A cyclostationarity-based wear monitoring framework of spur gears in intelligent manufacturing systems

Abstract

The gearbox is widely applied as the mechanical transmission system of intelligent manufacturing systems, such as machine tools and robotics. The harsh working environments make the gear surface prone to wear. The progression of surface wear can bring severe failures to the gear tooth, including gear tooth root crack, surface spalling of gear tooth, and tooth breaking, all of which could damage the whole transmission system. Hence, it is essential to monitor and evaluate the gear surface wear propagation. The gear wear has been proven highly relevant with the vibration second-order cyclostationary (CS2) characteristics. Therefore, this paper develops a novel cyclostationarity-based framework to monitor and evaluate gear wear propagation. More specifically, the squared envelope (SE) of the residual signal, removing deterministic components, is utilized to identify the gear wear distribution and its propagation trends, validated using the measured gear surface morphology. Moreover, a new CS2-based indicator is proposed to assess the severity of gear surface wear, achieving a high correlation with measured surface roughness: [Formula: see text] is more than 0.9. The developed cyclostationarity-based framework can comprehensively evaluate the degradation status of the gear system caused by surface wear, significantly benefiting the health management of the gear transmission system, which is of great practical value for the health management of intelligent manufacturing systems. A series of endurance tests are conducted to verify the effectiveness and superiority of the developed framework for gear wear monitoring compared with the conventional indicators.

Experimental‐based study of gear vibration characteristics incorporating the fractal topography of tooth surface

“…However, the partial area of a relatively rough surface tends to be rougher. According to the existing research, wear originates from the dedendum of the gear tooth 27 . The rougher surface always corresponds to intense vibration, which makes the tooth surface more prone to wear.…”

“…According to the existing research, wear originates from the dedendum of the gear tooth. 27 The rougher surface always corresponds to intense vibration, which makes the tooth surface more prone to wear. Thus, the wear of the tooth surface appears in the area circled in red, as shown in Figure 9B.…”

“…Considering the various spatial frequencies can affect the spectral content of the resulting gearmesh‐cyclic second‐order cyclostationary (CS2) components, Feng et al 26 proposed a vibration‐based wear mechanism identification and used an indicator of vibration CS to track the wear evolution. In addition, a novel cyclostationarity‐based framework, removing deterministic components of the squared envelope of the residual signal, was developed to monitor and evaluate gear wear propagation 27 based on the fact that gear wear is highly relevant to the vibration CS2 characteristics. Despite traditional indicators being developed to track the surface morphology during wear progressions, such as root‐mean‐square (RMS), 28 NA4, and FM4, 29 some developed cyclostationarity indicators can be applied for tracking the morphology with wear progression.…”

Robust fault diagnosis of quayside container crane gearbox based on 2D image representation in frequency domain and CNN

“…To obtain the actual FDMTF, it is generally necessary to normalize the FD signal to the interval [21,1], and the normalized series is given by:…”

“…Due to the unique advantages of stable transmission performance and high transmission efficiency, gearboxes are widely used in key transmission systems of various machinery, such as wind turbines automobile sectors, machining machines, robots, quayside container cranes (QCCs), etc. [1][2][3] As the key mechanical equipment of cargo transportation ports, the QCC is specially used for loading and unloading. 2 The QCC is located in a harsh working environment, which increases the failure rate of gearboxes that bears a huge dynamic load for a long time.…”