Research

19 pages, 11864 KiB

Open AccessArticle

Integration of Sensors for Enhanced Condition Monitoring in Polymer Gears: A Comparative Study of Acceleration and Temperature Sensors

by Sascha Hasenoehrl, Julian Peters and Sven Matthiesen

Appl. Sci. 2024, 14(6), 2240; https://doi.org/10.3390/app14062240 - 07 Mar 2024

Viewed by 422

Abstract

As an integral part of a machine, gears are subject to wear, which is influenced by a number of factors. For polymer gears in particular, the uncertainties due to wear are high. These uncertainties outweigh the advantages of polymer gears, such as lower [...] Read more.

As an integral part of a machine, gears are subject to wear, which is influenced by a number of factors. For polymer gears in particular, the uncertainties due to wear are high. These uncertainties outweigh the advantages of polymer gears, such as lower inertia. Improved condition monitoring, for example, with better data acquisition, could reduce these uncertainties and is therefore of great interest. This study addresses the challenges of condition monitoring in polymer gears by investigating the integration of sensors directly onto the gears for improved sensitivity. A compact sensor module mounted on a polymer gear is presented to demonstrate the benefits of integrated sensors. The research compares the effectiveness of integrated acceleration and temperature sensors with state of the art external methods. The results show that the in situ sensor module (ISM) provides reliable measurements for condition monitoring with integrated sensors. A comparative analysis with methods based on the current state of research highlights the increased sensitivity of condition monitoring based on the ISM acceleration sensors compared to traditional bearing block sensors. This increased sensitivity shows a clear advantage of integrated sensors over established methods. The temperature curve of the integrated sensors is sensitive to abrasive wear and gear failure, indicating the wider potential of integrated temperature sensors. In conclusion, this research lays the foundation for advanced condition monitoring using integrated sensors in polymer gears. The knowledge gained contributes to optimising gear applications, promoting cost-effectiveness and aligning with the principles of the Internet of Things and Industry 4.0. Full article

(This article belongs to the Special Issue Modern Research of Gears and Power Transmission)

► Show Figures

Figure 1

22 pages, 8462 KiB

Open AccessArticle

A Rapid and Inexpensive Method for Finding the Basic Parameters of Involute Helical Gears

by Stelian Alaci, Florina-Carmen Ciornei, Ionut-Cristian Romanu, Ioan Doroftei, Carmen Bujoreanu and Ioan Tamașag

Appl. Sci. 2024, 14(5), 2043; https://doi.org/10.3390/app14052043 - 29 Feb 2024

Viewed by 398

Abstract

The paper proposes a rapid, straightforward, and inexpensive method for finding the basic parameters of helical gears with an involute profile. The basic parameters envisaged are the normal module, normal profile shift coefficient, and the helix angle. The proposed method uses balls introduced [...] Read more.

The paper proposes a rapid, straightforward, and inexpensive method for finding the basic parameters of helical gears with an involute profile. The basic parameters envisaged are the normal module, normal profile shift coefficient, and the helix angle. The proposed method uses balls introduced between the teeth and, thus, the contact with the measuring device surfaces is of the point type, and the centres of the balls are positioned symmetrically with respect to the measuring direction. The condition that the centre of the ball occupies an imposed position is mandatory. Additionally, there is the condition of the positions of the contact points between the balls and the flanks of the teeth. Two sets of balls of different sizes are necessary for a measurement. The conditions of the balls’ positioning lead to a system of five unknowns. The methodology of solving the system is detailed and the method is exemplified for an actual helical gear. The new proposed method is based on the distance over pins but, using balls, presents the following advantages: It can be applied equally to all gears, regardless of the odd or even number of teeth. Furthermore, the dimension to be measured is singular compared to the dimension over pins when a maximum value must be found from several measurements. Full article

(This article belongs to the Special Issue Modern Research of Gears and Power Transmission)

► Show Figures

Figure 1

18 pages, 10836 KiB

Open AccessArticle

Shape Deviation Network of an Injection-Molded Gear: Visualization of the Effect of Gate Position on Helix Deviation

by Jing Chong Low, Daisuke Iba, Daisuke Yamazaki and Yuichiro Seo

Appl. Sci. 2024, 14(5), 2013; https://doi.org/10.3390/app14052013 - 29 Feb 2024

Viewed by 505

Abstract

The purpose of this study is to develop an evaluation method for assessing the relative relationship between gear tooth shape deviations on every gear tooth using network theory. Our previous study introduced a method for representing the phase difference between each helix deviation [...] Read more.

