Condition Monitoring System for Gears

Question: Discuss the condition monitoring system for gears? Answer: Introduction Condition monitoring facilitates monitoring the current condition and predicting the future condition of machines in operation. According to Randall [Randall2010] the external information about the internal effects should be obtained and analyzed during the operation of the machines. While machines are in operation, they require methodologies which will make it possible to detect their internal condition. This technique presents the condition of operating machines ( many of them run for long durations like 12 month or more), and decide whether the machine requires maintenance or not. In order to gain the information from internal issues of the machines, there are two main types of techniques used normally, viz., vibration analysis and lubricant analysis [Randall2010]. Onsy [Onsy2013] stated that Gears are among the most important parts of any mechanical transmission system, and effective monitoring techniques must be employed in order to achieve reliable operation. In this project, t he focus will be on gears condition monitoring techniques used to measure vibration, speed and temperature. Furthermore, several signal condition methods including time and frequency analysis will be applied. According to Modeley [Mobley2002] mechanical system or machines consist of most plant equipment, vibration monitoring is considering as the key component for most predictive maintenance techniques. In addition, for electromechanical system, the essential predictive maintenance tool is the vibration monitoring [Keith1999][Mobley2002]. Moreover, all mechanical equipment are suitable for using vibration analysis. However, a common yet invalid said that vibration analysis is restricted to simple rotating machines with running speed above 600 revolution per minute [Mobley2002]. In order to achieve the best operation condition for machine system, vibration analysis system need to set up properly [Mobley2002][Keith1999]. Throughout the operation periods, it is highly recommended that for the manufacturer is needed to identify the reliability of the machine system, which will naturally lead to the best level of maintenance [Adjallah2007]. Aims and objectives The main aim of the project is to develop condition monitoring system based on vibration analysis, which will work on to meet several subsequent objectives. Aims 1. To develop a condition monitoring system to detect the gear condition which will later provide reasonable predictions for remaining life for machine.2. To develop an effective system which will detect the failures in advance.3. To produce a best quality dissertation in practical fulfilment of a master degree in maintenance engineering. Objectives 1. To Identify the characteristics of the current condition monitoring system with focus on gear monitoring system.2. To Identify gear failure mechanisms.3. To get familiarization with data acquisition techniques (Lab VIEW).4. To develop an online data acquisition system which can display the measured data.5. To collect the data on gears with the use of software measurement.6. To perfom analysis and evaluate the data.7. To perform analysis for predicting the failure.8. To report findings in the proper format Methodologies The strategy to approach this project will have the following steps:1. Designing gear test bench system, In this part system measurement will be done first and Secondly, the condition of the test bench operation will be performed to set up the main element.2. The second objective of the project is to identify the gear failure in order to meet this requirement vibration analysis will be performed on gears of different condition.3. Inorder to display the system measurement data, the online data acquisition system will require the development in terms of insulation of sensors with the design as well as the connections to measurement elements.4. Final step is testing the validation of the operation system by implementing the evaluated data cambered with different gear cases. (Compare the data for different gear loads). Project plan References Adjallah, Kondo H. Advances in Degradations Monitoring and Predictive Maintenance. Bradford, GBR: Emerald Group Publishing Ltd; June 2007. Mobley, R. Keith. Plant Engineering : An Introduction to Predictive Maintenance , 2nd ed. Burlington, MA, USA: Butterworth-Heinemann; September 2002. Mobley, R. Keith. Vibration Fundamentals. Burlington, MA, USA: Butterworth-Heinemann; March 1999. ONSY, A., BICKER, R. SHAW, B.A. Predictive Health Monitoring of Gear Surface Fatigue Failure Using Model-based Parametric Method Algorithms; An Experimental Validation. SAE International Journal Aerospace 2013; Volume 6(Issue 1): . Randall, Robert Bond. Vibration-Based Condition Monitoring : Industrial, Automotive and Aerospace Applications. Hoboken, NJ, USA: John Wiley Sons; December 2010.