Chapter 1

INTRODUCTION
1.1 INTRODUCTION TO CONDITION MONITORING

Productivity is a key weapon for manufacturing companies to stay competitive in

a continuous growing global market. Increased productivity can be achieved through
increased availability. Managing industries into the 21st century is a challenging task.
Increasing global competition, fast technological change, consumers awareness towards
total quality, reliability, health and safety, environmental considerations and changes in
management structure not only provides many companies with considerable opportunities
to improve their performance but also the much needed competitive edge to those firms
that strategically plan for the future and will make use fully the advantages of modern
manufacturing techniques and methods.

Manufacturing productivity is found to be influenced by following major factors:

i) Greater availability of physical resources.

ii) Improvements in the quality of the human resources.

iii) Improved manufacturing methods and techniques.

It is the later sector of manufacturing to which condition monitoring contributes

significantly.

Today, most maintenance actions are carried out by either the predetermined
preventive or the corrective approach. The predetermined preventive approach has fixed
maintenance intervals in order to prevent components, sub-systems or systems to
degrade. The concept of condition monitoring is to select measurable parameters on the
machines, which will change as the health or condition of a machine. Regular monitoring
is done and the change is detected. Once a change is detected it is possible to make a
more detailed analysis of the measurements to determine what is the problem and hence
arrive at a diagnosis of the problem. The parameters most often chosen to detect this
change in conditions are either vibration, which tends to increase as a machine moves
away from a smooth running condition into a rough mode with development of a fault, or

1
an analysis of machine noise or acoustics, or machine lubricants where samples are tested
for items such as wear debris from a developing fault. There are various sensors to detect
and monitor the early signals of electrical, mechanical, electronic, pneumatic, hydraulic,
etc, and provide an aid to fault diagnosis to establish an effective maintenance
management procedure to predict and prevent system failure just in time.

A well designed condition monitoring strategy reduces production costs,

operating costs and labour costs.

1.2 CONDITION MONITORING TOOLS

Gearboxes are often critical components of machine requiring the application of

condition monitoring techniques. Condition monitoring of Gearboxes implies
determination of condition of gears and its change with respect to time. The condition of
these gears may be determined by the physical parameters like vibration, noise,
temperature, wear debris, oil contamination, etc. A change in any of these parameters
called signatures would thus indicate the change in the condition or health of the gears.

The major measurement techniques are given below:

1.2.1 Sound and Vibration

The most established and capable technology is sound and vibration analysis.
Almost all the machines vibrate and produce sound, and the link between this sound and
the machine condition is both easily measured and the results easily interpreted.
Transducers can be easily attached on a temporary basis to a machine, most often with a
strong magnet, so that collection of data is quick and efficient. A major benefit of
vibration however, is that different mechanical processes within the machine (e.g.
imbalance, gear mesh, bearing faults) will produce energy at different frequencies. If the
different frequencies are separate from one another through analyzer, the whole new level
of detail may be seen, with more advanced warning of development of faults.

1.2.2 Lubricant Analysis

The second most common technique is testing of lubricant samples. This can have
the major benefits as it can detect the root cause of a problem. Viscosity checks, moisture
content as well as detection of contaminants all fall into this category of test. The

2
technique can also look for the effects of wear site with the lubricant. But this technique
relies on the samples being taken away from machinery to a laboratory for full analysis to
be performed.

1.2.3 Thermography

Electrical departments were the first to benefit from the user of thermal imaging
cameras to obtain the temperature distribution maps, looking for a hot spot from the loose
connection. The technique is being widely used to look at the pipe work vessels, as well
as bearing and couplings. The cameras are getting smaller, lighter and the quality is better
all the time.

1.2.4 Ultrasonics, Acoustic Emission and High Frequency Vibration

Various techniques, using simpler approaches to vibration analysis, are used to

detect friction and presence of bursts of energy resulting from defects in rolling element
bearings, where a rolling element may be impacting defects in a race creating shocks and
spikes of energy. Whilst having merits of their own, the uses of these techniques often
use simpler transducers, mounted in the same locations as vibration analysis. The
combination of vibration with these techniques can therefore create economies in the time
and manpower needed to collect the data.

Table 1.1: Available condition monitoring and diagnostic techniques

A. Acoustic Monitoring B. Vibration Monitoring
a) Microphone a) Overall monitor
b) Spectral analysis b) Spectral analysis
c) Discrete frequency monitoring
c) FFT/ Zoom FFT d) Shock pulse monitoring
e) Signal averaging
C. Wear Debris Analysis D. Visual Inspection
a) Ferrography a) Radiography
b) Inductive sensors b) Eddy current
c) Capacitive sensors c) Ultrasonics
d) Spectrography

3
1.2.5 Wear Debris Monitoring

The condition of critical component surfaces subject to loading and relative

movement is assessed from wear debris, which they generate. They are usually oil
washed components and the collection and analysis of debris is done via lubricating oil.

Available condition monitoring and diagnostic techniques are listed in Table 1.1
and the selection of the condition monitoring technique is given in Table 1.2

4
 Table 1.2 Condition monitoring technique selectors.

Vibration Acoustic Acoustic Debris Thermal Corrosion

Analysis Analysis Emission Analysis Imaging Monitoring
Bearing
Boilers X X X X
Compressors X X
Coupling X X X 1
Elevators X X
Escalators X X X X X
Filters X X X X
Gearboxes
M/c Tools X X X X
Pressure Vessels X X X
Pumps X X
Structures X X X
Transformers X X X X X
Turbines
Welding X X X X X
I.C. Engine X X X X

1.3 GEARBOX MONITORING

1.3.1 Needs

Manufacturing industry drives the world. Every manufacturing industry is having

number of machines and gearboxes which are used for power conversion, speed
reduction and torque amplification, can control many of them.

It has been estimated that annually 10 million new gearboxes enter operation with
a combined component value of more than 5 billion dollars. Economics of industries
totally depend upon reliable operation of gear driven machinery and gearboxes.

5
 Any defect induced in gear might costs high at the time of failure. For that, early
prediction of breakage of gear tooth is essential to avoid stoppage of that machine thereby
increase in utilization.

1.3.2 Gearbox Diagnostic Techniques

There are number of causes, which lead to the failure of the gearboxes. The
various techniques are discussed in this chapter.

1.3.2.1 Noise and Vibration Sensing

Power losses in gearboxes are a normal consequence of less than perfect operating
efficiency. These power losses results in energy dissipation as vibration and heat. The
analysis for the detection of faults in the gearboxes is normally related to a change in the
characteristics of the gearbox vibration. This change may be in overall vibration
amplitude, change in the amplitude of certain frequencies of vibration, or in the pattern of
the vibration signature. Changes in these signal amplitudes can be used to indicate
degradation in these components and failure.

The analysis of gearbox vibration data can be broadly classified into two
categories; spectral analysis and feature analysis.

1.3.2.2 Acoustic analysis technique

Sound is found everywhere. Sound is defined as a mechanical energy vibrations

transmitted as waves through a solid, liquid, or a gas that can be detected by the human
ear. The study of sound is called acoustics and covers all fields of sound production,
sound propagation and sound reception, whether created and received by human beings
or by machines and measuring instruments. Sound usually arises when rubbing between
two material surfaces or rolling contact in bearings, gears etc., take place during its
operational life.

The acoustic noise measurement can also be used for condition monitoring.
Listening the noise of machines, as a means of detecting malfunction in them, the
analysis of noise signal is carried out much the same way as vibration signal using similar
instrumentation. By monitoring the acoustic conditions of plants and machineries at
critical position in a mechanical manner, and by analyzing the acoustic signal in an

6
intelligent way, it is possible to avoid the cost and avoidable breakdowns. The use of
acoustic analysis is not restricted to predictive maintenance but also this technique is
useful for diagnostic applications as well. Acoustic monitoring and analysis are primary
diagnostic tools for most mechanical systems that are used to manufacture products.
When used properly, acoustic data provides the means of maintaining optimum operating
conditions and efficiency of critical plant system.

The philosophy behind acoustic monitoring is to provide useful information to

designer and maintenance manager to enhance the operational reliability, minimize early
failures, and provide improved protection to operating personnel, extend the systems life
cycle and remain highly competitive in the global market.

As is well known, of the many parameters that can be monitored, acoustic

monitoring has been widely accepted as one of most powerful parameter, which can be
employed to diagnostic of fault and prevent machinery failures.

In acoustical analysis technique either sound pressure measurement or sound

intensity measurements are carried out. But sound intensity measurement is having
distinct advantages. As it is vector quantity it gives sound pressure as well as direction of
sound so it gives idea about the location of fault.

1.3.2.3 Oil Debris Detection

While vibration analysis may allow one to know gear faults, monitoring of the
lubricating oil flow for metallic debris is a more direct method for the detection of wear
and surface failure type faults in gearboxes. Two different approaches are commonly
used. One involves the analysis of the oil samples and/or debris in an off line laboratory.
The second involves detecting particles on line and in real time.

Oil debris detection can provide a good backup to vibration monitoring, especially
in complex gearboxes or where vibration levels are high enough to render conventional
vibration analysis ineffective.

1.3.2.4 Thermal Diagnostic Techniques

Perhaps the most economical monitor of gearbox condition is temperature. A rise

in oil temperature increases the power loss in the gearbox. This is almost near to the

7
failure. Parameters such as rate of temperature increase and the increase of this rate are
useful in the detection in the final stages. The use of temperature is recommended as a
monitor of the lubricating system operation, as the failure of this function may lead to the
gearbox damage.

8
 Chapter 2

OBJECTIVES OF THE PROJECT

Condition monitoring is rises from being critical need into activity and spread out
use as a critical element in the management strategy of companies operating rotating
machines all over world. However, it is historically been focused on the technology
involved in making the measurements, and not on achieving financial benefits.

2.1. FUTURE SCOPE OF WORK

In this project work, the technique of condition monitoring is applied to selected

gear to assess the condition of gear teeth.

It is well knownfact that any change in condition of gear such as wear, crack, lack
of oil or break will cause a corresponding change in the motion and hence in the vibration
acoustic pattern. These signals for known defect are collected by vibration accelerometer
and sound pressure level probe (microphone) during workingofgearbox. The gear box is
considered as a linear mechanical system and an individual meshed gear vibrate and
produces sound which propagates from individual meshing gears to measuring points
which is in gear box casing.

By introducing gears of known faults, the vibration and acoustic spectrum are
collected by using Fast Fourier Transformer (FFT) and the corresponding change in
pattern is compared with the signals obtained from gear without fault. These changes in
signals are correlated to the faults of gear tooth.

The main focus of the work as shown here is:

1. The different faults in gears can be detected without dismantling any gearbox for
the diagnosis of faults.
2. To match the FFT results with concerned faults to prove the correctness of
condition monitoring is successfully conducted.
3. To create particular precise defects in gears.
4. To learn use of FFT instrumentation to know its various applications.

