Multidimensional Data Interpretation of Vibration Signals Registered in Different Locations for System Condition Monitoring of a Three-Stage Gear Transmission Operating under Difficult Conditions

Dynamic characteristics of scraper conveyor chain drive system under the impact condition of lump coal

Scraper conveyor is the most important transportation equipment in the comprehensive mining equipment, and the chain drive system is its core subsystem, its dynamic characteristics will significantly affect the efficiency of coal transportation in the comprehensive mining face. In this paper, the dynamic characteristics of chain drive system when impacted by falling coal are investigated by means of test. The impact test bench of scraper conveyor was set up to analyze the effects of chain speed, impact height and impact load mass on the dynamic characteristics of the chain drive system of scraper conveyor under the working conditions of unloaded and loaded. The results show that the longitudinal vibration of the scraper conveyor is most obvious when it is impacted by the falling coal, and the chain speed, impact height and impact load mass of the scraper conveyor all play an excitation role on the vibration of the chain drive system, and the vibration of the chain ring is the most intense in the chain drive system, and the loaded coal pile conveyed on the scraper conveyor plays an inhibiting role on the vibration of the chain drive system. This study can help to identify the location where the scraper conveyor fails first in the impact condition, so as to provide a basis for its structural design and improvement, which is of great significance for the stable operation and structural optimization of the scraper conveyor.

Study of the Impact of Coals and Claystones on Wear-Resistant Steels

This paper discusses the impact of coal abrasive materials of varied petrographic composition and claystones containing admixtures of coal matter on the surface wear of wear-resistant martensitic steels. Wear tests were conducted at a test stand for three petrographic varieties of hard coal: vitrinite, clarinite, and durinite, and five samples of claystone. These tests revealed no significant effect of the type of coal abrasive used on the value of mass loss from the surface of the wear-resistant steel samples. The reason behind the foregoing is the observed tendency of coal abrasives, irrespective of their petrographic variety, to penetrate surface irregularities, especially those attributable to previous surface treatment of the samples and the impact of wear products. The dominant forms of surface damage were surface fatigue chipping and scratches caused by the particles which detached themselves from the surface of the steel samples, as observed for all the analysed coal variants. On the surfaces of the samples seasoned in the presence of claystones, highly varied forms of damage were observed: microcutting, scaly surface cracks, delamination, and deep cracks. In these cases, it was possible that the abrasive grains had been pressed into the steel surface irregularities, but no layered forms of the pressed-in abrasive material were observed to have developed. The paper also presents a model for the formation of coal films and discusses their possible effect on wear minimisation.

Research on Vibroactivity of Toothed Gears with Highly Flexible Metal Clutch under Variable Load Conditions

The article provides a discussion on a methodology intended for testing of power transmission systems featuring an innovative highly torsionally flexible metal clutch patented by the co-authors of this paper. What this methodology takes into account is the amplitude and frequency analyses discussed in the article, as well as a sensing system based on diverse piezoelectric and magnetic phenomena, the Doppler effect, etc. Both contact and non-contact (laser measurement) methods were used during the tests. The purpose of the tests conducted at the stand, originally designed by the authors in accordance with the methodology proposed, was to evidence that using the innovative and patented, highly torsionally flexible metal clutch makes it possible to reduce the vibrations of multi-stage toothed gears, consequently reducing the forces affecting the gear bearings and those acting at the tooth space, which is to enable the service life of individual components of the power transmission systems intended for mining scraper conveyors to be significantly extended. Based on the studies and analyses performed by the authors, one can observe and conclude that the methodology proposed in the paper makes it possible to use an example of a relatively complex power transmission system in order to examine the relationships between the processes at work, i.e., the decline of the linear vibrations of the gear housing (which is undoubtedly positive in power transmission systems) at the expense of increasing torsional vibrations of the innovative clutch, the latter not to be considered unfavourable to users in the case analysed.

Agile Development of Polymer Power Transmission Systems for e-Mobility-A Novel Methodology Based on an e-Bike Drive Case Study

The market for electric bicycles has grown extremely and developed rapidly in recent years. To enter such a market with a new product, the development process has to be fast, and throughout the process, feedback from future potential customer(s) should be sought in order to achieve the best possible market acceptance. The article presents the design process of a pedelec e-bike central drive system. The authors were members of the development team and the designers of the mechanical transmission, and therefore had a good overview of the whole project. The development process and the set-up of production require a certain amount of time, during which design changes are inevitable due to changes in customer expectations and demands. The development team should respond to these changes and take them into account during development. Only the ability to react to changes and constant communication with the customer will ultimately lead to a product that can be commercially successful. Based on a critical review of the successfully completed project, general guidelines were established for the development of mechatronic products that consider the principles of Agile methodology. Particular attention was paid to the development of polymer gears, as these were the most demanding components in the system. The presented guidelines were based on an overview of the e-bike R&D process presented, but they can be generalized and used in the development process of any technical physical product. Agile methods were developed in the field of software development and therefore cannot be directly transferred to the field of physical product development. The article highlights and discusses individual special features that distinguish agile development of physical products from software development.

