Fault Feature Analysis of Gear Tooth Spalling Based on Dynamic Simulation and Experiments

Abstract

Gear dynamics analysis based on time-varying meshing stiffness (TMS) is an important means to understand the gear fault mechanism. Based on Jones bearing theory, a bearing statics model was established and introduced into a gear system. The lateral–torsion coupling vibration model of the gear shaft was built by using a Timoshenko beam element. The lumped parameter method was used to build the dynamic model of a gear pair. The dynamic model of a spur gear system was formed by integrating the component model mentioned above. The influence of rectangular and elliptical spalling on TMS was analyzed by the potential energy method (PEM). The fault feature of tooth spalling was studied by dynamic simulation and verified by experiments. It is found that the gear system will produce a periodic shock response owing to the periodic change of the number of meshing gear teeth. Due to the contact loss and the decrease of TMS, a stronger shock response will be generated when the spalling area is engaged. In the spectrum, some sidebands will appear in the resonance region. The results can provide a theoretical guide for the health monitoring and diagnosis of gear systems.

AdaBoost Ensemble Approach with Weak Classifiers for Gear Fault Diagnosis and Prognosis in DC Motors

“…Faults within the gear mechanism, such as gear wear, misalignment, or damage, can impede the functionality of the starter motor system by disrupting the smooth transmission of rotational energy from the motor to the engine's flywheel [41]. For instance, worn or damaged gear teeth may lead to improper engagement and ineffective engine starting [42]. Similarly, misalignment of the gear components can cause uneven wear and increased friction, reducing the efficiency of the starter motor system.…”

“…Moreover, faults within the gear mechanism, particularly in the teeth, can have significant repercussions on the performance of the starter motor system [41]. When gear teeth are worn, damaged, or misaligned, the smooth transmission of rotational energy is compromised, leading to gear slippage, where the gear fails to engage with the flywheel properly [41,42]. Additionally, damaged or misaligned teeth can create uneven contact surfaces, increasing friction and wear on the gear components over time.…”

“…These problems can escalate if left unaddressed, potentially causing further damage to the motor and associated components [41]. Thus, addressing gear tooth problems is crucial to maintaining the integrity of the starter motor system and ensuring reliable engine start-up [42]. Given the inherent complexities of starter motor operation, accurately determining its lifespan is challenging.…”

Mathematical Complexities in Modelling Damage in Spur Gears

“…Spalling in gears has been modelled with surface areas that are rectangular [42,[58][59][60][61][62][63][64][65][66], circular [42,67], V-shaped [42], elliptical [59,68], the shape of a keyway [69,70], spherical [71], and shaped as an ellipsoid [72,73]. The models usually consider a single spall on the pinion [42,58,59,[68][69][70]72,73]. However, spalling may occur on multiple teeth for gears in operations.…”

Fault Critical Point Prediction Method of Nuclear Gate Valve with Small Samples Based on Characteristic Analysis of Operation

“…However, for large and complex equipment, this method has poor stability. The literature [4] also built a gear system dynamic model and developed a model-based fault feature extraction approach; however, fault prediction was not achieved. The literature [5,6] adopted dynamic Bayesian networks to form a state monitoring and fault prediction method for sensor faults and power transformer faults, effectively solving the problem of sensor and power transformer fault prediction.…”