Chapter 3

9
 LITERATURE REVIEW
3.1 INTRODUCTION

The literature review of this project work is broadly divided into two parts. The
first part gives the history of vibration monitoring and its use to diagnose the machinery
faults. It covers the development in signature analysis technique due to the digital
frequency analyzer. The measuring and analyzing techniques of gearbox vibration, which
are offered by different researchers, are discussed in second part. Scope of this chapter is
to get familiar with work done by various investigators in the field of condition
monitoring and gearbox fault diagnostics.

3.2 DEVELOPMENT OF DIAGNOSTIC TECHNIQUE THROUGH ACOUSTICS

The architecture of condition monitoring system today has largely been dictated
by the technical focus but prior to World War II, the practical solution of incipient failure
through acoustics was more of an art rather than a science and was dependent on
experience and expertise of the user. It requires a certain skill, which often is very high
on the part of the `listener and the result is not getting perfect information about
malfunction. This was primarily due to the absence of experimental tools to determine
nature of noise causing problem. There was virtually nothing, which the engineer could
measure other than noise level and frequency except on relatively, low speed machines.

However the rapid development of low cost high performance frequency analyzer
since the late 1970s was due to the rapid performance microprocessors and analog to
digital (A/D) voltage converters.

By mid forties a series of electrical transducers and recorders were developed to

measure and store data in electrical form. The advancement in data storage provides
means of conditioning data continuously for all forms of analysis, line spectrum, power
spectral density, and correlation etc. without transport of the analyses equipment in to
factory.

10
3.3 WAVELET ANALYSIS

There are many analysis techniques, which have been fully developed and
established overthe years for processing vibration signals to obtain diagnostic information
about progressing gear faults. Earlier research on gear failure detection focused on the
use oftime-averaged vibration signal, spectrum and amplitude and phase modulation
techniques to detect different types of gear failures. Most of these conventional
approaches work well to detect abnormality and indicate faults without providing much
information about them, such as location and severity of the faults. Application of these
methods to detect gear faults can be found.

During the last decade, some timefrequency methods have received growing
attention and gained reliable acceptance in the field of condition monitoring.Generally,
the dynamic signals in the field of engineering problems such as vibration, sound so on,
have been analyzed using the Fast Fourier transform (FFT). The FFT has been the most
common method to analyze frequency properties of the signals. In the FFT analysis, the
signal as the function of time is converted to the power spectra in a frequency domain.
However except for a special case, the frequency components of the most signals
encountered in the engineering problem change with time. Based on the FFT alone, it is
hard to investigate whether the frequency components of the signals vary with time or
not, even though the phase of the Fourier transform relates to time shifting. The FFT
analysis is no more adequate for those applications. Therefore, it is significant and
important to adopt the time frequency analysis for those signals varying with time.

3.4GEARBOX FAULT DIAGNOSTIC EVOLUTION

Gearbox is used in various engineering applications such as in machine tools,

automobiles, helicopters, etc. for torque and speed conversions or to achieve definite
torque and speed requirement. In gearbox as the number of stages increase, fault
diagnosis becomes more difficult. Some important inventions in gearbox fault diagnostics
are as follows.

N. Baydar& A. Ball have presented [1]

Detection of gear failures via vibration
and acoustic signals using wavelet transforms. In their work they have used vibration
and acoustic signals for detection failure of gear. Two commonly encountered local

11
faults, tooth breakage and tooth crack, were simulated. The results of acoustic signals
were compared with vibration signals.

Yuji Ohue& Akira Yoshida have presented [2]

New evolution method on
dynamics using continuous and discrete wavelet transforms. This paper deals with the
new method of gear dynamics using the continuous and discrete wavelet transform. In
order to evaluate the difference in the gear dynamics due to the gear materials, which are
sintered & steel ones, the dynamic characteristics of gears were measured using a power
circulating gear testing machine. The gear dynamics were analyzed in a time frequency
domain by the continuous & discrete wavelet transforms. The new evaluation method
using the wavelet transform proposed in this paper was more useful compared with the
conventional one to investigate the damping characteristics & the dynamic of the gear
equipment.

Wen-xian Yang & Peter W. Tse have presented [3]

An advanced strategy for
detecting impulses in mechanical signals. The appearance of overlapping in the results
derived by continuous wavelet transform (CWT) smears the spectral features and makes
the results difficult to interpret. This will significantly affect the accuracy of analysis of
anomalous signals. Aiming at minimizing the undesired effect of overlapping a new soft-
thresholding method in terms of exponential functions is proposed. Using the proposed
soft-threshold & combining with Donohos approach for reducing the structures induced
by noise, a strategy for purifying the results derived by the CWT are further purified &
thereby the spectral features of the inspected signal become more explicit & much more
easily identified.

Peter W. Tse, Y. H. Peng, Richard Yam haspresented [4] Wavelet analysis and
envelope detection for rolling element bearing fault diagnosis- Their effectiveness and
flexibilities. This paper commences with technique of wavelet analysis and envelope
detection for fault diagnosis. The components which often fail in a rolling element
bearing are the outer race, the inner race, and the cage. Such failure generates a series of
impact vibrations in short time intervals, which occur at
BearingCharacteristicsFrequencies (BCF). Since BCF contain very little energy, and are
usually affected by noise and higher levels of micro structural vibrations, they are

12
difficult to find in their frequency spectra when using the common technique of Fast
Fourier Transform. Therefore, Envelope Detection (ED) is always used with FFT to
identify faults occurring at the BCF. However computation of ED is complicated, and
requires expensive equipment and experienced operators to process. This, coupled with
the incapacity of FFT to detect nonstationary signals, makes wavelet analysis a popular
alternative for machine fault diagnosis. Wavelet analysis provides multi- resolution in
time-frequency distribution for easier detection of abnormal vibration signals. From the
results of extensive experiments performed in a series of motor pump driven systems,
the methods of wavelet analysis and FFT with ED are proven to be efficient in detecting
some types of bearing faults.

D.F. Shi, W. J. Wang and L. S. Qu have presented [5]

Defect detection for
bearing using envelope spectra of wavelet transform. This paper considers wavelet
transform for defect detection of bearing. In order to overcome the shortcoming in the
traditional envelope analysis in which manually specifying a resonant frequency band is
required, a new approach based on the fusion of the wavelet transform and envelope
spectrum is proposed for detecting and localized defects in rolling element bearing. This
approach is capable of completely extracting the characteristics frequencies related to the
defect from the resonant frequency band. Based on the Shannon entropy of wavelet-
based envelope spectra, a criterion to select optimal scale to monitor the condition of
bearings is also presented. Experiment results show that proposed approach is sensitive
and reliable in detecting defects on the outer race, inner race, and rollers of bearing.

Jing Lin, Ming J. Zuo, Ken R. Fyfe have presented [6] Mechanical fault detection
based on the wavelet de-noising technique. This paper commences with technique of
wavelet de-noising for mechanical fault detection. For gears and roller bearings, periodic
impulses indicate that there are faults in the components. However, it is difficult to detect
the impulses at the early stage of fault because they are rather weak and often immersed
in heavy noise. Existing wavelets, which do not match the impulse very well and do not
utilize prior information on the impulses, a new method for wavelet threshold de-noising
is proposed in this paper; it not only employs the Morlet wavelet as the basic wavelet for
matching the impulses, but also uses the maximum likelihood estimation for thresholding
by utilizing prior information on the probability density of the impulse. This method has

13
performed excellently when used to de-noise mechanical vibration signals with a low
signal-to-noise ratio.

Jing Lin, Ming J Zuo have presented [7]

Extraction of periodic components for
gearbox diagnosis Combining wavelet filtering and cyclostationary analysis. This paper
commences with wavelet filtering is combined with cyclostationary analysis for detection
of gear tooth faults in a gearbox. The parameters of the wavelet filter are optimized by
using the proposed entropy minimization rule. This method is shown to be effective in
detecting gear faults when cyclostationary analysis by itself fails.

W. X Yang and X.M. Ren have presented [8]

Detecting impulses in mechanical
signals by wavelets. This paper commences development of an effective impulses
detection technique is necessary and significant for revaluating the working condition of
these machines ,diagnosing their malfunctions, and keeping them running normally over
prolong periods. With the aid of wavelet transforms, a wavelet based envelope analysis
method is proposed. In order to suppress any undesired information and highlight the
features of interest, an improved soft threshold method has been designed so that
inspected signal is analyzed in a more exact way. Furthermore,an impulse detection
technique is developed based on the aforementioned methods .The effectiveness of the
proposed technique on the extraction of impulsive features of mechanical signals has
been proved by both simulated and practical experimental.

Martin J. Dowling has presented [9]

Application of nonstationary analysis to
machinery monitoring. The paper discusses how non-stationary signal processes such as
the wavelet transform and wigner-ville distribution can be applied to machinery
monitoring and diagnostic in industry.

F. A. Andrade, I. Esat and N. M. Badihave presented [10]A new approach to time-

domain vibration condition monitoring: gear tooth fatigue crack detection
andidentification by the Kolmogorov Smirnov Test (KST). The paper introduces a new
technique for early identification of spur gear tooth fatiguecracks, namely the
KolmogorovSmirnov test. It has been shown that the KST test effectively distinguishes
vibration signatures bycomparing their CDFs, and can be used for the identification of
tooth fatigue cracks ongears.

14
 S. A. Adewusiand B. O. Al-Bedoorhave presented [11]
Wavelet analysis of
vibration signals ofan overhang rotor with a propagatingtransverse crack.It shows an
experimental study of the dynamic response of an overhang rotorwith a propagating
transverse crack using the discrete wavelet transform (DWT)a jointtime frequency
analysis technique.

H. Zheng, Z. Li and X. Chen have presented [12]

Gear fault diagnosis
basedoncontinuouswavelet transform. They concluded that the feature frequencies and
scales of gear meshing and gear fault vibration signals aredifferent. They can be easily
identified from the power spectrum.
[13]
Darley Fiacrio de Arruda Santiago and Robson Pederiva have presented
Application of wavelet transform to detect faults in rotating machinery. They shows
that the vibration in rotating machinery is mostly caused by unbalance, misalignment,
mechanical looseness, rubs, shaft crack, and other malfunctions.

Erik Olsson, Peter Funk and Marcus Bengtsson has presented [14]
Fault diagnosis
of industrial robots using acousticsignals and case-based reasoning. They told that, case-
based reasoning is a feasible method to identify faults based on sound recordings.

AbhinavSaxena, Biquing Wu, George Vachtsevanos has presented [15]

A
methodology for analyzing vibration data from planetary gear systems using complex
morlet wavelets.They shown that the proposed wavelet domain methodology for the
analysis and feature extraction of the vibration data from a planetary gear system of the
Blackhawk helicopter has been successful in identifying the fault condition in all cases.

D. F. Shi1, L. S. Qu and N. N. Gindyhave presented [16]General interpolated fast

fouriertransform: a new tool fordiagnosing large rotatingmachinery. They told that the
harmonicellipse and orbit can be reconstructed to retain the effects ofmalfunction-related
components after removing the noise and interference.

