Diagnostics of gear faults based on EMD and automatic selection of intrinsic mode functions

Signal processing is an important tool for diagnostics of mechanical systems. Many different techniques are available to process experimental signals, among others: FFT, wavelet transform, cepstrum, demodulation analysis, second order ciclostationarity analysis, etc. However, often hypothesis about data and computational efforts restrict the application of some techniques. In order to overcome these limitations, the empirical mode decomposition has been proposed. The outputs of this adaptive approach are the intrinsic mode functions that are treated with the Hilbert transform in order to obtain the Hilbert–Huang spectrum. Anyhow, the selection of the intrinsic mode functions used for the calculation of Hilbert–Huang spectrum is normally done on the basis of user’s experience. On the contrary, in the paper a merit index is introduced that allows the automatic selection of the intrinsic mode functions that should be used. The effectiveness of the improvement is proven by the result of the experimental tests presented and performed on a test-rig equipped with a spiral bevel gearbox, whose high contact ratio made difficult to diagnose also serious damages of the gears. This kind of gearbox is normally never employed for benchmarking diagnostics techniques. By using the merit index, the defective gearbox is always univocally identified, also considering transient operating conditions

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

Proceedings of COMADEM 201

Design of an intelligent embedded system for condition monitoring of an industrial robot

PhD ThesisIndustrial robots have long been used in production systems in order to improve productivity, quality and safety in automated manufacturing processes. There are significant implications for operator safety in the event of a robot malfunction or failure, and an unforeseen robot stoppage, due to different reasons, has the potential to cause an interruption in the entire production line, resulting in economic and production losses. Condition monitoring (CM) is a type of maintenance inspection technique by which an operational asset is monitored and the data obtained is analysed to detect signs of degradation, diagnose the causes of faults and thus reduce maintenance costs. So, the main focus of this research is to design and develop an online, intelligent CM system based on wireless embedded technology to detect and diagnose the most common faults in the transmission systems (gears and bearings) of the industrial robot joints using vibration signal analysis. To this end an old, but operational, PUMA 560 robot was utilized to synthesize a number of different transmission faults in one of the joints (3 - elbow), such as backlash between the gear pair, gear tooth and bearing faults. A two-stage condition monitoring algorithm is proposed for robot health assessment, incorporating fault detection and fault diagnosis. Signal processing techniques play a significant role in building any condition monitoring system, in order to determine fault-symptom relationships, and detect abnormalities in robot health. Fault detection stage is based on time-domain signal analysis and a statistical control chart (SCC) technique. For accurate fault diagnosis in the second stage, a novel implementation of a time-frequency signal analysis technique based on the discrete wavelet transform (DWT) is adopted. In this technique, vibration signals are decomposed into eight levels of wavelet coefficients and statistical features, such as standard deviation, kurtosis and skewness, are obtained at each level and analysed to extract the most salient feature related to faults; the artificial neural network (ANN) is then used for fault classification. A data acquisition system based on National Instruments (NI) software and hardware was initially developed for preliminary robot vibration analysis and feature extraction. The transmission faults induced in the robot can change the captured vibration spectra, and the robot’s natural frequencies were established using experimental modal analysis, and also the fundamental fault frequencies for the gear transmission and bearings were obtained and utilized for preliminary robot condition monitoring. In addition to simulation of different levels of backlash fault, gear tooth and bearing faults which have not been previously investigated in industrial robots, with several levels of ii severity, were successfully simulated and detected in the robot’s joint transmission. The vibration features extracted, which are related to the robot healthy state and different fault types, using the data acquisition system were subsequently used in building the SCC and ANN, which were trained using part of the measured data set that represents the robot operating range. Another set of data, not used within the training stage, was then utilized for validation. The results indicate the successful detection and diagnosis of faults using the key extracted parameters. A wireless embedded system based on the ZigBee communication protocol was designed for the application of the proposed CM algorithm in real-time, using an Arduino DUE as the core of the wireless sensor unit attached on the robot arm. A Texas Instruments digital signal processor (TMS320C6713 DSK board) was used as the base station of the wireless system on which the robot’s fault diagnosis algorithm is run. To implement the two stages of the proposed CM algorithm on the designed embedded system, software based on the C programming language has been developed. To demonstrate the reliability of the designed wireless CM system, experimental validations were performed, and high reliability was shown in the detection and diagnosis of several seeded faults in the robot. Optimistically, the established wireless embedded system could be envisaged for fault detection and diagnostics on any type of rotating machine, with the monitoring system realized using vibration signal analysis. Furthermore, with some modifications to the system’s hardware and software, different CM techniques such as acoustic emission (AE) analysis or motor current signature analysis (MCSA), can be applied.Iraqi government, represented by the Ministry of Higher Education and Scientific Research, the Iraqi Cultural Attaché in London, and the University of Technology in Baghda

