锥齿轮传动智能综合检测系统研究与开发
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摘要
弧齿锥齿轮和准双曲面齿轮(以下简称锥齿轮)广泛用于车辆传动中，锥齿轮的传动噪声以及平稳性是影响整车性能的重要因素。在人们对于车辆乘坐舒适性提出更高要求的背景下，减振降噪以及产品的质量控制就成为当前锥齿轮行业的重要课题。因此，研究和开发一套锥齿轮智能检测系统具有一定的学术价值，建立锥齿轮传动智能综合检测系统具有重要的实际应用价值。
本文研究和开发的锥齿轮传动智能综合检测系统，能够进行锥齿轮副传动综合误差检测以及传动平稳性检测。利用Pro/E设计检测系统的机械结构并建立虚拟数字样机。针对检测综合误差和振动时对主轴转速的要求，采用变频电机来控制主轴转速，以满足系统对转速的要求。使用扭矩转速传感器来测量转速和载荷，并通过磁粉加载器来控制载荷。步进电机驱动滚珠丝杆从而带动主轴箱移动，采用长光栅检测锥齿轮副的安装距。系统实现了锥齿轮质量检测过程与检测结果分析的自动化。利用本系统检测一批传动性能良好的齿轮，并在此基础上建立质量标准。利用本系统能直接对齿轮传动质量进行检验，并可利用分析技术对测量结果进行分析。
本文利用目前流行的虚拟仪器开发软件LabWindows/CVI，开发出一套以计算机为中心、具有虚拟仪器面板的锥齿轮传动综合智能检测系统，具有操作简单的特点。本文所开发的系统软件主要由系统主控、控制、数据采集、数据分析处理以及数据管理五大模块组成，实现了软件模块化，因而具有较好的可移植性、可维护性，便于升级与扩展。
本文提出的锥齿轮智能检测系统可在锥齿轮制造过程中用作最终质量检测和质量控制工具。这将对我国锥齿轮产品质量的提高产生较大的影响。
Spiral bevel and hypoid gears have been widely used in the transmission system of automobile as one of the key parts. Their working performance will greatly affect the running quality of automobile. With the increasing requirement of people to the more comfortable automobiles, it is important to reduce the vibration and noise of the spiral bevel. Base on the reason mentioned above ,the study and development of an intelligent system, which can measure and check the transmission quality of spiral bevel and hypoid gears, have important academic signification. The system can be put into practical application in bevel gear industry.
In this paper, an intelligent system, which can check the compositive error along the pinion axis and can measure the vibration in location of bearing of headstock, is proposed, In Pro/E is applied to design the mechanical structure and to construct the digital virtual prototype. In this system, the variable frequency motor is applied to meet the requirement of low speed to check the compositive error and high speed to measure the vibration. The torque sensor is used to measure the load. The step motor and ball skew are used to drive the headstock. The system can operate and analyze automatically. A quality standard can be established by checking a batch of gears, which have good quality, on this machine. Then the machine can directly check out the gear parts, which has transmission fault. The frequency spectrum analysis is applied to analyze measuring results.
The measuring and controlling software of this intelligent check system is development by using the popular virtual instrument developing tool-LabWindows/CVI. The software realizes the system frame that the control computer is the key part in the system. The software has the virtual instrument panel and it is easy to operate. This software system has five key modules, include the main control module, control module, data collection module, data analysis and disposal module and data management module. With the modularize structure, this software can be easily transformed to another software environment, maintained, upgraded and expanded.
The intelligent check system proposed in this paper can be used as the final quality check and quality control tool in spiral bevel and hypoid gear manufacture process. It
will have great effect to the improvement of product quality spiral bevel and hypoid gears in our country.
