Gearbox Transmission Error Test Rig Research Based On Electrically Closed Theory

Gearbox is a key component in the vehicle transmission system to realize dynamic conversion,which is one of the main source of noise and vibration.During the working process of the gearbox,the gear transmission error,time-varying mesh stiffness and meshing impact will lead to internal excitation,while the fluctuation of the prime motor and load will generate external excitation.Vibration caused by internal and external excitations will transmit through gears,shafts and bearings to the gearbox housing,and the housing vibration will generate noise finally.Current research indicates that the existence of transmission error is the main excitation source of gearbox noise and vibration.Therefore,this paper developed a kind of gearbox transmission error test rig based on electrically closed theory.To determine the overall design scheme of the gearbox transmission error test rig,the paper investigates the measured object,the test rig structure form,dynamical system,measurement and control system.The test rig uses angle encoders to measure the gearbox transmission error,and the drive and load system of the test rig are constructed based on DC-BUS electrically closed principle.The control mainframe of the measurement and control system is a computer,and the Siemens SINAMICS S120 drive system is used to realize the driving and loading of the gearbox,the communication between the computer and Siemens SINAMICS S120 drive system is based on Profinet-PN communication protocol.The data acquisition system of the test rig is based on visual instruments technology,and the data acquisition system is constructed based on NI LabVIEW software,and the data acquisition card is used to acquire and process the signals of the angle encoders and torque sensors.The electromechanical system is an important part to realize the functions of the test rig.In order to match the power of the gearbox and load motor,a kind of two speed reducer is developed,and Romax Designer software is employed to realize static and modal analysis to ensure the structural strength and life of the reducer are qualified to transmit power.The angular displacement and torque of the gearbox are measured by Heidenhain ERA4280 C angle encoders and HBM T40 B torque flanges respectively,and a kind of transmission module is designed to integrate the two sensors.Siemens Sizer software is used to select the motor and drive system,and the power system of the test rig is constructed based on Siemens 1PH8 series motors and SINAMICS S120 drive system.The communication of the control computer and SINAMICS S120 drive system is realized by a PLC module.The measurement and control system of the test rig includes control system and data acquisition system.The Siemens Starter software is used to configurate and debug the SINAMICS S120 system,and the Siemens TIA Portal software is used to integrate PLC,control computer and SINAMICS S120 system.The control of the gearbox drive speed and load torque is realized by HMI control panel.The data acquisition system of the test rig is based on visual instruments technology,and uses NI LabVIEW software to acquire and process the signals of the angle encoders and torque sensors.The gearbox transmission error and housing vibration are measured,and the experimental results indicates that the measurement and control precision of the test rig is enough accurate,and the expected design goals are achieved.