Audio acoustic plant condition monitoring of spiral bevel gearbox

Abstract

Plant condition monitoring (PCM) is widely used by a variety of industries as part of a condition based maintenance programme. This replaces the previous ‘schedule’ based maintenance programme, in which individual components of a machine are replaced at specified intervals. With PCM the condition of the individual components is monitored, and they are only replaced when their performance is deemed unsatisfactory. PCM techniques are often capital and/or labour intensive, and their use limited to critical machines only. The objective of the present research is to develop a system comprised of microphones and accelerometers which is able to screen industrial environments, such as the hot rolling mill at Corus's Port Talbot plant, for machine faults. The system would use the minimum number of transducers to remotely screen the maximum number of machines, but is not required to provide detailed diagnostic information. To date, an omnidirectional microphone has been used successfully to detect badly damaged gear teeth. The method does not require the use of a soundproof enclosure to filter out background noise. A finite element analysis model of the test rig has been created to determine the eigenfrequencies and eigenmodes of the test rig and to improve the understanding of the vibration behaviour of the faults.