Research on Shape–Performance Integrated Monitoring Technology for Planetary Gearboxes Based on the Integration of Artificial Intelligence, Finite Element Analysis, and Multibody Dynamics Simulation

To address gear tooth damage and the difficulty of acquiring performance data under high-speed and high-load operating conditions of planetary gearboxes, a digital twin-based system for operational state recognition and performance prediction is proposed, integrating morphological and functional characteristics. Driven by experimental data, the system incorporates finite element analysis, multibody dynamics simulation, artificial intelligence algorithms, and 3D visualization to achieve a virtual mapping of the gearbox's geometric configuration, structural properties, and dynamic behavior. Structural performance is represented using finite element and dynamic simulation techniques combined with texture mapping, visualized through color gradients; dynamic performance is captured through multibody dynamics simulations and stored in a time-series database, presented as sequential images. The integrated system is constructed by combining a structural performance surrogate model, a system-driven model, and a dynamic performance database, enabling comprehensive functionality. Results demonstrate that the maximum error of the structural performance model is 3%, occurring only under specific working conditions, with negligible impact on the overall meshing performance evaluation of the sun gear. The maximum error in dynamic performance prediction is 1.68%, showing strong consistency with experimental data.