Diagnosing the Defects of the Gears of the Gearbox Using Vibration Analysis and Validating it by the Graphs of the CMM Machine

Subject Areas : journal of Artificial Intelligence in Electrical Engineering

Mohammad Esmaeil akbari ¹ , alireza mangouri ² , Sajjad Atazadeh ³

1 - Director-in-Charge
2 -
3 -

Received: 2025-02-11 Accepted : 2025-02-17 Published : 2025-02-17

Keywords: Gear Fault Diagnosis, Vibration Analysis, Artificial Neural Network (ANN), Machine Learning (ML), Industry 5.0, Signal Processing,

Abstract :

This study focuses on diagnosing gear defects in the S5-380 transmission using advanced vibration analysis and validating findings through the HÖFLER Gear Testing Machine. The research highlights key faults such as backlash, eccentricity, and shaft deflection identified via vibration measurements and confirmed using detailed gear profile and lead inspections. The vibration analysis employed V-SAM Vibrometer and V-SAM-Web Soft to detect critical parameters, including Gear Mesh Frequency (GMF) and Gear Hunting Tooth Frequency (GHTF). Results demonstrated the robustness of vibration analysis as an efficient, cost-effective alternative to Coordinate Measuring Machines (CMM) for end-of-line quality control. Furthermore, integrating vibration analysis with CMM-based validation provided precise fault identification, enabling targeted maintenance and enhanced gearbox performance. The findings underscore the potential of transitioning to AI-driven diagnostic systems in Industry 5.0 for real-time, scalable, and intelligent gearbox monitoring. This approach offers significant implications for improving durability, quality, and operational efficiency in gear manufacturing.

References:

[1] Allianz Versicherungs-AG, 1978, Handbook of LossPrevention, Springer-Verlag, Berlin.
[2] Blunt, D. M. &Forrester, B. D. 1995, “Health monitoring of blackhawk and seahawk main transmissionsusingvibrationanalysis”,Proceedings of the Sixth Australian Aeronautical Conference/Second PacificInternationalConferenceonAerospaceScienceand Technology, Melbourne,Australia.
[3] Braun,S.1975,“TheExtractionofperiodicwaveforms byTimedomainAveraging”,Acustica,Vol.32,pp.
[4] Braun,S.(editor),1986,MechanicalSignatureAnalysisTheory and applications, Academic Press Inc., London, UK.
[5] Cempel, C. &Staszewski, W. J. 1992, “Signal demodulationtechniques invibroacoustical diagnostics of machinery”, Machine Dynamics Problems, Vol. 5, pp. 161-173.
[6] Choy,F.K.,Mugler,D.H&Zhou,J.2003,“Damage IdentificationofaGearTransmissionUsingVibration Signatures”,Journal of Mechanical Design, Vol. 125, pp. 394-403.
[7] Decker, H. J. 2002, “Gear crack detection using toothanalysisatNASAResearchCenter”,National AeronauticsandSpaceAdministrationandUSArmy ResearchLaboratory,NASA/TM-2002-211491,ARL- TR-2681.
[8] Ebersbach, S., Peng, Z. & Kessissoglou, N. J. 2005, “Theinvestigationoftheconditionandfaultsof a spur gearbox using vibration and wear debris analysistechniques”,InternationalConferenceonWear of Materials, Vol. 260, pp. 16-24.
[9] Hu,T.,Lu,B.C.&Chen,G.J.2000,“A Rotary MachineryFaultDiagnosis ApproachBasedon RoughSetTheory”,3rd WorldCongressonIntelligent Control and Automation, Hefei, China, pp. 589-685.
[10] Lai,W.,Xuan,J.,Shi,T.&Yang,S.2003,“Research ofVigner-VilleTimeFrequencyand Applicationin DetectingGearPinionFault”, JournalofVibration Engineering, Vol. 16, pp. 247-250.
[11] Lin, J. & Zuo, M. J. 2003, “Gear box fault diagnosis usingadaptivewaveletfilter”, MechanicalSystems and Signal Processing, Vol. 17, No. 6, pp. 1259-1269.
[12] Martin,H.R.1989,“Statisticalmomentanalysisas ameansofsurfacedamagedetection”,Proceedings oftheSeventhInternationalModalAnalysisConference, Society for Experimental Mechanics, Schenectady, NY, pp. 1016-1021.
[13] McFadden,P.D.1986c,“Interpolationtechniquesfor the time domain averaging of vibration data with applicationtohelicoptergearboxmonitoring”,Aero PropulsionTechnicalMemorandum437,Department ofDefence, AeronauticalResearchLaboratory, September.
[14] Zakrajsek,J.J.1994,“A reviewoftransmission diagnosticsresearchatNASA LewisResearch Center”,TechnicalReportNASA TM-106746, ARL-TR-599,NASA andtheUSArmyResearch Laboratory, December.
[15] Stewart, R. M. 1977, “Some useful analysis techniques for gearbox diagnostics”, Technical ReportMHM/R/10/77,MachineHealthMonitoring Group, Institute of Sound and Vibration Research, University of Southampton, July.
[16] McFadden,P.D.1991,“ATechniqueforCalculating theTimeDomain AveragesoftheVibrationofthe IndividualPlanetGearsandSunGearinanEpicyclic Gearbox”, Journal of Sound and Vibration, Vol. 144, pp. 163-172.
[17] Rafiee,J.,Arvani,F.,Harifi,A.&Sadeghi,M.H.2007, “Intelligentconditionmonitoringofagearboxusing artificial neuralnetwork”,MechanicalSystemsand Signal Processing, Vol. 21,