Effectiveness and Sensitivity of Vibration Processing Techniques for Local Fault Detection in Gears

This paper deals with gear condition monitoring based on vibration analysis techniques. The detection and diagnostic capability of some of the most effective techniques are discussed and compared on the basis of experimental results, concerning a gear pair affected by a fatigue crack. In particular, the results of new approaches based on time-frequency and cyclostationarity analysis are compared against those obtained by means of the well-accepted cepstrum analysis and time-synchronous average analysis. Moreover, the sensitivity to fault severity is assessed by considering two different depths of the crack. The effect of transducer location and processing options are also shown. In the case of the experimental results considered in this paper, the power cepstrum is practically insensitive to the crack evolution. Conversely, the spectral correlation density function is able to monitor the fault development and does not seem to be significantly influenced by the transducer position. Analysis techniques of the time-synchronous average, such as the ‘residual’ signal and the demodulation technique, are able to localise the damaged tooth; however, the sensitivity of the demodulation technique is strongly dependent on the proper choice of the filtering band and affected by the transducer location. The wavelet transform seems to be a good tool for crack detection; it is particularly effective if the residual part of the time-synchronous averaged signal is processed.