Diagnostic Analyzer for Gearboxes (DAG): User's Guide

This documentation describes the Diagnostic Analyzer for Gearboxes (DAG) software for performing fault diagnosis of gearboxes. First, the user would construct a graphical representation of the gearbox using the gear, bearing, shaft, and sensor tools contained in the DAG software. Next, a set of vibration features obtained by processing the vibration signals recorded from the gearbox using a signal analyzer is required. Given this information, the DAG software uses an unsupervised neural network referred to as the Fault Detection Network (FDN) to identify the occurrence of faults, and a pattern classifier called Single Category-Based Classifier (SCBC) for abnormality scaling of individual vibration features. The abnormality-scaled vibration features are then used as inputs to a Structure-Based Connectionist Network (SBCN) for identifying faults in gearbox subsystems and components. The weights of the SBCN represent its diagnostic knowledge and are derived from the structure of the gearbox graphically presented in DAG. The outputs of SBCN are fault possibility values between 0 and 1 for individual subsystems and components in the gearbox with a 1 representing a definite fault and a 0 representing normality. This manual describes the steps involved in creating the diagnostic gearbox model, along with the options and analysis tools of the DAG software

Improving the Performance of the Structure-Based Connectionist Network for Diagnosis of Helicopter Gearboxes

A diagnostic method is introduced for helicopter gearboxes that uses knowledge of the gear-box structure and characteristics of the 'features' of vibration to define the influences of faults on features. The 'structural influences' in this method are defined based on the root mean square value of vibration obtained from a simplified lumped-mass model of the gearbox. The structural influences are then converted to fuzzy variables, to account for the approximate nature of the lumped-mass model, and used as the weights of a connectionist network. Diagnosis in this Structure-Based Connectionist Network (SBCN) is performed by propagating the abnormal vibration features through the weights of SBCN to obtain fault possibility values for each component in the gearbox. Upon occurrence of misdiagnoses, the SBCN also has the ability to improve its diagnostic performance. For this, a supervised training method is presented which adapts the weights of SBCN to minimize the number of misdiagnoses. For experimental evaluation of the SBCN, vibration data from a OH-58A helicopter gearbox collected at NASA Lewis Research Center is used. Diagnostic results indicate that the SBCN is able to diagnose about 80% of the faults without training, and is able to improve its performance to nearly 100% after training

Diagnosis of helicopter gearboxes using structure-based networks

A connectionist network is introduced for fault diagnosis of helicopter gearboxes that incorporates knowledge of the gearbox structure and characteristics of the vibration features as its fuzzy weights. Diagnosis is performed by propagating the abnormal features of vibration measurements through this Structure-Based Connectionist Network (SBCN), the outputs of which represent the fault possibility values for individual components of the gearbox. The performance of this network is evaluated by applying it to experimental vibration data from an OH-58A helicopter gearbox. The diagnostic results indicate that the network performance is comparable to those obtained from supervised pattern classification

Unsupervised Pattern Classifier for Abnormality-Scaling of Vibration Features for Helicopter Gearbox Fault Diagnosis

A new unsupervised pattern classifier is introduced for on-line detection of abnormality in features of vibration that are used for fault diagnosis of helicopter gearboxes. This classifier compares vibration features with their respective normal values and assigns them a value in (0, 1) to reflect their degree of abnormality. Therefore, the salient feature of this classifier is that it does not require feature values associated with faulty cases to identify abnormality. In order to cope with noise and changes in the operating conditions, an adaptation algorithm is incorporated that continually updates the normal values of the features. The proposed classifier is tested using experimental vibration features obtained from an OH-58A main rotor gearbox. The overall performance of this classifier is then evaluated by integrating the abnormality-scaled features for detection of faults. The fault detection results indicate that the performance of this classifier is comparable to the leading unsupervised neural networks: Kohonen's Feature Mapping and Adaptive Resonance Theory (AR72). This is significant considering that the independence of this classifier from fault-related features makes it uniquely suited to abnormality-scaling of vibration features for fault diagnosis

Model-based sensor location selection for helicopter gearbox monitoring

A new methodology is introduced to quantify the significance of accelerometer locations for fault diagnosis of helicopter gearboxes. The basis for this methodology is an influence model which represents the effect of various component faults on accelerometer readings. Based on this model, a set of selection indices are defined to characterize the diagnosability of each component, the coverage of each accelerometer, and the relative redundancy between the accelerometers. The effectiveness of these indices is evaluated experimentally by measurement-fault data obtained from an OH-58A main rotor gearbox. These data are used to obtain a ranking of individual accelerometers according to their significance in diagnosis. Comparison between the experimentally obtained rankings and those obtained from the selection indices indicates that the proposed methodology offers a systematic means for accelerometer location selection