本文研究和开发的锥齿轮传动智能综合检测系统，能够进行锥齿轮副传动综合误差检测以及传动平稳性检测。利用Pro/E设计检测系统的机械结构并建立虚拟数字样机。针对检测综合误差和振动时对主轴转速的要求，采用变频电机来控制主轴转速，以满足系统对转速的要求。使用扭矩转速传感器来测量转速和载荷，并通过磁粉加载器来控制载荷。步进电机驱动滚珠丝杆从而带动主轴箱移动，采用长光栅检测锥齿轮副的安装距。系统实现了锥齿轮质量检测过程与检测结果分析的自动化。利用本系统检测一批传动性能良好的齿轮，并在此基础上建立质量标准。利用本系统能直接对齿轮传动质量进行检验，并可利用分析技术对测量结果进行分析。
本文利用目前流行的虚拟仪器开发软件LabWindows/CVI，开发出一套以计算机为中心、具有虚拟仪器面板的锥齿轮传动综合智能检测系统，具有操作简单的特点。本文所开发的系统软件主要由系统主控、控制、数据采集、数据分析处理以及数据管理五大模块组成，实现了软件模块化，因而具有较好的可移植性、可维护性，便于升级与扩展。
本文提出的锥齿轮智能检测系统可在锥齿轮制造过程中用作最终质量检测和质量控制工具。这将对我国锥齿轮产品质量的提高产生较大的影响。
Spiral bevel and hypoid gears have been widely used in the transmission system of automobile as one of the key parts. Their working performance will greatly affect the running quality of automobile. With the increasing requirement of people to the more comfortable automobiles, it is important to reduce the vibration and noise of the spiral bevel. Base on the reason mentioned above ,the study and development of an intelligent system, which can measure and check the transmission quality of spiral bevel and hypoid gears, have important academic signification. The system can be put into practical application in bevel gear industry.
In this paper, an intelligent system, which can check the compositive error along the pinion axis and can measure the vibration in location of bearing of headstock, is proposed, In Pro/E is applied to design the mechanical structure and to construct the digital virtual prototype. In this system, the variable frequency motor is applied to meet the requirement of low speed to check the compositive error and high speed to measure the vibration. The torque sensor is used to measure the load. The step motor and ball skew are used to drive the headstock. The system can operate and analyze automatically. A quality standard can be established by checking a batch of gears, which have good quality, on this machine. Then the machine can directly check out the gear parts, which has transmission fault. The frequency spectrum analysis is applied to analyze measuring results.
The measuring and controlling software of this intelligent check system is development by using the popular virtual instrument developing tool-LabWindows/CVI. The software realizes the system frame that the control computer is the key part in the system. The software has the virtual instrument panel and it is easy to operate. This software system has five key modules, include the main control module, control module, data collection module, data analysis and disposal module and data management module. With the modularize structure, this software can be easily transformed to another software environment, maintained, upgraded and expanded.
The intelligent check system proposed in this paper can be used as the final quality check and quality control tool in spiral bevel and hypoid gear manufacture process. It
