Application of Audible Signals in Tool Condition Monitoring using Machine Learning Techniques

Machining is always accompanied by many difficulties like tool wear, tool breakage, improper machining conditions, non-uniform workpiece properties and some other irregularities, which are some of major barriers to highly-automated operations. Effective tool condition monitoring (TCM) system provides a best solution to monitor those irregular machining processes and suggest operators to take appropriate actions. Even though a wide variety of monitoring techniques have been developed for the online detection of tool condition, it remains an unsolved problem to look for a reliable, simple and cheap solution. This research work mainly focuses on developing a real-time tool condition monitoring model to detect the tool condition, part quality in machining process by using machine learning techniques through sound monitoring. The present study shows the development of a process model capable of on-line process monitoring utilizing machine learning techniques to analyze the sound signals collected during machining and train the proposed system to predict the cutting phenomenon during machining. A decision-making system based on the machine learning technique involving Support Vector Machine approach is developed. The developed system is trained with pre-processed data and tested, and the system showed a significant prediction accuracy in different applications which proves to be an effective model in applying to machining process as an on-line process monitoring system. In addition, this system also proves to be effective, cheap, compact and sensory position invariant. The successful development of the proposed TCM system can provide a practical tool to reduce downtime for tool changes and minimize the amount of scrap in metal cutting industry

Condition Monitoring and Fault Diagnosis of Roller Element Bearing

Rolling element bearings play a crucial role in determining the overall health condition of a rotating machine. An effective condition-monitoring program on bearing operation can improve a machine’s operation efficiency, reduce the maintenance/replacement cost, and prolong the useful lifespan of a machine. This chapter presents a general overview of various condition-monitoring and fault diagnosis techniques for rolling element bearings in the current practice and discusses the pros and cons of each technique. The techniques introduced in the chapter include data acquisition techniques, major parameters used for bearing condition monitoring, signal analysis techniques, and bearing fault diagnosis techniques using either statistical features or artificial intelligent tools. Several case studies are also presented in the chapter to exemplify the application of these techniques in the data analysis as well as bearing fault diagnosis and pattern recognition

Tool Life Prediction of Ti [C,N] Mixed Alumina Ceramic Cutting Tool Using Gradient Descent Algorithm on Machining Martensitic Stainless Steel

In automated manufacturing systems, most of the manufacturing processes, including machining, are automated. Automatic tool change is one of the important parameters for reducing manufacturing lead time. Machining studies on Martensitic Stainless Steel was conducted using Ti[C,N] mixed alumina ceramic cutting tool. Tool life was evaluated using flank wear criterion. The tool life obtained from experimental machining process was taken as training dataset and test dataset for machine learning. Tool life model was developed using Gradient Descent Algorithm. The accuracy of the machine learning model was tested using the test data, and 99.83% accuracy was obtained

Blind source separation and feature extraction in concurrent control charts pattern recognition: Novel analyses and a comparison of different methods

International audienceControl charts are among the main tools in statistical process control (SPC) and have been extensively used for monitoring industrial processes. Currently, besides the single control charts, there is an interest in the concurrent ones. These graphics are characterized by the simultaneous presence of two or more single control charts. As a consequence, the individual patterns may be mixed, hindering the identification of a non-random pattern acting in the process; this phenomenon is refered as concurrent charts. In view of this problem, our first goal is to investigate the importance of an efficient separation step for pattern recognition. Then, we compare the efficiency of different Blind Source Separation (BSS) methods in the task of unmixing concurrent control charts. Furthermore, these BSS methods are combined with shape and statistical features in order to verify the performance of each one in pattern classification. In additional, the robustness of the better approach is tested in scenarios where there are different non-randomness levels and in cases with imbalanced dataset provided to the classifier. After simulating different patterns and applying several separation methods, the results have shown that the recognition rate is widely influenced by the separation and feature extraction steps and that the selection of efficient separation methods is fundamental to achieve high classification rates

Singular spectrum analysis as a tool for early detection of centrifugal compressor flow instability

