Abstract

Gears are the crucial element of any transmission system which generally used for power
transmission along with other applications depending upon working requirements. Such type of
component must be check by using highly accurate methodology in order to assess its functional
performance in advance. The inspection methodology of gears should be accurate with less time
consuming procedure for its inspection. This objective is easily obtain by using Gear Test Rig.
This test rig will be able to carry out noise test, vibration analysis, and gear misrun.
1.INTRODUCTION

Any power transmission system of any machine consist of Gears which perform the task
of power transmission. The inspection methodology of such vital element plays important role in
its functional performance. The test rig can be developed for checking different parameters at a
time instead of checking individual error which consume lots of time for inspection. Mainly gear
test rig used for functional inspection method which involve checking of gears running with
other gear which consider as a master gear. The result of this testing method is in terms of
Composite error. The working principal of this test rig is similar to Parkinson Gear Tester in
which gear to be tested is rotated with the gear having very closed dimensional accuracy called
as master gear. This type of Gear Test Rig can be Developed for any type of gear box having
vertical axis of rotation in its working condition.
Today world requires speed on each and every field. Hence rapidness and quick working is the most important. Now
a day for achieving rapidness, man manufactures various machines and equipments. The engineer being constantly
conformed to the challenges of bringing ideas and new design in to reality. New machines, equipments and the
techniques are being developed continuously to manufacture various products at cheaper rates and high quality.
Design & Development of Parkinson gear tester for spur gear to check the Flank Surface being compact and
portable equipment, which is skilful and is having something precise in testing the gears being manufactured.
In order to check the combined tooth error different types of gear testing machines are used. Various machines have
its ability to check specified parameters only. Highly precise machine required special installation and space. For the
purpose of checking gear in machine shop while performing machine required such an arrangement which is robust
and quick one. This purpose can be solved using gear test rig. This type of gear test rig can be used for mass
production of gears of a particular gear box. Gear test rig is such arrangement which simplifies the measurement and
saves the labour time and labour cost with greater accuracy.
In gear test rig all the gears will be mounted on a plate which ay be fixed or stationary as per the requirement of
the measurement. While measuring the one gear remaining will act as a master gear. This will help in finding the
composite error. This test rig can be used in shop floor as it requires less pace and operator can use it as per need
without wasting much time. Various modes of gear failure are given as follows,

1.1 GEAR TERMINOLOGY AND ERRORS IN GEAR

1.2 Errors in Gear
1) Profile error
Maximum distance of any point on tooth profile form to the design profile
2) Pitch error
Difference between actual and design pitch
3) Cyclic error
Error occur in each revolution of gear
4) Run out
Total range of reading of fixed indicator with contact point applied to surface rotated, without axial movement,
about fixed axis.
5) Eccentricity
Halt the radial run out
6) Wobble
Run out measured parallel to axis of rotation at a specified distance from axis
7) Radial run out
Run out measured perpendicular to axis of rotation
8) Undulation
Periodical departure of actual tooth surface from design
Surface
9) Axial run out
Run out measured parallel to the axis of rotation at a speed
10) Periodic error
Errors occurring at regular intervals
1.3 Problem Statement
In conventional gear test rig there is scope for checking the composite error of any one kind of gear so that for
checking different type of gears in manufacturing process it required to have different test rigs, also accuracy of
checking composite error must have to increase. This problem gives out a way to develop modified gear test rig in
form of parkinson’s gear tester.

1.4 Need of Inspection

In old days the production was on a small scale, different component parts were made and assembled by the same
craftsman. If the parts did not fit properly at the time of assembly, he used to make the necessary adjustments in
either of the mating parts so that each assembly functioned properly.
Therefore, it was not necessary to make similar parts exactly alike or with same accuracy as there was no need of
inspection.
Due to technological development new production techniques have been developed. The products are being
manufactured on a large scale due to low cost methods of mass production. So, hand fit method cannot serve the
purpose any more. The modern industrial mass production system is based on interchangeable manufacture, when
the articles are to be produced on a large scale.
In mass production the production of complete article is broken up into various component parts. Thus the
production of each component part becomes an independent process. The different component parts are made in
large quantities in different shops. Some parts are purchased from other factories also and then assembled together at
one place. Therefore, it becomes essential that any part chosen at random should fit properly with any other mating
parts that too selected at random. This is possible only when the dimensions of the component parts are made with
close dimensional tolerances. This is only possible when the parts are inspected at various stages during
manufacturing.

