Friction, Vibration and Dynamic Properties of Transmission System under Wear Progression

This reprint focuses on wear and fatigue analysis, the dynamic properties of coating surfaces in transmission systems, and non-destructive condition monitoring for the health management of transmission systems. Transmission systems play a vital role in various types of industrial structure, including wind turbines, vehicles, mining and material-handling equipment, offshore vessels, and aircrafts. Surface wear is an inevitable phenomenon during the service life of transmission systems (such as on gearboxes, bearings, and shafts), and wear propagation can reduce the durability of the contact coating surface. As a result, the performance of the transmission system can degrade significantly, which can cause sudden shutdown of the whole system and lead to unexpected economic loss and accidents. Therefore, to ensure adequate health management of the transmission system, it is necessary to investigate the friction, vibration, and dynamic properties of its contact coating surface and monitor its operating conditions

Information Theory and Its Application in Machine Condition Monitoring

Condition monitoring of machinery is one of the most important aspects of many modern industries. With the rapid advancement of science and technology, machines are becoming increasingly complex. Moreover, an exponential increase of demand is leading an increasing requirement of machine output. As a result, in most modern industries, machines have to work for 24 hours a day. All these factors are leading to the deterioration of machine health in a higher rate than before. Breakdown of the key components of a machine such as bearing, gearbox or rollers can cause a catastrophic effect both in terms of financial and human costs. In this perspective, it is important not only to detect the fault at its earliest point of inception but necessary to design the overall monitoring process, such as fault classification, fault severity assessment and remaining useful life (RUL) prediction for better planning of the maintenance schedule. Information theory is one of the pioneer contributions of modern science that has evolved into various forms and algorithms over time. Due to its ability to address the non-linearity and non-stationarity of machine health deterioration, it has become a popular choice among researchers. Information theory is an effective technique for extracting features of machines under different health conditions. In this context, this book discusses the potential applications, research results and latest developments of information theory-based condition monitoring of machineries

Fault Detection in Rotating Machinery: Vibration analysis and numerical modeling

This thesis investigates vibration based machine condition monitoring and consists of two parts: bearing fault diagnosis and planetary gearbox modeling. In the first part, a new rolling element bearing diagnosis technique is introduced. Envelope analysis is one of the most advantageous methods for rolling element bearing diagnostics but finding the suitable frequency band for demodulation has been a substantial challenge for a long time. Introduction of the Spectral Kurtosis (SK) and Kurtogram mostly solved this problem but in situations where signal to noise ratio is very low or in presence of non-Gaussian noise these methods will fail. This major drawback may noticeably decrease their effectiveness and goal of this thesis is to overcome this problem. Vibration signals from rolling element bearings exhibit high levels of 2nd order cyclostationarity, especially in the presence of localized faults. A second-order cyclostationary signal is one whose autocovariance function is a periodic function of time: the proposed method, named Autogram by the authors, takes advantage of this property to enhance the conventional Kurtogram. The method computes the kurtosis of the unbiased autocorrelation (AC) of the squared envelope of the demodulated and undecimated signal, rather than the kurtosis of the filtered time signal. Moreover, to take advantage of unique features of the lower and upper portions of the AC, two modified forms of kurtosis are introduced and the resulting colormaps are called Upper and Lower Autogram. In addition, a new thresholding method is also proposed to enhance the quality of the frequency spectrum analysis. Finally, the proposed method is tested on experimental data and compared with literature results so to assess its performances in rolling element bearing diagnostics. Moreover, a second novel method for diagnosis of rolling element bearings is developed. This approach is a generalized version of the cepstrum pre-whitening (CPW) which is a simple and effective technique for bearing diagnosis. The superior performance of the proposed method has been shown on two real case data. For the first case, the method successfully extracts bearing characteristic frequencies related to two defected bearings from the acquired signal. Moreover, the defect frequency was highlighted in case two, even in presence of strong electromagnetic interference (EMI). The second part presents a newly developed lumped parameter model (LPM) of a planetary gear. Planets bearings of planetary gear sets exhibit high rate of failure; detection of these faults which may result in catastrophic breakdowns have always been challenging. Another objective of this thesis is to investigate the planetary gears vibration properties in healthy and faulty conditions. To seek this goal a previously proposed lumped parameter model (LPM) of planetary gear trains is integrated with a more comprehensive bearing model. This modified LPM includes time varying gear mesh and bearing stiffness and also nonlinear bearing stiffness due to the assumption of Hertzian contact between the rollers/balls and races. The proposed model is completely general and accepts any inner/outer race bearing defect location and profile in addition to its original capacity of modelling cracks and spalls of gears; therefore, various combinations of gears and bearing defects are also applicable. The model is exploited to attain the dynamic response of the system in order to identify and analyze localized faults signatures for inner and outer races as well as rolling elements of planets bearings. Moreover, bearing defect frequencies of inner/outer race and ball/roller and also their sidebands are discussed thoroughly. Finally, frequency response of the system for different sizes of planets bearing faults are compared and statistical diagnostic algorithms are tested to investigate faults presence and growth

