Tracking gear Mesh Frequency - gearbox Cement plant


Wi-care case study gearbox -1

Since the 90’s there has been no huge revolution in the technical aspect of vibration monitoring, the fundamentals of a spectrum analysis job itself are still the same. For last decades, the evolution revolution has taken place in the way the technology is applied. Today, the revolution is to partially reduce the human intervention and dematerialize the analysis/managing software. Wi-care system now offers the possibility to suppress manual data collection while focusing the human resources on the highest value task, the data analysis.

The following case study describes and explains a typical remote analysis application of a gear mesh fault detection and tracking. The continuous surveillance was set up in a very effective way for the customer and analyst 

Equipment, plant overview, Context

The Cement Plant is operating 24 Hours 7 days a week, established for in the Middle East operating classical machinery. The Equipment
analyzed is a large crusher. The Wi-care sensors (8) where installed on the motor, the intermediate shaft and the gearbox in both axial and radial direction. Customer wants to perform a routine inspection previous a planned shutdown in the preventive maintenance program. Due
to travel expenses and delay for paperwork accessing the site, I-Care suggest the installation of Wi-care wireless vibration/temperature monitoring.

Analyst diagnosis and spectrum justification: Gear Mesh Frequency

We detect a gear mesh frequency of the output pinion with the grith gear (22Xoutput speed of the gearbox, 56.3 Hz). The amplitudes measured on the motor (Sensor 6000) are higher than those measured on the pinion (Sensor 6300). In fact amplitudes are amplified by resonance. We recommend following amplitudes.

On trends (sensor 6000) amplitudes have decrease over last week. Amplitudes measured in axial are higher due to misalignment of the pinion with the grith gear. We always detect amplitudes modulations from a non-uniform meshing caused probably by a slightly oval shape of grith gear or wear problem on tooth.

We detect a frequency (16.6 Hz) which corresponds on motor rotation frequency. No action required. Balancing OK. Motor Alignment OK. We do not detect any bearing defect           


Wi-care case study gearbox -2





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