Gearbox Condition Monitoring with Ferrography and Vibration Analysis

Abstract

In this research, the status of a single-stage worm gearbox is monitored using ferrography and vibration analysis. Used oil examination can be a very useful tool for determining the condition of a gearbox. Ferrography is a technique that uses a microscope to examine a sample of oil under a high-powered field. The microscope can magnify the sample up to 1000 times, which allows the analyst to see any metal particles that are present. The amount of metal particles in the oil can be used to determine the condition of the gearbox. A high concentration of metal particles indicates that there is wearing on the gears or bearings.

Vibration analysis is a technique that uses sensors to measure the vibrations of a gearbox. The sensors are placed on the gearbox housing and they measure the vibrations in three directions. The vibrations are then analyzed using a computer to determine the frequency and amplitude of the vibrations. The frequency of the vibrations can be used to identify the source of the vibrations. For example, a high-frequency vibration is usually caused by a gear tooth rubbing against another gear tooth. The amplitude of the vibrations can be used to determine the severity of the problem. A large amplitude vibration indicates that there is a serious problem with the gearbox.

In this study, ferrography and vibration analysis were used to monitor the status of a single-stage worm gearbox. The results of the analysis showed that the gearbox was in good condition. The ferrous concentration in the oil was low, and the vibration levels were within acceptable limits. The results of this study show that ferrography and vibration analysis are effective tools for monitoring the condition of a gearbox.