In this paper a method is developed and described for the determination in real-time of the crack length at the root of a three-dimensional gear tooth of given thickness, based on the electrical potential difference method. Multi-Electrostatic analysis is carried out on multiparametric gear solid models using finite elements, by inserting direct current from a pair of pre-attached electrodes and measuring the potential field at selected locations via other dedicated pre-attached electrode pairs and the results are correlated with the crack length. This analysis is used to determine the sensitivity of the electric sensing layout to size and other parameters, including the width of a tooth, the module, and the mounting position of the sensing electrode pairs.
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