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

Proceedings of COMADEM 201

Utilizing the mechanical redundancy of parallel systems for condition monitoring hydraulic pumps in variable operation

This work investigates and develops an approach to resolve some of the unique challenges associated with condition monitoring variable duty equipment. The proposed solution utilizes the mechanical redundancy of parallel systems to create dynamic criterion for detecting incipient faults. In this context, parallel systems are those which contain multiple subsystems (with similar construction) having synchronized operating conditions. This work evaluates the proposed methodology through its application on parallel hydraulic gear pumps. By comparing the dynamic pressure and vibration signal features, it was found that this approach is capable of distinguishing various incipient failures while the pumps were in both stationary and non-stationary operation.Masters of Applied Science (MASc) in Natural Resources Engineerin

A Novel Method for Intelligent Single Fault Detection of Bearings Using SAE and Improved D–S Evidence Theory

In order to realize single fault detection (SFD) from the multi-fault coupling bearing data and further research on the multi-fault situation of bearings, this paper proposes a method based on features self-extraction of a Sparse Auto-Encoder (SAE) and results fusion of improved Dempster–Shafer evidence theory (D–S). Multi-fault signal compression features of bearings were extracted by SAE on multiple vibration sensors’ data. Data sets were constructed by the extracted compression features to train the Support Vector Machine (SVM) according to the rule of single fault detection (R-SFD) this paper proposed. Fault detection results were obtained by the improved D–S evidence theory, which was implemented via correcting the 0 factor in the Basic Probability Assignment (BPA) and modifying the evidence weight by Pearson Correlation Coefficient (PCC). Extensive evaluations of the proposed method on the experiment platform datasets showed that the proposed method could realize single fault detection from multi-fault bearings. Fault detection accuracy increases as the output feature dimension of SAE increases; when the feature dimension reached 200, the average detection accuracy of the three sensors for bearing inner, outer, and ball faults achieved 87.36%, 87.86% and 84.46%, respectively. The three types’ fault detection accuracy—reached to 99.12%, 99.33% and 98.46% by the improved Dempster–Shafer evidence theory (IDS) to fuse the sensors’ results—is respectively 0.38%, 2.06% and 0.76% higher than the traditional D–S evidence theory. That indicated the effectiveness of improving the D–S evidence theory by evidence weight calculation of PCC

An enhanced Teager Huang transform technique for bearing fault detection

Rolling element bearings are widely used in rotating machinery. Bearing health condition monitoring plays a vital role in predictive maintenance to recognize bearing faults at an early stage to prevent machinery performance degradation, improve operation quality, and reduce maintenance costs. Although many signal processing techniques have been proposed in literature for bearing fault diagnosis, reliable bearing fault detection remains challenging. This study aims to develop an online condition monitoring system and a signal processing technique for bearing fault detection. Firstly, a Zigbee-based smart sensor data acquisition system is developed for wireless vibration signal collection. An enhanced Teager-Huang transform (eTHT) technique is proposed for bearing fault detection. The eTHT takes the several processing steps: Firstly, a generalized Teager-Kaiser spectrum analysis method is suggested to recognize the most representative intrinsic mode functions as a reference. Secondly, a characteristic relation function is constructed by using cross-correlation. Thirdly, a denoising filter is adopted to improve the signal-to-noise-ratio. Finally, the average generalized Teager-Kaiser spectrum analysis is undertaken to identify the bearing characteristic signatures for bearing fault detection. The effectiveness of the proposed eTHT technique is examined by experimental tests corresponding to different bearing conditions. Its robustness in bearing fault detection is examined by the use of the data sets from a different experimental setup

On robust statistical outlier analysis for damage identification

This thesis aims to contribute towards the development of reliable and accurate damage detection monitoring frameworks, applicable for a range of structural health and condition monitoring problems. Central to this purpose, is to be able to detect damage patterns embedded in a system's vibration signal responses sufficiently early. This will enable a condition-based maintenance and inspection to be carried out so as to prevent potentially catastrophic events, as related to each application domain. Firstly, to obviate reliance on data labels, an inclusive outlier analysis study is conducted by means of robust multivariate statistical analysis and a range of other (more common) outlier detection techniques, in both multivariate and time-series settings. Given the parametric nature of robust multivariate statistical techniques, it has also been possible to characterise outliers according to their influence on a method's estimates. Secondly, novelty detection is explored, in which a set of samples representing the nominal state of the system, is assumed to be available. This set includes observations from a system with its dynamics being significantly influenced by environmental and operational variability. Finally, this thesis explored the potential of utilising certain robust techniques as a pre-processing step on damage sensitive features (contaminated with outliers) for novelty detection tasks. Given the large volume of observations, both experimental and computational, different damage sensitive features were extracted, some of which were specific to the range of problems / types of damage being investigated. The performance, in terms of both sensitivity in damage detection and immunity to environmental and operational variability, was assessed for each damage sensitive feature, in combination to the outlier and novelty detection technique used. This thesis has introduced to the condition and structural health monitoring fields a range of methods from robust statistics with attractive properties, such as the effective unmasking of outliers