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The hoist operation process consists of several key stages: initial acceleration, main acceleration, constant speed operation, deceleration, crawling, and rest. During most of these phases—except for the constant speed stage—the vibration signals from the gearbox are complex due to varying working conditions, making it challenging to select an effective signal processing method and extract meaningful fault features. As a result, this paper focuses on analyzing the vibration signals during the constant speed operation, when the gearbox operates in a stable state. This allows for more accurate extraction of fault characteristics and reliable assessment of the gearbox's condition.
Under normal operating conditions, frequency domain analysis of the vibration signal reveals the rotational frequency of the gear shaft at low frequencies, along with its harmonics. The spectrogram is dominated by the gear meshing frequency and its subsequent harmonics, which decrease in amplitude as the harmonic order increases.
In the case of a gear eccentricity fault, the pressure experienced by the gear changes periodically during each revolution, leading to modulation of the meshing vibration amplitude by the rotational frequency. This results in sidebands appearing around the meshing frequency and its harmonics. When a gear has a partial tooth breakage, the fault is characterized by a dominant meshing frequency and its higher harmonics, with sidebands spaced at intervals equal to the shaft's rotational frequency. These features are directly related to the severity of the fault, with amplitudes increasing as the fault worsens.
For gear wear faults, the frequency domain analysis of the vibration signal shows that as wear becomes more severe, the meshing frequency and its harmonics become more prominent. Additionally, sideband components around the rotational frequency increase in amplitude, indicating progressive degradation. These patterns provide valuable insights into the health of the gearbox and can be used for early fault detection and diagnosis.
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