Rumo a uma metodologia de manutenção preditiva de bombas hidráulicas

Hydraulic pumps, essential elements in water supply systems, are mainly responsible for the high energy consumption associated with these systems. It is, therefore, relevant to keep the pumps running in their best possible conditions in order to avoid further consumption and costs, and also to anticipate possible pump failures. The best strategy to anticipate the occurrence of failures is to implement preventive and predictive maintenance plans, instead of corrective maintenance that is still widely applied. Thus, with the goal of developing a predictive maintenance methodology applied to hydraulic pumps, this dissertation aims to explore and investigate the applicability of two techniques that can be integrated into a maintenance plan: the detection and classification of failures and the estimation of the remaining useful life (RUL) of the pump. To implement the proposed tasks, simulated data and measured data from real systems were used, taken from online data repositories, with values recorded by sensors and with the identified condition of the system. The first technique allowed, through sensor data with the respectively identified faults, to train classification algorithms able to identify failures. In the first of the evaluated case studies, the best of the implemented algorithms identified the failures associated with the pump data with an accuracy of 82.9%, whereas, in the second of the evaluated case studies, the algorithm that presented the best performance obtained an accuracy of 94.6% in identifying the failure mode associated with the pump. The decision tree and ensemble trees algorithms proved to be the most suitable for the studied purpose. The second technique allowed to estimate RUL values from sensor data recorded from normal operation to system failure. Although the first RUL implemented case study was an engine, the second case study was a water pump. The methodology of the RUL model proved to be relevant because it managed, even with some deviations from the true values, to estimate acceptable values of RUL. An economic analysis was also carried out, highlighting the relevance of applying RUL estimation models in predictive maintenance methodologies for hydraulic pumpsAs bombas hidráulicas, elementos essenciais nos sistemas de abastecimento de água, são os principais responsáveis pelos elevados consumos energéticos associados a estes sistemas. Torna-se, portanto, relevante manter as bombas a funcionar nas suas melhores condições possíveis de forma a evitar mais consumos e custos, e também antecipar possíveis falhas nas bombas. A melhor estratégia para antecipar o acontecimento de falhas passa pela implementação de planos de manutenção preventivos e preditivos, ao invés da manutenção corretiva que é ainda muito aplicada. Assim, com vista ao desenvolvimento de uma metodologia de manutenção preditiva aplicada às bombas hidráulicas, esta dissertação tem como objetivo a exploração e investigação da aplicabilidade de duas técnicas que podem ser integradas num plano de manutenção: a deteção e classificação de falhas e a estimativa do tempo de vida útil restante (RUL) de uma bomba. Para implementar as tarefas propostas utilizaram-se dados simulados e dados medidos a partir de sistemas reais, retirados de repositórios de dados online, com valores registados por sensores e com a condição do sistema identificada. A primeira técnica permitiu, através de dados de sensores com as respetivas falhas identificadas, treinar algoritmos de classificação capazes de identificar falhas. No primeiro dos casos de estudo avaliados, o melhor dos algoritmos implementados identificou as falhas associadas aos dados da bomba com uma classificação de desempenho de 82.9%, ao passo que, no segundo dos casos de estudo avaliados, o algoritmo que apresentou melhor desempenho obteve uma classificação de 94.6% na identificação do modo de falha associado à bomba. Os algoritmos de decision trees e ensemble trees demonstraram ser os mais indicados para o propósito estudado. A segunda técnica permitiu calcular previsões de valores do RUL a partir de dados de sensores registados desde uma operação normal até à falha do sistema. Apesar de o primeiro caso de estudo de implementação de RUL ter sido um motor, o segundo caso de estudo foi uma bomba de água. A metodologia do modelo de RUL demonstrou ser pertinente pois conseguiu, ainda que com alguns desvios em relação aos verdadeiros valores, estimar valores aceitáveis de RUL. Elaborou-se ainda uma análise económica que evidencia a relevância em aplicar modelos de cálculo de RUL em metodologias de manutenção preditiva de bombas hidráulicasMestrado em Engenharia Mecânic

Advanced Fault Diagnosis and Health Monitoring Techniques for Complex Engineering Systems

Over the last few decades, the field of fault diagnostics and structural health management has been experiencing rapid developments. The reliability, availability, and safety of engineering systems can be significantly improved by implementing multifaceted strategies of in situ diagnostics and prognostics. With the development of intelligence algorithms, smart sensors, and advanced data collection and modeling techniques, this challenging research area has been receiving ever-increasing attention in both fundamental research and engineering applications. This has been strongly supported by the extensive applications ranging from aerospace, automotive, transport, manufacturing, and processing industries to defense and infrastructure industries

