Professional Documents
Culture Documents
discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/262406047
CITATION READS
1 108
2 authors:
All in-text references underlined in blue are linked to publications on ResearchGate, Available from: Giuseppe Quaremba
letting you access and read them immediately. Retrieved on: 18 November 2016
Recent Researches in Multimedia Systems, Signal Processing, Robotics, Control and Manufacturing Technology
Abstract This article reports the results of several tests, carried out in optical gear whine noise to
evaluate the difference between the vibro-acoustic emission of two gearboxes of the same type, one,
in particular, showing a micro-geometrical error located on the side of tooth and characterized by
lack of material at the base of the tooth due to a slight drift of the production process. The tests were
carried out in fourth gear.
The user of the vehicle, in fact, seems to be particularly attentive to the vibro-acoustic emissions.
For that reason the major car manufacturers devote significant resources to the Noise, Vibration and
Harshness sector, which deals with noise and vibration of the vehicle to the vehicle driving comfort.
Key-Words: - vibro-acoustic emission, gearbox, gear whine noise, signal processing, automotive,
driving comfort.
The two gearboxes (same type) tested were 1 thermocouple, used to monitor the
made following the same manufacturing temperature inside the gearbox; it was
process. positioned directly in contact with
One of these belongs to a lot which showed lubricating oil;
abnormal micro geometrical parameters due to
the drift of the production process: significative 1 single-axis accelerometer used for
lack of material localized at the basis of tooth. vibration measurement; it was
For that reason the lack of material is not positioned at the bottom of the gearbox;
interested during the contact of the teeth: it
does not involve any meshing problem [6,7,8]. 3 microphones were used for the
This area, in fact, detected by means of a acoustic detection. They were arranged
micrometer at the base of the tooth is localized in a semicircle near the gearbox far
below the meshing profile. away one meter from it.
applied to the main shaft (Nm). On the third While the results performed on the gearbox
axis, the colour scale represents the values of with geometrical error is illustrated in the
sound pressure detected (dB (A)). Fig.2.
By observing the colour map we can By comparing the two diagrams it is possible to
understand which are the areas where the noise evaluate the noise level of the two gearboxes as
shows the highest value; in particular the areas function of the speed and torque applied to the
in red show the highest values while the lowest primary.
noise levels are pointed out in blue. In particular, for low values of speed, both
gearboxes show quite the same results; the
acoustic emission shows an increasing trend
directly proportional to the speed reached by
the gearboxes. We note that the maximum
value of 70 dB (A) was close to 2000 rpm.
When we operate at low range of revolutions
(10002000 rpm) most relevant critical issues
for both gearboxes highlight.
In particular the gearbox with geometrical error
is more noisy. In fact it has two critical areas of
interest, 24002600 rpm and 29003200 rpm.
The gearbox without geometrical errors reaches
critical level of noise only in one narrower
range 26002750 rpm.
Both gearboxes show the sound pressure level
close to 80 dB (A).
Fig. 1 - Gearbox without geometrical errors -
Finally, from 3000 to 4000 rpm the gearbox
4th gear, Acoustic pressure dB (A) vs Order of
with geometrical errors shows higher values if
meshing
compared to the gearbox without error, very
close to 70 dB (A).
quite similar; this means that the diagrams of Analyzing the results of test we can say that the
emission do not vary in terms of shape but, diagrams referred to the gearbox with
mainly, for the position of the applied torque geometrical errors appear shifted, due to the
and, in part, for the number of rpm. The figures different flexural response of teeth to external
below explain what we said (Figg. 3-6). forces.
The noise due to the phenomenon of gear
whine, in fact, is directly related to the
variation of error of transmission, mainly
because of the meshing stiffness.
Because of the decrease of cross section, due to
lack of material at the base, the teeth are less
rigid and therefore more flexible at the same
external stress.
This feature allows therefore to achieve in the
gearbox with geometrical error the point of
Fig. 3 Acoustic response at 2000rpm optimal functioning with torque values smaller
than those needed to gearbox without error.
The results show that the gearbox with
geometrical error focuses in the normal area of
functioning (i.e., the fourth gear) the highest
levels of noise. On the contrary the gearbox
without error in the same area (especially for
torque values from 90 to 150 Nm and for all
the range of rotation) is particularly noiseless,
limiting the maximum noise in smaller areas
and higher torque values (Figg. 7-8).
Fig. 4 - Acoustic response at 3000rpm The motor installed on the test car is a 1600 cc
four-cylinder engine powered by diesel, which
delivers a maximum torque of 290 Nm at 1500
rpm and a maximum power of 78 kW at 4000
rpm. By overlaying the characteristic curve of
that engine to color map it is possible to
identify the best operating conditions of the
power train.
Using the values of the characteristic curve of
the engine and vehicle data, the possible noise
levels found on the car were defined on the
Fig. 5 Vibrational response at 2000rpm color map. In advance, the data allow us to
confirm that the gearbox with geometrical error
may have critical importance for the
application on the car.
References
[1] E. Zwicker, H. Fastl, Psycho-acoustics:
Facts and Models, Springer-Verlag Berlin
Heidelberg, 2007.
[2] S.N. Doan, J. Ryborz and B. Bertsche,
Rattling and clattering noise in automotive
transmissions Simulation of drag torque and
noise, Tribology and Interface Engineering
Series, Vol. 43, pp. 109-121, 2003.
[3] A. Forcelli, A New Approach for Objective
Measurements of Transmission Gear Rattle
Fig.8 - Gearbox with geometrical errors - 4th Noise, JSAE Tokyo, 2004.
gear, Acoustic pressure dB (A) vs Order of [4] S.K. Jha, Characteristics and sources of
meshing noise and vibration and their control in motor
cars, JSV, Vol. 47, Issue 4, pp. 543-58, 22
august 1976.
[5] D.R. Houser, J. Harianto, Design
8 Conclusions Robustness and Its Effect on Transmission
This paper reports the results of several tests, Error and Other Design Parameters,
performed in optical Gear Whine Noise, for International Conference on Mechanical
evaluating the difference of the vibro-acoustic Transmissions, Chongqing, China, April 5-9,
emission of two gearboxes of the same type. 2001.
The customer need, in fact, seems to be [6] American National Standard, Fundamental
particularly aware to the vibro-acoustic Rating Factors and Calculation Methods for
emission of the vehicle [10]. Involute Spur and Helical Gear Teeth, AGMA
In particular, one gearbox has a micro Standard, ANSI/AGMA 2001-C95.
geometrical error on the flank of the tooth, [7] H. N. Ozguven and D. R. Houser,
characterized by lack of material located at the Mathematical Models Used in Gear Dynamics
base of the tooth and showing a slight drift due A Review, JSV, 121, pp. 383-411, 1988.
to the working process. The tests were carried
out in fourth gear.