pictogram Lifetime extension of pittings

Research Project: Lifetime Extension of Pittings

Institute of Machine Components (IMA)

Increasing the remaining useful life of gears through an adaptive operating strategy

For case-hardened gears, pitting damage occurs first on the weakest tooth. The other teeth are only pre-damaged or completely intact until failure (4% pitting area). Thus, there is a variation in the strength of the individual teeth and, at the same time, a potential for unused lifetime. The objective of this work is to use this potential to increase the remaining useful life of gears directly in operation by means of an adaptive operating strategy. Within the strategy, a local load reduction is applied to the pre-damaged tooth, thus delaying degradation. The other intact teeth compensate for the load reduction in order to achieve a constant average power, which represents a considerable advantage over the state of the art.

detailed project description (.pdf)


  1. Merkle, Lukas ; Binanzer, Lisa ; Dazer, Martin ; Nicola, Andreas: Artificial Intelligence for Sustainable Control of Wind Power Drives. In: Proceedings of CWD 2023 - Conference for Wind Power Drives. 21.-22.03.2023, Eurogress, Aachen, 2023, S. 172–180
  2. Binanzer, Lisa ; Merkle, Lukas ; Dazer, Martin ; Nicola, Andreas: Pitting Detection for Prognostics and Health Management in Gearbox Applications. In: Proceedings of the International Conference on Gears 2023. 13.-15.09.2023, Garching/Munich, 2023, S. 97–108
  3. Gretzinger, Yvonne: Steigerung der nutzbaren Restlebensdauer von Zahnrädern durch eine adaptive Betriebsstrategie: Dissertation, Universität Stuttgart, Institut für Maschinenelemente, 2022
  4. Gretzinger, Yvonne ; Kroner, Andreas ; Henß, Mark ; Dazer, Martin ; Bertsche, Bernd: Extended Evaluation of Pitting Degradation Tests to Increase the Remaining Useful Life of Gear Wheels. In: IOP Conf. Series: Materials Science and Engineering. Bd. 1097 (2021), Nr. 012006 — IMA-AT 247 (peer-review)
  5. Gretzinger, Yvonne ; Dazer, Martin ; Bertsche, Bernd: Using Life Data of Competing Failure Modes to Increase the Remaining Useful Life of Gear Wheels. In: RAMS 2020 Conference, 2020 — IMA-AT 244 (peer-review)
  6. Gretzinger, Yvonne ; Lucan, Kevin ; Stoll, Christian ; Bertsche, Bernd: Lifetime Extension of Gear Wheels using an Adaptive Operating Strategy. In: Proceedings IRF2020: 7th International Conference Integrity-Reliability-Failure, 2020, S. 703–710 — IMA-AT 245 (peer-review)
  7. Gretzinger, Yvonne ; Dazer, Martin ; Bertsche, Bernd: Lebensdauerpotentiale bei der Schadensart Zahnradgrübchen. In: Dresdner Maschinenelemente Kolloquium : sierke Verlag, 2019. — ISBN 978-3-96548-055-1, S. 209–218
  8. Gretzinger, Yvonne ; Nosch, Jonathan-Lee ; Bertsche, Bernd: Beeinflussung von Antriebsstrangschwingungen zur Lebensdauerverlängerung von Zahnradgetrieben. In: 2. VDI-Fachtagung „Schwingungen 2019“. Bd. VDI-Berichte, 2019, S. 261–270


This image shows Lukas Merkle

Lukas Merkle

M. Sc.

Deputy Head of Drive Technology Department

This image shows Lisa Binanzer

Lisa Binanzer

M. Sc.

Academic Staff

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