Data-based detection and diagnosis of faults in linear actuators

Modern industrial facilities, as well as vehicles and many other assets, are becoming highly automated and instrumented. As a consequence, actuators are required to perform a wide variety of tasks, often for linear motion. However, the use of tools to monitor the condition of linear actuators is not widely extended in industrial applications. This paper presents a data-based method to monitor linear electro-mechanical actuators. The proposed algorithm makes use of features extracted from electric current and position measurements, typically available from the controller, to detect and diagnose mechanical faults. The features are selected to characterize the system dynamics during transient and steady-state operation and are then combined to produce a condition indicator. The main advantage of this approach is the independence from a need for a physical model or additional sensors. The capabilities of the method are assessed using a novel experimental linear actuator test rig specially designed to recreate fault scenarios under different operating conditions

Estimation of powder mass flow rate in a screw feeder using acoustic emissions

Screw feeders are widely used in powder processes to provide an accurate and consistent flow rate of particles. However this flow rate is rarely measured or controlled. This investigation explores the use of generalised norms and moments from structural-borne acoustic emission (AE) measurements as key statistics indicators for the estimation of powder mass flow rate in a screw feeder. Experimental work was carried out acquiring AE measurements from an industrial screw feeder working with four different types of material at different dispensation rates. Signal enveloping was used in first place to eliminate high frequency components while retaining essential information such as peaks or bursts caused by particle impacts. Secondly a set of generalised norms and moments is extracted from the signal, and their correlation with mass flow rate was studied and assessed. Finally a general model able to estimate mass flow rate for the four different types of powders tested was developed

Statistical process monitoring of a multiphase flow facility

Industrial needs are evolving fast towards more flexible manufacture schemes. As a consequence, it is often required to adapt the plant production to the demand, which can be volatile depending on the application. This is why it is important to develop tools that can monitor the condition of the process working under varying operational conditions. Canonical Variate Analysis (CVA) is a multivariate data driven methodology which has been demonstrated to be superior to other methods, particularly under dynamically changing operational conditions. These comparative studies normally use computer simulated data in benchmark case studies such as the Tennessee Eastman Process Plant (Ricker, N.L. Tennessee Eastman Challenge Archive, Available at 〈http://depts.washington.edu/control/LARRY/TE/download.html〉 Accessed 21.03.2014). The aim of this work is to provide a benchmark case to demonstrate the ability of different monitoring techniques to detect and diagnose artificially seeded faults in an industrial scale multiphase flow experimental rig. The changing operational conditions, the size and complexity of the test rig make this case study an ideal candidate for a benchmark case that provides a test bed for the evaluation of novel multivariate process monitoring techniques performance using real experimental data. In this paper, the capabilities of CVA to detect and diagnose faults in a real system working under changing operating conditions are assessed and compared with other methodologies. The results obtained demonstrate that CVA can be effectively applied for the detection and diagnosis of faults in real complex systems, and reinforce the idea that the performance of CVA is superior to other algorithms

Data-Driven Wheel Slip Diagnostics for Improved Railway Operations

Wheel slip activity detection is crucial in railway maintenance, as it can contribute to avoiding wheel damage but also track deteriorations leading to significant maintenance costs, trains delays, as well as the risk of accidents. Wheel slip activity is characterised by lower adhesion between track and wheel, especially in braking conditions, locking the wheels. It is complex to model or predict, being influenced by a multitude of factors including ambient conditions, global vehicle load, track and axle quality, leaves and objects present on the rail, steep incline, oxidation of the rails, and braking forces applied to the wheels. This paper presents a combined wavelet and tuned Long-Short Term Memory (LSTM) approach for the detection of wheel slip from time series data collected from real-world trains. Results provide evidence of superior performance over methods such as decision trees and random forests, naïve Bayes, k-nearest neighbours, logistic regression, and support vector machines

Particle size distribution estimation of a mixture of regular and irregular sized particles using acoustic emissions

