Condition Monitoring and Failure Prediction of Gear Rotation Using a Contactless RF Magnetic Sensor

Abstract

Development of sensor devices that can precisely detect small tilt angles of an anomalously rotating gear is in great demand for real-time condition monitoring and predictive maintenance of gear-based machines. The utility of a high-frequency giant magnetoimpedance (GMI)-based sensor for real-time monitoring of a rotating gear has been demonstrated. The rotation speed and tilt position of a magnetically labeled rotating gear were measured remotely from a distance of 14 cm. Small changes in magnetic field, down to mOe level, were detected using an optimized Co69.25Fe4.25Si13B12.5Nb1 microwire sensor. The sensing element exhibited remarkable field sensitivity ( $$ \eta $$ ) and GMI ratio of 230%/Oe and 300%, respectively. This contactless magnetic sensor is useful for future development of real-time condition monitoring and predicting failure of a rotating object.