Multiscale analysis of the effect of debris on fretting wear process using a semi-concurrent method

Fretting wear is a phenomenon, in which wear happens between two oscillatory moving contact surfaces in microscale amplitude. In this paper, the effect of debris between pad and specimen is analyzed by using a semi-concurrent multiscale method. Firstly, the macroscale fretting wear model is performed. Secondly, the part with the wear profile is imported from the macroscale model to a microscale model after running in stage. Thirdly, an effective pad's radius is extracted by analyzing the contact pressure in order to take into account the effect of the debris. Finally, the effective radius is up-scaled from the microscale model to the macroscale model, which is used after running in stage. In this way, the effect of debris is considered by changing the radius of the pad in the macroscale model. Due to the smaller number of elements in the microscale model compared with the macroscale model containing the debris layer, the semi-concurrent method proposed in this paper is more computationally efficient. Moreover, the results of this semi-concurrent method show a better agreement with experimental data, compared to the results of the model ignoring the effect of debris

ADEPOS: Anomaly Detection based Power Saving for Predictive Maintenance using Edge Computing

In industry 4.0, predictive maintenance(PM) is one of the most important applications pertaining to the Internet of Things(IoT). Machine learning is used to predict the possible failure of a machine before the actual event occurs. However, the main challenges in PM are (a) lack of enough data from failing machines, and (b) paucity of power and bandwidth to transmit sensor data to cloud throughout the lifetime of the machine. Alternatively, edge computing approaches reduce data transmission and consume low energy. In this paper, we propose Anomaly Detection based Power Saving(ADEPOS) scheme using approximate computing through the lifetime of the machine. In the beginning of the machines life, low accuracy computations are used when the machine is healthy. However, on the detection of anomalies, as time progresses, the system is switched to higher accuracy modes. We show using the NASA bearing dataset that using ADEPOS, we need 8.8X less neurons on average and based on post-layout results, the resultant energy savings are 6.4 to 6.65XComment: Submitted to ASP-DAC 2019, Japa

Fretting : review on the numerical simulation and modelling of wear, fatigue and fracture

This chapter presents a general background and the state of the art of numerical simulation and modeling of fretting phenomenon in terms of wear, fatigue and fracture. First, an introduction of fretting and its implications is exposed. Second, different methodologies for wear modeling and simulation are described and discussed. Afterwards, fatigue and fracture analysis approaches are revised. To that end, multiaxial fatigue parameters are introduced putting an emphasis on the physical basis of the fretting phenomena and the suitability of each model. On the other hand, the propagation phase based on linear elastic fracture mechanics (LEFM) via the finite element method (FEM) and the eXtended finite element method (X-FEM) analysis methods is presented and compared. Finally, different approaches and latest developments for fretting fatigue lifetime prediction are presented and discussed

Machine Learning in Tribology

Tribology has been and continues to be one of the most relevant fields, being present in almost all aspects of our lives. The understanding of tribology provides us with solutions for future technical challenges. At the root of all advances made so far are multitudes of precise experiments and an increasing number of advanced computer simulations across different scales and multiple physical disciplines. Based upon this sound and data-rich foundation, advanced data handling, analysis and learning methods can be developed and employed to expand existing knowledge. Therefore, modern machine learning (ML) or artificial intelligence (AI) methods provide opportunities to explore the complex processes in tribological systems and to classify or quantify their behavior in an efficient or even real-time way. Thus, their potential also goes beyond purely academic aspects into actual industrial applications. To help pave the way, this article collection aimed to present the latest research on ML or AI approaches for solving tribology-related issues generating true added value beyond just buzzwords. In this sense, this Special Issue can support researchers in identifying initial selections and best practice solutions for ML in tribology

Intelligent Condition Monitoring and Prognostic Methods with Applications to Dynamic Seals in the Oil & Gas Industry

