NEW APPROACH FOR RELIABILITY- BASED DESIGN OPTIMIZATION： MINIMUM ERROR POINT

Conventional reliability-based design optimization (RBDO) requires to use the most probable point (MPP) method for a probabilistic analysis of the reliability constraints. A new approach is presented, called as the minimum error point (MEP) method or the MEP based method, for reliability-based design optimization, whose idea is to minimize the error produced by approximating performance functions. The MEP based method uses the first order Taylor's expansion at MEP instead of MPP. Examples demonstrate that the MEP based design optimization can ensure product reliability at the required level, which is very imperative for many important engineering systems. The MEP based reliability design optimization method is feasible and is considered as an alternative for solving reliability design optimization problems. The MEP based method is more robust than the commonly used MPP based method for some irregular performance functions.     

Reliability Design for Impact Vibration of Hydraulic Pressure Pipeline Systems

The research of reliability design for impact vibration of hydraulic pressure pipeline systems is still in the primary stage,and the research of quantitative reliability of hydraulic components and system is still incomplete.On the condition of having obtained the numerical characteristics of basic random parameters,several techniques and methods including the probability statistical theory,hydraulic technique and stochastic perturbation method are employed to carry out the reliability design for impact vibration of the hydraulic pressure system.Considering the instantaneous pressure pulse of hydraulic impact in pipeline,the reliability analysis model of hydraulic pipeline system is established,and the reliability-based optimization design method is presented.The proposed method can reflect the inherent reliability of hydraulic pipe system exactly,and the desired result is obtained.The reliability design of hydraulic pipeline system is achieved by computer programs and the reliability design information of hydraulic pipeline system is obtained.This research proposes a reliability design method,which can solve the problem of the reliability-based optimization design for the hydraulic pressure system with impact vibration practically and effectively,and enhance the quantitative research on the reliability design of hydraulic pipeline system.The proposed method has generality for the reliability optimization design of hydraulic pipeline system.     

ON DESIGN METHOD OF THE PRECISION CAM PROFILE WITH RANDOM PROCESSING ERRORS

Based on probability and statistic, a design method of precision cam profile concerning the influence of random processing errors is advanced. Combining the design with the process, which can be used to predict that cam profiles will be successfully processed or not in the design stage, design of the cam can be done by balancing the economization and reliability. In addition, an fuzzy deduction method based on Bayers formula is advanced to estimate processing reasonable of the designed precision cam profile, and it take few samples.     

Reliability-based robust optimization design of automobile components with non-normal distribution parameters

In the reliability designing procedure of the vehicle components, when the distribution styles of the random variables are unknown or non-normal distribution, the result evaluated contains great error or even is wrong if the reliability value R is larger than 1 by using the existent method, in which case the formula is necessary to be revised. This is obviously inconvenient for programming. Combining reliability-based optimization theory, robust designing method and reliability based sensitivity analysis, a new method for reliability robust designing is proposed. Therefore the influence level of the designing parameters’ changing to the reliability of vehicle components can be obtained. The reliability sensitivity with respect to design parameters is viewed as a sub-objective function in the multi-objective optimization problem satisfying reliability constraints. Given the first four moments of basic random variables, a fourth-moment technique and the proposed optimization procedure can obtain reliability-based robust design of automobile components with non-normal distribution parameters accurately and quickly. By using the proposed method, the distribution style of the random parameters is relaxed. Therefore it is much closer to the actual reliability problems. The numerical examples indicate the following: (1) The reliability value obtained by the robust method proposed increases (>0.04%) comparing to the value obtained by the ordinary optimization algorithm; (2) The absolute value of reliability-based sensitivity decreases (>0.01%), and the robustness of the products’ quality is improved accordingly. Utilizing the reliability-based optimization and robust design method in the reliability designing procedure reduces the manufacture cost and provides the theoretical basis for the reliability and robust design of the vehicle components.     

