Gear Condition Monitoring Technics: December 2017
Gear Condition Monitoring Technics: December 2017
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Contents
1.0 Types of Gears…………………………………………………………… 02
2.0 Gear Failures…………………………………………………………....... 06
3.0 Gear Condition Monitoring………………………………………………. 09
3.1 Signal Analyzing methods………………………………………… 10
3.2 Detection of gear failures………………………………………….. 15
3.2.1 Gear Wear………………………………………………... 16
3.2.2 Gear Misalignment Identification………………………… 18
3.2.3 Gear Crack………………………………………………... 20
3.2.4 Gear Pitting……………………………………………….. 22
Reference…………………………………………………………………….. 24
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Gear Condition Monitoring Technics
Figure 01
Figure 02
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Gear Condition Monitoring Technics
Mechanical gears have some special advantages than the other power transmission technics. They
can be listed as follows,
Since there are so many advantages of gears there are some disadvantages also. Gear
manufacturing process cost is much higher than the other power transmission technics other than
that gear transmitting is an effective method of transmitting power.
Gears can be categories in to several types. Some of them are listed below,
1. Spur gear
2. Helical gear
3. Herringbone gear
4. Bevel gear
5. Rack and pinion
6. Internal spur gear
Spur gears are the most commonly used gears in machines. Because of its low cost and easy
manufacturing process than the other gear types. These types of gears are used for parallel shafts.
Spur gears are mostly used on motor vehicle gearboxes, machine tool drives, electric motor gear
boxes etc. Childs, Peter R.N.. (2014)
Figure 03
Spur Gear
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Gear Condition Monitoring Technics
In helical gears gear teeth are arranged with an angle. Typically, the helix angles of the helical
gear lie between 150 – 300. Like spur gears helical gears are also used with parallel shafts. Noise
levels are much lower than the spur gear because teeth in mech makes point contacts always rather
than line contacts in spur gears. These gears need special tools to manufacture. Therefore, the
manufacturing costs are higher than the spur gear. These types of gears are normally used in heavy
duty applications such as turbine drivers, locomotive gear boxes etc.. Childs, Peter R.N.. (2014).
Figure 04
Helical Gear
Bevel gear is a special gear than can be able to change the direction of the motion. Bevel gears
have a conical shape and when connecting bevel gears ono to one ratio applied. In motor trans
mission differential, for valve control etc bevel gears are used. Childs, Peter R.N.. (2014)
Figure 05
Bevel Gear
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Gear Condition Monitoring Technics
Worm gears are another type of gears that can be used to reduce large speeds between two
perpendicular and non-intersecting shafts. Because of high speed reduction considerable frictional
heat is generated so continuous lubrication is necessary for the worm gear applications. Worm
gears are used in many applications such as steering gear, winch blocks, rotary tables etc.. Childs,
Peter R.N.. (2014).
Figure 06
Worm Gear
Rack and pinion mechanism is also a special gear type. This type of gears are used to convert the
rotary motion to straight line motion. Rack and pinion mechanism is widely used in machinery
tools and automotive applications such as vehicle steering rack. Childs, Peter R.N.. (2014).
Figure 07
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Gear Condition Monitoring Technics
In modern transmission systems because of weight reduction and cost reduction gear systems are
designed to be light weight. So, Failure of gears is a common phenomenon in modern transmission
systems (Guo, Shi and Yi, 2016). Gear wear and tear happens mostly on automobiles and other
machines. Specially in automobiles wear and tear happen even the vehicle maintained properly.
Specially in transmission control gears are subjected to high shocks when gear changes and
therefor wear, heat and noise happens (Rajagopalan et al., 2006).
Several types of gear failures can be happened in a gear system. Bending failure, pitting, scoring,
abrasive wear, case cracking, corrosive wear and misalignment are some of common failures
happen in gears (Rajagopalan et al., 2006) (Guo, Shi and Yi, 2016).
Bending failure happens if the acting load is greater than beam strength of the gear tooth. Due
than unbalance force bending occurs in gear tooth’s. To avoid such bending failures of gear teeth
face width of the gear has to be adjusted to withstand the acting load or the gear material has to
be changed.
Figure 08
Bending Failure
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Gear Condition Monitoring Technics
Pitting failure happens on the surface of the gear teeth. It is a fatigue failure and happens when
the surface contact stress is higher that the endurance limit of the material. Dynamic load between
the gear tooth the gear should be less than the rupture of the tooth surface.
Figure 09
Pitting Failure
Scoring happens when systems runs on lack of lubricants. When there is excessive surface
pressure on gear tooth excessive heat is generated. Therefore, it allows to metal to metal contact
which leads to local welding. It results tearing of local welded surface. This type of failures can
be minimized by providing proper flow of lubricants and by adjusting parameters such as speed,
pressure (Rajagopalan et al., 2006).
