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<p>In this contribution the electrical behavior of helical gear contacts is investigated. The investigation is based on impedance measurements obtained on an industrial gearbox test bench. The results are analyzed to identify the qualitative influence of rotation speed, load, rotation direction, load direction and surface alterations. Furthermore, potentials and limitations of utilizing the electrical behavior of helical gear contacts for condition monitoring applications are discussed. The investigations show that the lubrication condition can be qualitatively identified based on the characteristics of the electrical behavior of the gear contact. Important influencing factors for the lubrication film thickness and consequently the impedance of the gear contact can be determined to be rotation speed and load but also rotation and load direction. Surface alterations like damages but also tooth pitch deviations in the region of single digit micrometers can be seen to have a&#xa0;measurable influence on the impedance signal of the gear contact. These effects can potentially be used for condition monitoring approaches. However, the ambiguity of the impedance signal due to the high number of influencing factors remains a&#xa0;limitation of this new measurement method. Another factor for the ambiguity of the impedance signal is the simultaneous contact of multiple teeth which are not distinguishable in the impedance signal. This contribution shows the potentials and limitations for the sensory utilization of the electrical behavior of helical gear contacts and highlights novel research gaps.</p>

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Phenomenological analysis of the electrical behavior of helical gears to identify sensory utilizable effects for condition monitoring approaches

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年2月14日

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  • Maximilian Hausmann,
  • Florian Koetz,
  • Eckhard Kirchner

摘要

In this contribution the electrical behavior of helical gear contacts is investigated. The investigation is based on impedance measurements obtained on an industrial gearbox test bench. The results are analyzed to identify the qualitative influence of rotation speed, load, rotation direction, load direction and surface alterations. Furthermore, potentials and limitations of utilizing the electrical behavior of helical gear contacts for condition monitoring applications are discussed. The investigations show that the lubrication condition can be qualitatively identified based on the characteristics of the electrical behavior of the gear contact. Important influencing factors for the lubrication film thickness and consequently the impedance of the gear contact can be determined to be rotation speed and load but also rotation and load direction. Surface alterations like damages but also tooth pitch deviations in the region of single digit micrometers can be seen to have a measurable influence on the impedance signal of the gear contact. These effects can potentially be used for condition monitoring approaches. However, the ambiguity of the impedance signal due to the high number of influencing factors remains a limitation of this new measurement method. Another factor for the ambiguity of the impedance signal is the simultaneous contact of multiple teeth which are not distinguishable in the impedance signal. This contribution shows the potentials and limitations for the sensory utilization of the electrical behavior of helical gear contacts and highlights novel research gaps.