Detection of incipient gear failures using statistical techniques

Gears are important components in most power transmission mechanisms.Failures of gears can cause heavy losses in industry. Conditionmonitoring and fault diagnosis of gears is therefore importantto improve safety and reliability of gearbox operations andreduce losses caused by gear failures. This research proposesa new diagnostic approach based on the statistical analysisof data. It investigates the use of Principal Components Analysis(PCA) to detect growing local faults in a two-stage industrialhelical gearbox. In this research, the vibration signal is usedto monitor fault conditions and a broken tooth is simulatedas a local fault. Since the early detection of faults is a challenge,small fault conditions were tested first as well as severe faultconditions. In order to examine the ability of the PCA to detectfault conditions, first the PCA-based model was created fornormal operating conditions. Any unexpected event such as afault condition causes a significant deviation from the PCAmodel, which is obtained from the normal condition data of thegearbox. The Square Prediction Error (SPE) was calculated todetect the fault conditions. When the vibration signal fromthe gearbox is representative of normal operation, the valueof the SPE shows very little fluctuation and remains under acertain threshold value. However, in the presence of the faultthe SPE fluctuates considerably beyond the threshold value.It is shown that the PCA-based statistical approach cannot onlybe used to detect severe fault conditions, but that it alsoreveals small growing fault conditions at very early stage.The technique also provides information about the state of thefault such as the location of the fault as well as its severity. Received 5 March 2001. Revised 12 December 2001. Accepted 17 January 2002.