The purpose of this study is to develop an evaluation method for assessing the relative relationship between gear tooth shape deviations on every gear tooth using network theory. Our previous study introduced a method for representing the phase difference between each helix deviation as a network, demonstrating that it is possible to identify the relative relationship between gear tooth deviations. However, there has been no in-depth analysis of the impact of injection molding on the gear’s phase difference network. In this paper, we begin by measuring the gear tooth shape deviation, calculating the correlation coefficient, and expressing it as an adjacency matrix. When the adjacency matrix was visualized and displayed as a pixel plot, a periodic pattern was formed. The relationship between the position of the gate used to inject molten resin material into the injection mold and the pixel plot were then investigated in detail, and it was confirmed that the helix deviation network of a gear manufactured with the injection molding process is useful as a new indicator for the manufacturing error of injection-molded plastic gear. Full article

(This article belongs to the Special Issue Modern Research of Gears and Power Transmission)

► Show Figures

Figure 1

14 pages, 7462 KiB

Open AccessArticle

Investigation of the Influence of Contact Patterns of Worm-Gear Sets on Friction Heat Generation during Meshing

by Aleksandar Miltenović, Milan Banić, Nikola Vitković, Miloš Simonović, Marko Perić and Damjan Rangelov

Appl. Sci. 2024, 14(2), 738; https://doi.org/10.3390/app14020738 - 15 Jan 2024

Viewed by 609

Abstract

Friction losses and scuffing failures are interesting research topics for worm gears. One of the factors leading to scuffing is the heat generated in the contact of gear teeth. The contact geometry of worm gears is complex, leading to high friction between contact [...] Read more.

Friction losses and scuffing failures are interesting research topics for worm gears. One of the factors leading to scuffing is the heat generated in the contact of gear teeth. The contact geometry of worm gears is complex, leading to high friction between contact surfaces. High friction between contact surfaces during operation generates heat friction that causes the occurrence of scuffing, which in turn determines the scuffing load capacity. To analyse the thermal characteristics of a worm-gear pair and the thermal behaviour of contact teeth, a direct-coupled thermal–structural 3D finite element model was applied. The heat flux due to friction-generated heat was determined on the gear tooth to investigate thermal characteristics and predict transient temperature fields. This study permits an in-depth understanding of the temperature fields and the friction heat generation process. Also, better control of the contact pattern between worm-gear teeth would decrease friction heat and increase scuffing load capacity. This paper investigates the transient thermal behaviour among different pinion machine setting parameters that can result in an optimal tooth-contact pattern that produces a lower temperature field, thus achieving higher transmission efficiency. Full article

(This article belongs to the Special Issue Modern Research of Gears and Power Transmission)

► Show Figures

Figure 1

21 pages, 10459 KiB

Open AccessArticle

A Novel Method for the Analysis and Optimization of End Face Stress in Cycloidal Gears Based on Conformal Mapping

by Ning Jiang, Liquan Jiang, Jie Zhang and Shuting Wang

Appl. Sci. 2023, 13(21), 11805; https://doi.org/10.3390/app132111805 - 28 Oct 2023

Viewed by 682

Abstract

In the realm of precision engineering, the evaluation of stress distributions in complex geometries, such as the end face of gears, is paramount for determining performance characteristics, including the fatigue life of transmission devices. This research introduces a methodology that combines the method [...] Read more.

In the realm of precision engineering, the evaluation of stress distributions in complex geometries, such as the end face of gears, is paramount for determining performance characteristics, including the fatigue life of transmission devices. This research introduces a methodology that combines the method of conformal mapping for multiply connected regions with a proposed global scaling factor. This combination facilitates the transformation of stress computations from intricate geometries to a unit circle. By employing this method as a foundation for surrogate models, and by incorporating the Bayesian-enhanced least squares genetic algorithm optimization technique, this study refines the end face stress distribution, particularly considering variations induced by tooth profile modification errors. The results delineate a design parameter domain that is conducive to achieving uniform stress distribution, offering a refined perspective and methodology for the design of cycloidal wheels. Full article

(This article belongs to the Special Issue Modern Research of Gears and Power Transmission)

► Show Figures

Figure 1

13 pages, 377 KiB

Open AccessArticle

Vibration-Based Detection of Bearing Damages in a Planetary Gearbox Using Convolutional Neural Networks

by Julia Scholtyssek, Luka Josephine Bislich, Felix Cordes and Karl-Ludwig Krieger

Appl. Sci. 2023, 13(14), 8239; https://doi.org/10.3390/app13148239 - 16 Jul 2023

Viewed by 814

Abstract

Tapered roller bearings are used partly in very rough and highly stressful environmental conditions. Therefore, the need for condition monitoring is increasing. This study is intended to provide an approach for monitoring bearings in a two-stage planetary gearbox based on vibration analysis. In [...] Read more.

