Dynamics Simulation and Malfunction Diagnosis of Heavy ...

REFERENCE

Dynamics Simulation and Malfunction Diagnosis of Heavy Machinery Using MSC ADAMS

Dewen Kong, Professor, Jilin University, China

Jim M. Meagher, Professor, California Polytechnic State University

Xi Wu, Assistant Professor, California Polytechnic State University

- -

MSC.Software Confidential

1. Introduction

• Large mining excavators are widely used in

open pit mining industry for loading and

excavating operation. Electric shovel is one

of this kind of heavy machinery and its

weight can be as high as hundreds to

thousands tons. This study demonstrates the

efficacy of using MSC ADAMS software for

dynamics simulation and malfunction

diagnosis of a large mining excavator.

2009 4 13 2

Swing Bearing

Crawler Travelling System


2. Modeling the Electric Shovel

• 3-D CAD model is created for ADAMS simulation


3. Dynamics Simulation for Swing Bearing

To perform simulation, the driving torque and braking

torque are applied to the upper structure along with

the upper tracks, and the contact forces are applied

between rollers and tracks.


Simulation Results:

• Swing motion diagrams of the upper structure,

including angular velocity and acceleration in

a loading cycle

• Contact forces between the rollers and tracks


4. Dynamics Simulation of the Crawler Travelling System

• The driving torque from the traveling gearbox is

applied to the crawler driving tumbler, and the

resistant force is applied to the chassis frame. The

joint or cylindrical constraints are applied between

the wheels and the their shafts. The contact pairs

are applied between the crawler shoes and the

driving tumbler, the lower roller and the crawler

shoes. The simulation results show the x, y, and z

components of the contact forces between driving

tumbler and the crawler shoes.

3.0 4.0

TOne (,ee)

_750.0 -

750.0 -

1500.0 - ;========='=====;---lcort.cUV:':OL4.EIeme<tJ c<ce.X

- -.cort,cUvjor"JEIeme<tJc<ce.Y---".cortoct~ 4.EIeme<t fc<ce.I

_1500.0 ~~~~~~~~~~~~--10.0 1 .0

AnoIy,i, L.ct_RL<1

I]


Animation for the Crawler System Simulation

8.751'.006

i 7.51'.006•0J'

5.25E.OO6 t

5U"0061-~~~~~~~j0.0 0.5 1.0 1.5 2.0 2.5

AMIy,i, Lod_..... (1iUf_[14_23 21 :35:29


5.Gearbox Dynamics Simulation and Fault Diagnosis

The crawler travelling system is driven by a three-stage gear

transmission.

5.04.8754.75

MPRO_model

4.625

H -.CONTACT_2.ElementJorceyl

L! ). I ~ ! L k A ~ ~ ! l

I\lUl l\ 1\ J ~ h 1\ 1\ 11 r\ ~ ~ i\ 1\ ~ ! 1\ 1\ ~ ~ )1 1\ nn ~ H\J\f\ 1\ II !\ '\ 1\ I 1\ ~ 1\ AI\ 1 11 (\!1 IVt1

~ ~ ~ ~ \ \ ~/V \I\.~VV~\ J\N\ ~ IV ~ \ I\!~ I\J \1 \tl I~ V\1 \Jv . ~ ~ \ \ } U\!~1iV I~ V~ \!V \V\ A V~\ - ~ ~ \r r ~

y \(V v- \ \ IN\f'1 \(~

, r i"" v ,0·~.5

3.0E-+D06

c 2.25E-+D060

i1.5E-+D06c

'-"'Q)u

tE 7.5E-+D05

Time (sec)

I FFTMAG(Harilrflilig( .plot_3 ,curve_1 ,y_dMa) ,4Q9S} - c- --

I

f- + :- - + -

f- -~-----l I \ - - -

~ J-.... /'--.~ ~~ " .~ ~........1 --.-,

2,OE+O05

"2' 1.5E+O05o

~ -- ---.s 1.01::+005Q)u

tE 50000.0

130.0 135.0 140.0 145.0

Frequency (Hz)


• From the contact forces, we can get the meshing frequencies by FFT.


