Astute Gear Alignment Module

Gear Alignment Module - Overview

BACKGROUND
Correct alignment of gears is essential for reliable
long-term operation. Misalignment results in part of
the mesh being overloaded and can lead to
premature tooth failure. It can be due to bearing
wear, manufacturing error, incorrect design
(microgeometry) or deflection of the gearbox casing
under high loads.

Gear Alignment Module

Our Gear Alignment Module is a state-of-the-art
battery-powered miniature 8-channel system that
can be installed inside a gearbox, mounted on
rotating components.

Typical wind turbine

gear tooth damage
due to misalignment,
caused by bearing
wear.

Data to enable the evaluation of gear alignment in

the form of the relative load intensity distribution
factor, KH, as defined in Method A of ISO 6336, is
transmitted wirelessly to a nearby transceiver.
With a user-definable deep sleep mode, the
internal battery can survive months or years for
long-term installations. The module can be used
during type approval testing or as an in-service
condition monitoring tool.
JR Dynamics Ltd
Unit 4, Arcot Court,
Nelson Industrial Estate
Cramlington, Northumberland
NE23 1BB, UK

machine dynamics, noise and vibration, NVH

failure analysis, fatigue and accelerated life testing
specialised instrumentation, data acquisition and analysis
rotating machinery design and troubleshooting:
gearboxes, shafts, bearings, couplings, belts and chains

Company registered in England No. 3284935 VAT Registration No. GB 660 2407 64

T +44 (0) 191 58 000 58

F +44 (0) 191 58 000 59
E support@jrdltd.co.uk

www.jrdltd.co.uk

Astute Gear Alignment Module

Figure 1

GENERAL
The Gear Alignment Module acquires simultaneous
data from up to 8 strain gauges installed along the
width of a gear root, at up to 14 kHz per channel
(112 kHz aggregate data rate). Captured data can
be analysed using bespoke-supplied software, or
exported for external evaluation. An example of
the response from one gauge during a mesh cycle
is shown in detail in Figure 1, along with several
events over a longer period in Figure 2.
By evaluating the amplitude of these transient
events at all strain gauge positions, the relative
load intensity can be plotted, as shown for a range
of load conditions in Figure 3. In this example
there is only a minor misalignment of the mesh.

Figure 2

The data can also be used to evaluate load

sharing factor between multiple planet gears in
epicyclic systems, K (as defined in ISO 6336).

INSTRUMENTATION
The Gear Alignment Module is a self-contained
instrumentation and data analysis system
comprising of:

8 channel strain gauge signal conditioning,

accommodating full-, half- and quarterbridge gauges;
7 kHz low pass filter on each channel;
Tacho input can be used to trigger data
capture;
Temperature and battery level monitoring;
Comprehensive data handling and storage.

Figure 3

Data is downloaded to a PC over a high-speed,

robust Bluetooth pairing to a telemetry
transceiver, giving a range of up to 100 m.
The PC application software bundled with the Gear
Alignment Module allows hardware configuration,
sleep-mode configuration, impact calibration, live
streaming mode (telemetry), data logging
configuration, data download and analysis in one
simple package.

APPLICATIONS

New gearbox design verification and type

approval
In-service condition monitoring.

JR Dynamics Ltd

Page 2

Example of bespoke instrumentation and

battery housings, installed on a planet to be
used inside an epicyclic gearbox

More information, including a technical

specification, is available from our website.

www.jrdltd.co.uk