Analysis and Simulation for Planetary Gear Fault of Helicopter Based on Vibration Signal

Fault diagnosis for helicopter's main gearbox based on vibration signals by experiments always requires high costs. To solve this problem,a helicopter's planetary gear system is taken as an example. Firstly,a simulation model is established by McFadden,and analyzed under ideal condition. Then this model is developed and improved as the delay-time model of the vibration signal which determines the phase-change of sidebands when the system is running. The cause and change-rules of planetary gear system's vibration signal are analyzed to establish the fault diagnosis model.At the same time,the vibration signal of fault condition is simulated and analyzed. This simulation method can provide a reference for fault monitoring and diagnosis for planetary gear system.

Research on Instantaneous Angular Speed Signal Separation Method for Planetary Gear Fault Diagnosis

Planetary gear train is a critical transmission component in large equipment such as helicopters and wind turbines. Conducting damage perception of planetary gear trains is of great significance for the safe operation of equipment. Existing methods for damage perception of planetary gear trains mainly rely on linear vibration analysis. However, these methods based on linear vibration signal analysis face challenges such as rich vibration sources, complex signal coupling and modulation mechanisms, significant influence of transmission paths, and difficulties in separating damage information. This paper proposes a method for separating instantaneous angular speed (IAS) signals for planetary gear fault diagnosis. Firstly, this method obtains encoder pulse signals through a built-in encoder. Based on this, it calculates the IAS signals using the Hilbert transform, and obtains the time-domain synchronous average signal of the IAS of the planetary gear through time-domain synchronous averaging technology, thus realizing the fault diagnosis of the planetary gear train. Experimental results validate the effectiveness of the calculated IAS signals, demonstrating that the time-domain synchronous averaging technology can highlight impact characteristics, effectively separate and extract fault impacts, greatly reduce the testing cost of experiments, and provide an effective tool for the fault diagnosis of planetary gear trains.

The numerical simulation and inversion fitting of radon concentration distribution in homogeneous overburden above active fault zones

Based on the convection and diffusion mechanisms of radon migration, in this paper we deduce the two-dimensional differential equation for radon transportation in the overburden above active fault zones with an unlimited extension along the strike. Making use of the finite difference method, the radon concentration distribution in the overburden above active faults is calculated and modeled. The active fault zone parameters, such as the depth and the width of the fault zone, and the value of radon concentration, can be inverted from the measured radon concentration curve. These realize quantitative interpretation for radon concentration anomalies. The inversion results are in good agreement with the actual fault zone parameters.

WEDM oriented micro gear design and mesh simulation

For the design of gears manufactured with wire electrical discharge machining （WEDM） technology, determination of the primary gear parameters is discussed considering the characteristics of the machining method. Some constraint conditions on gear parameters are abnegated, which makes micro gear design more flexible. Based on gear mesh theory, the algorithm of generating gear tooth profiles is studied, which includes involute and non-involute curve segments. The phenomena of tooth profile interferences during gear mesh are analyzed, and a gear mesh simulation algorithm is designed. Based on ACIS, the WEDM oriented software for the design and mesh simulation of micro gears is developed, by which the modeling, mesh simulation and interference check can be implemented. An experiment is carried out to design and manufacture a pair of micro involute gears, and the proposed method is proved feasible.

Magnetic Force Simulation of Cables in Microgrid during Faults

In recent years, more and more electric utilities are using underground cables to distribute electric power rather than overhead transmission line. However, the cost of installation and maintenance of underground cables is very expensive. Thus, the proper design and damage prediction of cables are crucial. This paper is focused on the magnetic force waveforms simulation of cables under different types of faults using PSCAD and COMSOL. The results show that three-phase fault leads to the largest magnetic forces and the maximum magnitude of the forces in the x-direction is about 2.5 N. Also, the magnetic fields surrounding the cables are different depending on the arrangements of cables buried method. Although the magnitude is small, considering the long distance and long operating time of underground cables, the forces between cables can cause failures under some conditions. In the future, more types of faults such as high impedance fault and different protecting technologies can be studied.

