Fault detection in rotating machinery using acoustic emission

This thesis was submitted for the award of Doctor of Philosophy and was awarded by Brunel University LondonRotating machinery is a critical asset of industrial plants worldwide. Bearings and gearboxes are two of the most common components found in rotating machinery of industrial plants. The malfunction of bearings and gearboxes lead the machine to fail and often these failures occur catastrophically leading to personnel injuries. Therefore it is of high importance to identify the deterioration at an early stage. Among the techniques applied to detect damage in rotating machinery, acoustic emission has been a prevalent field of research for its potential to detect defects at an earlier stage than other more established techniques such as vibration analysis and oil analysis. However, to reliably detect the fault at an early stage de-noising techniques often must be applied to reduce the AE noise generated by neighbouring components and normal component operation. For this purpose a novel signal processing algorithm has been developed combining Wavelet Packets as a pre-processor, Hilbert Transform, Autocorrelation function and Fast Fourier transform. The combination of these techniques allows identification of g repetitive patterns in the AE signal that are attributable to bearing and gear damage. The enhancement for early stage defect detection in bearings and gears provided by this method is beneficial in planning maintenance in advance, reducing machinery down-time and consequently reducing the costs associated with bearing breakdown. The effectiveness of the proposed method has been investigated experimentally using seeded and naturally developed defects in gears and bearings. In addition, research into the optimal Wavelet Packet node that offers the best de-noising results has been performed showing that the 250-750 kHz band gives the best SNR results. The detection of shaft angular misalignment using Acoustic Emission has been investigated and compared with acceleration spectra. The results obtained show enhancements of AE in detection shaft angular misalignment over vibration analysis in SNR and stability with varying operational conditions

Development of new fault detection methods for rotating machines (roller bearings)

Abstract Early fault diagnosis of roller bearings is extremely important for rotating machines, especially for high speed, automatic and precise machines. Many research efforts have been focused on fault diagnosis and detection of roller bearings, since they constitute one the most important elements of rotating machinery. In this study a combination method is proposed for early damage detection of roller bearing. Wavelet packet transform (WPT) is applied to the collected data for denoising and the resulting clean data are break-down into some elementary components called Intrinsic mode functions (IMFs) using Ensemble empirical mode decomposition (EEMD) method. The normalized energy of three first IMFs are used as input for Support vector machine (SVM) to recognize whether signals are sorting out from healthy or faulty bearings. Then, since there is no robust guide to determine amplitude of added noise in EEMD technique, a new Performance improved EEMD (PIEEMD) is proposed to determine the appropriate value of added noise. A novel feature extraction method is also proposed for detecting small size defect using Teager-Kaiser energy operator (TKEO). TKEO is applied to IMFs obtained to create new feature vectors as input data for one-class SVM. The results of applying the method to acceleration signals collected from an experimental bearing test rig demonstrated that the method can be successfully used for early damage detection of roller bearings. Most of the diagnostic methods that have been developed up to now can be applied for the case stationary working conditions only (constant speed and load). However, bearings often work at time-varying conditions such as wind turbine supporting bearings, mining excavator bearings, vehicles, robots and all processes with run-up and run-down transients. Damage identification for bearings working under non-stationary operating conditions, especially for early/small defects, requires the use of appropriate techniques, which are generally different from those used for the case of stationary conditions, in order to extract fault-sensitive features which are at the same time insensitive to operational condition variations. Some methods have been proposed for damage detection of bearings working under time-varying speed conditions. However, their application might increase the instrumentation cost because of providing a phase reference signal. Furthermore, some methods such as order tracking methods still can be applied when the speed variation is limited. In this study, a novel combined method based on cointegration is proposed for the development of fault features which are sensitive to the presence of defects while in the same time they are insensitive to changes in the operational conditions. It does not require any additional measurements and can identify defects even for considerable speed variations. The signals acquired during run-up condition are decomposed into IMFs using the performance improved EEMD method. Then, the cointegration method is applied to the intrinsic mode functions to extract stationary residuals. The feature vectors are created by applying the Teager-Kaiser energy operator to the obtained stationary residuals. Finally, the feature vectors of the healthy bearing signals are utilized to construct a separating hyperplane using one-class support vector machine. Eventually the proposed method was applied to vibration signals measured on an experimental bearing test rig. The results verified that the method can successfully distinguish between healthy and faulty bearings even if the shaft speed changes dramatically

