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Gearbox Vibration

Analysis

Contents

Case No.1 - Gearwear 1.83 rpm


Case No.2 - Chipped Tooth 42 rpm
Case No.3 - Gearwear 8052 rpm
Case No.4 - Chipped Tooth 1239 rpm
Case No.5 - Misaligned Gears 146 rpm
Case No.6 - Gearwear 97 rpm
Case No.7 - Misaligned Gears 5 rpm
Case No.8 - Bearing defect 9 rpm
Case No.9 - Bearing defect 231 rpm

Cases highlighted in red show the possibilities of


vibration provided the information on the machine
is correct and a good set-up is used. Selecting the
correct sensor is also important.

Phone: +44 (0)1206 791917 Email: Info@rms-reliability.com Web: rms-reliability.com


Vibration Analysis - Gearbox Examples

Case No.1 Slow Speed Pulp Press Gearbox Localised Gearwear ( 1.83 rpm Output )

Gearbox measured similar to one above.

Prs - PULP PRESS 3 STORD 980


PULPPRESS3-5RP GBX SHAFT 5 RIGHTFRONT AXIAL PKV
0.025
ANALYZE SPECTRUM
PK Acceleration in G-s

0.020 M M M 01-Dec-00 16:44:20


(PkVue- HP 500 Hz)
OUTPUT GEARMESH WITH HARMONICS & SIDEBANDS PK = .1391
0.015
LOAD = 100.0
RPM = 2.
0.010 RPS = .03

0.005 M=4TH RED WHEEL


: 58.00
0
0 100 200 300 400 500 600 700
Frequency in Orders
2.0
WAVEFORM DISPLAY
1.5 01-Dec-00 16:44:20
Acceleration in G-s

(PkVue- HP 500 Hz)


PK = .1410
1.0
PK(+) = 1.86
PK(-) = .1044
0.5 CRESTF= 18.64

-0.5 1 REV 1 REV


Ordr: 58.00
0 10 20 30 40 50 60 70 80 Freq: 1.770
Time in Seconds Spec: .01370
Localised damage to output gear

Set-up: Slow speed sensor, Fmax 1200 cpm, 1600 Lines, Acceleration, Magnet mount, PkVue 500
Hz filter, Normal low freq readings taken also.
Case No.2 Slow Speed Pulp Press Gearbox Chipped Tooth ( 42 rpm second shaft )

PULP - PULP PRESS NO2


37PRSS0002-L2S GBOX 1st SET LEFT (320L MAG) STD
0.005
ROUTE SPECTRUM

RMS Acceleration in G-s


0.004 E E E E E E E E E E 19-Jan-01 10:21:18
HARMONICS OF GEARMESH WITH SIDEBANDS @42CPM (SST-Corrected)
OVERALL= .0133 A-DG
0.003
RMS = .0133
LOAD = 100.0
0.002 RPM = 41.
RPS = .69
0.001
E=GMF 17T : 704.8
0
0 4000 8000 12000 16000
Frequency in CPM
0.12
0.09 ONCE PER REV IMPACT (CHIPPED TOOTH) WAVEFORM DISPLAY
19-Jan-01 10:21:18
Acceleration in G-s

0.06 RMS = .0135


0.03 PK(+) = .0827
PK(-) = .1050
0.00
CRESTF= 7.75
-0.03
-0.06
-0.09
-0.12
Freq: 704.80
0 1 2 3 4 5 6 7 Ordr: 17.00
Time in Seconds Spec: .00010

Set-up: Slow speed sensor, Fmax 14000 cpm, 6400 Lines Res, Acceleration, Magnet mount, SST
Enabled. PkVue also taken.

