Gearbox variable conditions testing

The following data was obtained from a test rig composed of the following components: an AC motor with speed control, driving a two-stage gearbox, from now on named as "Test Gearbox" with the following tooth gear distribution: 29/100 and 36/90; this is followed by another two-stage gearbox, from now on named as "Load Gearbox" to bring up the speed again with the following tooth gear distribution: 55/21 and 88/27; and finally, the system is connected to a load motor controlled via torque control.
The tests consists in four different scenarios in order to compare them and scale test complexity:
1 - Baseline with all healthy components
2 - Broken gear tooth. The broken gear corresponds to the 36 tooth gear in the Test Gearbox
3 - Outer Race failure in the Test Gearbox input bearing, this is before the 29/100 gear. The bearing reference is ER-16KCL with the following frequency factors: 0.402 FTF, 3.572 BPFO, 5.43 BPFI, 2.322 BSF.
4 - Both broken gear tooth and bearing outer race failures combined in the same test.
Furthermore, for each scenario, four different conditions are set:
1 - Stationary testing for data validation running at 1500 RPM and 70% motor load
2 - Stationary 70% load with variable speed increasing from 840 to 1400 RPM in 5.5 seconds and decreasing from 1400 to 1000 RPM in 4.5 seconds.
3 - Stationary 1500 RPM speed with variable load increasing from 20% to 80% in 5.5 seconds and decreasing from 80 to 50% in 4.5 seconds.
4 - Both speed and load varying at the same ratios as stated in points 2 and 3 combined.
Regarding sensor distribution the testrig is equipped with different sensors in order to have as much context information as needed. In the case of vibration sensors, Vertical or Horizontal directions are always radial, while Axial direction is specified in the sensor name. Sensor name is included in data header.
- Tachometer measures drive motor speed.
- Two encoders measure both drive and load motor speeds.
- Torque sensor.
- Two current transformers measuring 2 of the 3 phases of the drive motor.
- 8 accelerometers placed in the drive motor, in the input (Bearing input Vertical, Axial) and output of the Test Gearbox (Bearing Output Horizontal), in the input (Load Bearing Vertical) and output (Load Bearing Horizontal) Load Gearbox and in the load motor.
- A force transducer rading the axial force of the bearing in the Test Gearbox.
The test distribution goes as follows:
1 - Baseline variable speed
2 - Baseline variable load
3 - Baseline stationary
4 - Baseline variable speed and load
5 - Gear failure variable speed
6 - Gear failure variable load
7 - Gear failure variable speed and load
8 - Gear failure stationary
10 - Gear and bearing failure variable load
11 - Gear and bearing failure variable speed and load
12 - Gear and bearing failure stationary
14 - Bearing failure variable load
15 - Bearing failure stationary
16 - Bearing failure variable speed and load