CN-122014828-A - Multi-sensor integrated intelligent gear

CN122014828ACN 122014828 ACN122014828 ACN 122014828ACN-122014828-A

Abstract

The invention discloses a multi-sensor integrated intelligent gear which comprises a gear body, a PCB (printed circuit board) integrating a plurality of functional modules and a sealing cover plate. The intelligent gear integrating the multiple sensors integrates the sensing function, the wireless communication function and the gear body into a whole, realizes the real-time sensing, wireless transmission, display and storage of stress, acceleration, temperature and noise information under the working state of the gear, and realizes an intelligent gear part. The intelligent gear integrating the multiple sensors is characterized in that a groove is formed in the end face or the radial plate of the gear body, an annular or fan-shaped PCB (printed Circuit Board) designed according to different gear sizes is embedded into the groove, and the intelligent gear integrating the sensing function, the wireless communication function and the gear is integrated by utilizing screws or bonding fixation and sealing through a sealing cover plate. The intelligent gear integrated by the multiple sensors has the functions of real-time sensing and wireless communication, does not need additional sensors and communication devices, is compact in structure and high in integration level, and meanwhile, achieves the intellectualization of gear parts by considering dynamic balance.

Inventors

WANG PENG
SONG YI
ZHANG CHUNQI
Qiao Baofang
LI DUO
CHEN YANG
ZHANG LIANG

Assignees

北京工业大学

Dates

Publication Date: 20260512
Application Date: 20260115

Claims (10)