Yang Yu, YuDejie and Cheng Junshenghave presented [17]

A roller bearing fault
diagnosis method basedon EMD energy entropy and ANN. In this paper they showed
that according to the non-stationary characteristics of roller bearing faulty signals, a fault
diagnosis methodbased on EMD and ANN can be possible.

15
 P. Vecer, M. Kreid and R. Smid have presented[18]Condition indicators for
gearboxcondition monitoring systems. They presented that condition indicators are
based on detecting of differencesbetween the amplitude distribution of a vibration signal
withoutfiltered gear mesh frequencies and the distribution ofthe signal for a gearbox in
good condition.

Jong Eok Ban, ByoungHoo Rho and Kyung Woong Kim have presented[19]A
study on the sound of roller bearings operating under radial load. In this paper they
showed in order to obtain sound characteristics ofthe roller bearings operating under
radial load, the rollingcontact load and the sound pressure level distributionswere
analyses and compared with each other for various operational conditions.

S. J. Loutridis has presented[20]Self-similarity in vibration timeseries: application

to gear faultdiagnostics. He showed that the proposed diagnostic procedure is
fast,straightforward, and does not require any prior knowledge of thesystem under
examination.

KobraHeidarbeigi, HojatAhmadi and M.Omid has presented[21]Adaptive

vibration condition monitoring techniques for local toothdamage in gearbox. They told
that the technique in a machine condition monitoring program provides useful reliable
information, bringingsignificant cost benefits to industry.

Christopher G. Cooley, Robert G. Parker and SandeepM. Vijayakarhave

presented[22]A frequency domain finiteelement approach forthree-dimensional
geardynamics. A computationally efficient frequency domain formulation forgear
dynamics has been developed. The finite element/contact mechanicsformulation
accurately predicts the dynamic response ofmultiple three-dimensional spur and helical
gear pairs.

16
 Chapter 4

VIBRATION AND SOUND MEASUREMENT

4.1. INTRODUCTION

The measurement of vibration sound and its characteristics plays an important

role in development of a systematic approach to vibration and acoustic analysis. In
particular, the measurement of overall vibration and sound levels can be used to
determine demand with regulations. These measurements can also be used to assess the
effectiveness of various conditions monitoring technique and to establish realistic goals.
Measuring vibration and sound level is an essential aspect of characterizing vibration and
acoustic analysis as shown in Fig.4.1.1 & Fig.4.1.2. Today, vibration and sound
measurement instrumentation represents a wide range of complexity and sophistication as
explained. This chapter of project discusses the various instruments.

Fig. 4.1.1.Basic vibration measurement system

Fig.4.1.2.
Basic sound measurement system

17
4.2 CAUSES OF MACHINE VIBRATION AND SOUND

To generate noise from machine the primary cause must be a force variation
which generates a vibration (in components), which is then transmitted to the surrounding
structure. It is only when the vibration excites external panels that the airborne noise is
produced.

4.2.1 Overall Path of Vibration Noise

Gear Errors, Deflections, Distortions, etc.

Transmission Error

Gear Body Vibrations

Bearing Housing Forces

Panel Vibrations

Noise

Fig. 4.2.1. Path of Vibration and Noise in Gearbox

4.3 FUNDAMENTALS OF VIBRATION AND ACOUSTICS

Vibrations are always resent in any rotating/ moving machine. These cant be
eliminated but can be controlled. It is important to keep the vibrations in a machine
within acceptable limits for its good health. Vibration as a parameter, therefore, can be
used as an indicator of the health of a machine is considered good. However, when these
levels become unacceptable, some malfunction in the machine is indicated.

Basically, vibration is oscillating motion of a particle or body about a fixed

reference point. Suchmotion may be simple harmonic (sinusoidal) or complex (non-

18
sinusoidal). It can also occur in variousmodes - such as bending or translational modes -
and, since the vibration can occur in more than onemode simultaneously, its analysis can
be difficult.

Units of vibration are:

The units of vibration depend on the vibration parameter, as follows:

a) Acceleration, measured in [g]or [m/s2].

b) Velocity, measured in [m/s].

c) Displacement, measured in [m].

The displacement is the simplest vibration signature.It can be represented

mathematically by a sine function and therefore is called simple harmonic motion. Time
to complete one cycle is as called time period T. Frequency, representing the number of
vibration cycles completed in unit time is equal to 1/T. When unit of time is sec, the
unit of frequency f is Hertz (Hz). The maximum displacement of the body from its
mean position is termed as amplitude (dB)decibel of vibration, and if it is X then the
displacement can be expressed as

X = X sin t

= 2f

where is the angular velocity in radian / sec.

The mass vibrating about its mean position is also subjected to velocity and
acceleration. When the body is at its extreme positions, it is at rest, i.e. its velocity as
these positions is zero, but it is subjected to maximum acceleration. Their nature of
variation is similar to that of displacement. Only difference is that velocity plot is
advanced by /2 and acceleration plot is advanced by with respect to the
displacement as shown below.

X = X sin t

The velocity of motion is:

x = dx / dt

19
 x = X cost = X sin (t + /2)

x = d / dt(dx / dt)

x = -2X sin t = 2 sin (t + )

The following relations relate amplitudes of velocity and acceleration to

displacement amplitude:

V = Xand A = 2X

Velocity is a good parameter for mid frequency range. The division by to

obtain displacement attenuates low frequency signals. The multiplication by to
obtain acceleration emphasizes high frequency signals.

4.3.1Accelerometers

Accelerometers are seismic type transducers, which have to be attached to the

vibrating object. Inside the accelerometer is a mass mounted on a spring and damper.
These devices are used for the measurement of absolute vibration in those cases where a
fixed reference for relative motion is not available as in the case of a moving vehicle. In
many other situations measurement of absolute motion is easier and more desirable.

Fig.4.3.1 Constructional Features of Accelerometer

As shown in Fig.4.3.1, the transducer is attached to the object whose motion is to

be measured. Inside the transducer, is a mass m supported on a spring of stiffness k
and a viscous damper, with damping coefficient c. The motion of the mass relative to
the frame or case gives an indication of the motion of the object and is the output of the
instrument. These device may be used to measure acceleration at frequencies < 0.3
<n. n is the natural frequency of the spring mass system of the accelerometer. In case

20
the value of frequency of the object is high, nof the device should be high or a stiff
spring should be used.

Basically a seismic transducer consists of a mass supported on a spring with

damper, with a relative motion transducer is shown in the figure.

There crystal is fairly stiff and held in compression by a spring. Quartz is a natural
piezoelectric material used in accelerometers. Lead, zircon and ceramic are another
common material used, after it has been polarized. These devices are very sensitive, light
weight, small sized and can be used over a wide frequency range.

4.3.2Acoustic (Noise) monitoring

The sound travels in the form of a longitudinal pressure waves. Noise is defined
as unwanted sound. The audible frequency range of sound is from 20 Hz to 20 kHz.

4.3.3. Sound Pressure

The total instantaneous atmospheric pressure at a point, minus the static (average)
pressure at that point.P is the symbol used for sound pressure. If the sound pressure is
given in logarithmic or relative units, it is called sound pressure level.

4.3.3.1 Sound Pressure Measurement

Sound pressure measurementin decibels is defined as:

LP = 10 Log (P / Po) 2dB

Where,P is sound pressure measured and Po is the reference sound pressure

measured of 20 Pa. Pascal is N/m2. Reference value of 20 Pa is chosen as it is the
quantity that represents the threshold of hearing of an average person.The logarithmic
scale of noise measurements is used to accommodate this large ratio.The sound pressure
is a scalar quantity. In a free field condition (i.e. where there are no reflecting surfaces
present) inverse square law applies according to which the Sound Pressure Level (SPL)
decreases by 6 dB for each doubling of distance (i. e. if the SPL at 1 meter distance is 90
dB then at 2 meters it will be 84 dB)

The transducer for noise measurements is called a microphone. Two types of

microphones are commonly used for noise measurements condenser and electrets type.

21
Condenser microphones are of high performance and expensive. In the condenser
microphone, its diaphragm is set in motion by sound pressure as shown in Fig.4.3.3.1

Fig.4.3.3.1. Microphone

22
 Chapter 5

GEARBOX VIBRATION AND NOISE:

CAUSES AND ANALYSIS METHOD

5.1 INTRODUCTION

As discussed in previous chapter the vibration and noise of machinery can be

measured by selecting proper transducer, check points and mounting method. The time
and frequency domain data is used to monitor the condition of machine and hence to
diagnosis the faults of machinery.

In case of gear box, vibration and noise is generated at meshing of the gear and
transmits through the shaft and bearing to other parts of the gear box. This vibration and
noise in a gear box may result into sever failure of machines. Therefore, it is necessary to
be aware of causes of this vibration and noise. Vibration and noise signals from gear box
are measured and the information from these signals is extracted by signal analysis. In
gear box vibration and acoustical diagnosis, it is extensively for assessing the condition
and hence the causes of this vibration and noise. Signal analysis can be done in time
domain or frequency domain.

This chapter deals with various causes of gear box vibration and noise such as,
defect in gear, shaft and bearing, type of housing etc, but more emphasis is on defects
related with gear and discusses various signal analysis techniques used for diagnostic of
gear box.

5.2 CAUSES OF GEARBOX VIBRATION AND NOISE

To generate vibration and noise from gears the primary cause must be a force
variation (in the components), which is then transmitted to the surrounding structure. It is
only when vibration excites external panels that airborne noise is produced.

5.2.1 Transmission Error

Transmission Error is the error between teeth. Transmission Error (TE) is defined
as the deviation of the relative angular position of two gear shafts from the position

23
determined by the gear rotation and perfect conjugate mesh action. TE is a consequence
of a torsion vibration of the gear system and it is a function of tooth profile errors, tooth
meshing errors, tooth spacing errors, undercut, backlash, tooth surface roughness,
misalignment of gear tooth and an elastic deformation of gear tooth.

TE also denoted as static error, is very much related to vibration and noise of
gears. Common gear problems are usually easy to identify because the noise and
vibration usually occurs at a frequency equal to gear meshing frequency, i.e. the no. of
gear teeth times the rpm of faulty gear, but in complex gear drives several meshing
frequencies are possible. Common gear problems which results in noise and vibration at
gear meshing frequency includes excessive gear wear, improper adjustment of backlash
or excessive gear clearance, gear tooth inaccuracy, faulty lubrication, fatigue crack on
gear tooth or broken tooth of gear.

5.2.1.1 Uniform Wear

There is sliding action between the contacting teeth on either side of pitch circle,
but no sliding takes place at the pitch circle itself. Therefore the uniform wear tends to
twist the harmonic nature of tooth mesh cycle and results into higher amplitudes of tooth
mesh frequency and its harmonics. This effect does not become apparent until it becomes
larger than the effect due to tooth deflection. When monitoring the teeth wear using the
comparison of frequency spectrum of gear noise signals, it is essential to introduce at
least three harmonics of highest tooth mesh frequency in order to detect wear at earliest
possible stage.

