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Contribution of using Vibration Diagnostic Tools in Assessing the Condition of Gear Elements in Off-Road Vehicle Gearboxes

Aleksandar Djuric

Aleksandar Djuric

Military Academy, University of DefenceBelgrade, Serbia
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Djuric, Aleksandar
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Sreten Peric

Sreten Peric

Military Academy, University of DefenceBelgrade, Serbia
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Peric, Sreten
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Momir Drakulic

Momir Drakulic

Military Academy, University of DefenceBelgrade, Serbia
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Drakulic, Momir
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Aleksandar Bukvic

Aleksandar Bukvic

Military Academy, University of DefenceBelgrade, Serbia
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Bukvic, Aleksandar
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Snezana Jovanovic

Snezana Jovanovic

Technical Test Center, Serbian ArmyBelgrade, Serbia
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Jovanovic, Snezana
  
01 may 2025
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Publicado en línea: 01 may 2025
Páginas: 53 - 63
Recibido: 08 ago 2024
Aceptado: 21 mar 2025
DOI: https://doi.org/10.2478/msr-2025-0008
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© 2025 Aleksandar Djuric et al., published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Fig. 1.

Conversion of analog to digital signal.
Conversion of analog to digital signal.

Fig. 2.

Block diagram of the vibration diagnostic method.
Block diagram of the vibration diagnostic method.

Fig. 3.

Gearbox type 6MS 80: 1 – gearbox housing, 2 – input shaft, 3 – exit shaft, 4 – intermediate shaft, 5 – shaft for gear engagement, 6 – side cover, 7 – back cover, 8 – oil filler cap, 9 – forks, 10 – longitudinal fork support, 11 – pusher, 12 – carrier, 13 – flange.
Gearbox type 6MS 80: 1 – gearbox housing, 2 – input shaft, 3 – exit shaft, 4 – intermediate shaft, 5 – shaft for gear engagement, 6 – side cover, 7 – back cover, 8 – oil filler cap, 9 – forks, 10 – longitudinal fork support, 11 – pusher, 12 – carrier, 13 – flange.

Fig. 4.

Measurement device and vehicle FAP 1118, 4×4.
Measurement device and vehicle FAP 1118, 4×4.

Fig. 5.

Measurement chain diagram for vibration measurement on a vehicle gearbox.
Measurement chain diagram for vibration measurement on a vehicle gearbox.

Fig. 6.

The acceleration signal over time, for third gear ratio, accelerometer 1.
The acceleration signal over time, for third gear ratio, accelerometer 1.

Fig. 7.

Frequency spectrum, sensors 1 and 4.
Frequency spectrum, sensors 1 and 4.

Fig. 8.

Logarithm of frequency spectrum, sensors 1 and 4.
Logarithm of frequency spectrum, sensors 1 and 4.

Fig. 9.

Logarithm of the harmonics from gear mesh frequencies.
Logarithm of the harmonics from gear mesh frequencies.

Fig. 10.

Intermediate shaft speed harmonics.
Intermediate shaft speed harmonics.

Fig. 11.

Input shaft speed harmonics.
Input shaft speed harmonics.

Fig. 12.

Harmonics of the gear mesh frequency of permanent gears.
Harmonics of the gear mesh frequency of permanent gears.

Fig. 13.

Sidebands around the third gear mesh frequency.
Sidebands around the third gear mesh frequency.

Fig. 14.

Waterfall diagram of the signal from sensor 4.
Waterfall diagram of the signal from sensor 4.

Fig. 15.

The acceleration signal over time, third gear ratio, sensor 1, test 1.
The acceleration signal over time, third gear ratio, sensor 1, test 1.

Fig. 16.

Comparative logarithmic representation of the frequency spectrum, sensors 1 and 4.
Comparative logarithmic representation of the frequency spectrum, sensors 1 and 4.

Fig. 17.

Gear coupling frequency harmonics in constant coupling on the intermediate shaft.
Gear coupling frequency harmonics in constant coupling on the intermediate shaft.

Fig. 18.

Sidebands around the gear mesh frequency.
Sidebands around the gear mesh frequency.

Fig. 19.

Waterfall diagram, sensor 1, test 1.
Waterfall diagram, sensor 1, test 1.

Fig. 20.

Acceleration signal in time, sensors 1.
Acceleration signal in time, sensors 1.

Fig. 21.

The logarithm of the frequency spectrum, sensors 1 and 4, test 2.
The logarithm of the frequency spectrum, sensors 1 and 4, test 2.

Fig. 22.

Comparative frequency spectrum, test 1 and test 2, sensor 4.
Comparative frequency spectrum, test 1 and test 2, sensor 4.

Fig. 23.

The gear in third gear ratio of the gearbox on the output shaft.
The gear in third gear ratio of the gearbox on the output shaft.

Fig. 24.

The gear in third gear ratio of the gearbox after tests.
The gear in third gear ratio of the gearbox after tests.

6MS 80_P28 gearbox main characteristics_

Gear I II III IV V VI
Couple 50/12 36/15 32/22 26/27 24/36 19/41
Gear ratio 9 5.18 3.14 2.08 1.44 1
ωout [rpm] 222 386 637 962 1389 2000
fout [Hz] 3.7 6.4 10.6 16 23.15 33.3
Gm [rpm/Hz] 11100/185 13896/230 20381/340 25000/417 33336/556 38000/634

Third gear harmonics of conjunction frequency values_

Harmonic Frequency [Hz] Level [m/s2]
1 318.8 110.1
2 637.5 96.9
3 956.3 87.0
4 1275.0 90.5
5 1593.8 88.6
6 1912.5 90.2
7 2231.3 88.0
8 2550.0 93.0
9 2868.8 97.9
10 3187.5 95.1
11 3506.3 97.0
12 3825.0 95.5
13 4143.8 93.1
14 4462.5 85.3
15 4781.3 85.2

Sideband level around the gear mesh frequency of the third gear ratio_

Harmonic Frequency [Hz] Level [m/s2]
−4 318.8 110.1
−3 637.5 96.9
−2 956.3 87.0
−1 1275.0 90.5
0 1593.8 88.6
1 1912.5 90.2
2 2231.3 88.0
3 2550.0 93.0
4 2868.8 97.9
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