Reduction of PTO Rattle Noise of agricultural

Tractor Using an Anti-backlash Gear

2008 RecurDyn User’s

User s Conference
Sung-Bo Shim
Dept. of Biosystems Eng.
Seoul National University, Korea

Design of Off-Road Equipment and Soil-Machine Systems, SNU

1. Introduction

Development of direct
engine-PTO driveline BUT
Rattle noise occurred
from the PTO gearbox

The rattle noise

became a problem
to consumers
Reduction the production cost
Improvement in the transmission efficiency

Design of Off-Road Equipment and Soil-Machine Systems, SNU 2/22

 1. Introduction
What is rattle noise?
Driving gear Driving gear

θ&&1 θ&&1

98 θ&&2 θ&&2
Angular velocity, rad/s

96
Tdrag Tdrag
94
Driven gear Driven gear
92 (a) First impact by driving gear (b) Loss of contact

90 Driving gear

θ&&1
Measured angular velocity of driving gear
θ&&2

Tdrag
Driven gear
(c) Second impact by driven gear

Caused by engine torque fluctuation

Design of Off-Road Equipment and Soil-Machine Systems, SNU 3/22

2. Object of this study

Design of anti-backlash gear

Development of anti-backlash gear model

Simulation of the driving and anti-backlash gears

O ti i ti off design
Optimization d i parameters
t about
b t anti-backlash
ti b kl h gear

Investigate the effects of anti-backlash gear on the rattle noise

Design of Off-Road Equipment and Soil-Machine Systems, SNU 4/22

 3. Material and Method

Anti-backlash gear

Modeling of anti-backlash gear

Measurements of angular velocity and rattle noise

Verification of anti-backlash gear model

Design of Off-Road Equipment and Soil-Machine Systems, SNU 5/22

Anti-backlash gear 3. Material and Method

Anti-backlash gear was developed as a rattle noise reducer

F
δ
d

T : initial Load, N·mm

T = k δd n
k : spring stiffness, N/mm
δ : initial deflection of the spring, mm
d : distance between the center of gear
and spring axis, mm

Design of Off-Road Equipment and Soil-Machine Systems, SNU 6/22

 Modeling of Anti-backlash gear 3. Material and Method

Driving gear model Anti-backlash

Anti backlash gear model

Error, % : 0.6% in weight

Design of Off-Road Equipment and Soil-Machine Systems, SNU 7/22

Velocity & rattle noise measurements

3. Material and Method

PTO shaft
Magnetic pick-up
Magnetic pick-up
Flywheel
Anti-backlash gear Driving gear
Coupling

PTO clutch

Engine
Gear 49T

Magnetic pick-up

Microphone

before the anti-backlash gear was installed

105.7 dBA
Design of Off-Road Equipment and Soil-Machine Systems, SNU 8/22
 Verification of anti-backlash gear model
3. Material and Method

34
k=9.81 N/ mm, δ=5 mm simulated
measured

ocity, rad/s
32
30
Angular velo
28
26
24
22 1 1.05 1.1 1.15 1.2 1.25
Time, sec
34
k=30.64 N/mm, δ=5 mm simulated
32 measured
Angular velociity, rad/s

30
28
26
24
22
1 1.05 1.1 1.15 1.2 1.25
Time, sec

Design of Off-Road Equipment and Soil-Machine Systems, SNU 9/22

Verification of anti-backlash gear model

3. Material and Method

0.8 0.6
k = 9.810 N/mm k = 30.64 N/mm
0.7 0.5
0.6 x = 5 mm x = 5 mm
0.5 0.4
0.4 0.3
0.3 0.2
Angular velocityy, rad/s

0.2
0.1 0.1
0 0 0
20 40 60 80 100 0 20 40 60 80 100
(a) Measured (a) Measured
0.8 0.6
k = 9.810 N/mm k = 30.64 N/mm
0.7 0.5
0.6 x = 5 mm x = 5 mm
0.5 0.4
0.4 0.3
0.3 0.2
0.2
0.1 0.1
0 0
0 20 40 60 80 100 0 20 40 60 80 100
Frequency, Hz Frequency, Hz
(b) Simulated
Si l t d (b) Simulated

Primary frequency 22 Hz 44 Hz
k = 9.81 N/mm k = 30.64 N/mm k = 9.81 N/mm k = 30.64 N/mm
Spring δ=5 mm δ=5 mm δ=5 mm δ=5 mm

Angular Measured 0.74 0.55 0.27 0.24

velocity,
rad./s Simulated 0.72 0.56 0.28 0.25

% error 2.7 1.8 3.7 4.2

Design of Off-Road Equipment and Soil-Machine Systems, SNU 10/22

 4. Results and discussion

Simulation

¾ Cause of rattle noise

¾ Optimization of design parameters

Reduction of rattle noise using anti-backlash gear

Design of Off-Road Equipment and Soil-Machine Systems, SNU 11/22

Simulation
4. Results and discussion

measurement data of the driving gear Simulated data of the anti-backlash gear
100 34
Angularr velocity, rad/s

98 k=9.81 N/mm, x=5 mm

32
96
94 30
92
90 28
88
86 26
84
820 0.05 0.1 0.15 0.2 0.25 24
22
1 1.05 1.1 1.15 1.2 1.25
Time, sec
Input data

Output data

Design of Off-Road Equipment and Soil-Machine Systems, SNU 12/22

 Simulation - cause of rattle noise
4. Results and discussion

0.3
Relativee angular displacement, °

0.2
0.1
0
-0.1
This relative displacement and velocity
-0.2 caused the impact
-0.3
1.5 1.52 1.54 1.56 1.58 1.6 1.62 1.64
Time, sec
(a)
4
Relative angular velocity, rad/s

A
2
The impact
0
B caused the rattle noise
-2

-4
1.5 1.52 1.54 1.56 1.58 1.6 1.62 1.64
Time, sec
(b)
Simulated relative angular displacement and velocity
between driving and driven gears.