Tapered roller bearings are used partly in very rough and highly stressful environmental conditions. Therefore, the need for condition monitoring is increasing. This study is intended to provide an approach for monitoring bearings in a two-stage planetary gearbox based on vibration analysis. In total, the data of six damage phenomena and one healthy bearing are collected. A convolutional neural network (CNN) is trained and evaluated by using the balanced accuracy. Mainly, it is investigated how many damage severities can be detected. In addition, the robustness of the model regarding unknown speeds and damage phenomena should be proven. The results show a very good differentiation up to all of the presented damage phenomena. The classifier reaches an averaged balanced accuracy of 0.96. Also, samples collected at unknown speeds can be classified well for speed values within the known range. For unknown damage phenomena, the classifier shows limits so that a reliable classification is only applicable with a binary classifier, which differentiates between healthy and damaged. The investigations therefore show that a reliable detection of bearing damage is possible in a two-stage planetary gear. Furthermore, the transferability of the model is successfully tested and implemented for the binary classifier. Full article

(This article belongs to the Special Issue Modern Research of Gears and Power Transmission)

► Show Figures

Figure 1

19 pages, 3607 KiB

Open AccessArticle

Multi-Objective Optimization of a Two-Stage Helical Gearbox Using Taguchi Method and Grey Relational Analysis

by Xuan-Hung Le and Ngoc-Pi Vu

Appl. Sci. 2023, 13(13), 7601; https://doi.org/10.3390/app13137601 - 27 Jun 2023

Cited by 3 | Viewed by 879

Abstract

This paper presents a novel approach to solve the multi-objective optimization problem designing a two-stage helical gearbox by applying the Taguchi method and the grey relation analysis (GRA). The objective of the study is to identify the optimal main design factors that maximize [...] Read more.

This paper presents a novel approach to solve the multi-objective optimization problem designing a two-stage helical gearbox by applying the Taguchi method and the grey relation analysis (GRA). The objective of the study is to identify the optimal main design factors that maximize the gearbox efficiency and minimize the gearbox mass. To achieve that, five main design factors. including the coefficients of wheel face width (CWFW) of the first and the second stages, the allowable contact stresses (ACS) of the first and the second stages, and the gear ratio of the first stage were chosen. Additionally, two single objectives, including the maximum gearbox efficiency and minimum gearbox mass, were analyzed. In addition, the multi-objective optimization problem is solved through two phases: Phase 1 solves the single-objective optimization problem in order to close the gap between variable levels, and phase 2 solves the multi-objective optimization problem to determine the optimal main design factors. From the results of the study, optimum values of five main design parameters for designing a two-stage helical gearbox were first introduced. Full article

(This article belongs to the Special Issue Modern Research of Gears and Power Transmission)

► Show Figures

Figure 1

16 pages, 3259 KiB

Open AccessArticle

A Dynamic Analysis of the Cycloid Disc Stress-Strain State

by Milos Matejic, Mirko Blagojevic, Aleksandar Disic, Marija Matejic, Vladimir Milovanovic and Ivan Miletic

Appl. Sci. 2023, 13(7), 4390; https://doi.org/10.3390/app13074390 - 30 Mar 2023

Cited by 3 | Viewed by 1280

Abstract

The problem of internal forces that occur on the cycloid disc during the cycloid speed reducer operation so far has not been considered in a way that reflects its actual workloads and stresses in the cycloid disc itself. This paper presents a dynamic [...] Read more.