5.2.1.2 Backlash

Excessive gear clearance or improper adjustment of backlash may result into

frequency modulation and will give rise to excessive noise at gear mesh frequency. So far
it has been assumed that the rotational speed of gear is constant, and tooth spacing
perfectly uniform, but if either of the condition is violated, frequency modulation of the
tooth meshing frequency may occur. If the gear clearances are within tolerances and
gears are properly lubricated, the transfer of load from one tooth to next will be in the
form of tooth impact and result will be increasing noise. If gear tooth clearances increases
more, the initial tooth may cause the gear tooth to bounce in the clearances available,

24
which results in sound or vibrating frequency at harmonics of gear mesh frequency. This
is 1x, 3x or perhaps even higher multiples of gear meshes frequency.

5.2.1.3 Eccentricity

Eccentricity occurs when shaft centerline does not coincide with the gear
geometric centerline. It is common source of unbalance, resulting in more weight on the
gear geometric centerline. It is common source of unbalance, resulting in more weight on
one side of rotating centerline than on the other side. Eccentric gear can produce reaction
forces because of cam like action against the meshing gear. Eccentricity of one gear or
misalignment may give rise to amplitude modulation by frequency corresponding to its
rotational frequency. Since the gear noise results from excessive misalignment, the gear
frequency noise or vibration is actually modulated by the noise and vibration at rotation
speed frequency, producing side band frequencies at gear mesh frequency plus or minus
gear rpm. The predominant noise due to misalignment is 2x shaft rpm, additional side
band frequency plus or minus 2 x rpm may also be present.

5.2.1.4 Cracked Tooth

As the gear rotates, the space left by the chipped tooth increases the mechanical
clearance between the pinion and gear. The result is low amplitude sideband to the left of
actual gear mesh frequency. When the next (i.e. undamaged) teeth mesh, the additional
clearance results in higher amplitude as a result; the paired sidebands have
nonsymmetrical amplitude, which is due to the disproportional clearance and impact.

5.2.1.5 Broken Tooth

Broken tooth results mechanical clearance between the teeth. While shifting load
from one tooth to another, impact is going to occur, this results in increase the noise of
gear box.

5.2.1.6 Improper Lubrication

Proper lubrication is essential for gear box because majority of the problems arise
due to lack of lubrication. Due to lubrication problem, chip formation is developed on the
tooth flank, leading to rough gear mesh and rapid deterioration occurs in spectrum near

25
meshing frequency. There will be increase in the amplitude of fundamental frequency
and its harmonics due to improper lubrication.

5.2.2 Gearbox Internal Responses

When the internal responses of gearbox are considered, the input is relative
vibration between gear teeth and the outputs (as far as noise is concerned) are the
vibration forces transmitted the bearings to gear case. In general the output force through
the bearing should have six components: three forces and three moments and theyare
usually neglected. But it gives axial forces which results in end panel vibration of
gearbox and causes the noise. Internal responses such as

1. Gear Defects
2. Bent shaft
3. Misalignment
4. Effect of bearing characteristics
5. Type of housing

5.2.3Gearbox External Responses

The external responses are gear case or structure. In certain situation, vibration
transmits through gear case or main structure and that becomes predominant source of
noise.

5.3 TRANSMISSION PATH OF NOISE

The vibration transmission path starts from the combination of manufacturing

errors, design errors, tooth and gear deflection to generate Transmission Error (T.E.)

The T.E. is then source of the vibration and it drives the internal dynamics of the
gear to give vibration forces through the bearing support. In turn, this bearing force drives
the external gear case vibration or via isolation mounts, drives the external structure
which causes airborne noise as shown in detail in Fig.5.3.1

26
 Thermal Distortion
Pinion Distortion Wheel Distortion
Gear case deflection Gear case accuracy
Pinion Movement Wheel movement
Pinion Tooth Deflection Wheel Tooth deflection
Pinion Profile accuracy Wheel Profile Accuracy
Pinion Pitch Accuracy Wheel Pitch Accuracy
Pinion Helix Accuracy Wheel Helix Accuracy

Transmission Error

Gear Masses Support Stiffness Combined Damping

Internal Dynamic Response

Bearing Forces

Casing Masses Casing Stiffness Casing Damping

Gear Case Foot Vibrations

Anti Vibration Mounts

Transmitted Structure Vibration

Sound Radiating Panel

Airborne Noise

Fig. 5.3.1 Vibration Excitation and Transmission Path

27
5.4 ANALYSIS METHODS

In this chapter review is made of some current vibration and acoustic analysis
techniques used for condition monitoring in geared transmission systems. The perceived
advantages, disadvantages, and the role each of these techniques may play in the
diagnosis of safety critical failure modes are discussed. A summary of the findings is
then made to establish which techniques to pursue further, and to identify any
deficiencies which need to be addressed.

5.4. 1.1. a) Peak.

The peak level of the signal is defined simply as half the difference between the
maximum and minimum vibrationand acoustic levels.

5.4.1.1. b) RMS.

The RMS (Root Mean Square) value of the signal is the normalized second
statistical moment of the signal (standard deviation)

Where T is the length of the time record used for the RMS calculation and is
the mean value of the signal.

For discrete (sampled) signals, the RMS of the signal is defined as;

28
 The RMS of the signal is commonly used to describe the steady-state or
continuous amplitude of a time varying signal.

5.4. 1.1. c) Crest Factor.

The crest factor is defined as the ratio of the peak value to the RMS of the signal.

The crest factor is often used as a measure of the relative or impulsive nature of a
signal. It will increase the presence of discrete impulses which are larger in amplitude
than the background signal but which do not occur frequently enough to significantly
increase the RMS level of the signal.

5.4.1.1. d) Kurtosis.

Kurtosis is the normalized fourth statistical moment of the signal. For continuous
time signals this is defined as,

For discrete signal,

The KurtosisLevel of a signal is used in a similar fashion to the crest factor that is
to provide a measure of the impulsive nature of the signal. Raising the signal to the
fourth power effectively amplifies isolated packs in the signal.

29
5.4. 1.1.e) Overall vibration or noise level.

The most basic vibration or noise monitoring technique is to measure the overall
vibration or noise level over a broad band of frequencies. The measured vibration or
noise level is trended against time as in indicator of deteriorating machine condition and /
or compared against published vibration or noise criteria for exceeders.The
measurements are typically peak or RMS velocity recordings which can be easily made
using a velocity transducer (or integrating) and an RMS meter.

Because the peak level is not a statistical value, it is often not a reliable indicator
of damage; data caused by statistically insignificant noise may have a significant effect
on the peak level. Because of this, the RMS level is generally preferred to the peak level
in machine condition monitoring applications.

Trending of overall vibration or noise level may indicate deteriorating condition

in a simple machine; however it provides no diagnostic information and will not detect
faults until they cause a significant increase in the overall in the overall vibration or noise
level. Localized faults in complex machinery may go undetected until significant
secondary damage or catastrophic failure occurs.

5.4.1.1.f). Wave shape metrics.

The overall vibration or noise level provides no information on the wave form of
the vibration or noise signal. With a member of fault, types, the shape of the signal is a
better indicator of damage then the overall vibration or noise level. For example, faults
which produce short term impulses such as bearing faults and localized tooth faults may
not significantly alter the overall vibration or noise level but may cause a statistically
significant change in the shape of the signal.

5.4.1.1. g). Frequency band analysis.

Often, the fault detection capability using overall vibration or noise level and / or
waveshape metrics can be significantly improve by dividing the vibration or noise signal
into a number of frequency bands prior to analysis. This can be done with a simple
analogue band pass filter between the vibration sensor or noise sensor and the
measurement device. The rationale behind the use of band pass filtering is that, even

30
through a fault may not cause a significant change in overall vibration signal (due to
masking by higher energy, non fault related vibrations), it may produce a significant
change in change in a band of frequencies in which the non fault related vibrations are
sufficiently small. For a simple gearbox, with judicious selection of frequency bands are
frequency band may be dominated by shaft vibrations, another by gear tooth meshing
vibrations and another by excited structural resonances, providing relatively good
coverage of all gearbox components.

5.5.1. Applicability to safety critical failure modes.

Simple time domain signal metrics, even with the use of band pass filtering, do
not provide any diagnostic information and, therefore, cannot be used to distinguish any
of the safety critical failure modes from other failure modes.

For very simple safety critical systems, overall vibration or noise level and / or
Kurtosis Level (in combination with oil debris and / or temperature monitoring) may be
useful as part of a cost effective failure detection system.

5.5.2.Spectral Analysis

Spectral (or frequency) analysis is a term used to describe the analysis of the
frequency domain representation of a signal. Spectral analysis is the most commonly
used vibration or noise analysis technique for condition monitoring in graced
transmission systems and has proved a valuable tool for detection and basic diagnosis of
faults in simple rotating machinery.Whereas the overall vibration or noise level is a
measure of the vibration or noise product over a broad band of frequencies, the spectrum
is measure of the vibrations or noise over a large number of discrete continous narrow
frequency bands.

The fundamental process common to all spectral analysis techniques is the

conversion of a time domain representation of the vibration or noise signal into a
frequency domain representation. This can be achieved by the use of narrow band filters,
or more commonly in recent times, using the Discrete Fourier Transform (DFT) of
digitized data. The vibration level at each frequency represents the vibration over a

31
narrow frequency band centered at the designated frequency with a bandwidth
determined by the conversion process employed.

For the machines operating at a known constant speed, the frequencies of the
vibrations produced by the various machine components can be estimated. Therefore, a
change in vibration level within a particular frequency band can usually be associated
with a particular machine component. Analysis of the relative vibration levels at
different frequency bands can often give an indication of the nature of a fault, providing
some diagnostic capabilities.

5.5.3.1. Conversion to the frequency domain.

The frequency domain representation of a signal can be described by the Fourier

transform of its time domain representation.

The inverse process Inverse Fourier Transform can be used to convert from a
frequency domain representation to the time domain.

There are a number of limitations inherent in the process of converting vibration

data from the time domain to the frequency domain.

5.5.3.2 Bandwidth time limitation.

All frequency analysis is subject to a bandwidth time (often called the

uncertainty principle due to the analogous concepts in quantum mechanics, declared by
Werner Hirschberg in 1927)

Frequency analysis made with bandwidth of B hertz for each measurement and
duration in time of T seconds has bandwidth time limitation of,

32
 If an event lasts for T seconds, the best measurement bandwidth (the minimum
resolvable frequency) which can be achieved is 1/T Hertz. If an analyzing filter with a
bandwidth of BHertz is used, at least 1/B seconds will be required for a measurement.

