Method for a cloud based remaining-service-life-prediction for vehicle-gearboxes based on big-data-analysis and machine learning

Most vehicle-gearboxes operating today are designed for a limited service-life. On the one hand, this creates significant potential for decreasing cost and mass as well as reduction of the carbon-footprint. On the other hand, this causes a rising risk of failure with increasing operating time of the machine. Especially if a failure can result in a high economic loss, this fact creates a conflict of goals. On the one hand, the machine should only be maintained or replaced when necessary and, on the other hand, the probability of a failure increases with longer operating times. Therefore, a method is desirable, making it possible to predict the remaining service-life and state of health with as little effort as possible. Centerpiece of gearboxes are the gears. A failure of these components usually causes the whole gearbox to fail. The fatigue life analysis deals with the dimensioning of gears according to the expected loads and the required service-life. Unfortunately, there is very little possibility to validate the technical design during operation, today. Hence, the goal of this paper is to present a method, enabling the prediction of the remaining-service-life and state-of-health of gears during operation. Within this method big-data and machine-learning approaches are used. The method is designed in a way, enabling an easy transfer to other machine elements and kinds of machinery.