Gears play a vital role in industrial transmission systems, yet they are prone to degradation and localized faults such as spalling under complex working conditions. Early and accurate fault diagnosis is essential to ensure operational reliability and reduce maintenance costs. Dynamic transmission error (DTE) is defined as the deviation between the actual and theoretical meshing positions of gears. It serves as a key indicator of meshing accuracy and dynamic behavior, directly reflecting the health status of gears. However, conventional analytical approaches for DTE calculation rely on precise physical modeling and known parameters, limiting their adaptability in real-world applications. Meanwhile, encoder-based DTE measurement methods are often impractical for enclosed gearboxes due to installation constraints and susceptibility to environmental interference. To address these limitations, this paper proposes an in-situ DTE-driven lightweight intelligent fault diagnosis (IDLIFD) framework for gear spalling fault diagnosis. First, an in-situ DTE reconstruction and enhancement method is developed to obtain meshing deviation information from in-situ vibration signals, enabling practical DTE measurement in enclosed environments. Then, a lightweight wide-area deconstruction network (WDNet) is designed to extract discriminative spalling-related features from enhanced DTE signals while maintaining a compact structure and low computational complexity. Finally, experimental validation on a self-made gearbox test bench demonstrates that the proposed IDLIFD framework outperforms existing computational methods and lightweight diagnosis models in terms of DTE calculation, diagnosis accuracy, and real-world deployment.
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