The measurement uncertainty due to the bandwidth time limitation imposes a

resolution restriction on the frequency conversion. To resolve frequencies separated by
BHertz at cast 1/B seconds of data must be taken.

5.5.3.3 FFT Analyzers.

Most modern spectrum analyzers use the Fast Fourier Transform (FFT), which is
an efficient algorithm for performing a Discrete Fourier Transform (DFT) of discrete
sampled data.

The Discrete Fourier Transform is defined as,

And the Inverse discrete Fourier Transform is,

The sampling process used to convert the continuous time signal into a discrete
signal can cause some undesirable effects.

5.5.3.4. a) Aliasing.

Frequencies which are greater than half the sampling rate will be aliased
(assumed) to lower frequencies due to the stroboscope effect. To avoid aliasing,
analogue low pass ant aliasing filter is used prior to sampling to ensure that there are
no frequencies above half the sampling rate.

33
5.5.3.4. b) Leakage.

When applying the FFT, it is assured that the sampled data is periodic with the
time record. If this is not case, false results can arise from discontinuities between the
start and end points of the time record. This leakage is normally compensated for by
applying a smooth window function which has zero values at the start and end of the tie
record. This restricts a resolution trade off since it effectively reduces the time duration
of the signal. For a simple machine, the time record can be synchronized with the
rotation of the machine, ensuring that the major vibration components are periodic within
the time record; this is difficult to achieve with complex machines due to the large
number of non harmonically frequencies.

5.5.3.4. c) Picket Fence Effect.

The Picket Fence Effect is a result of the discrete frequency nature of the FFT,
where a frequency does not lie on one of the discrete frequency lines, the amplitude will
be reduced. If the frequency is well separated from other frequency components, a
correction can be made by curve fitting to samples around the peak. Windowing reduces
the effect due to the increase in bandwidth caused by the windowing process.

5.5.3.4.d) Speed Variations.

The ability to resolve frequency components is not only related to the bandwidth-
time limitation but also to the stability of the vibration signal over the analysis period.
For FFT analyzers, the resolution imposed by the bandwidth time limitation is constant
for all frequencies, however, the frequency of vibration signals due to the mechanically
linked rotational speed of the machine, imposing a resolution limitation which is a
constant percentage of the frequency.

Even with constant speed machines, some drift in operating speed over time
likely to occur and in some casesthere may cause frequency variations (and uncertainty)
which are greater than those due to the bandwidth time limitations. For example,
performing and FFT on one second of data would give a spectrum with a resolution of
one Hz, however, a one percent speed variation over the analysis period would cause a 5
Hz uncertainty at a frequency of 500 Hz.

34
5.5.3.5.a) Synchronous Sampling.
The effects of speed variations can be overcome to a certain extent by the use of
synchronous sampling in which the sampling rate of the analyzer is linked to the speed
of the machine. However, this adds further complication to the monitoring process as it
requires a speed attached to the machine being monitored, a frequency multiplier to
convert the speed signal into a clock pulse signal suitable for driving the signal
analyzer, and often needs on external anti aliasing filter to avoid aliasing problems
(although almost all modern FFT analyzers have in built anti aliasing filters, when
they are driven from an external clock these are often bypassed or have inappropriate
frequencies due to the unknown external clock frequency)

5.5.3.6Fault Detection.
The fault detection is discussed hereunder:

5.5.3.6.a) Spectral Comparison.

The most common spectral analysis technique used for machine condition
monitoring is spectral comparison, where a baseline power (magnitude squared) spectrum
is taken under well defined normal operating conditions with the machine in known good
condition (preferably soon after commissioning). This baseline spectrum is used as
reference for subsequent power spectra taken at regular intervals throughout the machine
life under similar operating conditions. The comparison is usually done on a logarithmic
amplitude scale, with increase of 6-8 dB considered to be significant and changes greater
than 20 dB from the baseline considered serious.

5.5.3.6b) Spectral Trending.

In addition to spectral comparisons, various forms of spectral trending can be

used to give some indication of the rate of fault progression. In its simplest form, spectral
trending involves the trending of the changes in amplitude of all (or a number of selected)
spectral lines over time. For complex machines, this can often involve a large amount of
data, resulting in information overload due to the large number of significant spectral
lines. In an attempt to simplify the detection process, a number of parameters based on
spectrum have been proposed which provides statistical measurements of spectral
differences.

35
5.5.3.6.c) Spectral Masks.

Spectral Masks is a method of spectral comparison sometimes employed to

identify and evaluate changes in the signature spectrum, with allowances made for
variation in operating condition. A spectral mask is derived from the baseline spectrum
by adding an allowable tolerance limit to the logarithmic amplitude. To allow for
variations in speed, the constant bandwidth spectrum is sometimes converted to a
constant percentage bandwidth spectrum, with the percentage bandwidth being
determined by the estimated speed differences which can occur between recordings. Once
a spectral mask is defined, comparison of individual recordings is made with reference to
the mask to identify exceeders.

5.5.3.7 Fault Diagnosis.

Even for relatively simple machines, the vibration spectrum can be quite complex
due to the multiple harmonic structures of the vibration from various components in
combination with the transmission path effects. This makes detailed diagnostic analysis
of an individual spectrum very difficult. The diagnostic process is simplified when
performed in conjunction with spectral comparison and/ or trending; typically, only the
frequencies identified as having significant changes are analyzed in detail for diagnostic
purposes. Distributed faults with cause significant change in the mean amplitude of the
vibration at discrete frequencies, such as heavy wear and unbalance, should be relatively
simple to diagnose using spectral analysis, as they would translate to changes in a few
associated frequency lines in the spectrum.

5.5.3.8. Applicability to safety critical failure modes.

For relatively simple machines, and those where the first few harmonics of the
shaft vibration frequencies can be identified (i. e. can be well separated from other
vibration frequencies within the limits of bandwidth and / or speed variations), diagnosis
of shaft related faults (fracture, unbalance, misalignment and bent shaft) should be quiets
simple with spectral analysis, by trending of the amplitudes of the shaft related vibrations
or use of spectral masks.

36
 Chapter 6

TEST CRITERIA AND SPECIFICATION

6.1 INTRODUCTION

In previous chapter different measurement and analysis techniques has been

discussed. As per the objective of dissertation work to measure the vibration and sound
pressure of a gears for condition monitoring the following tests were carried out.

Extensive experimentation is donein M/s. G3S Components Pvt. Ltd.Pune for

measurement of vibration and sound pressure level. Keeping in view the financial
constraints a commercially available geared motor is chosen for experimentation
eliminating the need of a separate costlier gearbox. For giving the rated load on geared
motor, a rope-brake dynamometer is used, where by varying load the power can also be
varied and it is easy to achieve the same condition for taking readings for different gears.

It is decided to make deliberate faults, such as wear, crack on one tooth of gear,
and one tooth broken on spur gear and lack lubrication of the gearbox. The analysis of
vibration and acoustic signals of each fault is carried out separately. For that purpose,
gears of same specifications is taken and on each gear separate faults are made. The
vibrationand acoustic signals of each faulty gear and gear without any fault is obtained.
Thus the signals obtained is analyzed which are valuable for the fault diagnosis.

6.2 EXPERIMENTAL SETUP

The schematic diagram of vibration and acoustic measurement for fault diagnosis
of gearbox shown in Fig. 6.2.1 and a line diagram in Fig.6.2.2. The geared motor is
rigidly mounted on concrete foundation to isolate vibration and acoustics from
foundation.

37
Accelerometer and Microphone Gearbox

Pre- amplifier

Band pass filter

Full wave rectifier

Data recorder
Low pass filter

A/D converter FFT Analyzer

Microcomputer

Fig. 6.2.1. Schematic setup forvibration and sound pressure measurement

Fig. 6.2.2.Line diagram for vibration and sound pressure measurement

38
6.3. SPECFICATIONS OF THE INSTRUMENTS

The equipments, which are used for carrying out the experimental procedure with
their specification, are explained below.

6.3.1 Geared Motor

Gearbox is the main part used for the experimentation. Here the geared motor of
following specification is selected.

1) The specification of the motor:

Sr. No. Particulars Specifications
1 Make Shri Shakti
2 Make No: SGO/63/4/B3
3 Motor type Squirrel cage induction motor
4 Phase 3 Phase
5 Power 0.18 kW/ 0.25 Hp.
6 Operating Voltage 400/440 volts
7 No. of cycles 50
8 Supply AC supply
9 Insulation B class
10 Type of mounting Horizontal foot mounted

2) The specifications of gearbox:

Sr. No. Particulars Specifications
1 Power 0.25 Hp
2 Input rpm 1420 rpm
3 Input frequency 1420/60 = 23.67 Hz
4 Output rpm 200 rpm
5 Output frequency 200/60 = 3.33 Hz
6 No. of stages 2 Stage

39
3) Types of gears:
First pinion
Sr. No. Particulars Specifications
1 Type Spur
2 No. of teeth 12
3 Pitch circle diameter 18 mm
4 Module 1.5
5 Speed 1420 rpm
6 Rotational frequency (rpm/60) Hz 1420/60 = 23.67 Hz
Tooth meshing frequency (rpm x no.
7 1420 x 12/60 = 284 Hz
of teethes/60) Hz
First Gear:
Sr. No. Particulars Specifications
1 Type Spur
2 No. of teeth 48
3 Pitch circle diameter 72 mm
4 Module 1.5
5 Speed 355 rpm
6 Rotational frequency (rpm/60) Hz 355/60 = 5.92Hz
Tooth meshing frequency(rpm x
7 355 x 48/60 = 284 Hz
no. of teethes/60) Hz
Second Pinion:
Sr. No. Particulars Specifications
1 Type Helical
2 No. of teeth 19
3 Pitch circle diameter 32.37 mm
4 Module 1.7
5 Speed 355 rpm
6 Rotational frequency (rpm/60) Hz 355/60 = 5.92 Hz
Tooth meshing frequency (rpm
7 355 x 19/60 = 112.42 Hz
x no. of teethes/60) Hz

40
Second gear:
Sr. No. Particulars Specifications
1 Type Helical
2 No. of teeth 34
3 Pitch circle diameter 57.8 mm
4 Module 1.7
5 Speed 200 rpm
6 Rotational frequency (rpm/60) Hz 200/60 = 3.33 Hz
Tooth meshing frequency (rpm
7 200 x 34/60 = 113.33 Hz
x no. of teethes/60) Hz

6.3.2. Digital Frequency Analyzer (FFT)

For the experimental work the digital analyzer is used (Make- Larson-
Davis,model 2900B). Facility of selecting various parameters such as scale (linear or
logarithmic), windows,base band,filters and zoom analysis is available with this
model.The specifications of FFT is as given below,
Sr. No. Particulars Specifications
1 Make and model Larson Davis 2900B
Size -28 cm (width) x 19.7 cm (height) x
2 Physical Characteristics 6.1 cm (thick)
Weight- 3.4 Kg
Measuring range-10-200 dB
Impedance-10 G
Polarization Voltage-0, 28, 200 VDC
3 Input Characteristics
Gain-30 to 90 dB in 10 dB steps
Analog Input filters -High pass 1 Hz, 20Hz
-Low pass 10 kHz, 20 kHz
Digitization-16-bit A: D per channel
4 Digital Characterization Dynamic Range->80 dB
Amplitude stability- 0.1 dB

41

5 Fast Fourier Transform
6 Power
7 Display Characteristics
8 Environmental
Lines 100,200.400,800 line FFT analyzer
Limit-Upper frequency limit: 20 kHz
Battery-Nickel Metal Hydride
DC Power-1.5 A @ 11 V and 0.5 A@ 216
V
Internal LCD
Backlighting : Electroluminescent
Resolution : 128 x 489 , with full graphics
External Display- 1,2 or 4 display
Operating Temperature- 10C to 50 C

6.3.3. Acoustic Pickup (Sound Pressure Probe)

Condenser microphone is used for measuring sound pressure.