Figure 10
Scoring Failure
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Gear Condition Monitoring Technics
Wear is the most common gear failure occurs in gears. Wear can be divided as local wear,
distributive wear and gear backlash (Rajagopalan et al., 2006). If one or two gear teeth are
damaged due to wear it is called local wear. Distributive wear occurs when there is a sliding
motion between gear teeth (Guo, Shi and Yi, 2016). Gear backlash failure is due to thinning of
the gear teeth and it leads to improper gear operations (Rajagopalan et al., 2006). If the lubricant
of gears contaminated with the foreign particles such as dirt, dust gear wear increases. So, by
providing filters for the lubricate and by adding high viscus lubricants can avoid wear.
Figure 10
Gear wear
Gear corrosion is another special type of gear failure. Corrosion of gears happens mainly due to
contact of gears with corrosive elements such as water and other additives existing in the lubricant
oil. To minimize or reduce the corrosive wear anti-corrosive additives has to be added to the
lubricants or minimize the contact of corrosive elements can be done.
Figure 11
Corrosive wear
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Faults identification and prediction is done by analyzing vibration signals taken from the machine
gear box casing (Dalpiaz, Rivola and Rubini, 2017). Acetometers are used to convert the vibration
signals into electrical signals to analyze the data (Lebold, et al., 2000). To analyse the vibration
data signal various signal processing method were developed. Those methods were developed on
time domain, frequency domain and time-frequency domain (Guo, Shi and Yi, 2016).
Analysis of vibration signals is done by comparing previous signals and currents signals. Before
a signal to be analyzed signal conditioning has to be done (Lebold, et al., 2000). The vibration
data signal might contain noises, DC offsets and other unwanted signal. Before the signals is to
be processed those unwanted signals have to be removed from the vibration data set. There are
several signal conditioning techniques that used in signal processing. Signal correction, low pass
filtering, amplifying, time synchronize averaging and mean value removal are some of those
signal conditioning methods (Lebold, et al., 2000).
In gear vibration tooth meshing frequency, harmonics of the meshing frequency and side bands
are the most important parameters in gear vibration analysis. By analyzing the changes of
amplitudes and number of side bands faults conditions can be predicted and identified (Dalpiaz,
Rivola and Rubini, 2017). But analysis of such components of the vibration signal is difficult in
simple spectral analysis in early stage of gear faults. So different methods of signal analyzing have
been developed by researches (Dalpiaz, Rivola and Rubini, 2017) to overcome those scenarios.
A single crack on the surface of the gear wheel create a unusual signal in the vibration signal
which is mounted on the gear box casing (Dalpiaz, Rivola and Rubini, 2017). Larger the failure
much longer and considerable bursts generate in the vibration signal (Guimarães & Viana Duarte,
2000). Vibration signals are not measured when the machine is accelerating. Because of the
acceleration shaft speeds wary and therefore the frequency components so the vibration signals
will be changed.
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Gear Condition Monitoring Technics
Signal processing methods of gear fault detection can be divided into five main groups (Lebold,
et al., 2000). They are,
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Gear Condition Monitoring Technics
Below table shows some details about various preprocessing technics that using in gear fault
detection condition monitoring.
Signal
Analyzing Description Gear Faults can be Identified
Method
RMS and ✓ Root mean square and delta root ✓ Cannot be identified the
Delta RMS mean square are time analysis exact failure of the
method of a vibration signal. component. But can
✓ Delta RMS is the difference of detect the noise deferent
the present and the previous of the original gear and
RMS values. the faulting gear.
𝑁
1
𝑅𝑀𝑆 = √ × ∑ 𝑥𝑛2
𝑁
𝑛=1
𝑁 × (𝜎 2 )2
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Gear Condition Monitoring Technics
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Gear Condition Monitoring Technics
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Gear Condition Monitoring Technics
𝑁 3 ∑𝑁
𝑖=1(𝑑𝑖 − 𝑑)
8
𝐹𝑀4 = 4
[∑𝑁 2
𝑖=1(𝑑𝑖𝑗 − 𝑑) ]
Table 1
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Gear Condition Monitoring Technics
As mentioned in the above gears may fault because of different conditions and there are different
gear failures also. Most of the gear failures are happened because of fatigue conditions of the gear
(Onsy, et al., 2013). Early detection of such failures is very important because it will save the
machine, time and money.
