Vibration Measurement of an Unbalanced Metallic Shaft Using Electrostatic Sensors

Vibration measurement of a rotary shaft is essential for the diagnosis and prognosis of industrial rotating machinery. However, the imbalance of a shaft, as quantified through vibration displacement, is the most common cause of machine vibration. The objective of this study is to develop a novel technique through electrostatic sensing for the on-line, continuous and non-contact displacement measurement of a rotary shaft due to imbalance faults. A mathematical model is established to extract useful information about the shaft displacement vibration from the simulated signal in the frequency domain. Experimental tests were conducted on a purpose-built test rig to measure the displacement vibration of the shaft. An eccentric shaft was tested with the output signal from the electrostatic sensor analyzed. The effectiveness of the proposed method is verified through computer simulation and experimental tests. Results obtained indicate that the measurement system yields a relative error of within ±0.6% in the displacement measurement

Electrostatic Sensors – Their Principles and Applications

Over the past three decades electrostatic sensors have been proposed, developed and utilised for the continuous monitoring and measurement of a range of industrial processes, mechanical systems and clinical environments. Electrostatic sensors enjoy simplicity in structure, cost-effectiveness and suitability for a wide range of installation conditions. They either provide unique solutions to some measurement challenges or offer more cost-effective options to the more established sensors such as those based on acoustic, capacitive, optical and electromagnetic principles. The established or potential applications of electrostatic sensors appear wide ranging, but the underlining sensing principle and resultant system characteristics are very similar. This paper presents a comprehensive review of the electrostatic sensors and sensing systems that have been developed for the measurement and monitoring of a range of process variables and conditions. These include the flow measurement of pneumatically conveyed solids, measurement of particulate emissions, monitoring of fluidised beds, on-line particle sizing, burner flame monitoring, speed and radial vibration measurement of mechanical systems, and condition monitoring of power transmission belts, mechanical wear, and human activities. The fundamental sensing principles together with the advantages and limitations of electrostatic sensors for a given area of applications are also introduced. The technology readiness level for each area of applications is identified and commented. Trends and future development of electrostatic sensors, their signal conditioning electronics, signal processing methods as well as possible new applications are also discussed

An Improved Method for the Processing of Signals Contaminated with Strong Common-Mode Periodic Noise in Correlation Velocity Measurement

Electrostatic sensors have been successfully used for the velocity measurement of pneumatically conveyed particles and the rotational speed measurement. However, the signal from an electrostatic sensor is usually vulnerable and susceptible to contamination in a hostile environment. The acquired original signal may be contaminated by different types of noise that can be within or outside the frequency range of the signal. This paper presents a novel correlation signal processing method to minimise the impact of noise in the signal through a de-noising process and hence improve the performance of correlation-based measurements in general. The method is applied to the rotational speed measurement based on electrostatic sensors in particular. The de-noising process is an essential task in digital signal processing to improve the signal-to-noise ratio before implementing the measurement algorithm. A hybrid de-noising method is proposed to combine a cut-off frequency method to remove the noise components outside the signal bandwidth and a median filter to smooth the signal. Subsequently, the signal is de-noised in the time domain by employing an advanced digital filtering method based on correlation techniques to suppress the noise frequency components mixed with the original signal. The rotational speed measurement system with the proposed technique has proven to be effective in de-noising signals that are buried in noise with which they are correlated. Moreover, the technique is capable of producing more accurate and repeatable measurements with a wider measurement range than the existing system. Experimental results suggest that the relative error of the improved system is mostly within ±0.1% over the speed range of 300 rpm - 3000 rpm and within ±0.2% over the speed range of 40-300 rpm