6.3.4 Vibration Pickup

As the acceleration signals gives good results for wide frequency range, the
piezoelectric accelerometer is chosen for this work. The specification is given as follows.

Make- Dytran

Sensitivity- 10mV/g

6.4 CREATION OF FAULTS ON GEAR TOOTH

For creation of artificial faults on gear tooth, four different gears are procured. For
that, the spur gear having 48 teeth and module of 1.5 is selected.
The common faults of gear tooth are as follows.
1. Wear on one tooth
2. Crack on one tooth
3. One tooth broken or missed
4. Lack of lubrication

42
1. Wear:
Wear on one tooth of gear is made by filing one tooth and removing material from
tooth in direction of rotation. The wear is made near the pitch circle of gear.

Fig. 6.4.1.Wear on one tooth

2. Crack on one Tooth:
A crack is produced on one tooth of gear. This is made by cutting the tooth with
the hacksaw blade at the root of tooth in the direction of rotation.

Fig. 6.4.2.Crack on one tooth

43
3. Broken Tooth:
For making this fault, one tooth of gear is removed by hacksaw blade and original
non-defective gear is replaced with this gear.

Fig. 6.4.3One tooth broken

4. Inadequate Lubrication: -
Many times unsatisfactory operation of gearbox may be caused by failure of
lubrication. To enable one, to identify this condition an experiment is carried out by
removing lubrication oil from the gearbox.

6.5. EXPERIMENTAL PROCEDURE

In experimental procedure the gearboxis allowed to run at its rated power and
speeds by applying different load condition of 0 kg, 2.5 kg, 5 kg, and 7.5 kg on rope
break dynamometer having diameter of pulley 71.38 mm. .

The positioning of sound pressure level probe is done properly on the top of the
gear under consideration for measuring sound pressure. For vibration measurement
accelerometer is kept on the top of gearbox.

By making all above arrangements, readings are taken for non-defective gear and
good lubrication condition. This data is stored in FFT analyzer for further analysis.

44
 Vibration and noise spectrums are taken for gears having various faults and the
data is stored in computer for further analysis. For different condition of faults and
different load conditions data is collected.

45
 Chapter 7

RESULT ANALYSIS
7.1 INTRODUCTION

As discussed in previous chapter, the various faults were created deliberately on

spur gear of gearbox and acoustic pressure and vibration signatures were obtained. In this
present chapter these signatures are compared with good gear signatures and an attempt is
made to correlate them with their faults. The aim is to check the features of acoustic
spectrum and vibration spectrum for different faults of gear tooth to condition monitoring
and hence fault diagnose of gearbox.

7.2 VIBRATION SPECTRAL ANALYSIS

Variousvibration spectrums are taken for healthy and various defective gears and
are discussed below.

7.2.1Spectrum of Healthy Gear

Fig. 7.2.1 shows the vibration spectrum of healthy (non-defective) gear. It shows
that there is remarkable vibration level at gear mesh frequency, which is may be due to
the inherent unbalance in gear and manufacturing defects. It is, therefore obvious that,
there will be some vibration level at gear mesh frequency due to created faults.

VIBRATION SPECTRUM OF HEALTHY GEAR AT NO LOAD

0
0 500 1000 1500 2000 2500 3000
-10

-20
AMPLITUDE

-30
-40 HEALTHY
-50

-60

-70

-80

FREQUENCY

Fig. 7.2.1 vibration spectrum of healthy (non-defective) gear at no load

46
 Below figures respectively shows comparison of cracked tooth and healthy gear
spectrums,broken tooth and healthy gear ,wear of teeth and healthy gear , improper
lubrication and healthy respectively. As the crack was produced on the gear, it reflects the
change in vibration spectrum. From above results following characteristics can be
associated to fault.
The amplitude level in dB increases considerably at gear mesh frequency in Hz.
The amplitude level increases by considerable margin at side bands.

7.2.2 Crack on One Tooth

VIBRATION SPECTRUM OF CRACK ON TOOTH Vs HEALTHY

0
0 500 1000 1500 2000 2500 3000
-10

-20
AMPLITUDE

-30
HEALTHY
-40
CRACK ON TOOTH
-50

-60

-70

-80

FREQUENCY

Fig. 7.2.2 Vibration spectrum of crack on tooth Vs healthy tooth

7.2.3 Gear with Broken Tooth

VIBRATION SPECTRUM OF BROKEN TOOTH Vs HEALTHY

0
0 500 1000 1500 2000 2500 3000
-10

-20
AMPLITUDE

-30
HEALTHY
-40
BROKEN TOOTH
-50

-60

-70

-80

FREQUENCY

Fig. 7.2.3 Vibration spectrum of broken tooth Vs healthy tooth

47
7.2.4 Wear of Teeth

VIBRATION SPECTRUM OF WEAR OF TEETH VS HEALTHY

0
-10 0 500 1000 1500 2000 2500 3000
AMPLITUDE

-20
-30
HEALTHY
-40
WEAR OF TEETH
-50
-60
-70
-80

FREQUENCY

Fig. 7.2.4 Vibration spectrum of wear of teeth Vs healthy teeth

7.2.5 Improper Lubrication Condition

VIBRATION SPECTRUM OF IMPROPER LUBRICATION Vs

HEALTHY

0
-10 0 500 1000 1500 2000 2500 3000
AMPLITUDE

-20
-30
HEALTHY
-40
-50 IMPROPER
LUBRICATION
-60
-70
-80

FREQUENCY

Fig. 7.2.5.1 Vibration spectrum of wear of improper lubrication Vs healthy teeth

48
 VIBRATION SPECTRUM OF HEALTHY Vs ALL FAULTS

0 HEALTHY
-10 0 500 1000 1500 2000 2500 3000
AMPLITUDE
-20 CRACK ON TOOTH
-30
-40
BROKEN TOOTH

-50
WEAR ON TEETH
-60
-70 IMPROPER
-80 LUBRICATION
FREQUENCY

Fig. 7.2.5.2 Vibration spectrum of healthy Vs all faults on tooth

Fig. 7.2.5.2 shows comparison of vibration signatures of all faults, stated above
with each other. From this figure, it is also seen that the amplitude change of mesh
frequency occurs during tooth wear. In terms of crack on tooth the amplitude at gear
mesh frequency increases considerably. While improper lubrication results in only spikes
i.e., momentary increases at meshing frequency and its harmonics, for worn-out teeth the
amplitude level increases significantly.

7.3 ACOUSTIC SPECTRAL ANALYSIS

Various acoustic spectrums are taken for healthy and various defective gears and
are discussed below

7.3.1Spectrum of Healthy Gear

Fig. 7.3.1 shows the acoustic spectrum of healthy (non-defective) gear. It shows
that there is remarkable sound pressure level at gear mesh frequency, which is may be
due to the inherent unbalance in gear and manufacturing defects. It is, therefore obvious
that, there will be some sound pressure level at gear mesh frequency due to created faults.

49
 ACOUSTIC SPECTRUM OF HEALTHY GEAR AT NO LOAD

90
80
70
AMPLITUDE

60
50
HEALTHY
40
30
20
10
0
0 500 1000 1500 2000 2500 3000

FREQUENCY

Fig. 7.3.1Acoustic spectrum of healthy gear at no load

Below figures shows comparison of cracked tooth and healthy gear spectrums,
broken tooth and healthy gear,wear of teeth and healthy gear, improper lubrication and
healthy respectively. As the fault is produced on the gear, it reflects the change in
acoustic spectrum. It is observed that the amplitude of gear mesh frequency has increased
considerably. From above results following characteristics can be associated to fault.
The amplitude level increases considerably at gear mesh frequency.
The amplitude level increases by small margin at side bands.

7.3.2 Gear with crack on tooth

ACOUSTIC SPECTRUM CRACK ON TOOTH Vs HEALTHY

90
80

70
AMPLITUDE

60
50 HEALTHY
40
CRACK ON
30 TOOTH
20
10
0
0 500 1000 1500 2000 2500 3000

FREQUENCY

Fig. 7.3.2.1Acoustic spectrum crack on tooth Vs healthy tooth

50
 ACOUSTIC SPECTRUM OF BROKEN TOOTH TH Vs HEALTHY

90
80
70
AMPLITUDE

60
50 HEALTHY
40
30 BROKEN
TOOTH
20
10
0
0 500 1000 1500 2000 2500 3000

FREQUENCY

Fig. 7.3.2.2Acoustic spectrum of broken tooth Vs healthy tooth

7.3.3Wear of Teeth

ACOUSTIC SPECTRUM WEAR OF TEETH Vs HEALTHY

90
80
70
AMPLITUDE

60
50 HEALTHY
40 WEAR OF TEETH
30
20
10
0
0 500 1000 1500 2000 2500 3000

FREQUENCY

Fig 7.3.3 Acoustic spectrum wear of teeth Vs healthy teeth

51
7.3.4 Improper Lubrication Condition

ACOUSTIC SPECTRUM IMPROPER LUBRICATION Vs HEALTHY

90
80
70
AMPLITUDE

60
50 HEALTHY
40
30
IMPROPER
LUBRICATION
20
10
0
0 500 1000 1500 2000 2500 3000

FREQUENCY

Fig 7.3.4.1 Acoustic spectrum improper lubrication Vs healthy lubrication

ACOUSTIC SPECTRUM OF HEALTHY Vs ALL FAULTS

90
80 HEALTHY
70
AMPLITUDE

CRACK ON
60
TOOTH
50
BROKEN TOOTH
40
30 WEAR OF TEETH
20
10 IMPROPER
0 LUBRICATION
0 500 1000 1500 2000 2500 3000

FREQUENCY

Fig 7.3.4.2 Acoustic spectrum of healthy Vs all faults

Fig. 7.3.4.2 shows comparison of acoustic signatures of all faults, stated above with each
other. From this figure, it is also seen that the amplitude change of mesh frequency
occurs during tooth wear. In terms of crack on tooth the amplitude at gear mesh

52
frequency increases considerably. While improper lubrication results in only spikes at
meshing frequency and its harmonics. For worn-out teeth the amplitude level increases
significantly.

