Comparative case studies on ring gear fault diagnosis of planetary gearboxes using vibrations and acoustic emissions

The analysis of vibrations and acoustic emissions (AE) are two recognized non-destructive techniques used for machine fault diagnosis. In recent years, the two techniques have been comparatively evaluated by different researchers with experimental tests. Several evaluations have shown that the AE analysis has a higher potential than the vibration analysis for fault diagnosis of mechanical components for certain cases. However, the distance between the AE sensor and the fault is an important factor that can considerably decrease the potential to detect damage and that has not been sufficiently investigated. Moreover, the comparisons have not yet addressed conditions of slow speed that for example are usual for wind turbine gearboxes. Therefore, in this paper we present two comparative case studies that address both topics. Both case studies consider planetary gearboxes with faults in their ring gears. The first case study corresponds to a small planetary gearbox in which the AE and vibration sensors were installed together at two different positions. The second case study corresponds to a full-size wind turbine gearbox in which three pairs of AE and vibration sensors were installed on the outside of the ring gear from a low-speed planetary stage. The results of the evaluations demonstrate the important influence of the distance between sensors and fault. Despite this, the good results from the AE analysis indicate that this technique should be considered as an important complement to the traditional vibration analysis. The main contribution of this paper is comparing AE and vibration analysis by using not only experimental data from a small planetary gearbox but also from a full-size wind turbine gearbox. The comparison addresses the topics of proximity of the sensor to the fault and low-speed conditions.