Prediction on wear of a spur gearbox by on-line wear debris concentration monitoring

• Published in: Wear Vol. 336-337; pp. 1 - 8
• Main Authors: Feng, Song, Fan, Bin, Mao, Junhong, Xie, Youbai
• Format: Journal Article
• Language: English
• Published: Elsevier B.V 15.08.2015
• Subjects: Debris; Deposition; Ferrography; Gear; Gears; Mathematical models; Monitoring; On-line systems; Wear; Wear debris analysis; Wear monitoring; Wear particles; Wear debris analysis; Wear monitoring; Ferrography; Gear
• ISSN: 0043-1648; 1873-2577
• DOI: 10.1016/j.wear.2015.04.007

The aim of this work is to develop a method for quantifying and predicting gear wear based on on-line wear monitoring. A model of wear debris concentration has been built based on Kragelsky's method with different wear coefficients in corresponding wear stages. A gear test rig with oil-bath lubrication for accelerated wear test was built, and a full-life wear monitoring test was performed by employing an on-line visual ferrograph (OLVF). An index of particle coverage area (IPCA) characterizing wear debris concentration and an OLVF ferrogram were obtained by sampling in-use oil every 2min. The experiment results indicate that the IPCA curve is consistent with the proposed model, and the early-warning signs of abnormalities can also be observed. Additionally, depositing experiments show that appropriate depositing time (usually not less than 30s) is crucial for a valid OLVF sampling. Therefore, it is feasible to predict gear wear by on-line wear debris concentration monitoring. •Debris concentration was modeled considering time-varying wear coefficient.•A full-life gear wear monitoring was performed by on-line visual ferrograph.•Gear wear can be tracked, and early signs of abnormal wear can be captured.•Predicting gear wear by oil debris concentration monitoring was proposed.