The problem of internal forces that occur on the cycloid disc during the cycloid speed reducer operation so far has not been considered in a way that reflects its actual workloads and stresses in the cycloid disc itself. This paper presents a dynamic analysis of the stress-strain state of a cycloid disc by using experimental and numerical methods. The following cases of meshing are presented in the paper: a single-tooth, double-tooth, and triple-tooth meshing of the cycloid disc and the ring gear. The cycloid disc was chosen for this study because it is one of the main elements and the most critical element of the cycloid speed reducer. An experimental physical model of the cycloid disc and the meshing elements of the cycloid speed reducer was made based on a previously performed 3D CAD model. The numerical analysis of the stress-strain state of the cycloid disc was performed with the identically defined external load using the transient stress method. The paper presents a comparative analysis of the experimental and numerical results, which gives a solid insight into what is happening in the cycloid disc during the cycloid speed reducer operation. The experimental and simulation results both give the results with a deviation between 3% and 15%. After the detailed analyses, it is shown that the most critical element of cycloid speed reducer are output rollers, which need further study. Full article

(This article belongs to the Special Issue Modern Research of Gears and Power Transmission)

► Show Figures

Figure 1

24 pages, 5554 KiB

Open AccessArticle

A Comparison between Two Statistical Methods for Gear Tooth Root Bending Strength Estimation Starting from Pulsator Data

by Luca Bonaiti, Michael Geitner, Thomas Tobie, Carlo Gorla and Karsten Stahl

Appl. Sci. 2023, 13(3), 1546; https://doi.org/10.3390/app13031546 - 25 Jan 2023

Cited by 2 | Viewed by 1935

Abstract

Due to their cost-effectiveness, pulsator tests are widely adopted as a testing methodology for the investigation of the effects of material and heat and surface treatment on the gear strength with respect to tooth root fatigue fracture. However, since no meshing contact is [...] Read more.

Due to their cost-effectiveness, pulsator tests are widely adopted as a testing methodology for the investigation of the effects of material and heat and surface treatment on the gear strength with respect to tooth root fatigue fracture. However, since no meshing contact is present in pulsator tests, there are differences between the test case and the real-world application scenario where gears are rotating under load. Those differences are related to both statistical and fatigue phenomena. Over the years, several methodologies have been developed in order to handle this problem. This article summarizes them and proposes a first comparison. However, no complete comparison between the different estimation methodologies has been conducted so far. This article aims to partially cover this gap, first by presenting and comparing the methodologies proposed in the literature and then via a deeper comparison between two different elaboration methodologies. Those two methodologies, which have been developed by examined to the same test rig configuration, are also discussed in detail. The comparison is performed based on an actual database composed of 1643 data points from case-hardened gears, divided into 76 experimental campaigns. Good agreement between the estimated gear strengths was found. The database is also adopted in order to make further considerations about one methodology, providing additional validation and defining the specimen numerosity required. Full article

(This article belongs to the Special Issue Modern Research of Gears and Power Transmission)

► Show Figures

Figure 1

18 pages, 6124 KiB

Open AccessArticle

Numerical and Experimental Analysis of the Oil Flow in a Planetary Gearbox

by Marco Nicola Mastrone, Lucas Hildebrand, Constantin Paschold, Thomas Lohner, Karsten Stahl and Franco Concli

Appl. Sci. 2023, 13(2), 1014; https://doi.org/10.3390/app13021014 - 11 Jan 2023

Cited by 3 | Viewed by 3033

Abstract

The circular layout and the kinematics of planetary gearboxes result in characteristic oil flow phenomena. The goal of this paper is to apply a new remeshing strategy, based on the finite volume method, on the numerical analysis of a planetary gearbox and its [...] Read more.

The circular layout and the kinematics of planetary gearboxes result in characteristic oil flow phenomena. The goal of this paper is to apply a new remeshing strategy, based on the finite volume method, on the numerical analysis of a planetary gearbox and its evaluation of results as well as its validation. The numerical results are compared with experimental data acquired on the underlying test rig with high-speed camera recordings. By use of a transparent housing cover, the optical access in the front region of the gearbox is enabled. Different speeds of the planet carrier and immersion depths are considered. A proper domain partitioning and a specifically suited mesh-handling strategy provide a highly efficient numerical model. The open-source software OpenFOAM^® is used. Full article

(This article belongs to the Special Issue Modern Research of Gears and Power Transmission)

► Show Figures

Figure 1

Journal Menu

Journal Browser

Modern Research of Gears and Power Transmission

Share This Special Issue

Special Issue Editors

Special Issue Information

Keywords

Published Papers (10 papers)

Research

Further Information

Guidelines

MDPI Initiatives

Follow MDPI