Design of Off-Road Equipment and Soil-Machine Systems, SNU 13/22

Simulation – optimization of design parameters

4. Results and discussion

k=100 N/mm, x=0.01 mm k=100 N/mm, x=0.29 mm

Relative dissplacement, °

k=100 N/mm, x=0.2 mm k=100 N/mm, x=0.45 mm

0.42 0.44 0.46 0.48 0.5 0.52 0.54 0.42 0.44 0.46 0.48 0.5 0.52 0.54 0.56

Time, sec Time, sec

Simulated relative angular displacement.

x = 0.45
0 45 mm

Minimum initial deflection of spring

for zero relative angular displacement

Design of Off-Road Equipment and Soil-Machine Systems, SNU 14/22

 Simulation – optimization of design parameters
4. Results and discussion

30000
T = 23.56 k + 4364.7
R² = 0.9988
25000
T : Initial load, k : Spring stiffness

Initial loadd , N· mm
20000

15000

10000

5000

0
0 100 200 300 400 500 600 700 800 900 1000
Spring stiffness k, N/mm
Minimum initial load as a function of spring stiffness of anti-backlash gear.

Initial load increase with spring stiffness

T = 23.56k + 4364.7

Design of Off-Road Equipment and Soil-Machine Systems, SNU 15/22

Simulation – optimization of design parameters

4. Results and discussion

T = k δd n (1)

Tmin. = 23.6k + 4364.7 (2)

Substituting Eq. (1) into Eq. (2) yields

k δ d n = 23.6k + 4364.7 (3)

d = 50 mm, n = 3 then,

4364.7
k≥ (4)
150δ − 23.6
Design of Off-Road Equipment and Soil-Machine Systems, SNU 16/22
 Simulation – optimization of design parameters
4. Results and discussion

Zero relative angular displacement region

No rattle noise occurrence region

Relationship between the spring stiffness and initial deflection

of anti-backlash gear for zero relative angular displacement.

Design of Off-Road Equipment and Soil-Machine Systems, SNU 17/22

Reduction of rattle noise using anti-backlash gear

4. Results and discussion

Performance Tests
Engine
PTO
gearbox
Transmission

PTO shaft
Driving gear

Anti-backlash
gear

Microphone

Design of Off-Road Equipment and Soil-Machine Systems, SNU 18/22

 Reduction of rattle noise using anti-backlash gear
4. Results and discussion

Rattle noise
40
30 Non anti-backlash gear used.
20
10
0
-10
Sound pressure level, Pa (A)

-20
-30
-40 0.2 0.5
0.05 0.1 0.15 0.25 0.3 0.35 0.4 0.45
40
Anti-backlash gear used.
30
20
10
0
-10
-20
20
-30
-40
0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
Time, sec.

Design of Off-Road Equipment and Soil-Machine Systems, SNU 19/22

Reduction of rattle noise using anti-backlash gear

4. Results and discussion

Rattle noise
110
100 Non anti-backlash gear used.
90
80
70
Soound pressure level, dBA re 20µPa

60
50
40
30
20
2k 4k 6k 8k 10k 12k
110
100 Anti-backlash gear used.
90
80
70
60
50
40
30
20
2k 4k 6k 8k 10k 12k
Frequency, Hz

Design of Off-Road Equipment and Soil-Machine Systems, SNU 20/22

 Reduction of rattle noise using anti-backlash gear
4. Results and discussion

Measured PTO rattle noise when different spring stiffness and initial deflections
were used for anti-backlash gear
Initial
I i i l deflection,
d fl i Sound
S d pressure Reduction,
R d i
Stiffness, N/mm
mm level, dBA dBA
9.81 2 94.8 10.9
17.71 2 93.3 12.4
30.64 2 93.3 12.4
61.34 2 91.0 14.7
111.67 2 90.0 15.7
9.81 5 94.3 11.4
17.71 5 91.6 14.1
30.64 5 90.7 15.0
61.34 5 88.8 16.9
111.67 5 90.9 14.8

Design of Off-Road Equipment and Soil-Machine Systems, SNU 21/22

5. Conclusions

Anti-backlash gear can reduce effectively the PTO rattle noise

Zero relative angular displacements are required to reduce the rattle noise

A region of zero relative angular displacement can be identified from the

initial deflection and stiffness of the springs.
p g

The rattle noise can be further decreased with increasing spring stiffness
when the relative angular displacement was zero.

Design of Off-Road Equipment and Soil-Machine Systems, SNU 22/22