30th International Conference on Condition Monitoring and Diagnostic Engineering Management (COMADEM 2017)

Proceedings of COMADEM 201

Acoustic Condition Monitoring & Fault Diagnostics for Industrial Systems

Condition monitoring and fault diagnostics for industrial systems is required for cost reduction, maintenance scheduling, and reducing system failures. Catastrophic failure usually causes significant damage and may cause injury or fatality, making early and accurate fault diagnostics of paramount importance. Existing diagnostics can be improved by augmenting or replacing with acoustic measurements, which have proven advantages over more traditional vibration measurements including, earlier detection of emerging faults, increased diagnostic accuracy, remote sensors and easier setup and operation. However, industry adoption of acoustics remains in relative infancy due to vested confidence and reliance on existing measurement and, perceived difficulties with noise contamination and diagnostic accuracy. Researched acoustic monitoring examples typically employ specialist surface-mount transducers, signal amplification, and complex feature extraction and machine learning algorithms, focusing on noise rejection and fault classification. Usually, techniques are fine-tuned to maximise diagnostic performance for the given problem. The majority investigate mechanical fault modes, particularly Roller Element Bearings (REBs), owing to the mechanical impacts producing detectable acoustic waves. The first contribution of this project is a suitability study into the use of low-cost consumer-grade acoustic sensors for fault diagnostics of six different REB health conditions, comparing against vibration measurements. Experimental results demonstrate superior acoustic performance throughout but particularly at lower rotational speed and axial load. Additionally, inaccuracies caused by dynamic operational parameters (speed in this case), are minimised by novel multi-Support Vector Machine training. The project then expands on existing work to encompass diagnostics for a previously unreported electrical fault mode present on a Brush-Less Direct Current motor drive system. Commonly studied electrical faults, such as a broken rotor bar or squirrel cage, result from mechanical component damage artificially seeded and not spontaneous. Here, electrical fault modes are differentiated as faults caused by issues with the power supply, control system or software (not requiring mechanical damage or triggering intervention). An example studied here is a transient current instability, generated by non-linear interaction of the motor electrical parameters, parasitic components and digital controller realisation. Experimental trials successfully demonstrate real-time feature extraction and further validate consumer-grade sensors for industrial system diagnostics. Moreover, this marks the first known diagnosis of an electrically-seeded fault mode as defined in this work. Finally, approaching an industry-ready diagnostic system, the newly released PYNQ-Z2 Field Programmable Gate Array is used to implement the first known instance of multiple feature extraction algorithms that operate concurrently in continuous real-time. A proposed deep-learning algorithm can analyse the features to determine the optimum feature extraction combination for ongoing continuous monitoring. The proposed black-box, all-in-one solution, is capable of accurate unsupervised diagnostics on almost any application, maintaining excellent diagnostic performance. This marks a major leap forward from fine-tuned feature extraction performed offline for artificially seeded mechanical defects to multiple real-time feature extraction demonstrated on a spontaneous electrical fault mode with a versatile and adaptable system that is low-cost, readily available, with simple setup and operation. The presented concept represents an industry-ready all-in-one acoustic diagnostic solution, that is hoped to increase adoption of acoustic methods, greatly improving diagnostics and minimising catastrophic failures

Unsupervised Methods for Condition-Based Maintenance in Non-Stationary Operating Conditions

