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sound and vibration

Respected Sir I am doing a project to detect the fault gears based on Sound Analysis, from microphone but the readings are varying from day to day. Please tell me the steps should i follow to get the better results. First am finding FFT of the signal and the power spectrum, to find defect am using OAT envelope detection of Power spectrum. based on SPL i am diffrentiating the gears is this correct.
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