Case No.3 High Speed 13MW Steam Turbine Gearbox Input Gearwear ( 8052 rpm Input )
43 - Steam Turbine 13MW
Turb -2V Turbine DE Vertical
7
RMS Velocity in mm/Sec

ANALYZE SPECTRUM
6
25.00

17-Jan-01 13:54:14
5 25 Tooth input gear with RMS = 13.25
LOAD = 55.0
4 fault sidebands at 8052 cpm
RPM = 8052.
3 RPS = 134.20
1xrpm
2
1.00

1
0
0 4 8 12 16 20 24 28 32 36 40
Frequency in Orders

30 WAVEFORM DISPLAY
17-Jan-01 13:54:14
Acceleration in G-s

20
PK = 19.32
10 PK(+) = 33.69
0 PK(-) = 42.78
-10 CRESTF= 3.13
-20
-30
-40
-50 HIGH G LEVELS IN WAVEFORM
Ordr: 25.00
0 40 80 160 120
200 240 280 320 Freq: 3354.7
Time in mSecs Spec: 4.539
Label: HIGH GEARMESH WITH SIDEBANDS

Set-up: Fixed sensor, Fmax 650000 cpm, 6400 Lines Res, Acceleration..
PkVue also taken.
Case No.4 Reduction Gearbox Chipped Tooth ( 1239 rpm )

Fts - Gearbox ( CHIPPED TEETH )


Gearbox -GIV GEARBOX INPUT VERTICAL DE
2.7

RMS Velocity in mm/Sec


ROUTE SPECTRUM
2.4 J J 10-MAY-99 15:31:33
2.1 OVRALL= 4.80 V-DG
1.8 RMS = 4.76
LOAD = 100.0
1.5 Low level sidebands surround gearmesh MPM = 794.
1.2 RPM = 1239.

0.9 J=GMF : 33.46K


0.6
0.3
0
0 20000 40000 60000 80000 100000
Frequency in CPM

12 ROUTE WAVEFORM
9 10-MAY-99 15:31:33
Acceleration in G-s

RMS = 1.97
6
PK(+) = 13.16
3 PK(-) = 14.53
0 CRESTF= 7.39
-3
-6
-9
-12
-15
Once per rev impacting ( Waveform Key to analysis)
-18
Freq: 1238.8
0 60 120 180 240 300 Ordr: 1.000
Time in mSecs Spec: 1.052

Set-up: Standard Magnet sensor, Fmax 90000 cpm, 6400 Lines Res, Vel, Acceleration.
Fts - Gearbox ( CHIPPED TEETH )
Gearbox -GIV GEARBOX INPUT VERTICAL DE
6
ANALYZE SPECTRUM
RMS Acceleration in G-s

5 10-MAY-99 09:46:16
(PkVue-HP 1000 Hz)
4 RMS = 8.51
Typical Faulty Gear Spectrum ( PkVue ) LOAD = 100.0
MPM = 875.
3
RPM = 1365.

0
0 20000 40000 60000
Frequency in CPM
80
ANALYZE WAVEFORM
10-MAY-99 09:46:16
Acceleration in G-s

60 (PkVue-HP 1000 Hz)


RMS = 9.06
40 PK(+) = 75.36
PK(-) = 6.16
CRESTF= 8.32
20

Waveform once per rev impact


-20
Freq: 1365.3
0 100 200 300 400 500 600 700 800 Ordr: 1.000
Time in mSecs Spec: 4.279
Label: PKVUE CHIP TOOTH

Set-up: Same fault as prev, Standard Magnet Sensor. Fmax 60000cpm, Accl, PkVue 1000Hz Filter
6400 Lines.
Case No.5 Ball Mill Output Gears Misaligned Gears ( 146 rpm )

Fts - Gearbox ( MISALIGNED GEARS )


Misalign -B2H Output bearing outboard horiz
0.5
ROUTE SPECTRUM
14-DEC-99 14:25:02

OVRALL= 4.84 V-DG


RMS = .4014
0.4 MISALIGNED OUTPUT GEARS LOAD = 100.0
RPM = 147.
RPS = 2.44
RMS Acceleration in G-s

3XGMF

0.3

0.2

2XGMF
0.1
1XGMF Wear sidebands @ 146 rpm

0
Freq: 2784.9
0 4000 8000 12000 Ordr: 19.00
Frequency in CPM Spec: .03485
Label: Misaligned gears / worn input

Set-up: Standard Magnet sensor, Fmax 10000 cpm, 6400 Lines Res, Acceleration.
Case No.6 Extruder Gearbox Damaged Gear ( 97 rpm )