Maintenance and operation of modern dynamic engineering systems requires the use of robust maintenance strategies that are reliable under uncertainty. One such strategy is condition-based maintenance (CBM), in which maintenance actions are determined based on the current health of the system. The CBM framework integrates fault detection and forecasting in the form of degradation modeling to provide real-time reliability, as well as valuable insight towards the future health of the system. Coupled with a modern information platform such as Internet-of-Things (IoT), CBM can deliver these critical functionalities at scale. The increasingly complex design and operation of engineering systems has introduced novel problems to CBM. Characteristics of these systems - such as the unavailability of historical data, or highly dynamic operating behaviour - has rendered many existing solutions infeasible. These problems have motivated the development of new and self-sufficient - or in other words - unsupervised CBM solutions. The issue, however, is that many of the necessary methods required by such frameworks have yet to be proposed within the literature. Key gaps pertaining to the lack of suitable unsupervised approaches for the pre-processing of non-stationary vibration signals, parameter estimation for fault detection, and degradation threshold estimation, need to be addressed in order to achieve an effective implementation. The main objective of this thesis is to propose set of three novel approaches to address each of the aforementioned knowledge gaps. A non-parametric pre-processing and spectral analysis approach, termed spectral mean shift clustering (S-MSC) - which applies mean shift clustering (MSC) to the short time Fourier transform (STFT) power spectrum for simultaneous de-noising and extraction of time-varying harmonic components - is proposed for the autonomous analysis of non-stationary vibration signals. A second pre-processing approach, termed Gaussian mixture model operating state decomposition (GMM-OSD) - which uses GMMs to cluster multi-modal vibration signals by their respective, unknown operating states - is proposed to address multi-modal non-stationarity. Applied in conjunction with S-MSC, these two approaches form a robust and unsupervised pre-processing framework tailored to the types of signals found in modern engineering systems. The final approach proposed in this thesis is a degradation detection and fault prediction framework, termed the Bayesian one class support vector machine (B-OCSVM), which tackles the key knowledge gaps pertaining to unsupervised parameter and degradation threshold estimation by re-framing the traditional fault detection and degradation modeling problem as a degradation detection and fault prediction problem. Validation of the three aforementioned approaches is performed across a wide range of machinery vibration data sets and applications, including data obtained from two full-scale field pilots located at Toronto Pearson International Airport. The first of which is located on the gearbox of the LINK Automated People Mover (APM) train at Toronto Pearson International Airport; and, the second which is located on a subset of passenger boarding tunnel pre-conditioned air units (PCA) in Terminal 1 of Pearson airport. Results from validation found that the proposed pre-processing approaches and combined pre-processing framework provides a robust and computationally efficient and robust methodology for the analysis of non-stationary vibration signals in unsupervised CBM. Validation of the B-OCSVM framework showed that the proposed parameter estimation approaches enables the earlier detection of the degradation process compared to existing approaches, and the proposed degradation threshold provides a reasonable estimate of the fault manifestation point. Holistically, the approaches proposed in thesis provide a crucial step forward towards the effective implementation of unsupervised CBM in complex, modern engineering systems

Bearing condition monitoring using acoustic emission and vibration: The systems approach

This thesis was submitted for the degree of Doctor of Philosophy and was awarded by Brunel University.This thesis proposes a bearing condition monitoring system using acceleration and acoustic emission (AE) signals. Bearings are perhaps the most omnipresent machine elements and their condition is often critical to the success of an operation or process. Consequently, there is a great need for a timely knowledge of the health status of bearings. Generally, bearing monitoring is the prediction of the component's health or status based on signal detection, processing and classification in order to identify the causes of the problem. As the monitoring system uses both acceleration and acoustic emission signals, it is considered a multi-sensor system. This has the advantage that not only do the two sensors provide increased reliability they also permit a larger range of rotating speeds to be monitored successfully. When more than one sensor is used, if one fails to work properly the other is still able to provide adequate monitoring. Vibration techniques are suitable for higher rotating speeds whilst acoustic emission techniques for low rotating speeds. Vibration techniques investigated in this research concern the use of the continuous wavelet transform (CWT), a joint time- and frequency domain method, This gives a more accurate representation of the vibration phenomenon than either time-domain analysis or frequency- domain analysis. The image processing technique, called binarising, is performed to produce binary image from the CWT transformed image in order to reduce computational time for classification. The back-propagation neural network (BPNN) is used for classification. The AE monitoring techniques investigated can be categorised, based on the features used, into: 1) the traditional AE parameters of energy, event duration and peak amplitude and 2) the statistical parameters estimated from the Weibull distribution of the inter-arrival times of AE events in what is called the STL method. Traditional AE parameters of peak amplitude, energy and event duration are extracted from individual AE events. These events are then ordered, selected and normalised before the selected events are displayed in a three-dimensional Cartesian feature space in terms of the three AE parameters as axes. The fuzzy C-mean clustering technique is used to establish the cluster centres as signatures for different machine conditions. A minimum distance classifier is then used to classify incoming AE events into the different machine conditions. The novel STL method is based on the detection of inter-arrival times of successive AE events. These inter-arrival times follow a Weibull distribution. The method provides two parameters: STL and L63 that are derived from the estimated Weibull parameters of the distribution's shape (y), characteristic life (0) and guaranteed life (to). It is found that STL and 43 are related hyperbolically. In addition, the STL value is found to be sensitive to bearing wear, the load applied to the bearing and the bearing rotating speed. Of the three influencing factors, bearing wear has the strongest influence on STL and L63. For the proposed bearing condition monitoring system to work, the effects of load and speed on STL need to be compensated. These issues are resolved satisfactorily in the project.Royal Thai government and the Department of Physics, Faculty of Science, Chulalongkorn Universit