Volume 3 – Conference

We are pleased to present the conference proceedings for the 12th edition of the International Fluid Power Conference (IFK). The IFK is one of the world’s most significant scientific conferences on fluid power control technology and systems. It offers a common platform for the presentation and discussion of trends and innovations to manufacturers, users and scientists. The Chair of Fluid-Mechatronic Systems at the TU Dresden is organizing and hosting the IFK for the sixth time. Supporting hosts are the Fluid Power Association of the German Engineering Federation (VDMA), Dresdner Verein zur Förderung der Fluidtechnik e. V. (DVF) and GWT-TUD GmbH. The organization and the conference location alternates every two years between the Chair of Fluid-Mechatronic Systems in Dresden and the Institute for Fluid Power Drives and Systems in Aachen. The symposium on the first day is dedicated to presentations focused on methodology and fundamental research. The two following conference days offer a wide variety of application and technology orientated papers about the latest state of the art in fluid power. It is this combination that makes the IFK a unique and excellent forum for the exchange of academic research and industrial application experience. A simultaneously ongoing exhibition offers the possibility to get product information and to have individual talks with manufacturers. The theme of the 12th IFK is “Fluid Power – Future Technology”, covering topics that enable the development of 5G-ready, cost-efficient and demand-driven structures, as well as individual decentralized drives. Another topic is the real-time data exchange that allows the application of numerous predictive maintenance strategies, which will significantly increase the availability of fluid power systems and their elements and ensure their improved lifetime performance. We create an atmosphere for casual exchange by offering a vast frame and cultural program. This includes a get-together, a conference banquet, laboratory festivities and some physical activities such as jogging in Dresden’s old town.:Group 8: Pneumatics Group 9 | 11: Mobile applications Group 10: Special domains Group 12: Novel system architectures Group 13 | 15: Actuators & sensors Group 14: Safety & reliabilit

Volume 1 – Symposium

We are pleased to present the conference proceedings for the 12th edition of the International Fluid Power Conference (IFK). The IFK is one of the world’s most significant scientific conferences on fluid power control technology and systems. It offers a common platform for the presentation and discussion of trends and innovations to manufacturers, users and scientists. The Chair of Fluid-Mechatronic Systems at the TU Dresden is organizing and hosting the IFK for the sixth time. Supporting hosts are the Fluid Power Association of the German Engineering Federation (VDMA), Dresdner Verein zur Förderung der Fluidtechnik e. V. (DVF) and GWT-TUD GmbH. The organization and the conference location alternates every two years between the Chair of Fluid-Mechatronic Systems in Dresden and the Institute for Fluid Power Drives and Systems in Aachen. The symposium on the first day is dedicated to presentations focused on methodology and fundamental research. The two following conference days offer a wide variety of application and technology orientated papers about the latest state of the art in fluid power. It is this combination that makes the IFK a unique and excellent forum for the exchange of academic research and industrial application experience. A simultaneously ongoing exhibition offers the possibility to get product information and to have individual talks with manufacturers. The theme of the 12th IFK is “Fluid Power – Future Technology”, covering topics that enable the development of 5G-ready, cost-efficient and demand-driven structures, as well as individual decentralized drives. Another topic is the real-time data exchange that allows the application of numerous predictive maintenance strategies, which will significantly increase the availability of fluid power systems and their elements and ensure their improved lifetime performance. We create an atmosphere for casual exchange by offering a vast frame and cultural program. This includes a get-together, a conference banquet, laboratory festivities and some physical activities such as jogging in Dresden’s old town.:Group A: Materials Group B: System design & integration Group C: Novel system solutions Group D: Additive manufacturing Group E: Components Group F: Intelligent control Group G: Fluids Group H | K: Pumps Group I | L: Mobile applications Group J: Fundamental