Acquisition and processing of new data sources for improved condition monitoring of mechanical systems

190 p.Este trabajo está centrado en el desarrollo de nuevas formas de monitorización en línea del estado de salud de sistemas mecánicos mediante tecnologías poco utilizadas hasta ahora en este campo. En particular, se han investigado el uso de la monitorización de la viscosidad del aceite lubricante y la tecnología de análisis de las características de la corriente que alimenta el motor para obtener conocimiento sobre el estado de las cajas de engranajes. Por un lado, se presenta una nueva solución basada en materiales magnetoelásticos para la monitorización de la viscosidad del aceite lubricante. Por el otro, el análisis de la corriente alimentación del motor (MCSA por sus siglas en inglés) se presenta como alternativa de los acelerómetros tradicionales para la monitorización de anomalías mecánicas.En particular, se ha desarrollado un sensor magnetoelástico de viscosidad cinemática para mediciones en línea. La principal ventaja del sensor propuesto es su capacidad de medir en una amplia gama de valores de viscosidad (desde 32 cSt hasta 320 cSt). No se conoce ningún otro sensor equivalente comercialmente disponible con un rango similar.Con respecto al análisis de las características de la corriente de alimentación del motor (MCSA), el objetivo de la Tesis es poder diseñar un sistema para monitorizar una caja de engranajes en funcionamiento normal. En este sentido, se ha abordado el análisis de transitorios de velocidad, manteniendo la carga fija. Se ha utilizado un banco de pruebas de cajas de engranajes para reproducir diferentes fallos y adquirir datos en diferentes condiciones de operación

Acquisition and processing of new data sources for improved condition monitoring of mechanical systems

190 p.Este trabajo está centrado en el desarrollo de nuevas formas de monitorización en línea del estado de salud de sistemas mecánicos mediante tecnologías poco utilizadas hasta ahora en este campo. En particular, se han investigado el uso de la monitorización de la viscosidad del aceite lubricante y la tecnología de análisis de las características de la corriente que alimenta el motor para obtener conocimiento sobre el estado de las cajas de engranajes. Por un lado, se presenta una nueva solución basada en materiales magnetoelásticos para la monitorización de la viscosidad del aceite lubricante. Por el otro, el análisis de la corriente alimentación del motor (MCSA por sus siglas en inglés) se presenta como alternativa de los acelerómetros tradicionales para la monitorización de anomalías mecánicas.En particular, se ha desarrollado un sensor magnetoelástico de viscosidad cinemática para mediciones en línea. La principal ventaja del sensor propuesto es su capacidad de medir en una amplia gama de valores de viscosidad (desde 32 cSt hasta 320 cSt). No se conoce ningún otro sensor equivalente comercialmente disponible con un rango similar.Con respecto al análisis de las características de la corriente de alimentación del motor (MCSA), el objetivo de la Tesis es poder diseñar un sistema para monitorizar una caja de engranajes en funcionamiento normal. En este sentido, se ha abordado el análisis de transitorios de velocidad, manteniendo la carga fija. Se ha utilizado un banco de pruebas de cajas de engranajes para reproducir diferentes fallos y adquirir datos en diferentes condiciones de operación

An Investigation into Vibration Based Techniques for Wind Turbine Blades Condition Monitoring