While diagnosing gearbox, gear mesh faults prove the importance of spectrum
comparison. By monitoring changes over the time that the seriousness of developing
problem can be estimated.

7.4 EFFECT OF LOAD ON CRACK ON ONE TOOTH

Variousvibration and acoustic spectrums are taken for healthy gear at various
loads and are discussed below. Below figures respectively shows comparison of cracked
tooth at no load, at 2.5 kg load,at 5 kg load and at 7.5 kg load. As the load was given on
the gear, it reflects the change in vibration spectrum. From above results following
characteristics can be associated to varying load.

The amplitude level increases considerably at gear mesh frequency.

The amplitude level increases by considerable margin at side bands.

53
 Vibration Spectrum of crack on teeth at various loads

VIBRATION SPECTRUM OF CRACK ON TEETH AT NO LOAD

CONDITION

0
0 500 1000 1500 2000 2500 3000
-10

-20
AMPLITUDE

-30

-40 NO LOAD
-50
-60

-70

-80

FREQUENCY

Fig. 7.4.1 Vibration spectrum of crack on teeth at no load condition

VIBRATION SPECTRUM OF CRACK ON TEETH -NO LOAD Vs 2.5

KG LOAD

0
0 500 1000 1500 2000 2500 3000
-10

-20
AMPLITUDE

-30
NO LOAD
-40
2.5 KG LOAD
-50

-60

-70

-80

FREQUENCY

Fig. 7.4.2 Vibration spectrum of crack on teeth at no load Vs 2.5 kg load

54
 VIBRATION SPECTRUM OF CRACK ON TEETH - NO LOAD
CONDITION Vs 5KG LOAD

0
-10 0 500 1000 1500 2000 2500 3000
AMPLITUDE

-20
-30
NO LOAD
-40
-50
5 KG LOAD

-60

-70
-80

FREQUENCY

Fig. 7.4.3 Vibration spectrum of crack on teeth at no load Vs 5 kg load

VIBRATION SPECTRUM OF CRACK ON TEETH - NO LOAD Vs

7.5 KG LOAD

0
0 500 1000 1500 2000 2500 3000
-10
AMPLITUDE

-20
-30
NO LOAD
-40
7.5 KG LOAD
-50

-60
-70

-80

FREQUENCY

Fig. 7.4.4 Vibration spectrum of crack on teeth at no load Vs 7.5 kg load

55
 VIBRATION SPECTRUM OF CRACK ON TETH - NO LOADS Vs
ALL LOADS

0
0 500 1000 1500 2000 2500 3000
-10
-20
AMPLITUDE

NO LOAD
-30
2.5 KG LOAD
-40
5 KG LOAD
-50
7.5 KG LOAD
-60
-70

-80

FREQUENCY

Fig. 7.4.5 Vibration spectrum of crack on teeth at no load Vs all loads

Acoustic Spectrum of crack on teeth at various loads

ACOUSTIC SPECTRUM OF CRACK ON TEETH - NO LOAD

80
70
AMPLITUDE

60
50
40 NO LOAD
30
20
10
0
0 500 1000 1500 2000 2500 3000

FREQUENCY

Fig. 7.4.6 Acoustic spectrum of crack on teeth at no load condition

56
 ACOUSTIC SPECTRUM OF CRACK ON TEETH - NO LOAD Vs
2.5 KG LOAD

90
80
AMPLITUDE

70
60
50 NO LOAD
40 2.5 KG LOAD
30
20
10
0
0 500 1000 1500 2000 2500 3000

FREQUENCY

Fig. 7.4.7 Acoustic spectrum of crack on teeth at no load Vs 2.5 kg load condition

ACOUSTIC SPECTRUM OF CRACK ON TEETH - NO LOAD Vs 5

KG LOAD

90
80
AMPLITUDE

70
60
50 NO LOAD
40 5 KG LOAD
30
20
10
0
0 500 1000 1500 2000 2500 3000

FREQUENCY

Fig. 7.4.8 Acoustic spectrum of crack on teeth at no load Vs 5 kg load condition

57
 ACOUSTIC SPECTRUM OF CRACK ON TEETH - NO LOAD Vs 7.5
KG LOAD

80
70
AMPLITUDE

60
50
NO LOAD
40
7.5 KG LOAD
30
20
10
0
0 500 1000 1500 2000 2500 3000

FREQUENCY

Fig. 7.4.9 Acoustic spectrum of crack on teeth at no load Vs 7.5 kg load condition

ACOUSTIC SPECTRUM OF CRACK ON TEETH - NO LOAD Vs

ALL LOADS

90
80
70
AMPLITUDE

60 NO LOAD
50 2.5 KG LOAD
40 5 KG LOAD
30 7.5 KG LOAD
20
10

0
0 500 1000 1500 2000 2500 3000

FREQUENCY

Fig. 7.4.10 Acoustic spectrum of crack on teeth at no load Vs all loads condition

58
7.5 EFFECT OF LOAD ON BROKEN TOOTH

Variousvibration and acoustic spectrums are taken for healthy gear at various
loads and are discussed below.

Below figures respectively shows comparison of broken tooth at no load, at 2.5 kg

load,at 5 kg load and at 7.5 kg load. As the load is given on the gear, it reflects the change
in vibration and acoustic spectrum. From above results following characteristics can be
associated to varying load.

The amplitude level increases considerably at gear mesh frequency.

The amplitude level increases by considerable margin at side bands

Vibration Spectrum of crack on teeth at various loads

VIBRATION SPECTRUM OF BROKEN TEETH NO LOAD

0
0 500 1000 1500 2000 2500 3000
-10

-20
AMPLITUDE

-30

-40 NO LOAD
-50

-60

-70

-80

FREQUENCY

Fig. 7.5.1 Vibration spectrum of broken teeth at no load condition

59
 VIBRATION SPECTRUM OF BROKEN TEETH - NO LOAD Vs 2.5
KG LOAD

0
0 500 1000 1500 2000 2500 3000
-10

-20
AMPLITUDE

-30
NO LOAD
-40
2.5 KG LOAD
-50

-60

-70

-80

FREQUENCY

Fig. 7.5.2 Vibration spectrum of broken teeth at no load Vs 2.5 kg load condition

VIBRATION SPECTRUM OF BROKEN TEETH - NO LOAD Vs 5 KG

LOAD

0
-10 0 500 1000 1500 2000 2500 3000
AMPLITUDE

-20
-30
NO,LOAD
-40
-50
5 KG LOAD
-60
-70
-80

FREQUENCY

Fig. 7.5.3 Vibration spectrum of broken teeth at no load Vs 5 kg load condition

60
 VIBRATION SPECTRUM OF BROKEN TEETH - NO LOAD Vs 7.5
KG LOAD

0
-10 0 500 1000 1500 2000 2500 3000
AMPLITUDE

-20
-30
NO,LOAD
-40
-50
7.5 KG LOAD
-60
-70
-80

FREQUENCY

Fig. 7.5.4 Vibration spectrum of broken teeth at no load Vs 7.5 kg load condition

VIBRATION SPECTRUM OF BROKEN TEETH - NO LOAD Vs

ALL LOADS

0
-10 0 500 1000 1500 2000 2500 3000
-20
AMPLITUDE

NOLOAD
-30
2.5 KG LOAD
-40
5 KG LOAD
-50
7.5 KG LOAD
-60
-70
-80
FREQUENCY

Fig. 7.5.5 Vibration spectrum of broken teeth at no load Vs all loads condition

61
Acoustic Spectrum of crack on teeth at various loads

ACOUSTIC SPECTRUM OF BROKEN TEETH AT NO LOAD

80
70
AMPLITUDE

60
50
40 NO LOAD
30
20
10
0
0 500 1000 1500 2000 2500 3000

FREQUENCY

Fig. 7.5.6 Acoustic spectrum of broken teeth at no load condition

ACOUSTIC SPECTRUM OF BROKEN TEETH - NO LOAD Vs 2.5

KG LOAD

80
70
AMPLITUDE

60
50
NO,LOAD
40
2.5 KG LOAD
30
20
10
0
0 500 1000 1500 2000 2500 3000

FREQUENCY

Fig. 7.5.7 Acoustic spectrum of broken teeth at no load Vs 2.5 kg load condition

62
 ACOUSTIC SPECTRUM OF BROKEN TEETH - NOLOAD Vs 5
KG LOAD

90
80
70
AMPLITUDE

60
50 NO LOAD
40 5 KG LOAD
30
20
10
0
0 500 1000 1500 2000 2500 3000

FREQUENCY

Fig. 7.5.8 Acoustic spectrum of broken teeth at no load Vs 5 kg load condition

ACOUSTIC SPECTRUM OF BROKEN TEETH - NO LOAD Vs

7.5KG LOAD

80

70

60
AMPLITUDE

50
NO LOAD
40
7.5 KG LOAD
30

20
10

0
0 500 1000 1500 2000 2500 3000

FREQUENCY

Fig. 7.5.9 Acoustic spectrum of broken teeth at no load Vs 7.5 kg load condition

63
 ACOUSTIC SPECTRUM OF BROKEN TEETH - NO LOAD Vs ALL
LOADS

90
80
70
AMPLITUDE

60 NO LOAD
50 2.5 KG LOAD
40 5 KG LOAD
30
7.5 KG LOAD
20
10
0
0 500 1000 1500 2000 2500 3000

FREQUENCY

Fig. 7.5.10 Acoustic spectrum of broken teeth at no load Vs all load conditions

7.6 TIME DOMAINANLYSIS OFVIBRATION SIGNAL

HEALTHY - NO LOAD - TIME DOAMAIN VIBRATION DATA

4
3
AMPLITUDE

2
1
0 Series1
-1 0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18
-2
-3
-4

TIME

Fig. 7.6.1 Healthy-No Load-Time Domain Vibration Data

64
 CRACK ON T00TH - NO LOAD - TIME DOMAIN VIBRATION DATA

6
5
4
3
AMPLITUDE

2
1
0 Series1
-1 0 0.05 0.1 0.15 0.2
-2
-3
-4
-5
-6
TIME

Fig. 7.6.2 Crack on tooth-No Load-Time Domain Vibration Data

BROKEN TOOTH - NO LOAD - TIME DOMAIN VIBRATION DATA

8
7
6
5
4
AMPLITUDE

3
2
1
0 Series1
-1
-2 0 0.05 0.1 0.15 0.2
-3
-4
-5
-6
-7
TIME

Fig. 7.6.3 Broken tooth-No Load-Time Domain Vibration Data

65
 WEAR OF TEETH - NO LOAD - TIME DOMAIN VIBRATION DATA

9
8
7
6
5
4
3
AMPLITUDE

2
1
0 Series1
-1
-2 0 0.05 0.1 0.15 0.2
-3
-4
-5
-6
-7
-8
-9
TIME

Fig. 7.6.4 Wear of teeth-No Load-Time Domain Vibration Data

IMPROPER LUBRICATION -NO LOAD -TIME DOMAIN VIBRATION

DATA

12
10
8
6
4
2
AMPLITUDE

0
-2 0 0.05 0.1 0.15 0.2 Series1
-4
-6
-8
-10
-12
-14
-16
-18
TIME

Fig. 7.6.5 Improper Lubrication-No Load-Time Domain Vibration Data

66
7.7 TIME DOMAIN ANALYSIS OF ACOUSTIC (NOISE) SIGNAL

HEALTHY - NO LOAD - TIME DOMAIN NOISE DATA

60000
50000
40000
AMPLITUDE

30000
20000
10000
0 Series1
-10000 0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18
-20000
-30000
-40000
-50000
-60000

