Monitoring of misalignment in low speed geared shafts with acoustic emission sensors

The most common condition monitoring method applied to rotating machines is vibration measurement, although recently it has been proposed that acoustic emission (AE) offers additional advantages in early fault detection and low speed rotation systems. Capturing the AE signals is conditioned by the severe attenuation with distance and the presence of material discontinuities between source and sensor, therefore measurement device placement is more important than in traditional accelerometry. In this study AE signals are measured in gearboxes at misalignment conditions for the revision of signal characteristics from the generated signal due to the interaction of shafts, bearings and gears. For this purpose, several tests are performed using combinations of speed and varying load, considering the effect of lubricating oil temperature. Fixed measurements are taken over the bench supports, and on-board, where the sensors are rotating with the shafts. In parallel to acoustic emission a vibration analysis is done in order to contrast and analyze differences between both technologies at different operation states. Acquired data is processed to obtain statistical parameters from measurements in order to verify the values and tendencies due to transient phenomena related to changes in speed and load. AE provides better results than vibration employing the same time domain condition indicators. On the contrary, vibration recognizes clearly the fault through frequency analysis. (C) 2019 Elsevier Ltd. All rights reserved.