Analysis of gear failure is done by using various methods as mentioned in the signal analyzing
methods section previously. Mainly in vibration analysis of a signal cepstrum analysis technique
is used. It is the simplest method of detecting gear faults. But identification of all failures by
cepstrum analysis is somewhat difficult than other methods like Demodulation Analysis,
cyclostationary analysis and wavelet transform (Dalpiaz, Rivola and Rubini, 2017).
Cepstrum analysis is a development of the spectrum analysis. Cepstrum analysis have a good
resolution than the spectrum analysis (Dalpiaz, Rivola and Rubini, 2017). Spectrum analysis is
done by using fast fourier transform and the x axis of the amplitude graph of the spectrum analysis
labeled as frequency. But is cepstral analysis the cepstrum analysis graph represent the logarithmic
value of the amplitude and the frequency of the amplitude spectrum is replaced by quefrency in
the cepstral analysis graph. Quefrency represents modulation period and the reciprocal of the
signals modulating frequency (Dalpiaz, Rivola and Rubini, 2017).
Figure 12
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Gear Condition Monitoring Technics
Figure 13
In a frequency spectrum of a gear which has wear typically gives the rotating shaft frequency of
the gear, gear meshing frequency and harmonics of those frequency except the noise. With respect
to the development of the gear wear in the gear wheel the second and third gear mesh harmonics
increase more significantly than the noises of the shaft rotating frequency and first gear mesh
frequencies (Guo, Shi and Yi, 2016).
The following figure 14 shows a healthy gear frequency spectrum which gear shaft and pinion
shaft rotation frequencies are 20 Hz and 47 Hz respectively (Guo, Shi and Yi, 2016).
Figure 14
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Gear Condition Monitoring Technics
GMF is the gear mesh frequency and other multiples of GMF are side bands of the gear mesh
frequencies. The following table show variations between several wear failure signals that taken
in several intervals of the gear fault. There are six signals different signals. As we can see in the
table 02 the second and the third GMF harmonics of the gear increase when the gear wear increase.
Anyhow, the gear mesh frequency is not changed (Guo, Shi and Yi, 2016).
If gear meshing second and third harmonics are increasing than the GMF states that the gear has
gear wearing problem. When the second and third harmonics amplitude increase the gear wear
also increases (Guo, Shi and Yi, 2016).
Table 02
Therefore, a gear that has a gear wear fault can be identified by analyzing the frequency spectrum
of the gear if second and third GMF harmonics of the gear increase slightly than the gear mesh
frequency.
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Gear Condition Monitoring Technics
Frequency spectrum of a healthy gear typically gives shaft frequency, gear mesh frequency and
its harmonics (Guo, Shi and Yi, 2016). Gear misalignment is a considerable problem for gear
because it could be the beginning for some serious faults in gears. So, by minimizing the
misalignment of gears we can protect the gear from serious injurious. The following figure 15 is
about a frequency spectrum of a healthy gear.
Figure 15
Table 03
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Gear Condition Monitoring Technics
When the misalignment occurs in a gear special changes happens in the frequency spectrum. Side
band responses around the shaft frequency GMF and other GMF harmonics are a common
phenomenon for misalignment gears. According to the table 03 there are seven different vibration
signals are analyzed using spectrum analysis. In every signal, the 2nd gear meshing frequency and
its side band are changing other than the other frequency signals such as first GMF and third GMF
and their side bands.
Figure 16
The figure 16 demonstrates how the misalignment faulting gear frequency spectrum differs from
the original gear frequency spectrum. As I mentioned above in the figure 16 we can clearly identify
the fundamental frequencies of the gear and its side bands. As in the table 03 we can see that the
second harmonic GMF frequency has a higher amplitude than the other component of the
spectrum.
Different kind of misalignment failures are there in gears. Anyway, in the frequency spectrum, all
the other frequencies are same as the original gear signal frequency spectrum other than the second
harmonic gear mesh frequency. When the gear misalignment increases it’s second gear harmonic
frequencies and its side bands are also assumed to be increased (Guo, Shi and Yi, 2016).
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Gear Condition Monitoring Technics
Gear crack and broken tooth problem appears mostly because of gear fatigue. If there is a single
crack on a gear tooth, when contacting that tooth there will be a little noise on the frequency
spectrum. If the fault intensity is larger the fault duration will be also larger than the single crack
problem (Guimarães & Viana Duarte, 2000) (Dalpiaz, Rivola and Rubini, 2017). So there will be
a family of sidebands on the frequency spectrum with equal spacing (Dalpiaz, Rivola and Rubini,
2017).
Figure 17
In the figure 17 shows three types of gear crack failures first one shows a gear with a one tooth
crack. Second one is a gear with one tooth broken. The third one is two teeth broken gear.