1. The intelligent gear integrated by multiple sensors is characterized by comprising a gear body, a Printed Circuit Board (PCB) and a sealing cover plate, wherein an annular embedded groove is formed in a radial plate on the end face of the gear body, the shape of the PCB is matched with that of the embedded groove, the PCB is arranged in an annular or fan-shaped mode and is embedded and fixed in the embedded groove through gluing or screws, the sealing cover plate is adaptive to the size of the embedded groove and is used for sealing and protecting the PCB from corrosion of liquid in a gear box, the sealing cover plate is made of radio frequency transparent materials, a signal output by a wireless communication module is guaranteed to penetrate through the sealing cover plate on the premise of sealing protection, and the PCB, the sealing cover plate and the gear body are integrated into an integral structure and synchronously rotate along with the gear.
2. The intelligent gear integrated by multiple sensors according to claim 1, wherein the embedded groove is formed in a low-stress area of a web plate on the end face of the gear, the position of the embedded groove is determined based on finite element load analysis, the groove body is an annular sinking groove matched with the shape of a Printed Circuit Board (PCB), the edge of the groove bottom adopts a fillet transition to reduce stress concentration, a threaded hole or a clamping structure for fixing the printed circuit board is arranged in the groove, and a wire through hole or a wireless transmission window is reserved in the groove.
3. A multi-sensor integrated intelligent gear according to claim 1 or 2 is characterized in that machining of an embedded groove adopts a numerical control milling or electric spark forming process, electric spark machining is adopted for a high-hardness gear subjected to heat treatment to avoid damage to material performance, or a metal additive manufacturing technology is adopted to integrally form a structure with a cavity and internal characteristics in the gear manufacturing process, and the embedded groove is formed to ensure structural integrity and functional integration reliability of a gear main body.
4. The multi-sensor integrated intelligent gear according to claim 1, wherein the PCB is integrated with: The multi-sensor sensing module is used for sensing gear running state data in the gear working process in real time, and the multi-sensor comprises a strain sensor, a temperature sensor and an acceleration sensor and is used for measuring signals of strain, temperature and acceleration in the gear working process in real time; the signal conditioning module is used for amplifying, filtering and A/D conversion processing signals acquired by the sensor and preprocessing the signals for wireless transmission; The wireless communication module is used for accurately outputting a gear state signal from the rotating gear, so that the real-time monitoring of the running state of the gear is realized; The power management module is used for conditioning the power supply of the multi-sensor sensing module and the wireless communication module and simultaneously carrying out charge management and discharge control on the battery; the battery is used as a power supply to supply power to the multi-sensor sensing module and the wireless communication module, and is used as a counterweight to adjust dynamic balance for the gear.
5. The intelligent gear integrated with multiple sensors according to claim 4, wherein the battery is a rechargeable micro lithium battery or a soft package battery with a customized shape, the mounting base is located in a preset mounting area in the gear end face embedded groove or directly fixed on a Printed Circuit Board (PCB), and dynamic balance adjustment is achieved by mounting the battery at different angular positions within a circumferential range and changing mass distribution of the system.
6. A multi-sensor integrated intelligent gear according to claim 4 or 5 is characterized in that in the design stage, unbalance is estimated according to a three-dimensional model of a system, the required mass moment range of a counterweight is calculated through a mass moment balance equation by referring to allowable unbalance, the nominal weight of a battery is selected, in the actual correction stage, the battery is matched with a miniature detachable counterweight, the final accurate position is determined through dynamic balance measurement and calculation, firstly, a component without the battery is subjected to dynamic balance test, the phase angle and the magnitude of the initial unbalance are measured, then, the polar coordinate angle of the battery to be installed in an annular area is determined through dynamic balance solution, and finally, fixing is carried out.
7. The multi-sensor integrated intelligent gear according to claim 1, wherein: according to the difference of the size of the gear and the space of the end face web, the scheme of the integral annular PCB aiming at the pinion is as follows; When the gear body is a pinion, the PCB is annular, and is embedded in an embedded groove at the radial plate of the gear end face around the gear axis, and the multi-sensor sensing modules are distributed to accurate positions along the circumferential direction after calibration; the gear end face sealing device also comprises an annular sealing cover plate which is detachably connected with the gear end face, and the sealing cover plate is fixed on the pinion body in an adhesive mode.
8. The multi-sensor integrated intelligent gear according to claim 1, wherein: according to the difference of the size of the gear and the space of the end face radial plate, the scheme of the combined fan-shaped PCB facing the big gear is as follows; When the gear body is a large gear, the PCBs are sector-shaped, a plurality of sector-shaped PCBs encircle the gear axis, are spliced to form a complete annular spliced PCB along the circumferential direction of the gear, or are symmetrically distributed along the axis of the end face of the gear, and the dynamic balance of the gear is realized by circumferentially distributing or symmetrically distributing the PCBs; the gear wheel is characterized by further comprising an annular sealing cover plate detachably connected with the end face of the gear wheel, and the cover plate is fixed on the large gear body in an adhesive mode.
9. A method for manufacturing a multi-sensor integrated intelligent gear based on the multi-sensor integrated intelligent gear of claim 1, wherein the multi-sensor integrated intelligent gear for a pinion comprises the following steps: Step 1, processing an annular embedded groove on the end face of a pinion body; Step 2, preparing an annular PCB, and integrating a multi-sensor sensing module, a signal preprocessing module, a wireless communication module, a power management module and a battery on the annular PCB; And 3, firstly placing the PCB into the embedded groove, fixing the PCB on the gear body through gluing or screws, and then assembling and fixing the sealing cover plate and the gear body in a gluing mode, so that the cover plate covers and seals the embedded groove.
10. A method for manufacturing a multi-sensor integrated intelligent gear based on the multi-sensor integrated intelligent gear of claim 1, wherein the multi-sensor integrated intelligent gear for a large gear comprises the following steps: step 1, processing an annular embedded groove on the end face of a large gear body; Step 2, preparing a fan-shaped PCB, and integrating a multi-sensor sensing module, a signal preprocessing module, a wireless communication module, a power management module and a battery on the PCB; Step 3, splicing a plurality of fan-shaped PCBs along the circumferential direction of the gear to form a complete annular spliced PCB, or symmetrically distributing the fan-shaped PCBs along the axial center of the end face of the gear in a multi-section mode, and realizing dynamic balance of the gear through the circumferential distribution or the symmetrical distribution of the PCBs; And 4, distributing a plurality of fan-shaped PCBs in the embedded grooves along the circumferential direction of the gear, fixing the fan-shaped PCBs on the gear body through gluing or screws, and then assembling and fixing the sealing cover plate and the gear body in a gluing mode, so that the cover plate covers and seals the embedded grooves.