Diagnosis of low-speed bearings via vibration-based entropy indicators and acoustic emissions

Tesi del Pla de doctorat industrial de la Generalitat de Catalunya. Tesi en modalitat compendi de publicacions, amb diferents seccions retallades per drets dels editorsWind energy is one ofthe main renewable energies to replace fossil fuels in the generation of electricityworldwide. To enhance and accelerate its implementation at a large scale, it is vital to reduce the costs associated with maintenance. As com ponent breakages force the turbine to stop for long repair times, the wind industry m ust switch from the old-fashioned preventive or corrective maintenance to condition-based maintenance (also called predictive maintenance). The condition­based maintenance of pitch bearings is especiallychallenging, as the operating conditions include high mechanical stress and low rotational speed. Since these operating conditions im pact negatively on the results of the standard methods and techniques applied in current condition-based monitoring systems, the condition-based maintenance of pitch bearings is still a challenge. Therefore, this thes is is focused on the research of novel methods and techniques that obtain reliable information on the state of pitch bearings for condition-based maintenance. lnitially, the acknowledgment ofthe state ofthe art is performed to recognize the methods and signals. This step endorses the decision to analyze the vibration signals and acoustic emissions throughout this thesis. Due to the particular operating conditions of pitch bearings, this research states the need to create data sets to replicate the particular operating conditions in a controlled laboratory experiment. As a res ult, a datas et based on vibrations, and a second datas et based on acoustic emissions are generated. The vibration datas et allows the validation of a novel algorithm for the low-speed bearing diagnosis, which is based on the concept of entropy by the definition of Shannon and Rényi. In com parison to the classical methods found in the literature, the diagnosis of low-speed bearings based on entropy-based indicators can extract more reliable information. Moreover, the research of the com bination of several indicators to improve the diagnosis revea Is that the entropy-based indicators can extract more information than regular indicators used in academia. The datas et of acoustic emissions from low-speed bearings helps to contribute to the development of methods for diagnosis. In this research, the analysis of the energyfrom the signals reveals a dependencyon the intensityand the presence of damage. In addition, a relation between the waveform ofthe analyzed energy and the existence of damage is em phas ized.La energía eólica es una de las principales energías renovables consideradas para reemplazar los combustibles fósiles en la generación de electricidad a nivel mundial. Para mejorar y acelerar su implementación a gran escala, es vital reducir los costes asociados con el mantenimiento. Como las roturas de los componentes obligan a la turbina a detenerse durante largos períodos de reparación, la industria eólica necesita cambiar del anticuado mantenimiento preventiv o correctivo al mantenimiento basado en la condición (también llamado mantenimiento predictivo). El mantenimiento basado en la condición de los rodamientos pitch es especialmente desafiante, porque las condiciones de operación incluyen un alto estrés mecánico y bajas velocidades de rotación. Debido a que estas condiciones de operación impactan negativamente en los resultados de los métodos y técnicas estándar aplicados en los sistemas actuales de monitoreo basados en el estado, el mantenimiento basado en el estado de los rodamientos pitch sigue siendo un desafío. Por tanto, esta tesis se centra en la investigación de métodos y técnicas novedosas que obtengan información fiable sobre el estado de los rodamientos pitch para el