Abstract
The paper is presenting a methodology for developing model-based method of gear fault diagnostics. First the simulation model of the helical gearbox is discussed allowing analysis of the phenomena taking place during teeth mating in the presence of manufacturing and assembly errors. It includes observation of influence of errors on the generated signals. The model was initially used to analyze the teeth contact in the presence of pitch errors and later to verify the sensitiveness of proposed diagnostic methods and their availability to detect the fatigue damages of teeth. The common feature of discussed approach is the direct use of time signal processing algorithms, and in contrary to the methods based on spectral analysis it allows precise localization of gear defects like pitting and tooth fracture associating them to the particular pinion or gear teeth. Their advantage is the simplicity and speed of action that is of great significance for the implementation in the autonomous transmission diagnostic systems and diagnostic systems working online. Presented methods of signal processing were first tested on a simulation model of the gear assembly and later verified during the experiments on a back-to-back test stand.
Highlights
The need to diagnose damages of rotating machinery, damages associated with the fatigue processes, forces the development of new methods to assess the durability of these devices
For example in [29], the time-domain fault detection method was presented based on the fast dynamic time warping and correlated kurtosis techniques for this purpose
Since Envelope contact factor (ECF) is a continuous function of time, it can be further analyzed by the methods used in the processing of time signals, especially on the aforementioned local meshing plane
Summary
The need to diagnose damages of rotating machinery, damages associated with the fatigue processes, forces the development of new methods to assess the durability of these devices. Local damages of gear teeth give rise to a transient, local, disturbances of the vibration signal repeated with every rotation of the transmission shaft, causing the phenomenon of phase and amplitude modulation [10,11,12] It can be shown [13] that in the early stages of defect when the energy changes of the signal are low, the signal is dominated by the phenomenon of phase modulation. For example in [29], the time-domain fault detection method was presented based on the fast dynamic time warping and correlated kurtosis techniques for this purpose This method was able to extract periodic impulse excitations caused from the faulty gear tooth using an estimated reference signal that has the same frequency as the nominal gear mesh harmonic and is built using vibration characteristics of the gearbox operated under presumed healthy conditions. It was used for assessing the sensitivity of diagnostic methods that were later tested during the experiments on a back-to-back test stand
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