{"id":2377,"date":"2022-03-05T11:05:36","date_gmt":"2022-03-05T07:35:36","guid":{"rendered":"https:\/\/steelworldreview.com\/checking-the-failure-of-industrial-gearboxes\/"},"modified":"2022-03-05T11:12:00","modified_gmt":"2022-03-05T07:42:00","slug":"checking-the-failure-of-industrial-gearboxes","status":"publish","type":"post","link":"https:\/\/steelworldreview.com\/en\/checking-the-failure-of-industrial-gearboxes\/","title":{"rendered":"Checking the failure of industrial gearboxes"},"content":{"rendered":"

Introduction<\/strong><\/h3>\n

Today, power transmission systems have a wide range of applications in industries and are mostly categorized into three groups sprocket system, belt drive sprocket system, and chain drive sprocket system.<\/p>\n

A system that can transfer rotation and torque from one shaft to another is called a (mechanical) power transmission system. Each of these systems based on their types and functional conditions has some advantages and disadvantages.<\/p>\n

The set of gearboxes uses various cogwheels to keep and transfer the power from the engine, and change the rotation and torque, simultaneously. By considering the high importance of gearboxes in industries, maintenance, and being informed about the probable failure processes of them have great effects on efficiency and reduction of the cost in a set.<\/p>\n

 <\/p>\n

In this study, common failures, traditional and novel methods in monitoring the condition and health information of the gearboxes are discussed. <\/a><\/p>\n

1. Types of Fatigue in Cogwheels<\/strong><\/span><\/h3>\n

American Gear Manufacturers Association (AGMA)[1],<\/a> categorized cogwheels\u2019 fatigue into four classes:<\/p>\n

<\/a>1.1 Wearing<\/strong><\/span><\/h4>\n

Uniform and non-uniform removal of metal from the surface of the teeth is called wearing.<\/p>\n

The main reasons for teeth wearing are, metal to metal contact because of the unsuitable thickness of lubricant, which the wearing particles in lubricant caused rapid wearing or scratch creation by breaking the lubricant layer, and in chemical wearing (erosion), lubricant composition, and additives.<\/p>\n

Wearing causes tooth thickness reduction and profile deformation, as a result, it is not in the desired condition anymore and lost its properties.<\/p>\n

Wearing especially in cogwheels that have to work at high speeds, is a significant issue. Certainly, wearing is not always a negative factor, a very small amount of wearing can modify the intermeshed tooth and coordinate them.<\/p>\n

<\/a>1.2. Plastic Deformation<\/strong><\/span><\/h4>\n

This kind of failure occurs when contact surfaces yielded and deform under heavy loads. The occurrence of this failure is seen at the top and the two bottom sides of the tooth. But when the sliding forces on the tooth surface are high, deformation happens in the tooth.<\/p>\n

In a way that the tooth surface becomes rippling. And this is called rippling plastic deformation. To prevent tooth deformation, the load can be decreased or the hardness of the tooth can be increased.<\/p>\n

Another form of plastic deformation is ridging, ridge is a narrow raised band on a surface, which happens by high sliding speeds in worms, worm gears, and hypoid gears.<\/a><\/p>\n

1.3. Tooth Failure<\/strong><\/span><\/h4>\n

Tooth failure is a kind of failure in which the whole or a significant part of a tooth is detached due to overloading, impact, or most of the time repetitive bending tensions that are higher than the cogwheel resistance. This kind of failure is the result of tooth bending fatigue under a bending force.<\/p>\n

<\/a>1.4. Detachment in Cogwheel Teeth<\/strong><\/span><\/h4>\n

Detachment in cogwheel teeth is the fatigue failure caused by contact tensions which result in detachment of some surface part of the teeth as a pit. Detachment based on the amount of damage it has made has three types:<\/p>\n

1. preliminary detachment: in this kind of detachment, the pit diameters are very small, and about 0.4 to 0.8 mm.<\/p>\n

2. destructive detachment: this kind of detachment is more intense and the pit diameters are greater.<\/p>\n

3. crashing detachment: this one is the higher kind of destructive detachment with greater diameters and covers a significant area.<\/p>\n