will have great effect to the improvement of product quality spiral bevel and hypoid gears in our country.
引文
[1] 郑昌启．弧齿锥齿轮和准双曲面齿轮．北京．机械工业出版社．1988：P312～P373
[2] 曾韬．螺旋锥齿轮设计与加工．哈尔滨．哈尔滨工业大学出版社．1989：P273～P253
[3] 国家机械工业委员会质量安全监督司．齿轮和蜗轮蜗杆的检查与测量．北京．机械工业出版社．1991：P166～P202
[4] 张兆龙．从’94西安国际齿轮制造技术交流会看齿轮量仪的发展．工具技术．1995，3：P26～P28
[5] National Instrument Corporation. LabWindows/CVI On Line Help. 1998
[6] 刘君华．现代检测技术与测试系统设计．西安．西安交通大学出版社．1999，4：P285～P287
[7] 张凤均等．LabWindows/CVI开发入门与进阶．北京．北京航空航天大学出版社．2001，12：P25～P35
[8] Huang ChangHua, etal. Lubrication and Tooth Contact Analysis of Sprial Bevel and Hypoid Gear. Chinese Journal of Mechanical Engineering(English Edition). 1995, 2:P104～P106
[9] Comparin, Singh R. Non-linear Frequency Response Characteristics of an Impact Pair. Journal of Sound and Vibration. 1989, 2.. P259～P290
[10] 舒大文、廖伯瑜．用振动和噪声信号诊断汽车变速箱齿轮故障的研究．昆明．昆明理工大学学报．1987，8：P54～P61
[11] 李润方、王建军．齿轮系统动力学—振动、冲击、噪声．北京．科学出版社．1996：P11～48，P353～371
[12] 陈良玉、蔡春源等．螺旋锥齿轮啮合振动的力学模型．东北工学院学报．1993，4：P146～148
[13] 刘光磊、沈允文、王三民．动态计入轮齿啮合力的弧齿锥齿轮转子系统振动模型．机械科学与技术．1998，11：P67～68
[14] 戴素江．准双曲面齿轮降噪的各种观点论谈．汽车研究与开发．2000，1 P40～41
[15] 王延忠、陈良玉等．螺旋锥齿轮噪声预测与降噪方法研究．机械设计与制造．1998，2P33～34
[16] 崔敏．齿轮径向综合误差的虚拟检测仪．新技术新工艺．2001，6：P8～P9
[17] 齿轮手册编委会．齿轮手册．机械工业出版社．北京．90，11：P18-75～P18-95
[18] 机械工程手册编辑委员会．机械工程手册(第二版)．北京．机械工业出版社．1997：P2-128～P2-133
[19] 谭浩强．C程序设计．北京．清华大学出版社．1991
[20] Dr. Hermann J Stadtfeld. Oerlikon Spiromatic context T20 CNC Bevel and Hypoid gear Tester. 1990, 12:P1～P12
[21] ADLINK Technology Inc. PCI-9111DG/HR Multi-Function Data Acquisition Card User's Guide. 2000: P38～P65
[22] 李方泽、刘馥清．工程振动测试与分析．北京．高等教育出版社．1992，10：P293～P301
[23] 金晶立、姚文兵等．弧齿锥齿轮的动态分析．沈阳工业大学学报．1992，12：P38～41
[24] Xiaodong Guo Runfang Li. Finite element modeling and software development for contact analysis of spiral bevel and hypoid gearing. International Journal of Creating and Transmission. 2001, No.3:P54-61
[25] Mcquiston. Virtual instruments for use in test system development. Proceedings of the IEEE System Readiness Technology Conference, AUTOTEATCON, IEEE Service Center. 1993: P639～P642
[26] 马宏伟、唐东红．面向齿轮误差检测的虚拟仪器研究．机械设计与制造工程．2001，3： P53～P54
[27] 石晓辉．可靠性设计数值方法及锥齿轮可靠性设计[博士论文]．重庆大学，1994： P130～P133
[28] National Instrument Corporation. LabWindows/CVI User's Guide. 1998
[29] 黄长艺、严普强．机械工程测试技术基础．北京．机械工业出版社．1994：P125～P146
[30] 肖忠祥．数据采集原理．西安．西北工业大学出版社．2001：P121～P127
[31] 邓星钟、周祖德．机械传动控制．武汉．华中理工大学出版社．1992：P256～P261
[32] 黄莜调、赵松年．机电一体化技术基础及应用．北京．机械工业出版社．1994：P101～P129
[33] 白恩远、孙爱国．现代数控机床伺服及检测技术．北京．国防工业出版社．2002，1：P23～P64
[34] 祝绍箕等．光栅数字显示技术及其应用．北京．机械工业出版社．1992：P122～P131
[35] 赵松龄．噪声的降低与隔离．上海．同济大学出版社．1985：P198～199
[36] 黄昌华、王季军等．一种间接评定准双曲面齿轮副啮合运转平稳性的方法．机械传动．1999，1：P18～P20
[37] 商维绿等．现代扭矩测量技术．上海．上海交通大学出版社．1999：P59～P101
[38] 商向东．齿轮加工精度．北京．机械工业出版社．2000：P163～170
[39] 吴大任、骆家舜．齿轮啮合理论．北京．科学出版社．1985
[40] Lyon, R .h.. Machinery Noise and Diagnostic. Butterworth Publishers. 1986:P23～P24
