The low-noise optimisation method for gearbox in consideration of operating conditions

This paper presents a comprehensive procedure to calculate the steady dynamic response and the noise radiation generated from a stepping-down gearbox. In this process, the dynamic model of the cylindrical gear transmission system is built with the consideration of the time-varying mesh stiffness, gear errors and bearing supporting, while the data of dynamic bearing force is obtained through solving the model. Furthermore, taking the data of bearing force as the excitation, the gearbox vibrations and noise radiation are calculated by numerical simulation, and then the time history of node dynamic response, noise spectrum and resonance frequency range of the gearbox are obtained. Finally, the gearbox panel acoustic contribution at the resonance frequency range is calculated. Based on the conclusions from the gearbox panel acoustic contribution analyses and the mode shapes, two gearbox stiffness improving plans have been studied. By contrastive analysis of gearbox noise radiation, the effectiveness of the improving plans is confirmed. This study has provided useful theoretical guideline to the gearbox design

Optimization of motor and gearbox for an ultra light electric vehicle

The integrated design of the drivetrain of a single person ultra light electric vehicle powered by batteries is optimized towards high efficiency and low mass. The drivetrain of each front wheel consists of an outer rotor permanent magnet synchronous motor (PMSM), a gearbox and the power electronics with converter and control print. The complete drivetrain is optimized for the New European Driving Cycle and the Federal Test Procedure. For the optimization of the complete drivetrain analytical models are used to calculate the losses and the efficiency. The analytical models are fast, and useful for designing a good PMSM in combination with a gearbox. The optimization of the drivetrain over the driving cycles makes it possible to choose the optimal combination of motor and gearbox for different gear ratios in order to have high efficiency and low weight. Comparing a single-stage gearbox with a twostage gearbox, a single-stage gearbox has a higher efficiency, but also a higher weight than a two-stage gearbox with the same properties. The optimization of the dynamic behavior of the drivetrain over the driving cycles yields a compromise between the total efficiency and the total mass of the drivetrain. The optimum choice will depend on the intended use of the vehicle (drive cycle)

An investigation of control strategies on gearbox damage

The impact of control on structural elements such as tower and blades have been thoroughly researched and the validity of analysis methods based on aeroelastic simulations is widely accepted. The implications on gearbox wear for various control strategies is less studied. Using RomaxDesigner for gearbox analysis, MLS and Romax have carried out an investigation where the impact of different control strategies on wear is assessed. The best measures accounting for gearbox damage are described and the different control strategies and their impact on the gearbox are detailed

OH-58 helicopter transmission failure analysis

The OH-58 main transmission gearbox was run at varying output torques, speeds, and oil cooling rates. The gearbox was subsequently run to destruction by draining the oil from the gearbox while operating at a speed of 6200 revs per minute and 36,000 inch-pounds output torque. Primary cause of gearbox failure was overheating and melting of the planet bearing aluminum cages. Complete failure of the gearbox occurred in 28 1/2 minutes after the oil pressure dropped to zero. The alternating and maximum stresses in the gearbox top case were approximately 10 percent of the endurance limit for the material. Deflection of the bevel gear at 67000 inch-pounds output torque indicate a marginal stiffness for the bevel gear supporting system

Advanced gearbox technology

An advanced 13,000 HP, counterrotating (CR) gearbox was designed and successfully tested to provide a technology base for future designs of geared propfan propulsion systems for both commercial and military aircraft. The advanced technology CR gearbox was designed for high efficiency, low weight, long life, and improved maintainability. The differential planetary CR gearbox features double helical gears, double row cylindrical roller bearings integral with planet gears, tapered roller prop support bearings, and a flexible ring gear and diaphragm to provide load sharing. A new Allison propfan back-to-back gearbox test facility was constructed. Extensive rotating and stationary instrumentation was used to measure temperature, strain, vibration, deflection and efficiency under representative flight operating conditions. The tests verified smooth, efficient gearbox operation. The highly-instrumented advanced CR gearbox was successfully tested to design speed and power (13,000 HP), and to a 115 percent overspeed condition. Measured CR gearbox efficiency was 99.3 percent at the design point based on heat loss to the oil. Tests demonstrated low vibration characteristics of double helical gearing, proper gear tooth load sharing, low stress levels, and the high load capacity of the prop tapered roller bearings. Applied external prop loads did not significantly affect gearbox temperature, vibration, or stress levels. Gearbox hardware was in excellent condition after the tests with no indication of distress

