect intolerant components. Based on multi-body dynamic theory, Hertzian contact theory, and a continuous contact model, this study proposed a modelling method that can describe the dynamic behaviour of planar mechanical multi-body systems containing a rolling ball bearing joint under impact. In this method, the rigid bodies and bearing joint were connected according to their joint force constraints; the impact constraint between the multi-body system and the target rigid body was constructed using a continuous contact force model. Based on this method, the reflection relationship between the external impacts of the mechanical multi-body system and the variation law governing the dynamic load on the rolling bearing joint were revealed. Subsequently, an impact multi-body system, which was composed of a sliding–crank mechanism containing a rolling ball bearing joint and the target rigid body with an elastic support, was analysed to explore the dynamic response of such a complex discontinuous dynamic system andthe relevant relationship governing the dynamic load on the rolling bearing joint. In addition, a multi-body dynamic simulation software was used to build a virtual prototype of the impact slider–crank system. Compared with the theoretical model, the prototype had an additional deep groove ball bearing. That is to say, the prototype model took account of the specific geometric structural characteristics and the complex contact relationship of the inner and outer races, rolling balls, and bearing cage. Finally, the effectiveness of the theoretical method proposed in this study was verified by comparative analysis of the results. The results suggested that the external impact of a mechanical multi-body system was prone to induce sudden changes in the equivalent reaction force on its bearing joint and the dynamic load carried on its rolling balls. This study provided an effective method for exploring the distribution characteristics of dynamic loads on rolling ball bearing joints under working impact load conditions. Moreover, it offered support for the parameter optimisation of geometric structure, performance evaluation, and dynamic design of the rolling ball bearings.     

Static and dynamic behavior of disk bearings for OSPG railway bridges under railway vehicle loading

The aim of the present study is to investigate the static and dynamic behavior of disk bearings under railway vehicle loadings. A disk bearing is operated as an elastic bearing in the vertical direction and is composed of a Polyether Urethane (Polyurethane) disk for elastic support and Polytetrafluoroethylene (PTFE) to accommodate lateral movements. Static tests are conducted in a laboratory to determine the static behavior of a Polyurethane disk. Finite Element (FE) analysis is also performed to assess the friction and the role of the pin inside a disk bearing. For dynamic behavior, four disk bearings having the identical Polyurethane disk, which are used in the static tests, are installed in a real railway bridge and tested under a running locomotive. From the test results, the static and dynamic stiffness of disk bearings are estimated and compared with each other. The estimated static stiffness of the disk bearing is almost half of that under dynamic loading. In addition, under relatively light loads the dynamic stiffness of a fixed disk bearing is approximately 80% greater than that of an expansion disk bearing since the PTFE deflects and the gap is closed in the expansion bearing. Deformation of the disk bearings in the real bridge is measured with varying locomotive speeds. The deformation of the disk bearings does not vary significantly with changes in the locomotive’s speed.