Modification design method for an enveloping hourglass worm gear with consideration of machining and misalignment errors

The influences of machining and misalignment errors play a very critical role in the performance of the anti-backlash double-roller enveloping hourglass worm gear(ADEHWG).However,a corresponding efficient method for eliminating or reducing these errors on the tooth profile of the ADEHWG is seldom reported.The gear engagement equation and tooth profile equation for considering six different errors that could arise from the machining and gear misalignment are derived from the theories of differential geometry and gear meshing.Also,the tooth contact analysis(TCA) is used to systematically investigate the influence of the machining and misalignment errors on the contact curves and the tooth profile by means of numerical analysis and three-dimensional solid modeling.The research results show that vertical angular misalignment of the worm wheel(Δβ) has the strongest influences while the tooth angle error(Δα) has the weakest influences on the contact curves and the tooth profile.A novel efficient approach is proposed and used to minimize the effect of the errors in manufacturing by changing the radius of the grinding wheel and the approaching point of contact.The results from the TCA and the experiment demonstrate that this tooth profile design modification method can indeed reduce the machining and misalignment errors.This modification design method is helpful in understanding the manufacturing technology of the ADEHWG.     

Quantitative damage detection for planetary gear sets based on physical models

Planetary gear set is the critical component in helicopter transmission train,and an important problem in condition monitoring and health management of planetary gear set is quantitative damage detection.In order to resolve this problem,an approach based on physical models is presented to detect damage quantitatively in planetary gear set.A particular emphasis is put on a feature generation and selection method,which is used for sun gear tooth breakage damage detection quantitatively in planetary gear box of helicopter transmission system.In this feature generation procedure,the pure torsional dynamical models of 2K-H planetary gear set is established for healthy case and sun gear tooth-breakage case.Then,a feature based on the spectrum of simulation signals of the dynamical models is generated.Aiming at selecting the best feature suitable for quantitative damage detection,a two-sample Z-test procedure is used to analyze the performance of features on damage evolution tracing.A feature named SR,which had better performance in tracking damage,is proposed to detect damage in planetary gear set.Meanwhile,the sun gear tooth-chipped seeded experiments with different severity are designed to validate the method above,and then the test vibration signal is picked up and used for damage detection.With the results of several experiments for quantitative damage detection,the feasibility and the effect of this approach are verified.The proposed method can supply an effective tool for degradation state identification in condition monitoring and health management of helicopter transmission system.     

Design and Test Analysis of a Solar Array Root Hinge Drive Assembly

A root hinge drive assembly is preferred in place of the classical viscous damper in a large solar array system.It has advantages including better deployment control and higher reliability.But the traditional single degree of freedom model should be improved.A multiple degrees of freedom dynamics model is presented for the solar arrays deployment to guide the drive assembly design.The established model includes the functions of the torsion springs,the synchronization mechanism and the lock-up impact.A numerical computation method is proposed to solve the dynamics coupling problem.Then considering the drive torque requirement calculated by the proposed model,a root hinge drive assembly is developed based on the reliability engineering design methods,and dual actuators are used as a redundancy design.Pseudo-efficiency is introduced and the major factors influencing the（pseudo-）efficiency of the gear mechanism designed with high reduction ratio are studied for further test data analysis.A ground prototype deployment test is conducted to verify the capacity of the drive assembly.The test device consists of a large-area solar array system and a root hinge drive assembly.The RHDA development time is about 43 s.The theoretical drive torque is compared with the test values which are obtained according to the current data and the reduction efficiency analysis,and the results show that the presented model and the calibration methods are proper enough.     

