Measured load spectra of the bearing in high-speed train gearbox under different gear meshing conditions

The load spectrum is a crucial factor for assess-ing the fatigue reliability of in-service rolling element bear-ings in transmission systems.For a bearing in a high-speed train gearbox,a measurement technique based on strain detection of bearing outer ring was used to instrument the bearing and determine the time histories of the distributed load in the bearing under different gear meshing conditions.Accordingly,the load spectrum of the total radial load car-ried by the bearing was compiled.The mean value and class interval of the obtained load spectrum were found to vary non-monotonously with the speed and torque of gear mesh-ing,which was considered to be caused by the vibration of the shaft and the bearing cage.As the realistic service load input of bearing life assessment,the measured load spectrum under different gear meshing conditions can be used to pre-dict gearbox bearing life realistically based on the damage-equivalent principle and actual operating conditions.

Theoretical research and experimental validation of quasi-static load spectra on bogie frame structures of high-speed trains

One of the major problems in structural fatigue life analysis is establishing structural load spectra under actual operating conditions.This study conducts theoretical research and experimental validation of quasi-static load spectra on bogie frame structures of high-speed trains.The quasistatic load series that corresponds to quasi-static deformation modes are identified according to the structural form and bearing conditions of high-speed train bogie frames.Moreover,a force-measuring frame is designed and manufactured based on the quasi-static load series.The load decoupling model of the quasi-static load series is then established via calibration tests.Quasi-static load–time histories,together with online tests and decoupling analysis,are obtained for the intermediate range of the Beijing—Shanghai dedicated passenger line.The damage consistency calibration of the quasi-static discrete load spectra is performed according to a damage consistency criterion and a genetic algorithm.The calibrated damage that corresponds with the quasi-static discrete load spectra satisfies the safety requirements of bogie frames.

Theoretical Research and Experimental Validation of Elastic Dynamic Load Spectra on Bogie Frame of High-speed Train

When a train runs at high speeds, the external exciting frequencies approach the natural frequencies of bogie critical components, thereby inducing strong elastic vibrations. The present international reliability test evaluation standard and design criteria of bogie frames are all based on the quasi-static deformation hypothesis. Structural fatigue damage generated by structural elastic vibrations has not yet been included. In this paper, theoretical research and experimental validation are done on elastic dynamic load spectra on bogie frame of high-speed train. The construction of the load series that correspond to elastic dynamic deformation modes is studied. The simplified form of the load series is obtained. A theory of simplified dynamic load–time histories is then deduced. Measured data from the Beijing–Shanghai Dedicated Passenger Line are introduced to derive the simplified dynamic load–time histories. The simplified dynamic discrete load spectra of bogie frame are established. Based on the damage consistency criterion and a genetic algorithm, damage consistency calibration of the simplified dynamic load spectra is finally performed. The computed result proves that the simplified load series is reasonable. The calibrated damage that corresponds to the elastic dynamic discrete load spectra can cover the actual damage at the operating conditions. The calibrated damage satisfies the safety requirement of damage consistency criterion for bogie frame. This research is helpful for investigating the standardized load spectra of bogie frame of high-speed train.

THEORETICAL ANALYSIS AND EXPERIMENTAL VERIFICATION ON TERNARY-WAVES METHOD TO COMPILE ACCELERATED SPECTRA

The equivalent damage calculation formulae of fatigue crack formation andgrowth are established. In order to compile the fatigue crack formation and growth accelerated loadspectra, the main wave shapes and load sequence of the actual load spectrum are kept constant, andthe carrier waves are cut off. And secondary waves are put together into new secondary waves toshorten the test time according to the equivalent damage calculation formulae respectively. Then bythe fatigue cumulative damage calculation of the fatigue crack formation and growth accelerated loadspectra, the one corresponding to the bigger damage is determined as the fatigue accelerated testload spectrum. Therefore in the test process, the fatigue accelerated test spectrum may be appliedtill fatigue failure, the engineering fatigue crack length of full-scale structure need not beinspected, and the fatigue crack formation accelerated load spectrum need not be transferred intothe fatigue crack growth accelerated load spectrum. Finally, it is verified by tests of two kinds ofspecimens that the damages of the specimens caused by the accelerated load spectra are near tothose by the actual load spectra; namely, the tested life of actual load spectra is similar to thatof accelerated load spectra. But the test time of accelerated load spectra is shortened by aboutthree-quarters that of actual load spectra. From these tests, it is also found that the fatigueaccelerated test spectrum has an advantage over FALSTAFF spectra.

Establishment Method of a Mixture Model and Its Practical Application for Transmission Gears in an Engineering Vehicle

Highly versatile machines, such as wheel loaders, forklifts, and mining haulers, are subject to many kinds of working conditions, as well as indefinite factors that lead to the complexity of the load. The load probability distribution function （PDF） of transmission gears has many distributions centers; thus, its PDF cannot be well represented by just a single-peak function. For the purpose of representing the distribution characteristics of the complicated phenomenon accurately, this paper proposes a novel method to establish a mixture model. Based on linear regression models and correlation coefficients, the proposed method can be used to automatically select the best-fitting function in the mixture model. Coefficient of determination, the mean square error, and the maximum deviation are chosen and then used as judging criteria to describe the fitting precision between the theoretical distribution and the corresponding histogram of the available load data. The applicability of this modeling method is illustrated by the field testing data of a wheel loader. Meanwhile, the load spectra based on the mixture model are compiled. The comparison results show that the mixture model is more suitable for the description of the load-distribution characteristics. The proposed research improves the flexibility and intelligence of modeling, reduces the statistical error and enhances the fitting accuracy, and the load spectra complied by this method can better reflect the actual load characteristic of the gear component.