Operational and Analytical Modal Analysis of a Bridge Using Low-Cost Wireless Arduino-Based Accelerometers

Arduino-based accelerometers are receiving wide attention from researchers to make long-term Structural Health Monitoring (SHM) feasible for structures with a low SHM budget. The current low-cost solutions found in the literature share some of the following drawbacks: (1) high noise density, (2) lack of wireless synchronization, (3) lack of automatic data acquisition and data management, and (4) lack of dedicated field tests aiming to compare mode shapes from Operational Modal Analysis (OMA) with those of a digital model. To solve these problems, a recently built short-span footbridge in Barcelona is instrumented using four Low-cost Adaptable Reliable Accelerometers (LARA). In this study, the automatization of the data acquisition and management of these low-cost solutions is studied for the first time in the literature. In addition, a digital model of the bridge under study is generated in SAP2000 using the available drawings and reported characteristics of its materials. The OMA of the bridge is calculated using Frequency Domain Decomposition (FDD) and Covariance Stochastic Subspace Identification (SSI-cov) methods. Using the Modal Assurance Criterion (MAC), the mode shapes of OMA are compared with those of the digital model. Finally, the acquired eigenfrequencies of the bridge obtained with a high-precision commercial sensor (HI-INC) showed a good agreement with those obtained with LARA.

Nonlinear Dynamic Response Analysis of a Three-Stage Gear Train Based on Lightweight Calculation for Edge Equipment

Bevel gears are widely used in aerospace transmission systems as well as modern mechanical equipment. In order to meet the needs and development of aerospace, high-speed dynamic vehicles, and various defense special equipment, higher and higher requirements are made for the high precision and stability of gear transmission systems, as well as the prediction and control of noise and vibration. Considering the nonlinear factors such as comprehensive gear error and tooth side clearance, a dynamic model of the three-stage gear transmission system is established. The relevant physical parameters, geometric parameters, and load parameters in the gear system are considered random variables to obtain the stochastic vibration model. When the random part of the random parameters is much smaller than the deterministic part, the vibration differential equation is expanded into a first-order term at the mean of the random parameter vector according to the Taylor series expansion theorem, and the ordering equation is solved numerically. Based on the improved stochastic regression method, the nonlinear dynamic response analysis of the three-stage gear train is carried out. This results in a relatively stable system when the dimensionless excitation frequency is in the range of 0.716 to 0.86 and the magnitude of the dimensionless integral meshing error is < 1.089.

Dynamic Properties of Chain Drive in a Scraper Conveyor under Various Working Conditions

A scraper conveyor is important in coal mining. During operation, its working performance is affected by chain speed fluctuations, terrain fluctuations, and load changes. Thus, evaluating the influence of these factors on the dynamic properties of a scraper conveyor is important. This study first built a dynamic property test bench. Then, the vibration signals of the reducer output shaft were measured under various chain speed, terrain, and load conditions. Finally, the dynamic properties of a scraper conveyor were evaluated by conducting a frequency domain analysis of the measured vibration signals. The results show that the output shaft of the motor, the second shaft, and the second-stage meshing gear of the reducer are sensitive to external factors. Under the terrain conditions of “horizontal + vertical” bending, the middle chute was the most sensitive to the meshing frequency of the sprocket chain. This type of condition had a significant influence on the scraping phenomenon of the scraper and the middle chute. Under various load conditions, the amplitude of each shaft of the reducer decreased, especially the amplitude of the motor output shaft, but the scraping amplitude of the scraper and middle chute greatly increased. This study is of great significance for improving the dynamic properties and structural optimization of scraper conveyors.

A Scraper Conveyor Coal Flow Monitoring Method Based on Speckle Structured Light Data

Aiming at the problem of serious shutdowns of conveyors caused by abnormal coal flow of scraper conveyors, a coal flow monitoring method based on speckle structured light is proposed. The point cloud data of the coal body on the scraper conveyor is collected through the speckle structured light acquisition system. Then, the proposed PDS-Algorithm (Planar Density Simplification Algorithm) is used to complete the simplification and differentiation of the collected point cloud data, which provides a basis for constructing geometric characteristics of coal flow lineament. This paper uses the processed point cloud data to calculate the volume of the coal mass and monitor the coal flow of the scraper conveyor. Finally, this method is used in the detection of abnormal coal flow of a coal mine scraper conveyor, and the results show that the proposed abnormal flow monitoring method can meet the accuracy and real-time requirements of coal mine abnormal alarms.