Gearbox Vibration

Analysis

Contents
Case No.1
Case No.2
Case No.3
Case No.4
Case No.5
Case No.6
Case No.7
Case No.8
Case No.9

- Gearwear
- Chipped Tooth
- Gearwear
- Chipped Tooth
- Misaligned Gears
- Gearwear
- Misaligned Gears
- Bearing defect
- Bearing defect

1.83 rpm
42 rpm
8052 rpm
1239 rpm
146 rpm
97 rpm
5 rpm
9 rpm
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

PK Acceleration in G-s

0.025
M

0.020

0.015
0.010

ANALYZE SPECTRUM
01-Dec-00 16:44:20
(PkVue- HP 500 Hz)
OUTPUT GEARMESH WITH HARMONICS & SIDEBANDS PK = .1391
LOAD = 100.0
RPM = 2.
RPS = .03

0.005

M=4TH RED WHEEL

: 58.00

0
0

100

200

300
400
Frequency in Orders

500

600

700

Acceleration in G-s

2.0

WAVEFORM DISPLAY
01-Dec-00 16:44:20
(PkVue- HP 500 Hz)
PK = .1410
PK(+) = 1.86
PK(-) = .1044
CRESTF= 18.64

1.5
1.0
0.5
0
1 REV

-0.5
0

10

1 REV
20

30

40
50
Time in Seconds
Localised damage to output gear

60

70

80

Ordr: 58.00
Freq: 1.770
Spec: .01370

Set-up: Slow speed sensor, Fmax 1200 cpm, 1600 Lines, Acceleration, Magnet mount, PkVue 500
Hz filter, Normal low freq readings taken also.

RMS Acceleration in G-s

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
19-Jan-01 10:21:18
HARMONICS OF GEARMESH WITH SIDEBANDS @42CPM (SST-Corrected)
OVERALL= .0133 A-DG
RMS = .0133
LOAD = 100.0
RPM = 41.
RPS = .69

E E

0.004

E E E E E

0.003
0.002

E E E

0.001
E=GMF 17T : 704.8
0
0

4000

Acceleration in G-s

0.12
0.09

8000
Frequency in CPM

12000

16000

WAVEFORM DISPLAY
19-Jan-01 10:21:18
RMS = .0135
PK(+) = .0827
PK(-) = .1050
CRESTF= 7.75

ONCE PER REV IMPACT (CHIPPED TOOTH)

0.06
0.03
0.00
-0.03
-0.06
-0.09
-0.12
0

3
4
Time in Seconds

Freq: 704.80
Ordr: 17.00
Spec: .00010

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

7
6
5

43 - Steam Turbine 13MW

-2V Turbine DE Vertical

25 Tooth input gear with

fault sidebands at 8052 cpm

ANALYZE SPECTRUM
17-Jan-01 13:54:14
RMS = 13.25
LOAD = 55.0
RPM = 8052.
RPS = 134.20

25.00

Turb

3
1xrpm
2

1.00

RMS Velocity in mm/Sec

Case No.3 High Speed 13MW Steam Turbine Gearbox Input Gearwear ( 8052 rpm Input )

1
0
0

12

16
20
24
Frequency in Orders

28

32

36

WAVEFORM DISPLAY
17-Jan-01 13:54:14
PK = 19.32
PK(+) = 33.69
PK(-) = 42.78
CRESTF= 3.13

30
Acceleration in G-s

40

20
10
0
-10
-20
-30
-40
-50

HIGH G LEVELS IN WAVEFORM

40

80

120

160
200
Time in mSecs
Label: HIGH GEARMESH WITH SIDEBANDS

240

280

320

Set-up: Fixed sensor, Fmax 650000 cpm, 6400 Lines Res, Acceleration..
PkVue also taken.

Ordr: 25.00
Freq: 3354.7
Spec: 4.539

Case No.4 Reduction Gearbox Chipped Tooth ( 1239 rpm )

Fts - Gearbox ( CHIPPED TEETH )
Gearbox -GIV GEARBOX INPUT VERTICAL DE

RMS Velocity in mm/Sec

2.7
2.4

ROUTE SPECTRUM
10-MAY-99 15:31:33
OVRALL= 4.80 V-DG
RMS = 4.76
LOAD = 100.0
MPM = 794.
RPM = 1239.

