I have been approached by a manufacturer -with a claim that Acoustic Emission can be used for condition monitoring of the Gear Boxes in more effective way.

I wish to use some equipment for predictive maintenance.

I am quite new to this technology. Can some one through more light on this?

Acoustic Emission uses the principle of detection of high frequency stress waves that are created whenever rubs or impacts occur.

I have been using AE for condition monitoring for the last 5 years & find it okay, but good for low speed applications. As far as gearboxes are concerned, it would be excellent for checking the condition of the low speed bearings, as well as the lube condition. Works well with plain bearings also.

However, I have never picked up any gear problems with it, which were however evident by vibration analysis. Also, do not rely on it for high speed gearboxes, I see it missing bearing problems in 3000 RPM machines regularly.

Regards,

Aditya

Thanks,

I wish to use it for about 200 gearboxes, Worm gearbox and Helical of defferent reduction ratios, but the drive motor has 1450 rpm rotation in almost all of it.This means input side of the gearbox will have same rpm where as the other side will have( 110 to 30 rpm)

In my previous querry the forum engineers suggested Vibration analysis and Oil check for preventive maintenance, but the cost is too high. I have Rs. 7.5lac as my budget and thought of getting one SKF hand held oil analyser( about 60-70 Thousand)and one Vibration/ Ultrasound/AE system.
It seems that you are monitoring roting equipment since many years. Can you suggest me some combination to predict the failure of gearboxes.

The forum recommendations are absolutely correct, I would follow the same. Check with Mechanalysis India (ceo@mechanalysisindia.com), they have some good AE & Vibration Analyzers at a decent price.

Frankly, at that budget, I would go for a good vibration analyzer along with a low frequency accelerometer; and buy the other stuff next year.

Regards,

Aditya