• To simulate the fault mode of gearbox, a pinion with chopped tooth joints in the ADAMS model, and the meshing frequency of the fault tooth of the pinion can be detected by wavelet transform after the contact force simulation.


6. Planetary Gearbox Dynamics Simulation and

Fault Diagnosis

• This is a 3ZII type

planetary gearbox

with large gear

ratio. Here is a

scaled model with

module 2 and gear

ratio 134.

170.0

_____'~_'3ZI'_m'-C.....""""<0""0 I

I!

I '~=·COO=.,.,'.,-••,'.-,C,',',-,,·"...'_ fl=0=0

_100.0

_!S C100.0

,g _200.0

- _300.0_400.0 - .CooTACT_151 .EIeme<tJc<ce.X

t~c-~-C.J";'-:':C'~~;"'C';~-~"'~"',-,,~-J,,",,""'J._5000,~0.0 0.1 0.2 0.3 0.4 0.5 0.5 0.7 0.8 0.9 1.0

AMIy,i, Lost_RL<1 Trne(,oc) 2009_[14_1015:07:15


6.1 Simulation for the Gearbox with perfect teeth

'

00

-150.0I'

-30000'Oc--------CO"2"S--------COCSc--------COC7"S--------~,0

Ana~sis Last_Run Time (sec) 2009-04-10 160715

15.0,,==============;------------------,FFTMA.G(Hammin9(plot 11.curve 3y data),4096)]

coo 10.0

l:""~o 5.0"

t t

I , .LL .I . I •. L

500.0 10000 1500.0 2000.0Frequency (Hz)


Contact Force between sun gear and planet gear, and its

FFT Plot

• The peaks in FFT plot shows the meshing frequencies and meshing stiffness frequencies.

Chopped~

1110

i0~

=111>u"0~

.0 0.1

Ana~is Last Run

0.2 0.3 0.4 0.5

Time (sec)

0.6 0.7

-CONTACT 1Element ForceX_. ,CONTACT=1,Element=Force.Y--CONTACT 1,Elemenl ForceMa

2009-04-11 145630

"2 45,00

33.75'i05 2250~ 11250~

O~O

-FFTMAG(Hamming(ploC12culYe_1 y_data),4096

5000 10000

Frequency (Hz)

15000 20000


6.2 Simulation for the Gearbox with chopped tooth on sun

gear

• The FFT for the contact force shows the modulated side bands because of tooth malfunction.

3.E1ement ForceX- --'.CONTACT 3.E1ement ForceY- - .CONTACT-3 .Element-Force.Ma- -

070605

Time (sec)

040302-5000~0 0 1

Si m3ZII_m2_sun_planeCchopped10000.0,---~~~~~~~~~~~~========~~~~~~~~~~---,

5000.0

00

Ana~sis Last Run

150.0ci 112.5

c 75.0

37.5

-FFTMAG(Hammi ng(ploC22 curve_1Ldata) ,4096

375.0 750.0 1125.0

I

1500.0

Frequency (Hz)


6.3 Simulation for the Gearbox with Chopped Tooth on Sun

Gear and Planet Gear

• The hunting tooth frequency shows up when teeth malfunction occurs on both pinion and gear.


7. Conclusion

• The VPD technology can largely reduce the heavy

machinery R&D cost by cutting down some of the

physical test on site.

• The simulation results revealed dynamics

performance of the huge machine in several working

conditions. By post-processing the results of the

dynamics simulation, techniques for gearbox

malfunction diagnosis are possible.

• The signatures for gear faults can be obtained by

FFT and wavelet transform.


Thank you for your patience!

- -


Contact Details :

• For further information please contact

Dewen Kong College of Mechanical Science and Engineering, Jilin University

5988 Renmin st., Changchun, Jilin Province

College of Mechanical Science and Engineering, Jilin University, Nanling Campus

130025

P. R. China 86-431-85095078 [email protected]

Jim Meagher

Mechanical Engineering Department, California Polytechnic State University

San Luis Obispo, CA93407

1-805-756-1115

[email protected]

2009 4 13 18

mailto:[email protected]

mailto:[email protected]

Dynamics Simulation and Malfunction Diagnosis of Heavy ...

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