mantenimiento basado en la condición. Inicialmente, se realiza el reconocimiento del estado del arte para reconocer los métodos y señales utilizados. Este paso avala la decisión de analizar las señales de vibración y las emisiones acústicas a lo largo de esta tesis. Debido a las condiciones de funcionamiento particulares de los rodamientos pitch, esta investigación reconoce la necesidad de crear un conjunto de datos para replicar las condiciones de funcionamiento particulares del rodamiento pitch en una experiencia de laboratorio controlado. Como resultado, se genera un conjunto de datos basado en vibraciones y un segundo conjunto de datos basado en emisiones acústicas. El conjunto de datos de vibraciones permite la validación de un algoritmo novedoso para el diagnóstico de rodamientos de baja velocidad, el cual se basa en el concepto de la entropía según la definición de Shannon y Rényi. En comparación con los métodos clásicos que se encuentran en la literatura, el diagnóstico de rodamientos de baja velocidad basado en indicadores basados en la entropía puede extraer información más confiable. Además, la investigación de la combinación de varios indicadores para mejorar el diagnóstico revela que los indicadores basados en la entropía pueden extraer más información que los indicadores habituales utilizados en la academia. El conjunto de datos de las emisiones acústicas de los rodamientos de baja velocidad ayuda a contribuir al desarrollo de métodos de diagnóstico. En esta investigación, el análisis de la energía de las señales revela una dependencia de la intensidad y la presencia de daño. Además, se enfatiza una relación entre la forma de onda de la energía analizada y la existencia de daño.L'energia eòlica és una de les principals energies renovables considerades per reemplaçar els combustibles fòssils en la generació d'electricitat a nivell mundial. Per millorar i accelerar la seva implementació a gran escala, és vital reduir els costos associats amb el manteniment. Com els trencaments dels components obliguen a la turbina a aturar-se durant llargs períodes de reparació, la industria eòlica necessita canviar de l'antiquat manteniment preventiu o correctiu al manteniment basat en la condició (també anomenat manteniment predictiu). El manteniment basat en la condició dels rodaments de pas és especialment desafiant, perquè les condicions d’operació inclouen un alt estrès mecànic i baixes velocitats de rotació. A causa de que aquestes condicions d’operació impacten negativament en els resultats dels mètodes i tècniques estàndard aplicats en els sistemes actuals de monitorització basats en l'estat, el manteniment basat en l'estat dels rodaments de pas segueix sent un desafiament. Per tant, aquesta tesi se centra en la investigació de mètodes i tècniques noves que obtinguin informació fiable sobre l'estat dels rodaments de pas per al manteniment basat en la condició. Inicialment, es realitza el reconeixement de l'estat de l'art per reconèixer els mètodes i senyals utilitzats. Aquest pas avala la decisió d'analitzar els senyals de vibració i les emissions acústiques al llarg d'aquesta tesi. A causa de les condicions de funcionament particulars dels rodaments de pas, aquesta investigació reconeix la necessitat de crear un conjunt de dades per replicar les condicions de funcionament particulars del rodament de pas en un experiment de laboratori controlat. Com a resultat, es genera un conjunt de dades basat en vibracions i un segon conjunt de dades basat en emissions acústiques. El conjunt de dades de vibracions permet la validació d'un algoritme nou per al diagnòstic de rodaments de baixa velocitat, el qual es basa en el concepte de l'entropia segons la definició de Shannon i Renyi. En comparació amb els mètodes clàssics que es troben a la literatura, el diagnòstic de rodaments de baixa velocitat basat en indicadors basats en l'entropia pot extreure informació més fiable. A més, la investigació