The rapid expansion of wind power has been accompanied by reported reliability problems and the aim is to provide a means of increasing wind turbine reliability, prevent break downs, increase availability and reduce maintenance costs and power outages. This research work reports the development of condition monitoring (CM) for early fault detection in wind turbine blades based on vibration measurements. The research started with a background and a survey of methods used for monitoring wind turbines. Then, finite element modelling (FEM) of three bladed horizontal axis wind turbine (HAWT) was developed to understand the nature and mechanism of the induced vibration. A HAWT test rig was constructed and equipped with computerised vibration measuring system for model verification. Statistical and spectral processing parameters then were used to analyse vibration signals that collected in healthy and faulty cases. Results obtained using time and frequency based techniques are not suitable for extracting blades condition related information. Consequently, empirical mode decomposition method (EMD), principal component analysis method (PCA) and continuous wavelet transform (CWT) are applied for extraction blade condition related features from the measured vibration. The result showed that although these methods generally proved their success in other fields, they have failed to detect small faults or changes in blade structure. Therefore, new techniques were developed using the above mentioned methods combined with feature intensity level (FIL) and crest factor. Namely, those are EDFIL, RMPCA and wavelet based FIL. The new techniques are found to be reliable, robust and sensitive to the severity of faults. Those analysis techniques are suitable to be the detection tool for an integrated wind turbine condition monitoring system. Directions for future work are also given at the end of the thesis

Transfer Learning Based Fault Detection for Suspension System Using Vibrational Analysis and Radar Plots

The suspension system is of paramount importance in any automobile. Thanks to the suspension system, every journey benefits from pleasant rides, stable driving and precise handling. However, the suspension system is prone to faults that can significantly impact the driving quality of the vehicle. This makes it essential to find and diagnose any faults in the suspension system and rectify them immediately. Numerous techniques have been used to identify and diagnose suspension faults, each with drawbacks. This paper’s proposed suspension fault detection system aims to detect these faults using deep transfer learning techniques instead of the time-consuming and expensive conventional methods. This paper used pre-trained networks such as Alex Net, ResNet-50, Google Net and VGG16 to identify the faults using radar plots of the vibration signals generated by the suspension system in eight cases. The vibration data were acquired using an accelerometer and data acquisition system placed on a test rig for eight different test conditions (seven faulty, one good). The deep learning model with the highest accuracy in identifying and detecting faults among the four models was chosen and adopted to find defects. The results state that VGG16 produced the highest classification accuracy of 96.70%

A new fault diagnosis algorithm for helical gears rotating at low speed using an optical encoder

Helical gears are widely used in gearboxes due to its low noise and high load carrying capacity, but it is difficult to diagnose their early faults based on the signals produced by condition monitoring systems, particularly when the gears rotate at low speed. In this paper, a new concept of Root Mean Square (RMS) value calculation using angle domain signals within small angular ranges is proposed. With this concept, a new diagnosis algorithm based on the time pulses of an encoder is developed to overcome the difficulty of fault diagnosis for helical gears at low rotational speeds. In this proposed algorithm, both acceleration signals and encoder impulse signal are acquired at the same time. The sampling rate and data length in angular domain are determined based on the rotational speed and size of the gear. The vibration signals in angular domain are obtained by re-sampling the vibration signal of the gear in the time domain according to the encoder pulse signal. The fault features of the helical gear at low rotational speed are then obtained with reference to the RMS values in small angular ranges and the order tracking spectrum following the Angular Domain Synchronous Average processing (ADSA). The new algorithm is not only able to reduce the noise and improves the signal to noise ratio by the ADSA method, but also extract s the features of helical gear fault from the meshing position of the faulty gear teeth, hence overcoming the difficulty of fault diagnosis of helical gears rotating at low speed. The experimental results have shown that the new algorithm is more effective than traditional diagnosis methods. The paper concludes that the proposed helical gear fault diagnosis method based on time pulses of encoder algorithm provides a new means of helical gear fault detection and diagnosis

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

Wind turbine fault detection and identification through PCA-based optimal variable selection

An effective condition monitoring system of wind turbines generally requires installation of a high number of sensors and use of a high sampling frequency in particular for monitoring of the electrical components within a turbine, resulting in a large amount of data. This can become a burden for condition monitoring and fault detection systems. This paper aims to develop algorithms that will allow a reduced dataset to be used in wind turbine fault detection. The paper firstly proposes a variable selection algorithm based on principal component analysis (PCA) with multiple selection criteria in order to select a set of variables to target fault signals while still preserving the variation of data in the original dataset. With the selected variables, the paper then describes fault detection and identification algorithms, which can identify faults, determine the corresponding time and location where the fault occurs, and estimate its severity. The proposed algorithms are evaluated with simulation data from PSCAD/EMTDC, SCADA (Supervisory control and data acquisition) data from an operational wind farm, and experimental data from a wind turbine test rig. Results show that the proposed methods can select a reduced set of variables with minimal information lost whilst detecting faults efficiently and effectively