A Simulation Study on Boiler Fault Diagnosis Expert System

The boiler is one of the key parts of power station. Monitoring the operation of the boiler automatically, continuously and accurately is very important. In case of malfunctions, an expert system might be helpful to find the sources of faults, and thereafter will assist the operator to act correctly and to prevent the fault from further development.In this paper, a simulation study of an expert system, which can diagnose the running faults of boiler system, is conducted. Shallow and deep two-layer knowledge base structure is used in this two layers of knowledge base. So. this kind of expert system can overcome the disadvantages of the old types of expert systems, which are only able to deal with experience rules base.A simulator of power boiler is used for the research on fault diagnose expert system. This boiler simulator gives all necessary information for the diagnosis. The knowledge base of expert system is built in hierarchies, so the speed of reasoning may be invreased. After the reasoning the

Statistical Modification Analysis of Helical Planetary Gears based on Response Surface Method and Monte Carlo Simulation

Tooth modification technique is widely used in gear industry to improve the meshing performance of gearings. However, few of the present studies on tooth modification considers the influence of inevitable random errors on gear modification effects. In order to investigate the uncertainties of tooth modification amount variations on system＇s dynamic behaviors of a helical planetary gears, an analytical dynamic model including tooth modification parameters is proposed to carry out a deterministic analysis on the dynamics of a helical planetary gear. The dynamic meshing forces as well as the dynamic transmission errors of the sun-planet 1 gear pair with and without tooth modifications are computed and compared to show the effectiveness of tooth modifications on gear dynamics enhancement. By using response surface method, a fitted regression model for the dynamic transmission error（DTE） fluctuations is established to quantify the relationship between modification amounts and DTE fluctuations. By shifting the inevitable random errors arousing from manufacturing and installing process to tooth modification amount variations, a statistical tooth modification model is developed and a methodology combining Monte Carlo simulation and response surface method is presented for uncertainty analysis of tooth modifications. The uncertainly analysis reveals that the system＇s dynamic behaviors do not obey the normal distribution rule even though the design variables are normally distributed. In addition, a deterministic modification amount will not definitely achieve an optimal result for both static and dynamic transmission error fluctuation reduction simultaneously.

Dominant pulse simulation of near fault ground motions

In this study, a new mathematical model is developed composed of two parts, including harmonic and polynomial expressions for simulating the dominant velocity pulse of near fault ground motions. Based on a proposed velocity function, the corresponding expressions for the ground acceleration and displacement time histories are also derived. The proposed model is then fitted using some selected pulse-like near fault ground motions in the Next Generation Attenuation （NGA） project library. The new model is not only simple in form but also simulates the long-period portion of actual velocity near fault records with a high level of precision. It is shown that the proposed model-based elastic response spectra are compatible with the near fault records in the neighborhood of the prevailing frequency of the pulse. The results indicate that the proposed model adequately simulates the components of the time histories. Finally, the energy of the proposed pulse was compared with the energy of the actual record to confirm the compatibility.

Numerical simulation analysis of covering rock strata as mining steep-inclined coal seam under fault movement

The fault is one important factor for the stability of overburden strata caused by steeply inclined coal seam. The stress and displacement change of overburden strata caused by steeply-inclined coal seam mining activity under faulting was simulated by FLAC2D finite differential program on the basis of Zhaogezhuang mining example belonging to Kailuan Mining Group. From the results, the stress and displacement clouding image after mining became complex because of the fault, that is, a kind of weak structural plane. The stress concentration region concentrated around the goaf, and also around the fault plane. As the mining depth increases, the stress and displacement within the fault zone change significantly. This movement and deformation characteristic of overburden strata can provide theoretical basis for the similar mining condition.

Finite element analysis and simulation for cold precision forging of a helical gear

To investigate the effects of billet geometry on the cold precision forging process of a helical gear, six different billet geometries were designed utilizing the relief-hole principle. And the influences of the billet geometry on the forming load and the deformation uniformity were analyzed by three-dimensional （3D） finite element method （FEM） under the commercial software DEFORM 3D. The billet geometry was optimized to meet lower forming load and better deformation uniformity requirement. Deformation mechanism was studied through the distribution of flow velocity field and effective strain field. The forging experiments of the helical gear were successfully performed using lead material as a model material under the same process conditions used in the FE simulations. The results show that the forming load decreases as the diameter of relief-hole do increases, but the effect of do on the deformation uniformity is very complicated. The forming load is lower and the deformation is more uniform when do is 10 mm.

Meshing Theoretical Study and Simulation on Cylindrical Tri-sine Oscillating Tooth Gear Drive

The structure of cylindrical tri-sine oscillating tooth gear drive is presented. Based on the space meshing theory, equations of meshing and tooth profile are established and its meshing theory is studied. Using Pro/E, this system is modeled and simulated,which is compared with the above-established equations.

Numerical Simulation of Coal Floor Fault Activation Influenced by Mining

By means of the numerical simulation software ANSYS, the activation regularity of coal floor faults caused by mining is simulated. The results indicate that the variation in horizontal, vertical and shear stresses, as well as the horizontal and vertical displacements in the upper and the lower fault blocks at the workface are almost identical. Influ- enced by mining of the floor rock, there are stress releasing and stress rising areas at the upper part and at the footwall of the fault. The distribution of stress is influenced by the fault so that the stress isolines are staggered by the fault face and the stress is focused on the rock seam around the two ends of the fault. But the influence in fault activation on the upper or the lower fault blocks of the workface is markedly different. When the workface is on the footwall of the fault, there is a horizontal tension stress area on the upper part of the fault; when the workface is on the upper part of the fault, it has a horizontal compressive stress area on the lower fault block. When the workface is at the lower fault block, the maximum vertical displacement is 5 times larger then when the workface is on the upper fault block, which greatly in- creases the chance of a fatal inrush of water from the coal floor.

