Ultrasonic Testing for Gearboxes
Specialized Ultrasonic Testing programs for Industrial Gearbox Reliability & Maintenance.
Why it matters
Key Benefits
Leak Detection
Airborne ultrasonic detection identifies pressure and vacuum leaks in gearboxes systems that are inaudible to the human ear. Locating leaks quickly reduces energy waste and prevents process quality problems.
Bearing Lubrication Optimization
Ultrasonic monitoring of gearboxes bearings provides real-time feedback during grease application to prevent both under-lubrication and over-lubrication. Proper lubrication extends bearing life and reduces friction-related energy losses.
Early-Stage Fault Detection
Contact ultrasonic measurements on gearboxes detect high-frequency stress waves generated by metal-to-metal contact, friction, and impacts in the gear sets, input and output shafts, bearings, and oil distribution system. These signals appear weeks before vibration amplitude increases detectably.
Context
Challenge & Approach
The Reliability Challenge
Gearbox ultrasonic emission levels are dominated by gear mesh activity, requiring baseline establishment and trending to detect fault-related changes. Bearing acoustic emission must be isolated from gear mesh contributions, which may require frequency band selection or time-domain gating techniques. Slow-speed gearboxes produce low ultrasonic emission levels that challenge sensor sensitivity. Multi-stage gearboxes generate overlapping acoustic emission from multiple gear meshes and bearing sets. Oil splash noise creates background ultrasonic energy. Housing geometry and sensor placement affect signal transmission from internal components to the measurement point. Temperature changes alter lubricant viscosity and affect ultrasonic background levels.
Our Approach
We mount contact ultrasonic sensors (acoustic emission type, 100–400 kHz range) on gearbox housings near each bearing location and at gear mesh zones. RMS acoustic emission levels are trended over time to detect the gradual increases associated with bearing spall initiation and gear surface fatigue. Peak (burst) acoustic emission captures stress wave events from micro-cracking and impact loading. We use frequency band analysis to separate bearing from gear contributions where possible. Heterodyned audio in the ultrasonic range provides qualitative assessment of lubrication condition and surface contact quality. Results are correlated with vibration and oil analysis data for comprehensive condition assessment. Reports include acoustic emission trend charts, bearing and gear condition assessments, and recommended inspection or replacement timing based on combined monitoring data.
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Learn More →Ultrasonic testing detects bearing faults, lubrication deficiencies, internal leakage, and electrical discharge in gearboxes. Airborne ultrasonic detection locates pressure and vacuum leaks at joints, seals, and connections. Contact ultrasonic measurements identify early-stage metal fatigue and friction before vibration levels increase measurably.
Ultrasonic testing detects high-frequency stress waves that appear earlier in the fault progression than vibration amplitude increases in gearboxes. It is most sensitive to friction, impact, and turbulent flow, while vibration analysis excels at identifying specific fault types through frequency patterns. The two technologies are complementary rather than interchangeable for monitoring gearboxes.
Ultrasonic testing is effective on rotating and reciprocating components, pressure boundaries, and electrical systems associated with gearboxes. It is particularly valuable for slow-speed equipment where vibration signals are too weak for reliable analysis. Access to measurement points and background ultrasonic noise levels are the main factors that determine measurement quality.
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Tell us about your equipment and facility. Our reliability team will review your situation and recommend a tailored reliability program — no obligation.
Detect Gear Faults Before Vibration Can
Our acoustic emission monitoring detects micro-cracking and bearing spall initiation in gearboxes at earlier stages than conventional vibration analysis.
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