Centrifugal compressor machinery is subject to a potentially damaging phenomenon called surge at low mass flow rates. This effect may be preceded by a phenomena known as inlet recirculation — a flow reversal upstream of the impeller. A methodology to isolate inlet recirculation as a characteristic feature for monitoring of centrifugal compressor instability is presented in this study. The methodology is based on a nonparametric time series analysis technique called as singular spectrum analysis (SSA). SSA decomposes a signal into a number of Reconstructive Components (RCs), from which data trends and oscillatory components may be extracted. The frequency spectra of each RC and their relative contributions to the reconstruction of the original signal were examined and comparisons were made with spectral maps in existing literature. Individual and independent RCs were chosen to construct a compressor's instability monitoring system. Additionally, the performance of SSA was determined by the Window length parameter. The effect of modification of this parameter was also studied, and the various viable choices of component for the basis of inlet recirculation diagnosis were considered. The methodology was implemented in pressure dynamical signals measured in an experimental centrifugal compressor rig. High frequency pressure measurements were taken at a number of flow conditions and locations within the compressor. The results demonstrated the potential of a methodology based on SSA to identify and extract oscillatory components with information about the local effect of inlet recirculation and eventually successfully monitor centrifugal compressor's instability

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

Estimation of bearing fault severity in line-connected and inverter-fed three-phase induction motors

Producción CientíficaThis paper addresses a comprehensive evaluation of a bearing fault evolution and its consequent prediction concerning the remaining useful life. The proper prediction of bearing faults in their early stage is a crucial factor for predictive maintenance and mainly for the production management schedule. The detection and estimation of the progressive evolution of a bearing fault are performed by monitoring the amplitude of the current signals at the time domain. Data gathered from line-fed and inverter-fed three-phase induction motors were used to validate the proposed approach. To assess classification accuracy and fault estimation, the models described in this paper are investigated by using Artificial Neural Networks models. The paper also provides process flowcharts and classification tables to present the prognostic models used to estimate the remaining useful life of a defective bearing. Experimental results confirmed the method robustness and provide an accurate diagnosis regardless of the bearing fault stage, motor speed, load level, and type of supply.CAPES (process BEX552269/2011-5)National Council for Scientific and Technological Development (grant #474290/2008-3, #473576/2011-2, #552269/2011-5, #307220/2016-8

Linear friction weld process monitoring of fixture cassette deformations using empirical mode decomposition

Due to its inherent advantages, linear friction welding is a solid-state joining process of increasing importance to the aerospace, automotive, medical and power generation equipment industries. Tangential oscillations and forge stroke during the burn-off phase of the joining process introduce essential dynamic forces, which can also be detrimental to the welding process. Since burn-off is a critical phase in the manufacturing stage, process monitoring is fundamental for quality and stability control purposes. This study aims to improve workholding stability through the analysis of fixture cassette deformations. Methods and procedures for process monitoring are developed and implemented in a fail-or-pass assessment system for fixture cassette deformations during the burn-off phase. Additionally, the de-noised signals are compared to results from previous production runs. The observed deformations as a consequence of the forces acting on the fixture cassette are measured directly during the welding process. Data on the linear friction-welding machine are acquired and de-noised using empirical mode decomposition, before the burn-off phase is extracted. This approach enables a direct, objective comparison of the signal features with trends from previous successful welds. The capacity of the whole process monitoring system is validated and demonstrated through the analysis of a large number of signals obtained from welding experiments

Data Driven Approach to Non-stationary EMA Fault Detection and Investigation Into Remaining Useful Life

Growing interest in using Electromechanical Actuators (EMAs) to replace current hydraulic actuation methods on aircraft control surfaces has driven significant research in the area of prognostics and health management. Non- stationary speeds and loads in the course of controlling an aircraft surface make fault identification in EMAs difficult. This work presents a time- frequency analysis of EMA thrust bearing vibration signals using wavelet transforms. A relatively small EMA system is designed and built to allow for simple, quick, and repeatable component replacement. A simulated signal is developed to test four potential faults in the system. Classification is performed using an artificial neural network (ANN), which yields over 99% accuracy. Indentation faults from moderate and heavy loads are seeded in thrust bearings, which are then tested to generate data. The ANN achieves 95% classification accuracy in a two class scenario using healthy and moderately indented bearings. A three class test is executed using thrust bearings at each level of damage to perform preliminary remaining useful life (RUL) testing, where an ANN is able to identify the fault severity with an accuracy of 88%