2.1
1.8
1.5

Low level sidebands surround gearmesh

1.2
0.9

J=GMF

: 33.46K

0.6
0.3
0
0

20000

80000

100000

ROUTE WAVEFORM
10-MAY-99 15:31:33
RMS = 1.97
PK(+) = 13.16
PK(-) = 14.53
CRESTF= 7.39

12
9
6
3
0
-3
-6
-9
-12
-15
-18

Acceleration in G-s

40000
60000
Frequency in CPM

Once per rev impacting ( Waveform Key to analysis)

60

120

180
Time in mSecs

240

300

Freq: 1238.8
Ordr: 1.000
Spec: 1.052

RMS Acceleration in G-s

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

ANALYZE SPECTRUM
10-MAY-99 09:46:16
(PkVue-HP 1000 Hz)
RMS = 8.51
LOAD = 100.0
MPM = 875.
RPM = 1365.

5
4

Typical Faulty Gear Spectrum ( PkVue )

3
2
1
0
0

20000

40000

60000

Frequency in CPM

Acceleration in G-s

80

ANALYZE WAVEFORM
10-MAY-99 09:46:16
(PkVue-HP 1000 Hz)
RMS = 9.06
PK(+) = 75.36
PK(-) = 6.16
CRESTF= 8.32

60
40
20
0
Waveform once per rev impact

-20
0

100

200

300

400
Time in mSecs

500

600

700

800

Freq: 1365.3
Ordr: 1.000
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

MISALIGNED OUTPUT GEARS

0.4

RMS Acceleration in G-s

OVRALL= 4.84 V-DG

RMS = .4014
LOAD = 100.0
RPM = 147.
RPS = 2.44
3XGMF

0.3

0.2

2XGMF
0.1
1XGMF

Wear sidebands @ 146 rpm

0
0

4000

8000
Frequency in CPM

12000

Freq: 2784.9
Ordr: 19.00
Spec: .03485

Label: Misaligned gears / worn input

Set-up: Standard Magnet sensor, Fmax 10000 cpm, 6400 Lines Res, Acceleration.

RMS Acceleration in G-s

Case No.6 Extruder Gearbox Damaged Gear ( 97 rpm )

Fts - Ext - ( GEARWEAR )
Gearwear -G2A Gearbox Input Outboard Axial

0.004

ANALYZE SPECTRUM
11-MAR-98 14:56:28
RMS = .0112
LOAD = 100.0
RPM = 97.
RPS = 1.61

0.003

0.002

B=59 teeth : 5707.

GEARMESH WITH SIDEBANDS @ 97 CPM

0.001

0
0

4000

8000

12000
Frequency in CPM

16000

20000

Acceleration in G-s

0.03
0.02

WAVEFORM DISPLAY
11-MAR-98 14:56:28
RMS = .0106
PK(+) = .0319
PK(-) = .0320
CRESTF= 3.02

0.01
0
-0.01
-0.02
-0.03
-0.04
-0.05
0

0.3

0.6

0.9

1.2
1.5
Time in Seconds

1.8

2.1

2.4

Freq: 5706.7
Ordr: 59.00
Spec: .00199

2.7

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

PK Acceleration in G-s

0.0024
J

0.0016

ROUTE SPECTRUM
05-FEB-01 14:47:24
(SST-Corrected)
OVRALL= .0046 A-DG
PK = .0046
LOAD = 100.0
RPM = 5.
RPS = .08

3xgmf
Misaligned Gears

0.0008

J=Output Gear 25
: 125.8

2xgmf
1xgmf
0
0

100

200

300
Frequency in CPM

400

500

600

Acceleration in G-s

0.012

ROUTE WAVEFORM
05-FEB-01 14:47:24
PK = .0045
PK(+) = .0090
PK(-) = .0100
CRESTF= 3.14

0.008
0.004
0.000
-0.004
-0.008
-0.012
0

20

40

60

80
100
Time in Seconds

120

140

160

Freq: 126.37
Ordr: 25.12
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

PK Acceleration in G-s

0.00012
D

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

0.00008

0.00004

>SKF 24052C
D=BPFO : 104.5

0
0

400

800
Frequency in CPM

1200

1600

Acceleration in G-s

0.018

ANALYZE WAVEFORM
19-DEC-00 11:23:07
PK = .0036
PK(+) = .0123
PK(-) = .0141
CRESTF= 5.48

0.012
0.006
0.000
-0.006
-0.012
Impacting matches outer race impact freq

-0.018
0

12

15
18
Time in Seconds

21

24

27

30

33

Freq: 104.26
Ordr: 11.20
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