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During the gear hobbing machine process, the hob performance degradation assessment is significant for optimizing the tool changing frequency and improving machining efficiency. It is challenging to recognize hob wear state through vibration analysis and signal processing. Especially in the condition of intense vibration and noise interference, extracting signal features that reflect the wear state is challenging work. This paper proposes a feature extraction method called Cyclic Statistical Energy (CSE) to obtain the hob wear characteristics by tracking the sensitive frequency band. For the method, the vibration signal model of hob spindle is established first based on the vibration-generation mechanism of the machining process. Then, an index E is proposed to track the wear resonance frequency band of the vibration signal. Furthermore, the cyclic statistical order is analyzed and discussed. The hob performance degradation assessment can be realized by analyzing the energy index E with time variation. The experimental setup has been designed, and the two tests have been conducted in the production line: (1) impact hammer test and (2) hob whole life cutting test. The impact hammer test is set to obtain the modal parameters of the hob. Based on this, the whole life cutting test is designed and realized by which the vibration data of whole life with different wear states can be acquired. The proposed method CSE is successfully applied into online industry experiments test. The results show that the proposed method can give a more accurate performance degradation assessment curve for tool condition monitoring compared with traditional methods such as Wavelet Packet Decomposition (WPD). [ABSTRACT FROM AUTHOR]

An energy analyzing method called the Impact Energy Model (IEM) is introduced to assess and diagnose the rub–impact fault of a rotor system. The main purpose of the model is to indicate the probability of rub–impact or the severity level of the fault. Utilizing the nonlinear predictive energy, an effective quantitative evaluation index IEM is obtained from the model. Some work has been done elsewhere to partly demonstrate the IEM through experiments. In this paper we mainly discuss the variation of the IEM index with the speed ratio Ω at different levels of damping ratio ξ. The stagnation point is discussed in detail which is important to the assessment for the probability or severity of a rub–impact fault. The influence of dynamic stiffness is discussed which may affect the assessment result of the IEM. Furthermore, a sensitive area of the rotor operating system is presented. The result shows that this sensitive area provides a reference for the operation and design of a rotor system. [ABSTRACT FROM PUBLISHER]

The failure of rolling bearings is one of the most important factors for rotating machinery breakdown. The detection of initial fault in rolling bearings is crucial for the further prevention of equipment malfunction and failure. In this study, a new rolling bearing fault diagnosis method based on the singular value decomposition, slip Hankel matrix series construction and maximum singular value energy analysis is proposed. It has been validated that the proposed method has an excellent impulse recognition capacity, which can be further applied to design the optimal band‐pass filter for rolling bearing fault diagnosis. Then, the minimum entropy deconvolution (MED) technique is introduced to improve the fault extraction ability of the proposed method. Simulated signals and artificial fault tests are used to prove the capacity of the new method for rolling bearing fault detection. Furthermore, the result of accelerated life test indicates the initial bearing fault can be recognised by the proposed method, while the envelope spectrum cannot directly distinguish the failure type because of the redundant frequency interference. It can be concluded that the proposed method has the effectiveness of initial fault identification and redundant frequency elimination for rolling bearing fault diagnosis. [ABSTRACT FROM AUTHOR]

Due to planetary movement of planet gears, the vibration signal perceived by a stationary sensor is modulated and difficult to diagnose. This paper proposed a vibration separation methodology compensated by a time-varying transfer function (TVTF-VS), which is a further development of the vibration separation (VS) method in the diagnosis of non-hunting tooth planetary gearboxes. On the basis of VS, multi-teeth VS is proposed to extract and synthesize the meshing signal of a planet gear using a single transducer. Considering the movement regularity of a planetary gearbox, the time-varying transfer function (TVTF) is represented by a generalized expression. The TVTF is constructed using a segment of healthy signal and an evaluation indicator is established to optimize the parameters of the TVTF. The constructed TVTF is applied to overcome the amplitude modulation effect and highlight fault characteristics. After that, experiments with baseline, pitting, and compound localized faults planet gears were conducted on a non-hunting tooth planetary gearbox test rig, respectively. The results demonstrate that incipient failure on a planet gear can be detected effectively, and relative location of the local faults can be determined accurately. [ABSTRACT FROM AUTHOR]

As an essential part of the transmission system, gearboxes are considered as a major source of vibration. Signal identification of gear vibration is necessary for online monitoring of the mechanical systems. However, in engine-gearbox systems, the ignition impact of the engine is strong, so that the gear vibration is generally submerged. To overcome this issue, the resonance-based signal sparse decomposition (RSSD) method is used in this paper based on different oscillatory behaviors of the gear meshing impact and the engine ignition impact. To improve the accuracy of RSSD under interferences, the meshing frequency energy ratio (MF–ER) index is introduced into RSSD to adaptively choose the decomposition parameters. Before applying the RSSD method, the auto-regression (AR) model is used as a pre-whitening step to eliminate the normal gear meshing vibration, which improves the decomposition performance of RSSD. The effectiveness of the proposed AR-ORSSD (AR-based optimized RSSD) algorithm is tested using both simulated signals and measured vibration signals from an engine-gearbox system in a forklift. Comparisons were made with the RSSD algorithm based on a genetic algorithm. Experimental results indicate that the AR-ORSSD algorithm is superior at identifying gear vibration signals especially when under strong interferences. [ABSTRACT FROM AUTHOR]