Use of triple beam resonant gauges in torque measurement transfer standard

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.A new torque transfer standard using metallic TBTF resonant sensor was developed to overcome the overload capability problem which occurs with conventional metallic resistance strain gauges. Previous research work, however, has shown that the first prototype of the metallic TBTF resonant sensor was not suitable for use in a torque transfer standard due to its size and subsequent sensitivity to parasitic lateral forces. To maximize the benefits from this sensor, particularly overload capability and long-term stability, in the high accuracy torque measurement application area, there is a need to develop significantly smaller devices. The aim of this thesis is to research through FEA modelling and experimental characterisation the key performance parameters required to produce a miniaturised metallic TBTF resonant sensor that provides better performance when applied in a torque measurement system. For high accuracy any torque transducer using these sensors ought to have low sensitivity to parasitic influences such as bending moments and lateral forces, which can only be achieved with reduced size. The problems with the existing design, key design issues, possible configuration and packaging solutions of the metallic TBTF resonant sensor that could be used for achieving a higher accuracy torque transfer standard are considered. Two designs of miniaturised metallic TBTF resonant sensors, SL20 and SL12, are considered and experimentally investigated. The lateral forces are reduced by 52% for SL20 design and by 80% for SL12 design when compared to the original SL40 design. A torque transducer using the SL20 design was calibrated falling into the Torque Transfer Standard class of accuracy 1 category, uncertainty 0.8%. A torque transducer using the SL12 design was made and calibration showed a class of accuracy 0.5 category, uncertainty 0.2%. The results from this research indicate that the SL12 design is suitable for use in a torque transfer standard. The SL12 design is optimal and the smallest size possible based on the overload capability design criteria requiring the tine cross sectional area to remain constant

Optimization of electrostatic sensors for rotational speed measurement of a metallic rotor

Previous studies have demonstrated that it is feasible to apply the electrostatic sensing technique for speed monitoring of non-metallic rotating machinery. The attachment of electrostatic markers makes it possible to measure the rotational speed of metallic rotors with electrostatic sensors. The geometric shape and size of the electrodes and their spacing and distance to the rotor surface have a significant influence on the performance of electrostatic sensors. This paper presents a scheme for the optimization of electrostatic sensors applied in the rotational speed measurement of a metallic rotor. Through computational modelling, fundamental characteristics of the electrostatic sensor including spatial sensitivity, output response and frequency property are analyzed, then the optimal range of electrode parameters is obtained. An optimized sensor with double strip-shaped electrodes, is used to measure the rotational speed of a metallic rotor with a triboelectric marker attached. Experimental results indicate that, the electrostatic sensor coupled with correlation signal processing algorithms enables repeatable speed measurement of a metallic rotor, and the rangeability has been significantly extended. The system is capable of measuring the rotational speed as low as 30 rpm (revolution per minute) with a relative error within ±3.4% over the range of 30 to 120 rpm and within ±0.12% over the range of 120 to 3000 rpm

Development of an Electro-Centrifugal Spinning Setup for Nanofiber Production Research

Nanofiber production methods have been developed and improved over the course of decades. Each process allows for the creation of fibers with distinct properties that provide benefits to growing number of applications. On the same note, every process has shortcomings that keep them from being universally valid for all applications. This research considers electrospinning and centrifugal spinning systems and attempts to create a process which maintains high fiber qualities like small and consistent fiber diameters, and improved fiber alignment while providing a high fiber yield. The electro-centrifugal (EC) spinning machine that resulted was designed utilizing computer aided design (CAD) software to create crucial components and 3D print them with unique specifications that will help with vibration reduction, improved modularity, and facilitate cleaning procedure. When tested using 8 wt% polyethylene oxide (PEO) solution in deionized water (DI H2O), the machine was able to produce fibers at 2000, 3000 and 4000 rpm each run with a 0 V, 2000 V and 4000 V potential input. The produced fibers were measured using a scanning electron microscope (SEM) and ImageJ software. The tests showed that adjusting input voltage to higher values improved fiber quality and increased fiber yield. Increasing rotational velocity greatly increased fiber yield but increased fiber diameters. The results showed promise for future testing procedures that could be fine-tuned to produce fibers within the nanometer range (1 – 100 nm)