1.5 Methodology

COMMUNICATION

PLANNING

MODELING

CONSTRUCTION

DEPLOY

Figure 1.2: Waterfall Model

We have decided to complete the project in simple waterfall model

1.5.1 Communication Phase

Communication phase includes:

 Discussion of topic with guide

 Actual farm visit and understanding various farming method
 Literature survey
 Problem identification
 Analysis of problem
 Concept development
 Discussing various certainties and uncertainties

1.5.2 Planning Phase

Planning phase includes:

 Process planning
 Raw material planning
 Force analysis
  Process scheduling

1.5.3 Modeling Phase

Modeling phase includes:

 Design of various components

 CAD modeling of components
 Assembly model of component
 Prototype model making

1.5.4 Construction and Testing

Construction phase includes:

 Selection of proper manufacturing methods

 Working as per process scheduling and plan
 Testing of equipment on field
 Error analysis
 Repair if any

1.5.5 Deployment

 Comparing the project with the designed output

 Preparation of testing results
 Preparation of project report
 Final submission of project
2. Literature Survey
Gearbox is a basic transmission system, which is widely used in mechanism system. Its state is
directly correlated its running process. Presently, the common method on state monitoring and fault
diagnosis of gearbox without disassembly is the vibration diagnosis, but gearbox vibration signals
often mix much strong noise. On this condition, it is difficult to distinguish the gear fault
consequently. How to remove the strong noise, and extract the feature of pulse fault signal is a key
problem that we must resolve. Presently, wavelet transformation is widely used to resolve above
problems [1].
Extensive research, testing, and analysis have been performed by many corporations and university
researchers to increase the reliability of industrial and helicopter gearboxes. For example, helicopter
power trains comprise almost 30% of maintenance costs and 22% of mechanically related
malfunctions. Approximately 32% of serious rotorcraft accidents are due to transmission components
while gearboxes are often the component responsible for maintenance induced faults. Predicting
gearbox faults is particularly difficult since the calculated fatigue life of gearboxes has substantial
statistical error. Most gearbox analysis programs are focused on safety, cost reduction, attaining a
pre-defined gearbox life, and increasing the life of a gearbox. Studies are typically conducted by
analyzing vibration and temperature data captured from sensors that are carefully located on a
gearbox. Sometimes acoustic pick-ups are used to capture noise data and “hear” the characteristic
signature of a faulty gearbox nearing failure. Vibration waveforms are frequently compared to
nominal or parametric data to determine if a fault is present in the gearbox. However, these
techniques are somewhat limited due to the dynamics of speed versus load (torque) and the inability
to model the multi-dimensional dynamics that occur in the real world. More recent techniques such
as data fusion, neural networks, non-linear dynamical modeling and multivariate analysis have
rendered more robust and more accurate methods of modeling and diagnosing gearbox faults under
dynamic forces [2]
the current transients drawn by the induction motor. Three defective cases and three transient load
conditions are investigated. Advanced signal processing techniques such as discrete wavelet
transform (DWT) and a corrected multi resolution Fourier transform (MFT) are applied to investigate
the vibration and current transients. It is observed from the vibration transients that the load removal
is a high-frequency phenomenon. With increase in defect severity, not only the defective gear mesh
frequency gains energy, but also large impact energy appears in low-frequency regions. Whereas in
the current transients, though load removal is a low-frequency phenomenon, a very small transient is
observed at high-frequency regions for defective gears. With increase in defect severity, energy is
distributed to the sidebands of the gear mesh frequency across supply line frequency. A statistical
feature extraction technique is proposed in order to find a trend in detection of defects. A condition
monitoring scheme is devised that can facilitate in monitoring vibration and current transients in the
gearbox with simultaneous presence of transient loads and defects [3].