Numerical simulation of fault activity owing to hydraulic fracturing

We built a three-dimensional model to simulate the disturbance of the stress field near the reverse fault in Zhaziao, Leyi Township owing to hydraulic fracturing. The pore pressure, and shear and normal stresses during fracturing are analyzed in detail. Input rock mechanics parameters are taken from laboratory test data of shale samples from the study area. The simulation results suggest that after 16 hours of fluid injection, the pore-pressure variation can activate the reverse fault, i.e., we observe reverse slip, and the shear stress and displacement on the fault plane increase with time. The biggest stress–strain change occurs after one hour of fluid injection and the yield point appears about 0.5 h after injection. To observe the stress evolution in each section, the normal displacement on the boundary is constrained and the fault plane is set as nonpermeable. Thus, the sliding is limited and the shear displacement is only in the scale of millimeters, and the calculated magnitude of the induced earthquakes is between Mw-3.5 and Mw-0.2. The simulation results suggest that fluid water injection results in inhomogeneous fracturing. The main ruptured areas are around the injection positions, whereas the extent of rupturing and cracks in other areas are relatively small. Nevertheless, nonnegligible fault activation is recorded. Sensitivity analysis of the key parameters suggests that the pore pressure is most sensitive to the maximum unbalanced force and the internal friction angle strongly affects the fault slip. Finally, the comparison between the effective normal stress and the maximum and minimum principal stresses on the fault plane explains the fault instability, i.e., the Mohr circle moves towards the left with decreasing radius reduces and intersects the critical slip envelope, and causes the fault to slip.

3D simulation of near-fault strong ground motion: comparison between surface rupture fault and buried fault

In this paper, near-fault strong ground motions caused by a surface rupture fault （SRF） and a buried fault （BF） are numerically simulated and compared by using a time-space-decoupled, explicit finite element method combined with a multi-transmitting formula （MTF） of an artificial boundary. Prior to the comparison, verification of the explicit element method and the MTF is conducted. The comparison results show that the final dislocation of the SRF is larger than the BF for the same stress drop on the fault plane. The maximum final dislocation occurs on the fault upper line for the SRF; however, for the BE the maximum final dislocation is located on the fault central part. Meanwhile, the PGA, PGV and PGD of long period ground motions （≤ 1 Hz） generated by the SRF are much higher than those of the BF in the near-fault region. The peak value of the velocity pulse generated by the SRF is also higher than the BE Furthermore, it is found that in a very narrow region along the fault trace, ground motions caused by the SRF are much higher than by the BF. These results may explain why SRFs almost always cause heavy damage in near-fault regions compared to buried faults.

Prediction and Minimization of the Heat Treatment Induced Distortion in 8620H Steel Gear:Simulation and Experimental Verification

The considerable heat treatment induced runout value in the end face of the automobile main reducer gear is always dimensionally out of tolerance.It directly affects the dimensional accuracy,the grade of carburized and hardened gears,and the post-quenching manufacturing costs.In this study,three dimensional numerical models were developed to simulate the carburizing-quenching process of gear based on the multi-field coupling theory using DEFORM software.The results indicated that the ununiform cooling rate of the gear caused by the asymmetry of the web structure would result in the ununiform distribution of martensite,leading to the large runout value at the end face of the gear.Therefore,a novel method was proposed to minimize the heat treatment induced runout value.It was found that the heat treatment induced runout value could be effectively controlled by the addition of a compensation ring and the support of a rod structure.Further experiments showed that the average runout value of the gear end face before and after the proposed heat treatment method were about 0.023 mm and 0.059 mm respectively,which was in good agreement with the simulated results.The novel approach proposed in this study led to a reduction of the gear runout value by 70.0%‒76.9%compared to that of the original heat treatment process,which may serve as a practical and economical way to predict and minimize the heat treatment induced distortion in drive gear.

