Variable selection for wind turbine condition monitoring and fault detection system

With the fast growth in wind energy, the performance and reliability of the wind power generation system has become a major issue in order to achieve cost-effective generation. Integration of condition monitoring system (CMS) in the wind turbine has been considered as the most viable solution, which enhances maintenance scheduling and achieving a more reliable system. However, for an effective CMS, large number of sensors and high sampling frequency are required, resulting in a large amount of data to be generated. This has become a burden for the CMS and the fault detection system. This thesis focuses on the development of variable selection algorithm, such that the dimensionality of the monitoring data can be reduced, while useful information in relation to the later fault diagnosis and prognosis is preserved. The research started with a background and review of the current status of CMS in wind energy. Then, simulation of the wind turbine systems is carried out in order to generate useful monitoring data, including both healthy and faulty conditions. Variable selection algorithms based on multivariate principal component analysis are proposed at the system level. The proposed method is then further extended by introducing additional criterion during the selection process, where the retained variables are targeted to a specific fault. Further analyses of the retained variables are carried out, and it has shown that fault features are present in the dataset with reduced dimensionality. Two detection algorithms are then proposed utilising the datasets obtained from the selection algorithm. The algorithms allow accurate detection, identification and severity estimation of anomalies from simulation data and supervisory control and data acquisition data from an operational wind farm. Finally an experimental wind turbine test rig is designed and constructed. Experimental monitoring data under healthy and faulty conditions is obtained to further validate the proposed detection algorithms

Condition Monitoring of Slow Speed Rotating Machinery Using Acoustic Emission Technology

Slow speed rotating machines are the mainstay of several industrial applications worldwide. They can be found in paper and steel mills, rotating biological contractors, wind turbines etc. Operational experience of such machinery has not only revealed the early design problems but has also presented opportunities for further significant improvements in the technology and economics of the machines. Slow speed rotating machinery maintenance, mostly related to bearings, shafts and gearbox problems, represents the cause of extended outages. Rotating machinery components such as gearboxes, shafts and bearings degrade slowly with operating time. Such a slow degradation process can be identified if a robust on-line monitoring and predictive maintenance technology is used to detect impending problems and allow repairs to be scheduled. To keep machines functioning at optimal levels, failure detection of such vital components is important as any mechanical degradation or wear, if is not impeded in time, will often progress to more serious damage affecting the operational performance of the machine. This requires far more costly repairs than simply replacing a part. Over the last few years there have been many developments in the use of Acoustic Emission (AE) technology and its analysis for monitoring the condition of rotating machinery whilst in operation, particularly on slow speed rotating machinery. Unlike conventional technologies such as thermography, oil analysis, strain measurements and vibration, AE has been introduced due to its increased sensitivity in detecting the earliest stages of loss of mechanical integrity. This programme of research involves laboratory tests for monitoring slow speed rotating machinery components (shafts and bearings) using AE technology. To implement this objective, two test rigs have been designed to assess the capability of AE as an effective tool for detection of incipient defects within low speed machine components (e.g. shafts and bearings). The focus of the experimental work will be on the initiation and growth of natural defects. Further, this research work investigates the source characterizations of AE signals associated with such bearings whilst in operation. It is also hoped that at the end of this research program, a reliable on-line monitoring scheme used for slow speed rotating machinery components can be developed

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

Proceedings of COMADEM 201

Advanced techniques for aircraft bearing diagnostics

The task is the creation of a method able to diagnose and monitor bearings healthy, mainly in case of varying external conditions. The ability of the technique is verified through data acquisition on a laboratory test rig, where various operating conditions could be checked (load, speed, temperature). Signal processing techniques and data mining techniques are applied to analyse the data

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

Maintenance Management of Wind Turbines

“Maintenance Management of Wind Turbines” considers the main concepts and the state-of-the-art, as well as advances and case studies on this topic. Maintenance is a critical variable in industry in order to reach competitiveness. It is the most important variable, together with operations, in the wind energy industry. Therefore, the correct management of corrective, predictive and preventive politics in any wind turbine is required. The content also considers original research works that focus on content that is complementary to other sub-disciplines, such as economics, finance, marketing, decision and risk analysis, engineering, etc., in the maintenance management of wind turbines. This book focuses on real case studies. These case studies concern topics such as failure detection and diagnosis, fault trees and subdisciplines (e.g., FMECA, FMEA, etc.) Most of them link these topics with financial, schedule, resources, downtimes, etc., in order to increase productivity, profitability, maintainability, reliability, safety, availability, and reduce costs and downtime, etc., in a wind turbine. Advances in mathematics, models, computational techniques, dynamic analysis, etc., are employed in analytics in maintenance management in this book. Finally, the book considers computational techniques, dynamic analysis, probabilistic methods, and mathematical optimization techniques that are expertly blended to support the analysis of multi-criteria decision-making problems with defined constraints and requirements