<\/a>2. Maintenance and Repair Strategies<\/strong><\/span><\/h3>\n

Maintenance and repair (net) are two important and main categories fulfillment and achievement them, provide the survival and continuity of the various production lines and cost reduction. By complication of the tools and facilities that human beings are using to overcome their needs, optimal utilization and being cost-efficient of these tools and facilities has received more attention than ever before.<\/p>\n

Most systems that are used in productions, services, installations, or other cases, are failed and disabled during their life cycle, so they require maintenance and repair.<\/p>\n

Although the words \u201cmaintenance\u201d and \u201crepair\u201d in most applications are used as the same, they are different in meaning, and in maintenance and repair planning each one is being used by its special concept.<\/p>\n

The rapid progress of technology, the availability and expansion of industry all over the world, increment of investments in industries, the raw materials and resources limitations proposed efficiency and productivity as the most important issue for industrial owners and responsible managers of industries.<\/p>\n

Spending the least amount of time, labor, and equipment and reaching the highest efficiency in any mechanism is called productivity.<\/p>\n

In maintenance, condition monitoring is referred to a set of actions that determines the parameters such as vibrations, sound, function, lubrication, temperature, and machine condition by monitoring the machine condition and analyzing its changes during a period.<\/p>\n

Condition monitoring is one of the principal components of predictive maintenance. . In this method instead of periodical repairs, condition monitoring is done periodically, and repairs are performed only when the machine needs to be repaired.<\/p>\n

\"Equipment<\/p>\n

<\/a>Figure 1: An example of condition monitoring of equipment<\/p>\n

<\/a>3. Methods of Condition Monitoring<\/strong><\/span><\/h3>\n

<\/a>3.1. Continuous Maintenance<\/span><\/strong><\/h4>\n

In continuous maintenance, after installing the required sensors in different points of the machines, always attached to the same points and send the machine condition information to the main computer directly through the wirings, junction boxes, data loggers, or in some cases through an internet connection, and computer networks.<\/p>\n

The main computer that condition maintenance, analyzing, and diagnosis software has been installed on, maintain the whole machines of one or more units of a factory or all the factory, and if the domain of measured parameters approached the alarm or danger limits, issues the proper command.<\/p>\n

This method requires a heavy cost for sensors and junctions that is only cost-effective for very sensitive and vital machines that need security systems.<\/p>\n

<\/a>3.2. Discrete Maintenance<\/span><\/strong><\/h4>\n

This system is like a continuous maintenance system but this one has a sensor (for each parameter) to log the data, periodically.<\/p>\n

The considerable cost of sensors, cabling, and their appurtenance is eliminated, here. But use the same computer maintenance system to record the information, track the changes, notify alerts and dangers, and then analyze, diagnose, and report.<\/p>\n

In this system, data are logged from the intended parameters of all machines based on prior plans, in specific periods, and the determined points and directions.<\/p>\n

<\/a>4. Cogwheel Diagnosis<\/strong><\/span><\/h3>\n

The diagnosis of mechanical equipment and machines for preventing sudden failure, production shutdown, and other various damages leads to performing wide research in this scope.<\/p>\n

The accurate measurements of the equipment vibrating signals, using signal analyzing methods that can identify changes and defects, and also figuring out the way defects are affecting vibrating responses by modeling can help a lot to diagnose defects of the machines, timely. Thus, costs of maintenance decrease considerably.<\/p>\n

<\/a>4.1. Lubricant Analysis<\/strong><\/span><\/h4>\n

For equipment that is dependent on lubrication, a reliable lubricant has an important role and requires awareness about the condition and its efficiency.<\/p>\n

In recent years, maintenance managers use the information on lubricant properties, impurities, wearing (shavings) metal, and other performing parameters during planning and decision making for maintenance and they must do, increasingly.<\/p>\n

As a result, lubricant analysis plays an important role in equipment maintenance planning, based on maintenance conditions and repairs focused on reliability.<\/p>\n

Lubricant Analysis is a monitoring method that has been performed on a vast level. Based on this technology, information related to the performance or machine condition is determined by studying the amount of destruction and impurities of lubricant.<\/p>\n

It has been proven that lubricant analysis is an effective tool to monitor the status of equipment failure conditions in contact with lubricant and wearing. Nevertheless, for various reasons, not all equipment users benefit the condition monitoring.<\/p>\n