The capital-intensive oil & gas industry invests billions of dollars in equipment annually and it is important to keep the equipment in top operating condition to help maintain efficient process operations and improve the rate of return by predicting failures before incidents. Digitalization has taken over the world with advances in sensor technology, wireless communication and computational capabilities, however oil & gas industry has not taken full advantage of this despite being technology centric. Dynamic seals are a vital part of reciprocating and rotary equipment such as compressor, pumps, engines, etc. and are considered most frequently failing component. Polymeric seals are increasingly complex and non-linear in behavior and have been the research of interest since 1950s. Most of the prognostic studies on seals are physics-based and requires direct estimation of different physical parameters to assess the degradation of seals, which are often difficult to obtain during operation. Another feasible approach to predict the failure is from performance related sensor data and is termed as data-driven prognostics. The offline phase of this approach is where the performance related data from the component of interest are acquired, pre-processed and artificial intelligence tools or statistical methods are used to model the degradation of a system. The developed models are then deployed online for a real-time condition monitoring. There is a lack of research on the data-driven based tools and methods for dynamic seal prognosis. The primary goal in this dissertation is to develop offline data-driven intelligent condition monitoring and prognostic methods for two types of dynamic seals used in the oil & gas industry, to avoid fatal breakdown of rotary and reciprocating equipment. Accordingly, the interest in this dissertation lies in developing models to effectively evaluate and classify the running condition of rotary seals; assess the progression of degradation from its incipient to failure and to estimate the remaining useful life (RUL) of reciprocating seals. First, a data-driven prognostic framework is developed to classify the running condition of rotary seals. An accelerated aging and testing procedure simulating rotary seal operation in oil field is developed to capture the behavior of seals through their cycle of operation until failure. The diagnostic capability of torque, leakage and vibration signal in differentiating the health states of rotary seals using experiments are compared. Since the key features that differentiate the health condition of rotary seals are unknown, an extensive feature extraction in time and frequency domain is carried out and a wrapper-based feature selection approach is used to select relevant features, with Multilayer Perceptron neural network utilized as classification technique. The proposed approach has shown that features extracted from torque and leakage lack a better discriminating power on its own, in classifying the running condition of seals throughout its service life. The classifier built using optimal set of features from torque and leakage collectively has resulted in a high classification accuracy when compared to random forest and logistic regression, even for the data collected at a different operating condition. Second, a data-driven approach to predict the degradation process of reciprocating seals based on friction force signal using a hybrid Particle Swarm Optimization - Support Vector Machine is presented. There is little to no knowledge on the feature that reflects the degradation of reciprocating seals and on the application of SVM in predicting the future running condition of polymeric components such as seals. Controlled run-to-failure experiments are designed and performed, and data collected from a dedicated experimental set-up is used to develop the proposed approach. A degradation feature with high monotonicity is used as an indicator of seal degradation. The pseudo nearest neighbor is used to determine the essential number of inputs for forecasting the future trend. The most challenging aspect of tuning parameters in SVM is framed in terms of an optimization problem aimed at minimizing the prediction error. The results indicate the effectiveness and better accuracy of the proposed approach when compared to GA-SVM and XGBoost. Finally, a deep neural network-based approach for estimating remaining useful life of reciprocating seals, using force and leakage signals is presented. Time domain and frequency domain statistical features are extracted from the measurements. An ideal prognostic feature should be well correlated with degradation time, monotonically increasing or decreasing and robust to outliers. The identified metrics namely: monotonicity, correlation and robustness are used to evaluate the goodness of extracted features. Each of the three metric carries a relative importance in the RUL estimation and a weighted linear combination of the metrics are used to rank and select the best set of prognostic features. The redundancy in the selected features is eliminated using Kelley-Gardner-Sutcliffe penalty function-based correlation-clustering algorithm to select a representative feature from each of the clusters. Finally, RUL estimation is modeled using a deep neural network model. Run-to-failure data collected from a reciprocating set-up was used to validate this approach and the findings show that the proposed approach can improve the accuracy of RUL prediction when compared to PSO-SVM and XGBoost regression. This research has important contribution and implications to rotary and reciprocating seal domain in utilizing sensors along with machine learning algorithms in assessing the health state and prognosis of seals without any direct measurements. This research has paved the way to move from a traditional fail-and-fix to predict-and-prevent approach in maintenance of seals. The findings of this research are foundational for developing an online degradation assessment platform which can remotely monitor the performance degradation of seals and provide action recommendations on maintenance decisions. This would be of great interest to customers and oil field operators to improve equipment utilization, control maintenance cost by enabling just-in-time maintenance and increase rate of return on equipment by predicting failures before incidents