TIME

Fig. 7.7.1 Healthy-No Load-Time Domain Noise Data

CRACK ON TOOTH - NO LOAD - TIME DOMAIN NOISE DATA

60000
50000
40000
30000
AMPLITUDE

20000
10000
0 Series1
-10000 0 0.05 0.1 0.15 0.2
-20000
-30000
-40000
-50000
-60000
TIME

Fig. 7.7.2 Crack on tooth-No Load-Time Domain Noise Data

67
 BROKEN TOOTH - NO LOAD - TIME DOMAIN NOISE DATA

60000
50000
40000
30000
AMPLITUDE

20000
10000
0
Series1
-10000 0 0.05 0.1 0.15 0.2
-20000
-30000
-40000
-50000
-60000
-70000
TIME

Fig. 7.7.3 Broken tooth-No Load-Time Domain Noise Data

WEAR OF TEETH - NO LOAD - TIME DOMAIN NOISE DATA

70000
60000
50000
40000
30000
AMPLITUDE

20000
10000
0 Series1
-10000
-20000 0 0.05 0.1 0.15 0.2
-30000
-40000
-50000
-60000
-70000
TIME

Fig. 7.7.4 Wear of teeth-No Load-Time Domain Noise Data

68
 IMPROPER LUBRICATION - NO LOAD - TIME DOMAIN NOISE
DATA

60000
50000
40000
AMPLITUDE

30000
20000
10000
Series1
0
-10000 0 0.05 0.1 0.15 0.2
-20000
-30000
-40000
-50000
TIME

Fig. 7.7.5 Improper Lubrication-No Load-Time Domain Noise Data

7.8 EFFECT OFLOADON CRACKEDTOOTH

VIBRATION SIGNAL

CRACK ON T00TH - NO LOAD - TIME DOMAIN VIBRATION DATA

6
5
4
3
AMPLITUDE

2
1
0 Series1
-1 0 0.05 0.1 0.15 0.2
-2
-3
-4
-5
-6
TIME

Fig. 7.8.1 Crack on tooth-No Load-Time Domain Vibration Data

69
 CRACK ON TOOTH - 2.5 KG LOAD - TIME DOMAIN VIBRATION
DATA

5
4
3
AMPLITUDE

2
1
0 Series1
-1 0 0.05 0.1 0.15 0.2
-2
-3
-4
-5
TIME

Fig. 7.8.2 Crack on tooth-2.5 kg Load-Time Domain Vibration Data

CRACK ON TOOTH - 5 KG LOAD - TIME DOMAIN VIBRATION

DATA

7
6
5
4
AMPLITUDE

3
2
1 Series1
0
-1
-2 0 0.05 0.1 0.15 0.2
-3
-4
-5
TIME

Fig. 7.8.3 Crack on tooth-5 kg Load-Time Domain Vibration Data

70
 CRACK ON TOOTH - 7.5 KG LOAD - TIME DOMAIN
VIBRATION DATA

12
10
8
6
AMPLITUDE

4
2
0 Series1
-2 0 0.05 0.1 0.15 0.2
-4
-6
-8
-10
-12
TIME

Fig. 7.8.4 Crack on tooth-7.5 kg Load-Time Domain Vibration Data

ACOUSTIC SIGNAL

CRACK ON TOOTH - NO LOAD - TIME DOMAIN NOISE DATA

60000
50000
40000
30000
AMPLITUDE

20000
10000
0 Series1
-10000 0 0.05 0.1 0.15 0.2
-20000
-30000
-40000
-50000
-60000
TIME

Fig. 7.8.5 Crack on tooth-No Load-Time Domain Noise Data

71
 CRACK ON TOOTH - 2.5 KG LOAD - TIME DOMAIN NOISE DATA

80000
70000
60000
50000
40000
AMPLITUDE

30000
20000
10000 Series1
0
-10000
-20000 0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18
-30000
-40000
-50000
-60000
-70000
TIME

Fig. 7.8.6 Crack on tooth-2.5 kg Load-Time Domain Noise Data

CRACK ON TOOTH - 5 KG LOAD - TIME DOMAIN NOISE DATA

120000
100000
80000
60000
AMPLITUDE

40000
20000
0 Series1
-20000 0 0.05 0.1 0.15 0.2
-40000
-60000
-80000
-100000
-120000
TIME

Fig. 7.8.7 Crack on tooth-5 kg Load-Time Domain Noise Data

72
 CRACK ON TOOTH -7. 5 KG - TIME DOMAIN NOISE DATA

100000
80000
60000
40000
AMPLITUDE

20000
0 Series1
-20000 0 0.05 0.1 0.15 0.2
-40000
-60000
-80000
-100000
TIME

Fig. 7.8.8 Crack on tooth-7.5 kg Load-Time Domain Noise Data

7.9 EFFECTOF LOAD ON BROKEN TOOTH

VIBRATION SIGNAL

BROKEN TOOTH - NO LOAD - TIME DOMAIN VIBRATION DATA

8
7
6
5
4
AMPLITUDE

3
2
1 Series1
0
-1
-2 0 0.05 0.1 0.15 0.2
-3
-4
-5
-6
-7
TIME

Fig. 7.9.1 Broken tooth-No Load-Time Domain Vibration Data

73
 BROKEN TOOTH - 2.5 KG LOAD - TIME DOMAIN VIBRATION
DATA

10
8
6
AMPLITUDE

4
2
Series1
0
-2 0 0.05 0.1 0.15 0.2
-4
-6
-8
TIME

Fig. 7.9.2 Broken tooth-2.5 kg Load-Time Domain Vibration Data

BROKEN TOOTH - 5 KG LOAD - TIME DOMAIN VIBRATION DATA

8
7
6
5
4
AMPLITUDE

3
2
1 Series1
0
-1
-2 0 0.05 0.1 0.15 0.2
-3
-4
-5
-6
-7
TIME

Fig. 7.9.3 Broken tooth-5 kg Load-Time Domain Vibration Data

74
 BROKEN TOOTH -7.5 KG LOAD - TIME DOMAIN VIBRATION DATA

12
10
8
AMPLITUDE

6
4
2 Series1
0
-2 0 0.05 0.1 0.15 0.2
-4
-6
-8
TIME

Fig. 7.9.4 Broken tooth-7.5 kg Load-Time Domain Vibration Data

ACOUSTIC SIGNAL

BROKEN TOOTH - NO LOAD - TIME DOMAIN NOISE DATA

60000
50000
40000
30000
AMPLITUDE

20000
10000
0
-10000 0 Series1
0.05 0.1 0.15 0.2
-20000
-30000
-40000
-50000
-60000
-70000
TIME

Fig. 7.9.5 Broken tooth-No Load-Time Domain Noise Data

75
 BROKEN TOOTH - 2.5 KG LOAD - TIME DOMAIN
NOISE DATA

80000
60000
40000
AMPLITUDE

20000
0
Series1
-20000 0 0.05 0.1 0.15 0.2
-40000
-60000
-80000
-100000
TIME

Fig. 7.9.6 Broken tooth-2.5 kg Load-Time Domain Noise Data

BROKEN TOOTH - 5 KG LOAD - TIME DOMAIN NOISE DATA

100000
80000
60000
AMPLITUDE

40000
20000
Series1
0
-20000 0 0.05 0.1 0.15 0.2
-40000
-60000
-80000
TIME

Fig. 7.9.7 Broken tooth-5 kg Load-Time Domain Noise Data

76
 BROKEN TOOTH - 7.5 KG LOAD - TIME DOMAIN NOISE DATA

100000
80000
60000
AMPLITUDE

40000
20000
0 Series1
-20000 0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18
-40000
-60000
-80000
-100000
TIME

Fig. 7.9.8 Broken tooth-7.5 kg Load-Time Domain Noise Data

77
 CHAPTER 8

CONCLUSION
The condition monitoring of gears can significantly reduce the cost of
maintenance. Firstly, it can allow the early detection of major faults, which could be
extremely expensive to repair. Secondly, it allows the implementation of condition based
maintenance rather than periodic or failure based maintenance. In these cases delaying
scheduled maintenance can make significant savings until convenient or necessary.

Herevibration and acoustic signals were used for condition monitoring. It is

shown that various types of gear failures can be detected successfully by both vibration
and acoustic signals analysis.

In this dissertation work, experimentation is carried out to detect gear tooth

defects through vibration and acoustic analysis and feasibility of practical application is
seen. The acoustic and vibration spectrums obtained for different tooth defects are
presented in previous chapter based on which following conclusion can be drawn.

With comparison of faulty crack on tooth and healthy gear spectrums, broken
tooth and healthy gear,wear of teeth and healthygear, improper lubrication and healthy
respectively,it is shown that as the fault is produced on the gear, it reflects the change in
acoustic and vibration spectrum. It is observed that from the amplitude of gear mesh
frequency has increased considerably. From above results following characteristics can
be associated to fault.

1. The amplitude level increases considerably at gear mesh frequency.

2. The amplitude level increases by small margin at side bands.

3. It is also observed that as load is increased on the crack on tooth or broken tooth,
there is change in acoustic and vibration spectrum.

4. The amplitude level also increases at gear meshing frequency as load increases.

78
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81
 APPENDIX A
LIST OF INTERNATIONAL PAPERS PUBLISHED
[1] Mr.Vilas V. Choudhary and Prof.R.S.Jamgekar, Condition Monitoring: A
Convenient Technique for Vibration Analysis of Tooth Failure in Gear Box,
International Journal on Recent Technologies in Mechanical and Electrical
Engineering (IJRMEE) ISSN: 2349-7947Volume: 3 Issue: 10 04 09 IJRMEE,
October 2016.

82
 APPENDIX B

PHOTOGRAPHS OF EXPERIMENTATION

Fig.No.1. Position of vibration accelerometer near gearbox in one position.

Fig.No.2. Position of vibration accelerometer near gearbox in another

position.

83
 Fig.No.3. Rope Brake Dynamometer arrangement.

Fig.No.4. Rope Brake Dynamometer arrangement at various loads.

84
 Fig.No.5. FFT Analyzer

Fig.No.6. Acoustic Pickup (Sound Pressure Probe)

85