4.6 Article

Investigation into the Modulation Characteristics of Motor Current Signals in a Belt Transmission System for Machining Monitoring

Journal

APPLIED SCIENCES-BASEL
Volume 12, Issue 19, Pages -

Publisher

MDPI
DOI: 10.3390/app121910088

Keywords

condition monitoring; belt transmission; current modulation; spectral analysis; CNC lathes

Funding

  1. Special Projects in Key Areas in Fundamental and Foundational Applied Research of Guangdong Provincial Education Department [2021ZDZX1072]
  2. Open Fund Project of Key Laboratory of Science and Technology on Integrated Logistics Support [20210804023]
  3. Special Innovative Projects in Fundamental and Foundational Applied Research of Guangdong Provincial Education Department [2020KTSCX188]

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This study developed a dynamic model for belt-driven electromechanical spindle systems, which can couple multi-physics variables including mechanical dynamics and electromagnetic effects. It was found that belt transmission can cause rich harmonic sidebands in the motor current spectrum, and excessive wear and inadequate tension worsen belt wear.
Belt transmission is one of the most common forms of transmission on CNC lathes. To assess the impact of belt performance on monitoring machining conditions using motor current signal analysis, we developed a dynamic model for belt-driven electromechanical spindle systems. This model enables the coupling of multi-physics variables including mechanical dynamics, particularly the dynamic axil and belt bending motions of belt transmissions and electromagnetic effects. Thus, various changes in belt transmission, including different degrees of belt tension and defects with inherent motor and spindle errors, can be investigated. The modulation characteristics of the current and speed signals revealed that belt transmission can cause a high degree of modulation, reflected by the rich harmonic sidebands at the belt-passing frequency in the motor current spectrum. The rate and extent of belt wear worsened with excessive wear and inadequate tension. It was confirmed that the sideband at the spindle rotating frequency was slightly impacted by changes in the belt conditions. This model was verified based on a CNC lathe induced with different degrees of belt looseness. These conclusions drawn from the numerical analyses can be used for motor current signal analysis, providing reliable and accurate results for machining monitoring.

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