Numerical simulation of the anti-shock performance of a gear case

Both sea battles and testing of ship in underwater explosions reveal unacceptably poor anti-shock performance of important shipboard equipment. Anti-shock performance of shipboard equipment is a significant factor determining fighting strength and survivability. The anti-shock performance of a shipboard gear case based on BV043/85 was investigated using numerical simulation. A geometric model of the gear case was built using MDT software and meshed in HyperMesh software, and then the finite element model of the gear case was formed. Using ABAQUS software, the anti-shock performance of the gear case was simulated. First, shock response of typical regions of gear case was determined. Next, some generalizations were made about the anti-shock performance of the gear case by analyzing the Mises stress of typical regions varied with shock inputs. Third, weak regions were determined from simulation results. The threshold values of shock resistance of the gear case at different impulse widths were obtained through interpolating the numerical simulation results selected from the most dangerous spot. This research provides a basis for further optimization of the design of gear cases.

Numerical simulation on fault water-inrush based on fluid-solid coupling theory

About 75% water-inrush accidents in China are caused by geological structure such as faults, therefore, it is necessary to investigate the water-inrush mechanism of faults to provide references for the mining activity above confined water. In this paper, based on the fluid-solid coupling theory, we built the stress-seepage coupling model for rock, then we combined with an example of water-inrush caused by fault, studied the water-inrush mechanism by using the numerical software COMSOL Mutiphysics, analyzed the change rule of shear stress, vertical stress, plastic area and water pressure for stope with a fault, and estimated the water-inrush risk at the different distances between working faces and the fault. The numerical simula- tion results indicate that： （1） the water-inrush risk will grow as the decrease of the distance between working face and the fault; （2） the failure mode of the rock in floor with fault is shear failure; （3） the rock between water-containing fault and working face failure is the reason for water-inrush.

Model Parameter Transfer for Gear Fault Diagnosis under Varying Working Conditions

Gear fault diagnosis technologies have received rapid development and been effectively implemented in many engineering applications.However,the various working conditions would degrade the diagnostic performance and make gear fault diagnosis(GFD)more and more challenging.In this paper,a novel model parameter transfer(NMPT)is proposed to boost the performance of GFD under varying working conditions.Based on the previous transfer strategy that controls empirical risk of source domain,this method further integrates the superiorities of multi-task learning with the idea of transfer learning(TL)to acquire transferable knowledge by minimizing the discrepancies of separating hyperplanes between one specific working condition(target domain)and another(source domain),and then transferring both commonality and specialty parameters over tasks to make use of source domain samples to assist target GFD task when sufficient labeled samples from target domain are unavailable.For NMPT implementation,insufficient target domain features and abundant source domain features with supervised information are fed into NMPT model to train a robust classifier for target GFD task.Related experiments prove that NMPT is expected to be a valuable technology to boost practical GFD performance under various working conditions.The proposed methods provides a transfer learning-based framework to handle the problem of insufficient training samples in target task caused by variable operation conditions.

Dynamic Simulation for Rigid-Flexible Coupling Model of Gear Transmission System Based on ADAMS

The influence of the flexible body for the motion of gear transmission system is analyzed and the foundation for a more accurate assessment of gear transmission system is established when it has battle damage faults. By using Pro / E software,the virtual prototype model of gear transmission system in the speed reducer is established,and the rigid model and rigid-flexible coupling model are simulated respectively in ADAMS to obtain the data of gear meshing force. It can be concluded that rigid-flexible coupling model can reflect the real motion better than rigid model by comparing the simulation data of two models.

Geomechanics model test and numerical simulation of 2G-NPR bolt support effect in an active fault tunnel

Active faults are a common adverse geological phenomenon that can occur during tunnel excavation and has a very negative impact on the construction and operation of the tunnel.In this paper,the grade IV rock surrounding the cross-fault tunnel with poor geological conditions has been chosen for the study.The support capacity of 2^(nd) Generation-Negative Poisson’s Ratio(2G-NPR)bolt in an active fault tunnel has been carried out on the basis of relevant results obtained from the geomechanical model test and numerical investigations of failure model for existing unsupported fault tunnel.The investigation shows that surrounding rock of the tunnel is prone to shear deformation and crack formation along the fault,as a result,the rock mass on the upper part of the fault slips as a whole.Furthermore,small-scale deformation and loss of blocks are observed around the tunnel;however,the 2G-NPR bolt support is found to be helpful in keeping the overall tunnel intact without any damage and instability.Due to the blocking effect of fault,the stress of the surrounding rock on the upper and lower parts of the fault is significantly different,and the stress at the left shoulder of the tunnel is greater than that at the right shoulder.The asymmetrical arrangement of 2G-NPR bolts can effectively control the asymmetric deformation and instability of the surrounding rock.The present numerical scheme is in good agreement with the model test results,and can reasonably reflect the stress and displacement characteristics of the surrounding rock of the tunnel.In comparison to unsupported and ordinary PR(Poisson’s Ratio)bolt support,2G-NPR bolt can effectively limit the fault slip and control the stability of the surrounding rock of the fault tunnel.The research findings may serve as a guideline for the use of 2G-NPR bolts in fault tunnel support engineering.