In the field of automotive engineering, the performance and reliability of components such as gears and bearings are crucial for the smooth operation of the vehicle. This article focuses on the simulation analysis of the contact load bearing loss for automotive helical gears using the AMESim software. By accurately simulating the axial and radial loads at the contact of the helical gears and projecting them onto the bearings, this research aims to calculate the load contribution in the bearing loss, thereby reducing the cost of physical experiments and improving the design quality.
The background and significance of this research lie in the need to optimize the design of automotive components to enhance the performance and reliability of the vehicle. Bearings play a vital role in supporting the rotation of gears and transmitting loads, and their performance directly affects the efficiency and durability of the transmission system. Traditional methods of evaluating bearing performance through physical experiments or theoretical calculations can be time-consuming and costly. Therefore, using simulation tools like AMESim can provide a more efficient and cost-effective approach to analyze and optimize the bearing design.
Previous studies in this area have made significant contributions to the understanding of bearing behavior and its interaction with other components. For example, some researchers have focused on developing mathematical models to predict the friction and wear in bearings under different operating conditions. Others have investigated the influence of various factors such as load, speed, lubrication, and geometry on the performance of bearings. These studies have provided valuable insights into the mechanisms of bearing failure and have laid the foundation for further research in this field.
The main content of this research includes the establishment of the automotive helical gear pair and bearing model, the development of the bearing loss model, the introduction of the SKF equation for more accurate friction torque calculation, and the use of the PID controller for speed control in the AMESim simulation.
- Automotive Helical Gear Pair and Bearing Model
- Three-Dimensional Model of Automotive Helical Gear Pair and Bearings: A simplified 3D model of the automotive helical gear pair and bearings is established, including a small helical gear with two rolling bearings on its transmission shaft and a large helical gear with two rolling bearings on its transmission shaft. This model shows how the forces and torques from the helical gears are transmitted to the bearings through the transmission shaft.
- Bearing Loss Model: The bearing loss is related to the radial load, axial load, and lubricating oil of the gear pair. The general expression for the total torque loss is given by T = To + Tr + Ta, where To is the torque loss due to the lubricating oil, Tr is the torque loss caused by the equivalent radial load, and Ta is the torque loss caused by the equivalent axial load. The formulas for each component of the torque loss are provided.
- SKF Equation: The SKF model is introduced to more accurately calculate the friction torque in rolling bearings. The model takes into account various factors such as the contact area, design changes, internal and external influences, and the composition of the total rotating resistance of the bearing. The formulas for the rolling friction torque, sliding friction torque, sealing friction torque, and drag friction torque are given.
- PID Controller: The PID controller is used for speed closed-loop control in the simulation model. The general model of the PID controller is provided, and the parameters such as the proportional coefficient, integral time constant, and differential time constant are explained.
| Model Component | Details |
|---|---|
| Automotive Helical Gear Pair and Bearings 3D Model | Includes a small helical gear with two rolling bearings on its transmission shaft and a large helical gear with two rolling bearings on its transmission shaft. Shows the transmission of forces and torques from the gears to the bearings. |
| Bearing Loss Model | Total torque loss T = To + Tr + Ta, where To is related to the lubricating oil, Tr is caused by the equivalent radial load, and Ta is caused by the equivalent axial load. Formulas for each component are provided. |
| SKF Equation | More accurately calculates the friction torque in rolling bearings, considering factors such as contact area, design changes, and internal and external influences. Formulas for rolling, sliding, sealing, and drag friction torques are given. |
| PID Controller | Used for speed closed-loop control in the simulation model. The general model and parameters are explained. |
- Simulation Model Based on AMESim
- Setup of the Simulation Model: In AMESim, the simulation model for the bearing loss of the automotive helical gear pair is built. The model includes two helical gears forming a gear transmission group, and each transmission shaft is equipped with two ball bearings. The parameters such as the number of teeth, tooth top fillet radius, working transverse pressure angle, spiral angle, and bearing diameters are set.
- Parameters and Settings: The friction coefficients, load moment of inertia, viscous friction coefficient, controller settings (PI control, proportional and integral control coefficients, control output range, and PID controller time interval), control speed of the small helical gear shaft, simulation period, and total simulation time are specified.
- Simulation Results: The control speed and tracking speed of the PID controller are obtained, showing a good consistency and high control accuracy. The axial and radial forces on the bearings are also obtained, which change with the control speed. The forces on the bearings increase during the acceleration and deceleration of the rotating shaft and stabilize at a smaller value when the speed is constant.
| Simulation Aspect | Details |
|---|---|
| Setup of the Simulation Model | Includes two helical gears and four ball bearings. Parameters such as gear teeth, angles, and bearing diameters are set. |
| Parameters and Settings | Friction coefficients, load moment of inertia, viscous friction coefficient, controller settings, control speed of the small helical gear shaft, simulation period, and total simulation time are specified. |
| Simulation Results | PID controller shows good tracking performance. The forces on the bearings change with the control speed, increasing during acceleration and deceleration and stabilizing at a smaller value during constant speed. |
The main conclusions of this research are as follows:
- The simulation model based on AMESim can accurately simulate the contact load bearing loss of the automotive helical gear pair, providing a reference for the simulation measurement and analysis of the radial and axial loads of the bearing and the selection and design of the bearing.
- The PID controller achieves a high precision speed control effect, and the obtained force change curve on the bearing is consistent with the actual movement situation.
However, this research also has some limitations. For example, the model may not fully consider some factors that can affect the bearing performance in the real world, such as the temperature, vibration, and manufacturing tolerances. Future research could focus on improving the accuracy and completeness of the model by considering these factors and conducting more detailed experiments to validate the simulation results.
In conclusion, this research provides a valuable approach for analyzing the bearing loss of automotive helical gears, which can help optimize the design and improve the performance of the transmission system. Further research in this area can contribute to the development of more efficient and reliable automotive components.