de la combinació de diversos indicadors per millorar el diagnòstic revela que els indicadors basats en l'entropia poden extreure més informació que els indicadors habituals utilitzats en la literatura. El conjunt de dades de les emissions acústiques dels rodaments de baixa velocitat ajuda a contribuir al desenvolupament de mètodes de diagnòstic. En aquesta investigació, l’anàlisi de l'energia de les senyals revela una dependència de la intensitat i la presència de dany. A més, s'emfatitza una relació entre la forma d'ona de l'energia analitzada i l’existència de dany.Energia eolikoa mundu mailan elektrizitatea sortu eta erregai fosilak ordezkatzeko energia berriztagarri nagusietako bat da. Eskala handiko ezarpena hobetu eta bizkortzeko, ezinbestekoa da mantentze-lanekin lotutako kostuak murriztea. Osagaien hausturek turbina konponketa-aldi luzeetan gelditzera behartzen dutenez, industria eolikoak mantentze-lan prebentibo edo zuzentzaile zaharkitutik egoeran oinarritutako mantentzelanetara aldatu behar du (mantentze-lan prediktiboa ere esaten zaio). Pitch errodamenduen egoeran oinarritutako mantentzea bereziki desa atzailea da, tentsio mekaniko handiak jasaten baitituzte eta errotazio-abiadura txikietan egoten baitira abian. Operaziobaldintza horiek eragin negatiboa dutenez egoeran oinarritutako egungo monitorizazio sistemetan erabiltzen diren metodo eta teknika estandarren emaitzetan, pitch errodamenduen egoeran oinarritutako mantentze-lanak erronka bat izaten jarraitzen du. Tesi hau egoeran oinarritutako mantenurako pitch errodamenduen egoerari buruzko informazio dagarria lortzen duten metodo eta teknika berritzaileen ikerketan oinarritzen da. Hasieran, teknologiaren egungo egoera aztertzen da, erabilitako metodoak eta seinaleak ezagutzeko. Urrats honek tesi honetan zehar bibrazio-seinaleak eta emisio akustikoak aztertzeko erabakia bermatzen du. Pitch errodamenduen funtzionamendu baldintza bereziak direla eta, ikerketa honek adierazten du beharrezkoa dela datu multzo bat sortzea pitch errodamenduaren funtzionamendu baldintza partikularrak erreplikatzeko laborategi kontrolatuko testuinguru batean. Ondorioz, bibrazioetan oinarritutako datu-multzo bat eta emisio akustikoetan oinarritutako bigarren datu-multzo bat sortzen dira. Bibrazioen datu-multzoak abiadura txikiko errodamenduen diagnostikorako algoritmo berritzaile bat baliozkotzea ahalbidetzen du, zeina entropiaren kontzeptuan oinarritzen baita Shannon eta R enyiren de nizioaren arabera. Literaturan dauden metodo klasikoekin alderatuta, entropian oinarritutako adierazleek abiadura txikiko errodamenduen diagnostikorako informazio dagarriagoa atera dezakete. Gainera, diagnostikoa hobetzeko hainbat adierazleren konbinazioaren ikerketak agerian uzten du entropian oinarritutako adierazleek akademian erabiltzen diren ohiko adierazleek baino informazio gehiago atera dezaketela. Abiadura txikiko errodamenduen emisio akustikoen datu multzoak diagnostiko metodoak garatzen laguntzen du. Ikerketa lan honetan, seinaleen energiaren azterketak intentsitatearekiko eta kaltearen presentziarekiko dependentzia adierazten du. Gainera, aztertutako energiaren uhin-formaren eta kaltearen arteko erlazioa nabarmentzen da.Postprint (published version

Sensors Fault Diagnosis Trends and Applications

Fault diagnosis has always been a concern for industry. In general, diagnosis in complex systems requires the acquisition of information from sensors and the processing and extracting of required features for the classification or identification of faults. Therefore, fault diagnosis of sensors is clearly important as faulty information from a sensor may lead to misleading conclusions about the whole system. As engineering systems grow in size and complexity, it becomes more and more important to diagnose faulty behavior before it can lead to total failure. In the light of above issues, this book is dedicated to trends and applications in modern-sensor fault diagnosis