진동 생성 메커니즘을 고려한 초기 결함 단계의 베어링 진단 연구

학위논문(박사) -- 서울대학교대학원 : 공과대학 기계항공공학부, 2023. 2. 윤병동.The failure of rolling element bearings is a common fault in rotating machines. These failures can have catastrophic consequences, including fatal injuries and significant financial losses. To mitigate these risks, researchers have explored various ways to detect and prevent bearing failures as early as possible. One promising approach is the use of condition monitoring data; in this approach, vibration data has been found to be particularly effective for identifying and preventing potential failures. However, the use of vibration signals to diagnose bearings at the incipient fault stage is a challenging task, in part due to the gap between the controlled conditions under which research data is often generated and the actual field conditions in which these bearings operate. In particular, fault-related signals are weak and nonstationary; further, they are usually obscured by noise that arises from environmental factors. Additionally, these signals may be complicated or modulated, making them difficult to discern. To properly address these research issues, this dissertation aims at advancing two research thrusts focused on developing techniques for modeling and analyzing vibration signals based on physical phenomena. In Research Thrust 1, a quasi-periodic impulse train model with an impact force function is suggested to brtidge the gap between theory and reality. In this research, a pseudo second-order cyclostationary signal is modeled using the quasi-periodic impulse train model. In order to simulate the dynamic response of a system, considering the physical behaviors in bearings, the impact force function that reflects the change in contact stress is used. Finally, the proposed model is validated by performing signal processing on the synthesized signal, including simulation of the proposed model. The result confirm that an appropriate preprocessing process is essential to diagnose bearing failure at the incipient failure stage, further, that finding the frequency band that contains the failure information is essential for performance improvement. In Research Thrust 2, a new feature extraction method is proposed for bearing diagnosis using vibration signals, namely the linear power normalized cepstral coefficients (LPNCC). The proposed approach is designed to enhance the bearing signal, which is buried in noise that arises from environmental effects, and which contains mechanical phenomena. The proposed method consists of two sequentially executed steps: 1) extraction of the LPNCC and 2) demodulation analysis that is performed by examining the squared envelope spectra (SES). Combined, this approach is called LPNCC-SES. The performance of the proposed method is examined by applying it to both simulation data and experimental cases. The results show a high level of accuracy and robustness in the diagnostic capabilities of the method, making it suitable for use in maintenance and diagnostic routines.구름 베어링은 회전 기계 및 왕복동 기계의 핵심적인 요소부품으로 회전하거나 진동하는 구조를 지지하며 구성품 간의 하중을 전달한다. 따라서 구름 베어링의 고장은 시스템 전체의 고장으로 이어져 치명적인 인명 피해는 물론 막대한 재정적 손실을 초래할 수 있다. 이에 따라 조기에 베어링의 고장을 관측하고 진단하기 위해 상태관측 데이터를 활용한 많은 연구가 진행되어 왔으며 특히 진동신호를 활용한 진단이 널리 수행되었다. 베어링 초기 결함을 진단을 하는데 있어 어려움을 겪게 하는 이유로 환경 영향으로 인해 발생하는 잡음에 묻혀 있는 약한 결함 신호 및 베어링의 결함 관련 신호의 복잡한 변조를 들 수있다. 이러한 문제를 극복하기 위해 본 연구에서는 베어링 결함신호의 생성원리에에 기반한 신호 모델을 제안하였다. 베어링 신호는 본질적으로 비정상성을 띄며 또한 실제 현장에서 획득한 신호는 복잡하고 다양한 소스에서 발생하는 신호가 조합된다. 이론과 현실 사이의 격차를 해소하기 위해 해석적 신호 모델에 헤르츠 접촉 이론에 기반한 충격 메커니즘을 구현하였다. 시뮬레이션된 베어링 신호에 기어의 결정론적 신호, 회전축의 사인파 신호 및 가우시안 노이즈와 합성된 신호에 대한 전처리 분석을 통해 제안 모델의 타당성을 검증하였다. 이 후, 다양한 잡음 환경에서 여러 변조된 음성 신호를 효과적으로 판별하는 음성인식 방법을 기계시스템에 적용한 고장특징 추출 방법을 새로이 제안하여 캡스트럽에 기반한 특징인자를 추출하였다. 추출된 인자로부터 시간-주파수 영역에서 스펙트럼을 계산하여 효과적으로 베어링의 특성 주파수를 검출하였다. 제안된 방법의 검증을 위해 다양한 잡음 환경에서의 시뮬레이션 데이터와 실험데이터를 사용하였다. 또한 가속수명시험을 통한 데이터를 통하여 조기진단의 효과를 검증하였다.Chapter 1. Introduction 1 1.1 Motivation 1 1.2 Research Scope and Overview 3 1.3 Dissertation Layout 5 Chapter 2. Technical Background and Literature Review 6 2.1 Vibration Signals of Bearing Faults 6 2.1.1 Rolling Element Bearings 6 2.1.2 Failure of Rolling Element Bearings 7 2.1.3 Bearing Fault Signature and Its Frequencies 8 2.2 Vibration Techniques for Bearing Incipient Fault Diagnosis 10 2.2.1 Overview of Vibration Techniques for Bearings 10 2.2.2 Cepstrum-Based Fault Diagnosis Techniques 13 Chapter 3. Quasi Periodic Impulse Train Model with Impact Force Function 20 3.1 Vibration Modelling of Bearing Fault 21 3.1.1 General Mathematical Model 21 3.1.2 Quasi-periodic Model with Cyclostationary 22 3.1.3 Excitation Force Function in Dynamic Models 23 3.2 Quasi Period Impulse Model with Impact Function 26 3.2.1 Overall Process of Proposed Model 26 3.2.2 Modeling the Excitation Force 27 3.3 Numerical Results and Discussion 32 3.3.1 Necessity of Choosing an Appropriate Preprocessing Method 34 Chapter 4. Speech Recognition-Inspired Feature Engineering for Bearing Fault Diagnosis 48 4.1 Review of Power-Normalized Cepstral Coefficients (PNCC) 49 4.1.1 Basic Definition of Cepstrum 49 4.1.2 Characteristics of cepstrum in mechanical vibrations 50 4.1.3 Power-Normalized Cepstral Coefficients (PNCC) 52 4.2 Proposed Feature Extraction Method: Linear Power-Normalized Cepstral Coefficients (LPNCC) 55 4.3 Fault Diagnosis by Implementing LPNCC 57 4.3.1 Fault Diagnosis Method using LPNCC and Squared Envelope Spectrum (LPNCC-SES) 57 4.3.2 Effect of Linear Filter and Power-normalization 59 4.4 Experimental Application and Results 60 4.4.1 Case Study with Simulation Model 61 4.4.1.1. Simulation Data with White Gaussian Noise 61 4.4.1.2. Denoising Under Gaussian Noise 62 4.4.1.3. Reseults Under Non-gaussian Noise 66 4.4.2 Case Study with Experiment Data 67 4.4.2.1. Experimental Data: Case Western Reserve University Dataset 67 4.4.2.1.1. Compared Methods 67 4.4.2.1.2. Case 1: Impusive Noise 68 4.4.2.1.3. Case 2: Low Signal-to-noise Ratio (SNR) 69 4.4.2.1.4. Case 3: Multiple Defective Signals 71 4.4.2.2. Experimental Data: Naturally Degradation Data 72 Chapter 5. Conclusions 108 5.1 Summary of Dissertation 108 5.2 Contributions and Significance 110 5.3 Suggestions for Future Research 113 References 116 Abstract (Korean) 130박