.
This paper deals with an experimental investigation of fault diagnosis in a multistage gearbox under
transient loads. An induction motor drives the multistage gearbox, which is connected to a DC
generator for loading purpose. The signals studied are the vibration transients, recorded from an
accelerometer fitted at the tail-end bearing of the gearbox; and The diagnosis of artificial defects in a
single stage gearbox using two non-destructive techniques (vibration and AE) and advanced signal
processing techniques to discriminate between different load and defect states is the scope of the
present study. Wavelet based techniques were developed and utilized in order to evaluate the
vibration signals and extract diagnostic information out of them. A new concept of AE transducer
mounting on rotating structures, without the use of the expensive solution of the slip-ring is
presented. The AE signals are analyzed and their root-mean-square (RMS) values are calculated. The
capability of the new approach of AE acquisition in discriminating between different loading and
damage states is shown and discussed. Interesting findings on the effect of the oil temperature upon
AE recordings only speculated theoretically so far are also presented. Both methods yielded
interesting results and showed an ability to distinguish between healthy and defected gears [4].
Design & Test Rig
Various parts used in test rig
Master Gear
Gears are the very important part of the test rig , because the test rig is using the highly accurate master gear
to inspect the another gear. Master gears are as a gauge while inspecting with which we can compare the
accuracy of the other gear.

Dial gauge indicator:-

The dial gauge indicator is the mechanical comparator. The working principle of dial gauge indicator is
converting the linear motion into angular motion. For that purpose it use the gear train for magnification and
scale pointer as indicating device. The following figure shows the actual and 3d model of dial gauge indicator.
Accelerometer (Vibration sensor of smart phone):-
An accelerometer is a device that measures the vibration, or acceleration of motion of a structure.
Here this sensor attach to setup with the help of holder.

4.Working & Working Principle

Gear Test Rig

Gear test rig is such arrangement which make the task of inspection so easy that it can
be performed within few minutes. Simultaneously it saves the labor time and cost associated
with it with other different advantages.. In gear test rig all the gears are mounted on a plate which
may be fixed or stationary as per requirement of measurement. While measuring the one gear
remaining act as a master gear. This will help in finding the composite errors. Any error during
its inspection make that one gear defective which may be taken as a scrap or send for rework for
error removal process. This entire process of gear inspection is quick with clear result of
acceptance or rejection of gear.

Construction of Gear Test Rig

Working :
 The test rig has two section, Section A is of Noise and vibration test using accelerometer
of smart phone and section B is used to test misrun of gear which is purely based on parkinson’s
gear test principle.
Section A : Noise & Vibration test
In this section there is master gear which is driven by DC motor using belt pulley arrangement.
Gear to be tested is meshed with the master gear and vibration as well a noise frequency is
recorded using accelerometer of situated smartphone.
Section B : Gear misrun test
In development of test rig manual operating is used to rotate the master gear against the gear to
be tested. The gear to be tested is installed on the trolley gear shaft. The trolley being spring
loaded is in continuous close contact with the master gear. The master gear shaft is extended and
is coupled with the pulley assembly which is driven by DC motor. When the pair of master gear
and the gear to be tested is rotating and if there is any mis-run of the gear to be tested then the
same deflection is shown thus the operation of gear testing machine is done.

Application
 Used to check as well measure the errors in tooth form.
 Detect error in pitch.
 Detect errors in concentricity of pitch line.
 Detect the Total Composite Error: Double Flank.
 Detects vibration in gear.
 Composite errors can be checked by measuring the variations of centre distance when
gear under test is rolled under spring pressure against a master gear.

Conclusion:
 This project brought together several components and ideas to achieve a common goal
viz. person can check the composite error with higher accuracy.
 As springs and slider table provide with roller it will provide flexibility of checking
composite errors of different types of gear.
 Ultimately it overcomes the limitation of test rig for checking only spur gears.It provides
flexibility of checking gears having maximum outer diameter up to 150mm.
 Reduces time for checking composite error, initial cost and maintenance cost of test rig.
 It is very useful in mass production of any types of gear.