Description

Multi-sensor integrated intelligent gear Technical Field The invention belongs to the technical field of intelligent mechanical parts, and particularly relates to an intelligent gear integrated by multiple sensors. Background In recent years, with the continuous development of intelligent equipment and intelligent products, the demand for intelligent parts with sensing capability is increasing. The functions of sensing, communication, data processing, even power supply and the like are integrated on the part body, so that the part-level multi-information sensing function is realized, the intelligent level of equipment and products can be greatly improved, and the system design is simplified. The gear part is used as a core element of a transmission system, the working condition is quite complex, and the intellectualization of the gear part faces extremely urgent demands and great technical challenges. For example, multiple information sensing and reliable data transmission under complex system structure and operating condition constraints are critical technical challenges faced by intelligent gear parts. The structural integration challenge is that the gear teeth are subjected to a major alternating load, and the mechanical properties of the gear teeth are severely impaired by the openings or slots in the body thereof. The tooth surface is a working surface, so that the difficulty in installing devices is high. The integrated space is extremely limited, dynamic balance cannot be influenced after the integrated space is integrated, the energy source continuously has the challenges that gears are usually sealed in a box body to continuously run for a long time, charging opportunities cannot be obtained when a tool is replaced each time like a tool handle, external induction coils cannot be conveniently arranged like certain bearings, how to provide long-term, stable and maintenance-free energy for an electronic system integrated on the external induction coils is one of the biggest problems, and the signal transmission reliability has the challenges that the gearbox is usually in a metal closed environment and is seriously shielded from radio signals. In the continuous rotation and complex oil mist environment, how to realize the wireless transmission of the monitoring data with high reliability and low delay is a great technical problem. Publication number CN 115541224A discloses a gear intelligent monitoring system and method comprising multidimensional information fusion, a patent document sensing module is directly fixed on the end face of a gear and is installed in a coaxial mode with the gear, the scheme is based on an accessory component, publication number CN 117213839A discloses a WIFI-based embedded gear monitoring system and method, and the patent document adopts an additional embedded scheme, so that shafting dynamic balance is destroyed. These two disclosed representative sensing schemes involve modifications to existing mechanical systems and gear part structures, which have a significant adverse impact on the structural design, dynamic balance and reliability of the system. Therefore, the prior art lacks an intelligent gear part design scheme capable of integrating functions such as sensing, energy supply and communication in the gear part body in a highly integrated manner on the premise of not damaging the existing structure of the system, and realizing real-time sensing. Disclosure of Invention Aiming at the problems of indirect signals, incapability of accurate positioning, complex and unreliable wired slip ring system, low integration level of a wireless scheme, large structural change and the like existing in the prior art of gear state information sensing, the invention aims to provide an integrated, modularized and self-powered intelligent gear with multiple sensors and a manufacturing method thereof. The scheme aims to solve the difficult problems of high density and nondestructive integration of the sensing unit on the gear body and realize wireless power supply and communication, so that long-term, in-situ and maintenance-free real-time wireless sensing capability is provided for the gear on the premise of not damaging the structural strength and dynamic balance of the gear main body and the gear box body structure, and the intelligent design of the gear is realized. In order to achieve the above purpose, the present invention adopts the following technical scheme: A multi-sensor integrated intelligent gear comprises a gear body, a Printed Circuit Board (PCB) and a sealing cover plate. The gear body is characterized in that an annular embedded groove is formed in a spoke plate on the end face of the gear body, the shape of a PCB is matched with that of the embedded groove, gears with different sizes are matched to be annular or fan-shaped, the PCB is fixed in the embedded groove in an embedded mode through gluing or screw embedding, a sealing cover plate is matched with the size of t