Design and application of gearbox vibration testing system

Abstract

Judging the working status of a gearbox through the characteristics of vibration signals was an effective fault diagnosis method. In order to improve the efficiency and reliability of vibration detection, a multi node testing system based on a microcontroller was designed and validated. The system mainly consists of signal processing equipment, signal collector, upper computer, sensors, and experimental workbench. Under different types of gear faults, the vibration signals of ten sets of gearboxes were synchronously collected and processed. In order to ensure the resolution of frequency conversion and accurately locate frequency conversion, the low-pass filtered spectrum with a filtering frequency of 1000 was verified and used to calculate the amplitude of frequency conversion. The normalization of amplitude was more conducive to feature recognition, and the frequency amplitude was proportional to its corresponding energy. According to standard spectral data and spectral analysis, wear, pitting, fracture, and bonding faults in the gearbox were identified and classified. Through the verification of three order feature spectrum, it can be seen that the accuracy of fault prediction for gearbox through vibration signals is high, which can effectively reduce maintenance and repair costs.