Mathematical Model and Geometrical Model of Double Pitch ZN-type Worm Gear Set Based on Generation Mechanism

The current researches on the tooth surface mathematical equations and the theory of gearing mainly pay attention to the ordinary type worm gear set(e.g., ZN, ZA, or ZK). The research of forming mechanism and three-dimensional modeling method for the double pitch worm gear set is not enough. So there are some difficulties in mathematical model deducing and geometry modeling of double pitch ZN-type worm gear set based on generation mechanism. In order to establish the mathematical model and the precise geometric model of double pitch ZN-type worm gear set, the structural characteristics and generation mechanism of the double pitch ZN-type worm gear set are investigated. Mathematical model of the ZN-type worm gear set is derived based on its generation mechanism and the theory of gearing. According to the mathematical model of the worm gear set which has been developed, a geometry modeling method of the double pitch ZN-type worm and worm gear is presented. Furthermore, a geometrical precision calculate method is proposed to evaluate the geometrical quality of the double pitch worm gear set. As a result, the maximum error is less than 6′10–4 mm in magnitude, thus the model of the double pitch ZN-type worm gear set is available to meet the requirements of finite element analysis and engineering application. The derived mathematical model and the proposed geometrical modeling method are helpful to guiding the design, manufacture and contact analysis of the worm gear set.     

METHOD TO SOLVE ELASTIC CONJUGATE SURFACES IN MULTI-TEETH MESHING

A method to solve the elastic conjugate surfaces in multi-teeth meshing is presented. In mechanicalmanufacturing and design, there exist a lot of problems relating to conjugate surfaces, such as three-dimensionalengagement, steel rolling and workpiece machining, which cause great effects on the quality of machining andperformances of transmission. This method describes relation between conjugate motion and elastic deformation in theprocess of mesh-in and mesh-out, and can be used to determine the profile of gear tooth by a certain given load sharing.     

Markov Chain Modelling of Reliability Analysis and Prediction under Mixed Mode Loading

The reliability assessment for an automobile crankshaft provides an important understanding in dealing with the design life of the component in order to eliminate or reduce the likelihood of failure and safety risks.The failures of the crankshafts are considered as a catastrophic failure that leads towards a severe failure of the engine block and its other connecting subcomponents.The reliability of an automotive crankshaft under mixed mode loading using the Markov Chain Model is studied.The Markov Chain is modelled by using a two-state condition to represent the bending and torsion loads that would occur on the crankshaft.The automotive crankshaft represents a good case study of a component under mixed mode loading due to the rotating bending and torsion stresses.An estimation of the Weibull shape parameter is used to obtain the probability density function,cumulative distribution function,hazard and reliability rate functions,the bathtub curve and the mean time to failure.The various properties of the shape parameter is used to model the failure characteristic through the bathtub curve is shown.Likewise,an understanding of the patterns posed by the hazard rate onto the component can be used to improve the design and increase the life cycle based on the reliability and dependability of the component.The proposed reliability assessment provides an accurate,efficient,fast and cost effective reliability analysis in contrast to costly and lengthy experimental techniques.     

基于可靠性理论的齿轮强度设计(英文)

1IntroductionGeardrivesarewidelyusedinalmostallmechanicalsystems.Thegeardesignisimportantinthemechanicalfield,but,currentlyallgeardesignisbasedonthetradi-tionaldesignmethod,thatisthesafetyfactormethod,whichisshownasfollows:n=S/σ<犤n犦(1)wherenisthesafety…     

基于Monte Carlo行星齿轮减速器可靠性优化设计

以2K_H行星减速器为物理模型,运用可靠性设计和优化设计理论相结合的方法,建立了以体积最小为目标的可靠性优化设计模型.针对设计信息和参数的不确定性,采用蒙特卡洛模拟法确定设计变量的概率分布和数字特征,计算齿轮传动可靠度.利用MATLAB优化工具箱具有编程工作量少、语法符合工程设计要求等特点,在约束函数中充分考虑可靠性的...     

行星齿轮传动接触疲劳强度的模糊可靠性设计

本文以渐开线行星齿轮传动为研究对象，综合运用了模糊数学理论和可靠性设计方法，建立了模糊可靠性的数学模型及其计算公式，探讨了齿轮设计中模糊变量与随机变量同时存在时的接触疲劳强度可靠性设计方法，并给出了计算实例。其结果表明了模糊可靠性设计的可行性和实用性。     

齿轮接触疲劳强度计算方法的探讨

介绍了一种将齿轮接触疲劳强度的常规设计与可靠性设计相结合的改进计算方法.用常规设计方法计算齿轮的初始尺寸,同时用可靠性设计方法计算可靠性安全系数及可靠度.在保证齿轮合理可靠度的条件下,通过对计算结果的评价与调整,使齿轮的尺寸减小.供广大机械设计工作者在齿轮的小型化设计中选用.     

