RotasPro Gear Test and Noise Analysis

Torsional Analysis of Single Gears

MTE/Torsional Acceleration Measurement

Mechanical Layout of Test Machine

Rotas NVH Analysis

Tested Gear

GM
Mix

dBV
Ghost
Orders

80
2 *GM
70

Antrieb

Torsional
Accelerometer

60
50

40 Nm

10-40 Nm

40

Test Sequence is steady speed or ramp

50 60 70 80 90 100 110 120 130 Ord

n
3000

t
15-20 s

Revolution Synchronous Transmission Analysis

The transmission noise is the
sum of the noise originating from
the individual mechanical
components.

Input Shaft
Interm. Shaft

For the gear noise components,

the individual sources can be
isolated by
the transmission ratio.

Output Shaft

Synchronous
order analysis:
The signals are
acquired synchronous
to the inner shafts.
Acoustical
Stroboscope
Input Shaft

Interm. Shaft

Output Shaft

Torsional Accelerometer
10,00

Ansicht von oben

4x d=5,1
Nut 1x2
53,00

Nut 2x2

R 14,00

35,00

24,00

90,00

R 4,00

10,00

18,50

2,50

10,00

Power Transformer
Into Rotator

110,00

Optical Receiver

R 12,00
R 13,00
R 16,00

R 32,50

30,00

R 2,00
R 35,00

10,00
90,00

10,00

3,00

5,00

2,00

2x M2,5

1,00

5,00

LED Sender

20,00

3,00

2,50

35,00

Deckel 10x34,8x5 10,00

125,00
30,00

35,00
R 35,00
Nut 1x2
70,00
2x Bohrung u. Senkung M2,5

MATERIAL:
MASSTAB

1:1

90,00

gez.:J. Lorenz

2005-01-03

Sensor

ZEICHN.NR.

050103-6
1 von 1

BLATT

25,00

Rotational ensor
10,00

yxx

10,00

45,00

32,00

Sender

20,00

Accelerometers

Rotierender Sensor
Empfnger- Gehuse
Aluminium

IS C O M
Tel=0551/548330
Fax=0551/5483343

110,00

Empfnger

Lagergehuse
22,00

Rotierender Sensor
Abmae

D IS C O M
Tel=0551/548330
Fax=0551/5483343
gez.:J. Lorenz

MATERIAL: Aluminium/Kunsstoff
ZEICHN.NR.
MASSTAB

1:1

2004-12-20

041220-0
1 von 1

BLATT

Torsional Accelerometer
Accelerometers measure the
deviation from uniform circular
motion

Optical Receiver

Power Transformer
Into Rotator

Optical Sender

Accelerometers
Rotating Sensor

Single Flank Gear Tester Linnenbrink

Torsional Accelerometer
Test gear

Master Gear

Results from Crank/Cam Gear pairs

Graphs show one revolution of the crank and the cam gear when run as
pairs on the single flank gear tester. The faults can be easily detected.
Type: Cm-500 #0, Pz3
05-04-2005 11:09
HA 01R

Type: Cm-500 #0, Pz3

Cm-500 #35-CRK-DH1156, Pz3

05-04-2005 11:08
HA 01R

05-04-2005 09:54
HA 01R

Crank

Crank
0.2
0.2.

0.16
0.16.

0.1
0.1.

0.08
0.08.

0.0
0.0.

0.00
0.00.

-0.1
-0.1.

-0.1
-0.1.

-0.08
-0.08.

-0.2
-0.2.

-0.2
-0.2.

-0.16
-0.16.

0.2
0.2.

Crank
Gear

0.1
0.1.

0.0
0.0.

-0.3
0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

Rev

-0.3
0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

Rev

Cam
Gear

0.2
0.2.

0.2
0.2.

0.1
0.1.

0.1
0.1.

0.0
0.0.

0.0
0.0.

-0.1
-0.1.

-0.1
-0.1.

-0.2
-0.2.

-0.2
-0.2.

-0.3
0.2

0.3

0.4

0.5

0.6

0.7

Good Gear Set

0.8

0.9

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

Rev

-0.3
0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Eccentricity on
Cam Gear

0.8

0.9

Rev

0.9

Rev
V
V.

Cam_Shaft

Cam_Shaft

Cam_Shaft

0.1

-0.24
0.0

V
V.

V
V.

0.0

V
V.

V
V.

V
V.
Crank

0.16
0.16.

0.08
0.08.

0.00
0.00.

-0.08
-0.08.

-0.16
-0.16.

-0.24
0.0

0.1

0.2

0.3

0.4

0.5

0.6

Nick on
Cam Gear

0.7

0.8

0.9

Rev

Comparing DIN 3960 composite inspection

Graphs show one revolution of the cam gear when run as pairs on the single flank gear tester.
The good and the bad gear set show less variation with this method. Fi is even smaller for the bad gear

fk tooth to tooth
deviation
short wave
component
f k

Fi tangential
composite
deviation
Long wave
component

fk

Fi
Fi

Good Gear Set

Eccentricity on
Cam Gear

Synchronous Averaging III

Revolution synchronous averaging
gives periodic (cyclic) signals. This
corresponds to the cyclic nature of the
gear sets.
These signals can be transformed into
the spectral domain without any time
domain leakage windows.

dBV
GM

2 *GM
80

Mix
Ecc..

Ghost
Orders

Antrieb

This allows for high spectral resolution.

Eccentricities can be easily
distinguished from the gear mesh
orders. The noise components can be
attributed to their origins.

70
60

50

Blue: Conventional order spectrum with

Kaiser Bessel Window

40

Green: Revolution synchronous order

spectrum without window function
50 60 70 80 90 100 110 120 130 Ord

Results from Single Flank Gear Tester

Crank No 30-40
IndustrielleMe- undPrftechnik

05.04.05 10:19

Spectra / Pz1 Drive

/ SK1 / SpecReport
dBV
65

H3

H1

60

65
60

H2

55

Crank

Spectra / Pz2Coast
/ SK1 / SpecReport
dBV

50

55
50

45

45

40

40

35

35

30

30

25

25

20

20

15

15

10

20

40

60

80

100

120

Ord

10

Spectra / Pz1 / SK2 / SpecReport

Cam

dBV

65

65

60

60

55

55

50

50

45

45

40

40

35

35

30

30

25

25

20

20

15

15
0

40

80

120

160

200

240

40

60

80

100

120

Ord

Spectra / Pz2 / SK2 / SpecReport

dBV

10

20

Ord

10

40

80

120

160

200

240

Ord

Various filed units shown as stray bands. The gear mesh energies are clearly seen.

Measurement Statistics and Bench Comparison

Over 300
individual
measurement
results can be
evaluated.
The
comparison of
test benches
makes it easy
to administer
large
production
facilities.

Spectral Statistics
Order spectra of production units can be
displayed in Campbell or in 3-D graphs. Cuts in
the order or in the unit direction show order
amplitude versus units or the spectrum of one
unit. The pictures show the order spectra of 300
production units. A ghost order of 118 is present
in the first 40 units tested.