Misalignment diagnosis of a planetary gearbox based on vibration analysis

As a critical power transmission system, planetary gearbox is widely used in many industrial important machines such as wind turbines, aircraft turbine engines, helicopters. Early fault detection and diagnosis of the gearbox will help to prevent unexpected breakdowns of this important equip-ment. Misalignment is one of the major operating problems in the planetary gearbox which may be caused by inadequate system integration, variable operating conditions and differences of elastic deformations in the system. In this paper, the effect of varying degrees of installation misalignment of planetary gearbox are investigated based on vibration measurements using spectrum analysis and modulation signal bispectrum (MSB) analysis. It has shown that the misalignment can be diagnosed in the low frequency range in which the adverse effect due to co-occurrence of amplitude modula-tion and frequency modulation (AM-FM) effect is low compared with the components around meshing frequencies. Moreover, MSB produces a more accurate and reliable diagnosis in that it gives correct indication of the fault severity and location for all operating conditions. In contrast, spectrum can produce correct results for some of the operating conditions. Keywords: Planetary gearbox, Condition Monitoring, Misalignment, Modulation signal bispectrum

Optimal design and implementation of a drivetrain for an ultra-light electric vehicle

This paper presents an integrated design of a drivetrain for a single-person ultra-light electric vehicle (ULEV). To calculate losses and efficiency of the inverter, the permanent magnet synchronous machines (PMSMs) and the gearbox, parameterised analytical models are used. For the gearbox - which has a single gear ratio - the studied parameters are the gear ratio, the number of stages, the number of teeth and the module of each spur gear combination. The novelty of the paper is that it learns how the total average efficiency and the total mass of the drivetrain depend on the gear ratio, on the number of stages in the gearbox, on the motor parameters and on the chosen several driving cycles including the new European driving cycle (NEDC). On the basis of the presented results, it is possible to choose the right configuration of power electronics, PMSM and gearbox in order to have a good trade-off between high efficiency and low mass

Techno-economic comparison of operational aspects for direct drive and gearbox-driven wind turbines

The majority of wind turbines currently in operation have the conventional Danish concept design-that is, the three-bladed rotor of such turbines is indirectly coupled with an electrical generator via a gearbox. Recent technological developments have enabled direct drive wind turbines to become economically feasible. Potentially, direct drive wind turbines may enjoy higher levels of availability due to the removal of the gearbox from the design. However, this is only a theory: so far not substantiated by detailed analytic calculation. By providing such a calculation, this paper enables us to quantitatively evaluate technical and economic merits of direct drive and gearbox-driven wind turbines

Comparison of analysis and experiment for gearbox noise

Low contact ratio spur gears were tested in the NASA gear-noise rig to study the noise radiated from the top of the gearbox. Experimental results were compared with a NASA acoustics code to validate the code for predicting transmission noise. The analytical code is based on the boundary element method (BEM) which models the gearbox top as a plate in an infinite baffle. Narrow band vibration spectra measured at 63 nodes on the gearbox top were used to produce input data for the BEM model. The BEM code predicted the total sound power based on the measured vibration. The measured sound power was obtained from an acoustic intensity scan taken near the surface of the gearbox at the same 63 nodes used for vibration measurement. Analytical and experimental results were compared at four different speeds for sound power at each of the narrow band frequencies over the range of 400 to 3200 Hz. Results are also compared for the sound power level at meshing frequency plus three sideband pairs and at selected gearbox resonant frequencies. The difference between predicted and measure sound power is typically less than 3 dB with the predicted value generally less than the measured value

Remote data acquisition for condition monitoring of wind turbines

While the number of offshore wind turbines is growing and turbines getting bigger and more expensive, the need for good condition monitoring systems is rising. From the research it is clear that failures of the gearbox, and in particular the gearwheels and bearings of the gearbox, have been responsible for the most downtime of a wind turbine. Gearwheels and bearings are being simulated in a multi-sensor environment to observe the wear on the surface