[41] Dowling ,A .P.. Sound and Sources of Sound. Johnwiley and Sons. 1983:P65～P68
[2] 曾韬．螺旋锥齿轮设计与加工．哈尔滨．哈尔滨工业大学出版社．1989：P273～P253
[3] 国家机械工业委员会质量安全监督司．齿轮和蜗轮蜗杆的检查与测量．北京．机械工业出版社．1991：P166～P202
[4] 张兆龙．从’94西安国际齿轮制造技术交流会看齿轮量仪的发展．工具技术．1995，3：P26～P28
[5] National Instrument Corporation. LabWindows/CVI On Line Help. 1998
[6] 刘君华．现代检测技术与测试系统设计．西安．西安交通大学出版社．1999，4：P285～P287
[7] 张凤均等．LabWindows/CVI开发入门与进阶．北京．北京航空航天大学出版社．2001，12：P25～P35
[8] Huang ChangHua, etal. Lubrication and Tooth Contact Analysis of Sprial Bevel and Hypoid Gear. Chinese Journal of Mechanical Engineering(English Edition). 1995, 2:P104～P106
[9] Comparin, Singh R. Non-linear Frequency Response Characteristics of an Impact Pair. Journal of Sound and Vibration. 1989, 2.. P259～P290
[10] 舒大文、廖伯瑜．用振动和噪声信号诊断汽车变速箱齿轮故障的研究．昆明．昆明理工大学学报．1987，8：P54～P61
[11] 李润方、王建军．齿轮系统动力学—振动、冲击、噪声．北京．科学出版社．1996：P11～48，P353～371
[12] 陈良玉、蔡春源等．螺旋锥齿轮啮合振动的力学模型．东北工学院学报．1993，4：P146～148
[13] 刘光磊、沈允文、王三民．动态计入轮齿啮合力的弧齿锥齿轮转子系统振动模型．机械科学与技术．1998，11：P67～68
[14] 戴素江．准双曲面齿轮降噪的各种观点论谈．汽车研究与开发．2000，1 P40～41
[15] 王延忠、陈良玉等．螺旋锥齿轮噪声预测与降噪方法研究．机械设计与制造．1998，2P33～34
[16] 崔敏．齿轮径向综合误差的虚拟检测仪．新技术新工艺．2001，6：P8～P9
[17] 齿轮手册编委会．齿轮手册．机械工业出版社．北京．90，11：P18-75～P18-95
[18] 机械工程手册编辑委员会．机械工程手册(第二版)．北京．机械工业出版社．1997：P2-128～P2-133
[19] 谭浩强．C程序设计．北京．清华大学出版社．1991
[20] Dr. Hermann J Stadtfeld. Oerlikon Spiromatic context T20 CNC Bevel and Hypoid gear Tester. 1990, 12:P1～P12
[21] ADLINK Technology Inc. PCI-9111DG/HR Multi-Function Data Acquisition Card User's Guide. 2000: P38～P65
[22] 李方泽、刘馥清．工程振动测试与分析．北京．高等教育出版社．1992，10：P293～P301
[23] 金晶立、姚文兵等．弧齿锥齿轮的动态分析．沈阳工业大学学报．1992，12：P38～41
[24] Xiaodong Guo Runfang Li. Finite element modeling and software development for contact analysis of spiral bevel and hypoid gearing. International Journal of Creating and Transmission. 2001, No.3:P54-61
[25] Mcquiston. Virtual instruments for use in test system development. Proceedings of the IEEE System Readiness Technology Conference, AUTOTEATCON, IEEE Service Center. 1993: P639～P642
[26] 马宏伟、唐东红．面向齿轮误差检测的虚拟仪器研究．机械设计与制造工程．2001，3： P53～P54
[27] 石晓辉．可靠性设计数值方法及锥齿轮可靠性设计[博士论文]．重庆大学，1994： P130～P133
[28] National Instrument Corporation. LabWindows/CVI User's Guide. 1998
[29] 黄长艺、严普强．机械工程测试技术基础．北京．机械工业出版社．1994：P125～P146
[30] 肖忠祥．数据采集原理．西安．西北工业大学出版社．2001：P121～P127
[31] 邓星钟、周祖德．机械传动控制．武汉．华中理工大学出版社．1992：P256～P261
[32] 黄莜调、赵松年．机电一体化技术基础及应用．北京．机械工业出版社．1994：P101～P129
[33] 白恩远、孙爱国．现代数控机床伺服及检测技术．北京．国防工业出版社．2002，1：P23～P64
[34] 祝绍箕等．光栅数字显示技术及其应用．北京．机械工业出版社．1992：P122～P131
[35] 赵松龄．噪声的降低与隔离．上海．同济大学出版社．1985：P198～199
[36] 黄昌华、王季军等．一种间接评定准双曲面齿轮副啮合运转平稳性的方法．机械传动．1999，1：P18～P20
[37] 商维绿等．现代扭矩测量技术．上海．上海交通大学出版社．1999：P59～P101
[38] 商向东．齿轮加工精度．北京．机械工业出版社．2000：P163～170
[39] 吴大任、骆家舜．齿轮啮合理论．北京．科学出版社．1985
[40] Lyon, R .h.. Machinery Noise and Diagnostic. Butterworth Publishers. 1986:P23～P24
[41] Dowling ,A .P.. Sound and Sources of Sound. Johnwiley and Sons. 1983:P65～P68