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Analysis of the single stage cycloidal gearbox with lobe defects. Fault diagnosis attempts using coherence function and Morris minimum-bandwidth wavelets

Król Roman

Archive of Mechanical Engineering

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2023

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LXX, nr 3

409--431

EN

In this article, the frequency characteristics of the forces and torques in the various cycloidal gearbox designs were investigated. The aim of the article is the search for frequency patterns that could be used in the formulation of a fault diagnosis methodology. Numerical analysis was performed in the cycloidal gearbox without defects as well as in cycloidal gearboxes with lobe defects or with removed lobes. The results of the numerical analysis were obtained in the multibody dynamics model of the cycloidal gearbox, implemented in Fortran and using the 2nd-order Runge-Kutta method for the integration of the motion equations. The used model is planar and uses Hunt and Crossley’s nonlinear contact modelling algorithm, which was modified using the Heaviside function and backlash to fit cycloidal gearbox model convergence demands. In the analysis of fault diagnosis methods, the coherence function and Morris minimum-bandwidth wavelets were used. It is difficult to find a unique pattern in the results to use in the fault diagnosis because of the random characteristics of the torques at the input and output shafts. Based on obtained results, a promising, low-vibration cycloidal gearbox design with removed 7 lobes of the single wheel was studied using the FFT algorithm.

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Multibody dynamics model of the cycloidal gearbox, implemented in fortran for analysis of dynamic parameters influenced by the backlash as a design tolerance

Król Roman, Król Kazimierz

Acta Mechanica et Automatica

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2023

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Vol. 17, no. 2

272--280

EN

In this study, dynamical parameters of the cycloidal gearbox working at the constant angular velocity of the input shaft were investigated in the multibody dynamics 2D model implemented in the Fortran programming language. Time courses of input and output torques and forces acting on the internal and external sleeves have been shown as a function of the contact modelling parameters and backlash. The analysis results in the model implemented in Fortran were compared with the results in the 3D model designed using MSC Adams software. The values of contact forces are similar in both models. However, in the time courses obtained in MSC Adams there are numerical singularities in the form of peaks reaching 500 N for the forces at external sleeves and 400 N for the forces acting at internal sleeves, whereas in the Fortran model, there are fewer singularities and the maximum values of contact forces at internal and external sleeves do not exceed 200 N. The contact damping and discretisation level (the number of discrete contact points on the cycloidal wheels) significantly affect the accuracy of the results. The accuracy of computations improves when contact damping and discretisation are high. The disadvantage of the high discretization is the extended analysis time. High backlash values lead to a rise in contact forces and a decrease in the force acting time. The model implemented in Fortran gives a fast solution and performs well in the gearbox optimisation process. A reduction of cycloidal wheel discretisation to 600 points, which still allows satisfactory analysis, could reduce the solution time to 4 min, corresponding to an analysis time of 0.6 s with an angular velocity of the input shaft of 52.34 rad/s (500 RPM).

3

Analysis of the backlash in the single stage cycloidal gearbox

Król Roman

Archive of Mechanical Engineering

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2022

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LXIX, nr 4

693--711

EN

In this paper the analysis of backlash influence on the spectrum of torque at the output shaft of a cycloidal gearbox has been performed. The model of the single stage cycloidal gearbox was designed in the MSC Adams. The analysis for the excitation with the torque and the analysis with constant angular velocity of the input shaft were performed. For these analyses, the amplitude spectrums of the output torque for different backlashes was solved using FFT algorithm. The amplitude spectrums of the combined sine functions composed of the impact to impact times between the cycloidal wheel and the external sleeves were computed for verification. The performed studies show, that the backlash has significant influence on the output torque amplitude spectrum. Unfortunately the dependencies between the components of the spectrum and the backlash could not be expressed by linear equations, when vibrations of the output torque in the range of (350 Hz – 600 Hz) are considered. The gradual dependence can be found in the spectrum determined for the combined sine functions with half-periods equal impact-to-impact times. The spectrum is narrower for high values of backlash.

4

Resonance phenomenon in the single stage cycloidal gearbox. Analysis of vibrations at the output shaft as a function of the external sleeves stiffness

Król Roman

Archive of Mechanical Engineering

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2021

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LXVIII, nr 3

303--320

EN

In this paper a versatile analysis of the cycloidal gearbox vibrations and the resonance phenomenon was performed. The objective of this work was to show resonance phenomenon and vibrations study in the multibody dynamics model and in the finite element model of the cycloidal gearbox. The output torque was analyzed as a function of the external sleeves stiffness. The results from the multibody dynamics model were verified in the finite element model using natural frequency with load stiffening, direct frequency response and direct transient response analyses. It was shown that natural frequencies of the cycloidal gearbox undergo changes during motion of the mechanism. The gearbox passes through the thresholds of the increased vibration amplitudes, which lead to excessive wear of the external sleeves. The analysis in the multibody dynamics model showed, that the increase in the external sleeves stiffness increases frequency of the second-order fluctuation at the output shaft. Small stiffness of the external sleeves guarantees lower frequency of the second order vibrations and higher peak-to-peak values of the output torque. The performed research plays important role in the cycloidal gearbox design. This work shows gearbox dynamics problems which are associated with wear of the external sleeves.