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Consulting hotline: +86-0757-87655008 / +86-18007133141 (Mr.Guan)
Professional service provider for kiln transmission products
Consulting hotline: +86-0757-87655008 / +86-18007133141 (Mr.Guan)
17
2023
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04
Vibration Diagnosis and Case Analysis of Gear Faults
Common faults in gear transmission include tooth breakage, tooth wear, tooth surface fatigue, pitting (peeling), and improper gear installation.
Due to the structure and working force conditions, the vibration signals of gear transmission are relatively complex, and fault diagnosis requires both time-domain and frequency-domain analysis.
The frequency of the fault signal during gear operation is basically manifested in two parts: one is the carrier signal composed of the meshing frequency and its harmonics (high-frequency part); The second is the modulation signal composed of the amplitude and phase changes of low-frequency components.
1、 Meshing frequency and its harmonics
When the gear teeth enter or detach from meshing, the load and stiffness suddenly increase or decrease, forming meshing impact. The gear meshing frequency is Fm=f1 · z1=f2 · z2. When a gear malfunctions, it will cause changes in the meshing frequency and its harmonic amplitudes.
2、 The sideband composed of amplitude modulation and frequency modulation
1. Amplitude modulation
Amplitude modulation is equivalent to multiplying two signals in the time domain. Assuming that the carrier signal is g (t) and the modulation signal is e (t), the total time domain signal after modulation is X (t)=g (t) · e (t). If the above equation is converted to the frequency domain, it is X (f)=g (f) · e (f). Typically, the modulation frequency of amplitude modulation is rotational frequency.
2. Frequency modulation
The speed fluctuation of the gear, if the carrier signal is Asin (2 π fmt+ Φ 0), the modulation signal is β sin2∏fmt; Frequency modulation can be expressed as X (t)=Asin [2 π fmt+ β sin(2∏frt)+ Φ Frequency modulation not only generates a family of sidebands around the meshing frequency fm.
In addition, a sine wave is generated in the phase signal. Usually, the frequency of frequency modulation is the frequency conversion of differential gear. In fact, the phenomenon of AM and FM may exist simultaneously in gear failure, so the sideband formed under the combined influence of AM and FM can be obtained in the spectrum.
3. Additional pulses composed of low-order harmonics generated by gear rotation
The low-frequency faults of gears are imbalanced and uneven, which can also affect the time-domain waveform of gear vibration, but will not generate sidebands on both sides of the gear frequency
4. Hidden components formed by gear machining errors
The vibration of this component is usually caused by the indexing gear error of the machining machine, and it has little impact on the overall operation of the gear.
3、 The following is a case study of a gear failure
The transmission gear of crude oil export pump (screw pump) of an oil production platform is partially broken
(1) Equipment type and parameters: the motor drives the direct coupled twin screw pump. The screws are driven by synchronous gears. The number of gear teeth is Z=67, and the motor speed is n=995r/min (16.57HZ)
(2) Fault phenomenon
The vibration speed value of the non driving end of the pump (synchronous gear installed on this side) increases. Figure 1 and Figure 2 show the time-domain waveform and frequency spectrum.
(3) Vibration characteristics and analysis
The obvious impact peak appears in the time-domain waveform, indicating that there may be local defects in the gear. The spectrum shows the gear meshing frequency and double harmonic frequency, with rich edge frequencies. From Figure 3, it can be seen that the edge frequency is the rotor power frequency, indicating that the vibration amplitude of the meshing frequency is modulated by the rotor power frequency impact vibration.
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Vibration Diagnosis and Case Analysis of Gear Faults
The obvious impact peak appears in the time-domain waveform, indicating that there may be local defects in the gear. The spectrum shows the gear meshing frequency and double harmonic frequency, with rich edge frequencies. From Figure 3, it can be seen that the edge frequency is the rotor power frequency, indicating that the vibration amplitude of the meshing frequency is modulated by the rotor power frequency impact vibration.
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This seminar will exchange and discuss issues of concern to enterprises from the perspectives of industry trends, technology applications, etc., gather the resource advantages of government, industry, academia, and research, and promote the sustainable development of the Yuhuan gear industry chain.
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Keywords: Roller kiln drive, complete transmission of architectural ceramic roller kiln, complete transmission of foam ceramic roller kiln
