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Romax Simulation of FRO-16210C Noise

Romax Noise Simulation. CAViDS Consortium. Romax Simulation of FRO-16210C Noise. A CAViDS Consortium Project Started March 1, 2009. Advisory Council Review at WMU September 22, 2009. Romax Noise Simulation. CAViDS Consortium. Objective.

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Romax Simulation of FRO-16210C Noise

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  1. Romax Noise Simulation CAViDS Consortium Romax Simulation of FRO-16210C Noise A CAViDS Consortium Project Started March 1, 2009 Advisory Council Review at WMU September 22, 2009

  2. Romax Noise Simulation CAViDS Consortium Objective • Simulate noise and vibration generated by FRO-16210C transmission in selected gears and loads over the operating speed range

  3. Romax Noise Simulation CAViDS Consortium Technical Approach • Phase 1: Obtain software, hardware and training • Phase 2: Model FRO-16210C transmission and predict: • Shaft/bearing mode shapes • Location specific housing vibration at select conditions • Acoustic noise at same conditions

  4. Romax Noise Simulation CAViDS Consortium Project Plan Phase 1 Status: Complete Phase 2 : Built gear/shaft model with stiffness bearings Checked power flows Predicted gear/shaft/bearing mode shapes in high range Compare with experiments Integrated housing and bearing designs in model Predicted mode shapes in 10th gear Compare with experiments Predict vibration at select conditions in 10th gear 500 LB-FT Compare with experiments Link to Coustyx noise prediction software Predict noise at select conditions .

  5. Process Built countershafts with integral gear hubs and webs from print Rigidly attached countershaft gear rims to webs Built main shaft gear hubs and webs with integral clutches Rigidly attached mainshaft gear rims to webs Built input shaft, mainshaft and output shaft Attached stiffness bearings to shafts Positioned shafts and gears Constructed concept gears Constructed concept clutch attachments Did power flow analysis Replaced stiffness bearings with real bearings (no profile info) Extracted gears and shafts for specific ratios (one model for each) Did modal analysis for high range ratios Imported housing for 10th gear model Condensed housing with accelerometer node Constructed detailed gears with micro-geometry Did dynamic analysis for 10th gear Did modal analysis for 10th gear based on dynamic analysis

  6. Models All gears 10th gear 10th gear with housing

  7. Modal Analysis – No Housing

  8. Modal Analysis – No Housing 6rh 1000 LB-FT Second Bounce 697 Hz 6th 1000 LB-FT First Bounce 485 Hz 6th 1000 LB-FT First Rock 1059 Hz 6th 1000 LB-FT Second Rock 1332 Hz

  9. Dynamic Analysis with Housing10th Gear Accelerometer Location

  10. Gear Geometry - Dynamic Analysis

  11. Dynamic Analysis with Housing 10th Gear

  12. Dynamic Analysis with Housing10th Gear

  13. Modal Documentation 10th Gear – 500 LB-FT Eaton Experimental Noise Peaks 2240 Hz (drive set 1st harmonic) 2349 Hz (drive set 2nd harmonic) 3475 Hz (drive set 2nd harmonic) 3523 Hz (drive set 3rd harmonic) ROMAX Bounce 410 Hz 486 Hz 530 Hz Rock 994 Hz 1041 Hz Bending 2524 Hz 3223 Hz 3532 Hz

  14. Romax Assessment • Strengths • Ease of Modeling • Graphics • Support • Modal Visualization/Animation • Gear Modeling Flexibility/Power • Opportunities for Improvement • FEM Importation • Modal screening without housing • Harmonic plotting • Link to Coustyx

  15. Next Month’s Plans Add bearing profiles and study effect on results Analyze all high range ratios at 500 and 1000 LB-FT Compare results with experimental data Assess Coustyx link

  16. Romax Noise Simulation CAViDS Consortium Special thanks to: : Tom Chimner for garnering Eaton support and housing model Kevin Marsh (Eaton) for design details and general support Matt Glass (Eaton) for bearing details and modeling support Jerry Burke (Eaton) for FEA modeling assistance Sukumar (Eaton) for FEA modeling assistance Gary Jessel (Eaton) for gear and spline info Brian Wilson (Romax) for granting software Zach Wright (Romax) for installation and modeling support

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