Predictive Maintenance Support System in Industry 4.0 Scenario

The fourth industrial revolution that is being witnessed nowadays, also known as Industry 4.0, is heavily related to the digitization of manufacturing systems and the integration of different technologies to optimize manufacturing. By combining data acquisition using specific sensors and machine learning algorithms to analyze this data and predict a failure before it happens, Predictive Maintenance is a critical tool to implement towards reducing downtime due to unpredicted stoppages caused by malfunctions. Based on the reality of Commercial Specialty Tires factory at Continental Mabor - Indústria de Pneus, S.A., the present work describes several problems faced regarding equipment maintenance. Taking advantage of the information gathered from studying the processes incorporated in the factory, it is designed a solution model for applying predictive maintenance in these processes. The model is divided into two primary layers, hardware, and software. Concerning hardware, sensors and respective applications are delineated. In terms of software, techniques of data analysis namely machine learning algorithms are described so that the collected data is studied to detect possible failures

Neurofuzzy controller based full vehicle nonlinear active suspension systems

To design a robust controller for active suspension systems is very important for guaranteeing the riding comfort for passengers and road handling quality for a vehicle. In this thesis, the mathematical model of full vehicle nonlinear active suspension systems with hydraulic actuators is derived to take into account all the motions of the vehicle and the nonlinearity behaviours of the active suspension system and hydraulic actuators. Four robust control types are designed and the comparisons among the robustness of those controllers against different disturbance types are investigated to select the best controller among them. The MATLAB SIMULINK toolboxes are used to simulate the proposed controllers with the controlled model and to display the responses of the controlled model under different types of disturbance. The results show that the neurofuzzy controller is more effective and robust than the other controller types. The implementation of the neurofuzzy controller using FPGA boards has been investigated in this work. The Xilinx ISE program is employed to synthesis the VHDL codes that describe the operation of the neurofuzzy controller and to generate the configuration file used to program the FPGA. The ModelSim program is used to simulate the operation of the VHDL codes and to obtain the expected output data of the FPGA boards. To confirm that FPGA the board used as the neurofuzzy controller system operated as expected, a MATLAB script file is used to compare the set of data obtained from the ModelSim program and the set of data obtained from the MATLAB SIMULINK model. The results show that the FPGA board is effective to be used as a neurofuzzy controller for full vehicle nonlinear active suspension systems. The active suspension system has a great performance for vibration isolation. However the main drawback of the active suspension is that it is high energy consumptive. Therefore, to use this suspension system in the proposed model, this drawback should be solved. Electromagnetic actuators are used to convert the vibration energy that arises from the rough road to useful electrical energy to reduce the energy consumption by the active suspension systems. The results show that the electromagnetic devices act as a power generator, i.e. the vibration energy excited by the rough road surface has been converted to a useful electrical energy supply for the actuators. Furthermore, when the nonlinear damper models are replaced by the electromagnetic actuators, riding comfort and the road handling quality are improved. As a result, two targets have been achieved by using hydraulic actuators with electromagnetic suspension systems: increasing fuel economy and improving the vehicle performance

Applied Mathematics to Mechanisms and Machines

This book brings together all 16 articles published in the Special Issue "Applied Mathematics to Mechanisms and Machines" of the MDPI Mathematics journal, in the section “Engineering Mathematics”. The subject matter covered by these works is varied, but they all have mechanisms as the object of study and mathematics as the basis of the methodology used. In fact, the synthesis, design and optimization of mechanisms, robotics, automotives, maintenance 4.0, machine vibrations, control, biomechanics and medical devices are among the topics covered in this book. This volume may be of interest to all who work in the field of mechanism and machine science and we hope that it will contribute to the development of both mechanical engineering and applied mathematics

Advancements in Hydropower Design and Operation for Present and Future Electrical Demand

With current infrastructure, meeting the ever-growing demand for electrical energy across the globe is becoming increasingly difficult. The widespread adoption of both commercial and residential non-dispatchable renewable energy facilities, such as solar and wind, further taxes the stability of the electrical grid, often causing traditional fossil fuel power plants to operate at lower efficiency, and with increased carbon emissions. Hydropower, as a proven renewable energy technology, has a significant part to play in the future global electrical power market, especially as increasing demand for electric vehicles will further amplify the need for dispatchable energy sources during peak charging times. Even with more than a century of proven experience, significant opportunities still exist to expand the worldwide hydropower resources and more efficiently utilize existing hydropower installations. Given this context, this Special Issue of Energies intended to present recent developments and advancements in hydropower design and operation. This Special Issue includes five articles, authored by international research teams from Japan, Pakistan, Sweden, Norway, the United States, and China. The authors bring the collective expertise of government research laboratories, university professors, industry research engineers, computer scientists, and economists. The articles explore advancements in hydroturbine and pump-turbine design, power plant operation, auxiliary equipment design to mitigate environmental damage, and an exploration of community-owned small hydropower facilities