Fts - Ext - ( GEARWEAR )


Gearwear -G2A Gearbox Input Outboard Axial
0.004
ANALYZE SPECTRUM
RMS Acceleration in G-s B B B 11-MAR-98 14:56:28
0.003 RMS = .0112
LOAD = 100.0
RPM = 97.
RPS = 1.61
0.002
B=59 teeth : 5707.
GEARMESH WITH SIDEBANDS @ 97 CPM
0.001

0
0 4000 8000 12000 16000 20000
Frequency in CPM
0.03
WAVEFORM DISPLAY
0.02 11-MAR-98 14:56:28
Acceleration in G-s

0.01 RMS = .0106


PK(+) = .0319
0 PK(-) = .0320
CRESTF= 3.02
-0.01
-0.02
-0.03

-0.04
-0.05
Freq: 5706.7
0 0.3 0.6 0.9 1.2 1.5 1.8 2.1 2.4 2.7 Ordr: 59.00
Time in Seconds Spec: .00199
Label: Gearwear 59 tooth gear

Set-up: Standard Magnet sensor, Fmax 18000 cpm, 6400 Lines Res, Acceleration.

Case No.7 Diffuser Gearbox Misaligned Gears ( 5 rpm )


DG - Diffuser Gearbox Citreon Mes
Stream C -29H GBX 5th SHAFT MTRSIDE HORIZ
0.0024
ROUTE SPECTRUM
PK Acceleration in G-s

J J J J 05-FEB-01 14:47:24
(SST-Corrected)
0.0016 OVRALL= .0046 A-DG
3xgmf PK = .0046
Misaligned Gears LOAD = 100.0
RPM = 5.
RPS = .08
0.0008
2xgmf J=Output Gear 25
: 125.8
1xgmf
0
0 100 200 300 400 500 600
Frequency in CPM
0.012
ROUTE WAVEFORM
0.008 05-FEB-01 14:47:24
Acceleration in G-s

PK = .0045
0.004 PK(+) = .0090
PK(-) = .0100
CRESTF= 3.14
0.000

-0.004

-0.008

-0.012
Freq: 126.37
0 20 40 60 80 100 120 140 160 Ordr: 25.12
Time in Seconds Spec: .00005

Set-up: Slow speed sensor, Fmax 600 cpm, 1600 Lines Res, Acceleration, Magnet mount, SST
Enabled. PkVue also taken.
Case No.8 Slow Speed Diffuser Gearbox Bearing Defect ( 9 rpm shaft )

DG - Diffuser Gearbox Shackleton


Stream B -27A GBX 4th SHAFT MTRSIDE AXIAL
0.00012
ANALYZE SPECTRUM
PK Acceleration in G-s

D D D D D D D D D D D D 19-DEC-00 11:23:07
(SST-Corrected)
0.00008 PK = .0007
LOAD = 100.0
RPM = 9.
RPS = .16

0.00004 >SKF 24052C


D=BPFO : 104.5

0
0 400 800 1200 1600
Frequency in CPM
0.018
ANALYZE WAVEFORM
0.012 19-DEC-00 11:23:07
Acceleration in G-s

PK = .0036
0.006 PK(+) = .0123
PK(-) = .0141
CRESTF= 5.48
0.000

-0.006

-0.012

Impacting matches outer race impact freq


-0.018
Freq: 104.26
0 3 6 9 12 15 18 21 24 27 30 33 Ordr: 11.20
Time in Seconds Spec: .00001

Set-up: Slow speed sensor, Fmax 3000 cpm, 3200 Lines Res, Acceleration, Magnet mount, SST
Enabled. PkVue also taken.
Case No.9 Reduction Gearbox Bearing Defect ( 231 rpm shaft )

Set-up: Slow speed sensor, Fmax 30000 cpm, 6400 Lines Res, Acceleration, Magnet mount,
PkVue 500 Hz Filter.

Reliability Maintenance Solutions Ltd

Email : Info@rms-reliability.com

Websites: www.rms-training.com & www.rms-reliability.com

Head Office : +44 (0)1206 791917

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