This works investigates the possibility of using Acoustic Emissions (AE) to estimate the Particle Size Distribution (PSD) of a mixture of particles that comprise of particles of different densities and geometry. The experiments carried out involved the mixture of a set of glass and polyethylene particles that ranged from 150-212 microns and 150-250microns respectively and an experimental rig that allowed the free fall of a continuous stream of particles on a target plate which the AE sensor was placed. By using a time domain based multiple threshold method, it was observed that the PSD of the particles in the mixture could be estimated

Estimation of fine and oversize particle ratio in a heterogeneous compound with acoustic emissions

The final phase of powder production typically involves a mixing process where all of the particles are combined and agglomerated with a binder to form a single compound. The traditional means of inspecting the physical properties of the final product involves an inspection of the particle sizes using an offline sieving and weighing process. The main downside of this technique, in addition to being an offline-only measurement procedure, is its inability to characterise large agglomerates of powders due to sieve blockage. This work assesses the feasibility of a real-time monitoring approach using a benchtop test rig and a prototype acoustic-based measurement approach to provide information that can be correlated to product quality and provide the opportunity for future process optimisation. Acoustic emission (AE) was chosen as the sensing method due to its low cost, simple setup process, and ease of implementation. The performance of the proposed method was assessed in a series of experiments where the offline quality check results were compared to the AE-based real-time estimations using data acquired from a benchtop powder free flow rig. A designed time domain based signal processing method was used to extract particle size information from the acquired AE signal and the results show that this technique is capable of estimating the required ratio in the washing powder compound with an average absolute error of 6%

Online particle size distribution estimation of a mixture of similar sized particles with acoustic emissions

Particle processing plants regard the Particle Size Distribution (PSD) as a key quality factor as it influences the bulk and flow properties of the particles. In this work, Acoustic Emission (AE) is used to estimate the PSD of a mixture that comprise of similar sized particles. The experiments involved the use of regular sized particles (glass beads) and with the aid of a time domain based threshold analysis of the particle impacts the PSD of the mixtures could be estimated

Internet of Things - Enabled visual analytics for linked maintenance and product lifecycle management

When closed loop product lifecycle management was first introduced, much effort focused on establishing ways to communicate data between different lifecycle phase activities. The concept of a smart product, able to communicate its own identity and status, had a key role to play to this end. Such a concept has further matured, benefiting from internet things-enabled product lifecycle management advancements. Product data exchanges can now be brought closer to the point of end use consumption, enabling users to become more proactive actors within the product lifecycle management process. This paper presents a conceptual approach and a pilot implementation of how this can be achieved by superimposing middle of life relevant product information to beginning of life product views, such as a 3D product CAD model. In this way, linked maintenance data and knowledge become visual features of a product design representation, facilitating a user’s understanding of middle-of life concepts, such as occurrence of failure modes. The proposed approach can be particularly useful when dealing with product data streams as a natural visual analytics add-in to closed loop product lifecycle management

Size differentiation of a continuous stream of particles using acoustic emissions

Procter and Gamble (P&G) requires an online system that can monitor the particle size distribution of their washing powder mixing process. This would enable the process to take a closed loop form which would enable process optimization to take place in real time. Acoustic emission (AE) was selected as the sensing method due to its non-invasive nature and primary sensitivity to frequencies which particle events emanate. This work details the results of the first experiment carried out in this research project. The first experiment involved the use of AE to distinguish sieved particle which ranged from 53 to 250 microns and were dispensed on a target plate using a funnel. By conducting a threshold analysis of the peaks in the signal, the sizes of the particles could be distinguished and a signal feature was found which could be directly linked to the sizes of the particles

Online change detection techniques in time series: an overview

Time-series change detection has been studied in several fields. From sensor data, engineering systems, medical diagnosis, and financial markets to user actions on a network, huge amounts of temporal data are generated. There is a need for a clear separation between normal and abnormal behaviour of the system in order to investigate causes or forecast change. Characteristics include irregularities, deviations, anomalies, outliers, novelties or surprising patterns. The efficient detection of such patterns is challenging, especially when constraints need to be taken into account, such as the data velocity, volume, limited time for reacting to events, and the details of the temporal sequence.This paper reviews the main techniques for time series change point detection, focusing on online methods. Performance criteria including complexity, time granularity, and robustness is used to compare techniques, followed by a discussion about current challenges and open issue