Following figure 18 shows Frequency spectrums of healthy gear, one tooth crack gear, one tooth
broken gear and two teeth broken gear. Broken tooth problem happens because of gear tooth
cracks (JIn, et al., 2016).
(fm1, fm2 are gear meshing frequencies / fr1, fr2, fr3 are shaft frequencies of input, pinion and output)
Figure 18.a gives the healthy gear frequencies of the gear. 60Hz, 180 Hz and 300Hz are some
ghost frequencies appeared in the gear box.
In the gear crack case fm1 with sidebands and fr3 rotation frequency appear in the frequency
spectrum than the healthy gear frequency spectrum (figure 18.b).
In the gear one tooth and two teeth broken cases fm1 and fm2 with sidebands and fr3 appears in the
frequency spectrums of two vibration signals (figure 18.c & 18.d).
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Gear Condition Monitoring Technics
Figure 18
b). Gear crack, c).gear with broken tooth, d).Gear with two broken teeth
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Gear Condition Monitoring Technics
Detection of pitting gears is not an easy task for human eye. So further transformations of wave
analysis need for those examinations. FFT is a common gear fault identification method that
generates amount of amplitude for frequency axis. By that we can identify frequency variations
in the faulty and good signals by comparing the difference of those FFT’s.
Figure 19 shows a healthy gear frequency spectrum and frequency spectrum of a same type of
gear that have pitting failure figure 20. The following gear are meshed with a input shat speed of
3000 rpm and 50 Nm of load (Morsy & Achtenova, 2014).
In the healthy gear, constant gear teeth meshing frequency is generated with very low vibration
amplitudes both in pinion gear and gearwheel (Morsy & Achtenova, 2014) (Figure 19).
Gear meshing frequencies increase when a gear fault develops. So when comparing two frequency
spectrums we can clearly see that there is an amplitude incase in the fault signal spectrum. The
value that increased the most is the 2500 Hz frequency.
Figure 19
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Gear Condition Monitoring Technics
Increase of a certain frequency amplitude might be a gear misalignment problem. To identify such
problem advanced analysis needed. Unless in the fear misalignment case in hear we can see a huge
amplification in the 2500 Hz frequency. That is because gear meshing is not smoother in this case
than the healthy gear. When gear pitting happens gear, meshing is not smoother for the reason that
is gear teeth surface has small damages. So this case can be identified as a gear pitting case but
for further study advanced technological methods are needed (Morsy & Achtenova, 2014).
Figure 20
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Gear Condition Monitoring Technics
References
Childs, Peter R.N.. (2014). Mechanical Design Engineering Handbook. (pp. 317 - 457). Elsevier.
Online version available at:
http://app.knovel.com/hotlink/toc/id:kpMDEH0002/mechanical-design-engineering/mechanical-
design-engineering
Guimarães, T. A. & Viana Duarte, M. A., 2000. Detection of Faults in Gearboxes Through
Vibration Signals Time-Frequency Analysis. SAE Technical Paper Series, 2000-01-
3176(Congresso SAE Barsil).
Guo, D., Shi, Q. and Yi, P. (2016). Psychoacoustic Analysis of Gear Noise with Gear Faults.
SAE International Journal of Passenger Cars - Mechanical Systems, 9(2).
JIn, X. et al., 2016. A Comparative Study on Vibration- and Current-Based Approaches for
Drivetrain Gearbox Fault Diagnosis. IEEE.
Lebold, M. et al., May 1-4, 2000,. REVIEW OF VIBRATION ANALYSIS METHODS FOR
GEARBOX DIAGNOSTICS AND PROGNOSTICS. 54th Meeting of the Society for Machinery
Failure Prevention Technology, Virginia Beach, pp. p. 623-634.
Morsy, M. E. & Achtenova, G., 2014. Robust Diagnostic Concept for Vehicle Gearbox with
Artificial Pitting Defect in Gear Using Vibration Measurements. SAE TEchnical Paper, Issue
2014-32-0047.
morsy, M. E. & Achtenova, G., 2017. Value of Optimal Wavelet Function in Gear Fault Diagnosis.
SAE Technical Paper, Issue 2017-01-1771.
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Gear Condition Monitoring Technics
Onsy, A., Bicker, R. & Shaw, B. A., 2013. Predictive Health Monitoring of Gear Surface Fatigue
Failure Using Model-Based Parametric Method Algorithms; An Experimental Validation. SAE
International.
Rajagopalan, S., Habetler, T., Kral, C. and Pirker, F. (2006). Monitoring and Diagnostics for
Electric Drivetrain Components in HEVs. SAE Technical Paper Series.
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