Planetary Gear Fault Detection Based on Mechanical Torque and Stator Current Signatures of a Wound Rotor Induction Generator

In this paper, an approach for tooth localized fault detection in the sun gear of a planetary gear, using the measured mechanical torque and the stator current of a wound rotor induction generator (WRIG), is proposed. A theoretical background is developed to demonstrate that the faulty sun gear produces periodic fault signatures in the mechanical torque and consequently fault-related frequencies in the stator current of the WRIG. The employed technique needs knowledge of mechanical system torsional natural frequencies, which aid in identifying the most sensitive fault characteristic harmonics in both mechanical torque and stator current spectra. It is illustrated by simulation and experimental results that the amplitude of these harmonics can be used as a fault index for diagnosis of tooth localized defect in planetary gears. A test rig based on a 5.5 kW WRIG, shaft connected to the sun gear of a planetary gear through a high-speed shaft and couplings, was utilized for validation of the proposed technique.