Gear defects are the major sources of vibration in the gearbox. In gear defects, tooth fracture is the most serious fault in gearbox and it may cause complete failure of the gear. Early detection of the tooth crack is helpful in avoiding the disastrous breakdown of the gearbox. The present work is an attempt to investigate the vibration characteristics of the gearbox, which has cracked gear as the defect. Vibration signals are acquired using accelerometer placed on the bearing housing nearer to the gear pair. FFT spectrum and order tracking analysis are useful tools for the monitoring of machinery vibration. The gear mesh frequency in the FFT analysis and the sidebands in the vibration signal are useful in the gearbox fault diagnosis. Comparison is made between the signals of healthy gear and faulty gear at various speed and load conditions and analysis of the signals show distinct differences in the vibration characteristics between healthy and faulty gear systems.
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