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基于实测载荷谱的大马力拖拉机变速器动态损伤评估

Dynamic damage assessment of high horsepower tractor transmission based on measured load spectrum

  • 摘要: 针对Miner损伤法则在损伤评估时只考虑应力幅值的局限性,该研究提出一种考虑载荷梯度、频段损伤能量以及载荷峭度的动态损伤评估方法。首先搭建了拖拉机车轮驱动扭矩测试系统,通过扭矩传感器获取了车轮处的扭矩载荷数据;利用雨流计数法和统计方法得到了载荷的统计特性。随后对载荷梯度、频段损伤能量以及载荷峭度进行线性加权,构建损伤谱指数;基于网格搜索法和多载荷类型验证确定了加权系数分别为0.35、0.425、0.225。并通过sigmoid函数进行s型非线性压缩以抑制极端值的干扰;随后将载荷循环时间中心在动态损伤强度指数窗口进行索引,将时频特性融入循环损伤,形成了动态损伤评估框架。结果表明,改进后的方法能有效计算载荷分频段损伤,变速器轴载荷的归一化功率谱密度能量最高点为0.1 Hz,损伤最大频率为0.43 Hz,损伤值为1.78×10−8,验证了本方法的理论正确性;传统Miner损伤法则的计算相对误差值为51.11%,本方法的损伤预测相对误差为0.67%,该方法具有较高的损伤预测准确率和良好的可行性,为今后损伤评估方法的研究提供了理论依据和新思路。

     

    Abstract: This study takes the transmission shaft of a 162 kW four-wheel drive wheeled tractor as the research object and proposes a dynamic damage assessment method. By integrating multidimensional parameters and employing a dynamic weight allocation mechanism, the method overcomes the limitation of traditional Miner’s linear cumulative damage theory, which focuses solely on stress amplitude. A comprehensive damage assessment framework is established, encompassing the time-domain characteristics of loads, energy distribution in the frequency domain, and fluctuation features. First, a torque testing system based on the tractor’s transmission shaft was developed. This system integrates high-precision strain-based torque sensors and wireless data acquisition modules, enabling real-time capture of torque fluctuation signals under various operating conditions such as field operations and road transportation. The field-measured wheel torque signals were converted into equivalent torque at the transmission shaft through the wheel-side planetary reduction mechanism, central transmission, transfer case, creeper gear, and gearbox. Subsequently, the rainflow counting method was applied to identify load cycles in the torque data. Statistical characteristics of the loads were derived using statistical methods, providing a high-confidence data foundation for subsequent analysis. In the damage indicator construction phase, a composite model of "three-dimensional linear weighting–nonlinear compression" was innovatively proposed. Three indicators—load gradient, frequency-band damage energy, and load kurtosis—were linearly weighted. The weighting parameters for these three core indicators were optimized using a grid search algorithm, with the root mean square error and absolute percentage error employed to quantitatively evaluate the performance of different parameter combinations. The optimal weight allocation scheme was determined as 0.35, 0.425, and 0.225. To mitigate the influence of extreme values on the assessment results, an S-shaped compression mapping based on the sigmoid function was introduced, effectively balancing sensitivity and robustness. Subsequently, the load cycle time center was indexed within the dynamic damage intensity index window, and time-frequency characteristics were integrated into the cyclic damage for amplitude correction. A hazardous threshold based on the dynamic damage intensity index revealed exponential amplification of cyclic amplitudes. The Goodman formula was then used to convert the torque signals into equivalent zero-mean stress amplitudes, and the S-N curve of the transmission shaft was applied to compute the damage, resulting in a dynamic damage assessment methodology. Experimental results demonstrate that the improved method effectively calculates damage across load bands. The peak normalized power spectral density energy occurs at 0.1 Hz, while the maximum damage frequency band is at 0.43 Hz, with a damage value of 1.78×10-8. The fact that the peak power spectral density energy does not coincide with the maximum damage value effectively illustrates the limitations of traditional methods that consider only amplitude, thereby validating the theoretical correctness of the proposed approach. The relative error of the traditional Miner’s damage rule was 51.11%, whereas the relative error of the proposed damage prediction method was only 0.67%. This method exhibits high accuracy and feasibility in damage prediction, advancing the study of linear damage models beyond the perspectives of loading sequence and statistical analysis, and providing a theoretical basis and new insights for future research on damage assessment methods. Furthermore, this study not only proposes a concrete and engineerable dynamic damage assessment process but also constructs a three-dimensional damage feature space incorporating load gradient, frequency-band energy, and load kurtosis. This multidimensional parameter coupling mechanism offers dual value for subsequent research: it can be directly applied to life prediction of rotating machinery such as transmission shafts and gearboxes, and can also be extended to damage assessment in new structural domains such as composite materials and additive manufacturing components, providing a novel theoretical tool and quantitative methodology for intelligent operation and predictive maintenance.

     

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