<\/a>4.2. Acoustic Emission<\/strong><\/span><\/h4>\n

Acoustic emission is occurred due to the creation and propagation of an elastic wave in the ultrasonic range (20 kHz to 1 MHz). based on this, the acoustic emission test is receiving propagated waves in a solid material by specific sensors and making connections between the received signals and the applied changes on the source.<\/p>\n

Designing an acoustic emission inspector system for testing structures requires information related to elastic waves absorption and propagation, for working conditions of a particular structure.<\/p>\n

. For instance, corrosion agents, leakage, fluid type, flow type, pressure, factors related to structure size (diameter and wall thickness), coating type, environmental conditions, factors related to the defect such as geometry, and corrosion situation, and leakage has great influence in creation and propagation of elastic energy, in structures like reservoirs and pipes.<\/p>\n

\"Acoustic<\/p>\n

<\/a>Figure 2. Schematic of an acoustic emission monitoring system<\/p>\n

<\/a>5.1. Vibrations<\/strong><\/span><\/h4>\n

Quivering or mechanical vibrations are considered a kind of oscillating (move back and forth) dynamic systems motion, and this motion is repeated in a timespan.<\/p>\n

This type of motion can be simulated in the simplest form with a mass and a spring. By inducing an initial displacement to the mass attached to the spring and releasing it, oscillating motion occurs. There are two kinds of force in machines, static and dynamic.<\/p>\n

The vibrating forces are dynamic and created due to the presence of defects in machines. Since reaching ideal condition is not possible, there are always some vibrations in machines which is permitted. But over time, due to the subsequent problems, some vibrations exceed the permitted limitations that can be back to the prior condition by analyzing and performing the corrective actions.<\/p>\n

Some defects that are identified by vibration measuring and signal analysis of machine vibrations are<\/p>\n

mass imbalance, misalignment, resonance, mechanical looseness, cogwheel failure, bearing failure, center displacement, shaft bending, defective foundation, electrical problems.<\/p>\n

The important and key point in diagnosis by vibration analysis is each vibration in rotating equipment shows specific properties like domain, frequency, phase, etc.<\/p>\n

Vibrations as the best parameter to judge the machine condition, including imbalance, bearings stability.<\/p>\n

A variety of equipment and software for monitoring and analysis of vibration and device parameters are available. This technique is widely used in various industrial units.<\/p>\n

. Considering that each part of the machine during operation has its peculiar vibration, and incidence of defects, vibration level rises, by collecting and analyzing data, the machine condition is determined. The vibration analysis and the rusting particle analysis are two successful methods for recognition of failed parts and failure diagnosis of the machine.<\/p>\n

In the case of using just one of them, defects and problems are determined, while practical experiments show that using both gives more reliable and useful information related to the machine which is extremely cost-effective for industries.<\/p>\n

The vibration analysis as a maintenance method becomes an inclusive principle. As a general principle, none of the machine components failed without vibration rising. By measuring vibration and oscillation levels, the nature and intensity of the defect can be diagnosed and the intensity of the defect can be diagnosed and this way prevent device failure.<\/p>\n

. The vibration signals come from the structure and parts that are connected to each other. Due to the nature of the defect, each oscillation occurs with a particular frequency, it is possible to determine the frequency of each part by analyzing time and amplitude using the signal analysis technique.<\/p>\n

[1]<\/a>. American Gear Manufacturers Association<\/p>\n","protected":false},"excerpt":{"rendered":"

Introduction Today, power transmission systems have a wide range of applications in industries and are mostly categorized into three groups sprocket system, belt drive sprocket system, and chain drive sprocket system. A system that can transfer rotation and torque from one shaft to another is called a (mechanical) power transmission system. Each of these systems […]<\/p>\n","protected":false},"author":1,"featured_media":2330,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[249,242],"tags":[],"yoast_head":"\nChecking the failure of industrial gearboxes<\/title>\n<meta name=\"description\" content=\"In this study, common failures as well as conventional and modern methods in monitoring the status and health of industrial gearboxe are investigated.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/steelworldreview.com\/en\/checking-the-failure-of-industrial-gearboxes\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Checking the failure of industrial gearboxes\" \/>\n<meta property=\"og:description\" content=\"In this study, common 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