基于行星减速器的多目标可靠性优化设计方法研究

将优化技术与可靠性设计理论相结合,以齿轮疲劳强度可靠度和行星轮系配齿条件等为约束,以行星齿轮减速器传动效率高、重量轻、体积小为优化目标,根据工程实践和统一目标函数法建立其优化数学模型,应用混合惩罚函数法、Powell法等多种优化算法对其进行优化设计[1].通过实例说明,应用这种理论方法可在保证减速器使用寿命的前提下,得到满意的优化结果.     

基于线性疲劳累积损伤理论的直齿圆锥齿轮传动可靠度计算

线性疲劳累积损伤可靠性理论认为零部件的可靠度取决于抗疲劳损伤强度大于疲劳损伤量的概率,本文将此理论应用于直齿圆锥齿轮传动的可靠性设计,建立单级载荷谱工况下可靠度计算模型,通过分析和计算直齿圆锥齿轮设计算例,结果验证了基于线性疲劳累积损伤理论的可靠度计算模型在直齿圆锥齿轮传动可靠度计算中的可行性与合理性,为机械零部件的可靠性设计提供了理论依据。     

基于免疫算法的齿轮减速器模糊可靠性优化设计

将模糊可靠性优化设计方法应用于齿轮减速器设计,建立了斜齿圆柱齿轮减速器模糊可靠性优化设计的数学模型。本文应用所开发的免疫算法对三级斜齿圆柱齿轮减速器的模糊可靠性优化设计进行了分析计算,实例证明该方法非常有效。     

随机风载作用下风力发电机齿轮传动系统动态可靠性分析

运用最小二乘支持向量机(Sparse least squares support vector machines,SLS-SVM)机器学习方法建立风场随机风速模型,根据随机风速模型和空气动力学理论得到随机风引起的系统外部载荷激励,建立考虑齿轮时变啮合刚度和滚动轴承时变刚度的风力发电机行星齿轮传动系统齿轮—轴承耦合动力学模型,并对动力学模型进行仿真计算,分别得到各齿轮副的动态啮合力和滚动轴承动态接触力。以此为基础,将载荷作用过程视为随机过程,推导出随机载荷作用下的等效载荷累计分布函数。根据应力—强度干涉理论建立风力发电机齿轮传动系统各齿轮和轴承的动态可靠性模型,利用二阶矩和摄动方法求出各齿轮、轴承的动态可靠性指标,并计算出动态可靠度,研究各齿轮、轴承和传动系统的动态可靠度随时间的变化规律,为风力发电机齿轮传动系统动态可靠性设计奠定了基础。     

双轴来复传动圆柱齿轮减速器齿轮传动强度的模糊可靠性设计

采用改进模糊可靠性设计方法对双轴来复传动圆柱齿轮减速器齿轮传动强度进行了模糊可靠性设计，并对采用一般模糊可靠性设计方法和改进模型可靠性设计方法获得的结果进行了比较，结果表明，改进模型可靠性设计方法使设计结果更加科学合理。     

风力机齿轮箱布局的多目标可靠性优化设计

针对风力机齿轮箱布局设计中存在的问题,采用多目标可靠性优化设计方法,以风力机齿轮箱的箱体体积和齿轮体积最小化为设计目标,建立了风力机齿轮箱布局的多目标可靠性优化设计模型,分析比较了3种常见传动方案对风力机齿轮箱布局的影响,以某型号1.5 MW风力机齿轮箱为例进行了优化分析。研究结果表明,采用该设计方法得到的齿轮箱箱体体积和齿轮体积加权和值比以齿轮体积为目标的单目标设计方法更低。同时,分析结果表明,提高输入转速可大大降低齿轮箱成本。