NASA Tech Briefs Index, 1977, volume 2, numbers 1-4

Announcements of new technology derived from the research and development activities of NASA are presented. Abstracts, and indexes for subject, personal author, originating center, and Tech Brief number are presented for 1977

High temperature sensor/microphone development for active noise control

The industrial and scientific communities have shown genuine interest in electronic systems which can operate at high temperatures, among which are sensors to monitor noise, vibration, and acoustic emissions. Acoustic sensing can be accomplished by a wide variety of commercially available devices, including: simple piezoelectric sensors, accelerometers, strain gauges, proximity sensors, and fiber optics. Of the several sensing mechanisms investigated, piezoelectrics were found to be the most prevalent, because of their simplicity of design and application and, because of their high sensitivity over broad ranges of frequencies and temperature. Numerous piezoelectric materials are used in acoustic sensors today; but maximum use temperatures are imposed by their transition temperatures (T(sub c)) and by their resistivity. Lithium niobate, in single crystal form, has the highest operating temperature of any commercially available material, 650 C; but that is not high enough for future requirements. Only two piezoelectric materials show potential for use at 1000 C; AlN thin film reported to be piezoactive at 1150 C, and perovskite layer structure (PLS) materials, which possess among the highest T(sub c) (greater than 1500 C) reported for ferroelectrics. A ceramic PLS composition was chosen. The solid solution composition, 80% strontium niobate (SN) and 20% strontium tantalate (STa), with a T(sub c) approximately 1160 C, was hot forged, a process which concurrently sinters and renders the plate-like grains into a highly oriented configuration to enhance piezo properties. Poled samples of this composition showed coupling (k33) approximately 6 and piezoelectric strain constant (d33) approximately 3. Piezoactivity was seen at 1125 C, the highest temperature measurement reported for a ferroelectric ceramic. The high temperature piezoelectric responses of this, and similar PLS materials, opens the possibility of their use in electronic devices operating at temperatures up to 1000 C. Concurrent with the materials study was an effort to define issues involved in the development of a microphone capable of operation at temperatures up to 1000 C; important since microphones capable of operation above 260 C are not generally available. The distinguishing feature of a microphone is its diaphragm which receives sound from the atmosphere: whereas, most other acoustic sensors receive sound through the solid structure on which they are installed. In order to gain an understanding of the potential problems involved in designing and testing a high temperature microphone, a prototype was constructed using a commercially available lithium niobate piezoelectric element in a stainless steel structure. The prototype showed excellent frequency response at room temperature, and responded to acoustic stimulation at 670 C, above which temperature the voltage output rapidly diminished because of decreased resistivity in the element. Samples of the PLS material were also evaluated in a simulated microphone configuration, but their voltage output was found to be a few mV compared to the 10 output of the prototype

Design and Applications of Coordinate Measuring Machines

Coordinate measuring machines (CMMs) have been conventionally used in industry for 3-dimensional and form-error measurements of macro parts for many years. Ever since the first CMM, developed by Ferranti Co. in the late 1950s, they have been regarded as versatile measuring equipment, yet many CMMs on the market still have inherent systematic errors due to the violation of the Abbe Principle in its design. Current CMMs are only suitable for part tolerance above 10 μm. With the rapid advent of ultraprecision technology, multi-axis machining, and micro/nanotechnology over the past twenty years, new types of ultraprecision and micro/nao-CMMs are urgently needed in all aspects of society. This Special Issue accepted papers revealing novel designs and applications of CMMs, including structures, probes, miniaturization, measuring paths, accuracy enhancement, error compensation, etc. Detailed design principles in sciences, and technological applications in high-tech industries, were required for submission. Topics covered, but were not limited to, the following areas: 1. New types of CMMs, such as Abbe-free, multi-axis, cylindrical, parallel, etc. 2. New types of probes, such as touch-trigger, scanning, hybrid, non-contact, microscopic, etc. 3. New types of Micro/nano-CMMs. 4. New types of measuring path strategy, such as collision avoidance, free-form surface, aspheric surface, etc. 5. New types of error compensation strategy