Advanced Data Analytics for Data-rich Multistage Manufacturing Processes

Nowadays, multistage manufacturing processes (MMPs) are usually equipped with complex sensing systems. They generate data with several unique characteristics: the output quality measurements from each stage are of different types, the comprehensive set of inputs (or process variables) have distinct degrees of influence over the process, and the relationship between the inputs and outputs is sometimes ambiguous, and multiple types of faults repetitively occur to the process during its operation. These characteristics of the data lead to new challenges in the data analytics of MMPs. In this thesis, we conduct three studies to tackle those new challenges from MMPs. In the first study, we propose a feature ranking scheme that ranks the process features based on their relationship with the final product quality. Our ranking scheme is called sparse distance correlation (SpaDC), and it satisfies the important diversity criteria from the engineering perspective and encourages the features that uniquely characterize the manufacturing process to be prioritized. The theoretical properties of SpaDC are studied. Simulations, as well as two real-case studies, are conducted to validate the method. In the second study, we propose a holistic modeling approach for the MMPs, aiming at understanding how intermediate quality measurements of mixed profile outputs relate to sparse effective inputs. This model can identify the effective inputs, output variation patterns, and establish connections between them. Specifically, the aforementioned objective is achieved by formulating and solving an optimization problem that involves the effects of process inputs on the outputs across the entire MMP. This ADMM algorithm that solves this problem is highly parallelizable and thus can handle a large amount of data of mixed types obtained from MMPs. In the third study, a retrospective analysis method is proposed for multiple functional signals. This method simultaneously identifies when multiple events occur to the system and characterizes how they affect the multiple sensing signals. A problem is formulated using the dictionary learning method, and the solution is obtained by iteratively updating the event signatures and sequences using ADMM algorithms. In the end, the potential extensions to the general interconnect systems are discussed.Ph.D