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

An investigation of gear meshing behaviour of planetary gear systems for improved fault diagnosis

This research has presented gear dynamic models and associated simulations to improve gear fault detection. These models include the use of finite element and lumped parameter methods for both fixed axis and planetary gear systems. The findings in this research provide an improved understanding of the gear fault mechanism and advance the gear fault detection capability of the whole drive train system. It also suggests further effective ways of monitoring the whole gear train system

Planetary bearing defect detection in a commercial helicopter main gearbox with vibration and acoustic emission

The file attached to this record is the author's final peer reviewed version. The Publisher's final version can be found by following the DOI link.Helicopter gearboxes significantly differ from other transmission types and exhibit unique behaviors that reduce the effectiveness of traditional fault diagnostics methods. In addition, due to lack of redundancy, helicopter transmission failure can lead to catastrophic accidents. Bearing faults in helicopter gearboxes are difficult to discriminate due to the low signal to noise ratio (SNR) in the presence of gear vibration. In addition, the vibration response from the planet gear bearings must be transmitted via a time-varying path through the ring gear to externally mounted accelerometers, which cause yet further bearing vibration signal suppression. This research programme has resulted in the successful proof of concept of a broadband wireless transmission sensor that incorporates power scavenging whilst operating within a helicopter gearbox. In addition, this paper investigates the application of signal separation techniques in detection of bearing faults within the epicyclic module of a large helicopter (CS-29) main gearbox using vibration and Acoustic Emissions (AE). It compares their effectiveness for various operating conditions. Three signal processing techniques including an adaptive filter, spectral kurtosis and envelope analysis, were combined for this investigation. In addition, this research discusses the feasibility of using AE for helicopter gearbox monitoring

An Integrated Framework of Drivetrain Degradation Assessment and Fault Localization for Offshore Wind Turbines

As wind energy proliferates in onshore and offshore applications, it has become significantly important to predict wind turbine downtime and maintain operation uptime to ensure maximal yield. Two types of data systems have been widely adopted for monitoring turbine health condition: supervisory control and data acquisition (SCADA) and condition monitoring system (CMS). Provided that research and development have focused on advancing analytical techniques based on these systems independently, an intelligent model that associates information from both systems is necessary and beneficial. In this paper, a systematic framework is designed to integrate CMS and SCADA data and assess drivetrain degradation over its lifecycle. Information reference and advanced feature extraction techniques are employed to procure heterogeneous health indicators. A pattern recognition algorithm is used to model baseline behavior and measure deviation of current behavior, where a Self-organizing Map (SOM) and minimum quantization error (MQE) method is selected to achieve degradation assessment. Eventually, the computation and ranking of component contribution to the detected degradation offers component-level fault localization. When validated and automated by various applications, the approach is able to incorporate diverse data resources and output actionable information to advise predictive maintenance with precise fault information. The approach is validated on a 3 MW offshore turbine, where an incipient fault is detected well before existing system shuts down the unit. A radar chart is used to illustrate the fault localization result

Enhanced information extraction from noisy vibration data for machinery fault detection and diagnosis

As key mechanical components, bearings and gearboxes are employed in most machines. To maintain efficient and safe operations in modern industries, their condition monitoring has received massive attention in recent years. This thesis focuses on the improvement of signal processing approaches to enhance the performance of vibration based monitoring techniques taking into account various data mechanisms and their associated periodic, impulsive, modulating, nonlinear coupling characteristics along with noise contamination. Through in-depth modelling, extensive simulations and experimental verifications upon different and combined faults that often occur in the bearings and gears of representative industrial gearbox systems, the thesis has made following main conclusions in acquiring accurate diagnostic information based on improved signal processing techniques: 1) Among a wide range of advanced approaches investigated, such as adaptive line enhancer (ALE), wavelet transforms, time synchronous averaging (TSA), Kurtogram analysis, and bispectrum representations, the modulation signal bispectrum based sideband estimator (MSB-SE) is regarded as the most powerful tool to enhance the periodic fault signatures as it has the unique property of simultaneous demodulation and noise reduction along with ease of implementation. 2) The proposed MSB-SE based robust detector can achieve optimal band selection and envelope spectrum analysis simultaneously and show more reliable results for bearing fault detection and diagnosis, compared with the popular Kurtogram analysis which highlights too much on localised impulses. 3) The proposed residual sideband analysis yields accurate and consistent diagnostic results of planetary gearboxes across wide operating conditions. This is because that the residual sidebands are much less influenced by inherent gear errors and can be enhanced by MSB analysis. 4) Combined faults in bearings and gears can be detected and separated by MSB analysis. To make the results more reliable, multiple slices of MSB-SE can be averaged to minimise redundant interferences and improve the diagnostic performance

Unconditionally convergent time domain adaptive and time-frequency techniques for epicyclic gearbox vibration

Condition monitoring of epicyclic gearboxes through vibration signature analysis, with particular focus on time domain methods and the use of adaptive filtering techniques for the purpose of signal enhancement, is the central theme of this work. Time domain filtering methods for the purpose of removal of random noise components from periodic, but not necessarily stationary or cyclostationary, signals are developed. Damage identification is accomplished through vibration signature analysis by nonstationary timefrequency methods, belonging to Cohen’s general class of time-frequency distributions, strictly based in the time domain. Although a powerful and commonly used noise reduction technique, synchronous averaging requires alternate sensors in addition to the vibration pickup. For this reason the use of time domain techniques that employ only the vibration data is investigated. Adaptive filters may be used to remove random noise from the nonstationary signals considered. The well-known Least Mean Squares algorithm is employed in an adaptive line enhancer configuration. To counter the much discussed convergence difficulties that are often experienced when the least mean squares algorithm is applied, a new unconditionally convergent algorithm based on the spherical quadratic steepest descent method is presented. The spherical quadratic steepest descent method has been shown to be unconditionally convergent when applied to a quadratic objective function. Time-frequency methods are succinctly employed to analyse the vibration signals simultaneously in the time and frequency domains. Transients covering a wide frequency range are a clear and definite indication of impacting events as gear teeth mate, and observation of such events on a timefrequency distribution are used to indicate damage to the transmission. The pseudo Wigner-Ville distribution and the Spectrogram, both belonging to Cohen’s general class of time-frequency distributions are comparatively used to the end of damage identification. It is shown that an unconditionally convergent adaptive filtering technique used in conjunction with time-frequency methods can indicate a damaged condition in an epicyclic gearbox, where the non-adaptively filtered data did not present clear indications of damage.Dissertation (MEng (Mechanical Engineering))--University of Pretoria, 2007.Mechanical and Aeronautical EngineeringMEngMEngunrestricte