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Induction motor-planetary gearbox drivetrains are widely used for industrial productions, including machine tools in manufacturing systems. For fault diagnosis of planetary gearboxes in such electromechanical systems, motor current signal analysis provides an effective alternative approach, because motor current signals have easier accessibility and are free from time-varying transfer path effects. Planetary gearbox faults generate load torque oscillations, leading to both amplitude modulation and frequency modulation (AM-FM) effects on induction motor current signals. To thoroughly understand gear fault features in current signals, an AM-FM current signal model is derived through mechanical–magnetic–electric interaction analysis, explicit equation of Fourier spectrum is derived, and sidebands characteristics are summarized. To avoid an intricate sideband analysis, amplitude and frequency demodulation analyses are proposed, explicit equations of corresponding demodulated spectra are derived, and gear fault features are summarized. The theoretical derivations are validated through lab experiments. Localized fault on the sun, planet, and ring gears are all successfully diagnosed using the proposed method.

Induction Motor Stator Current AM-FM Model and Demodulation Analysis for Planetary Gearbox Fault Diagnosis