Signal Processing for the Condition-Based Maintenance of Rotating Machines via Vibration Analysis: A Tutorial.

One of the common methods for implementing the condition-based maintenance of rotating machinery is vibration analysis. This tutorial describes some of the important signal processing methods existing in the field, which are based on a profound understanding of the component's physical behavior. Furthermore, this tutorial provides Python and MATLAB code examples to demonstrate these methods alongside explanatory videos. The goal of this article is to serve as a practical tutorial, enabling interested individuals with a background in signal processing to quickly learn the important principles of condition-based maintenance of rotating machinery using vibration analysis.

Anomaly Detection and Remaining Useful Life Estimation for the Health and Usage Monitoring Systems 2023 Data Challenge.

Gear fault detection and remaining useful life estimation are important tasks for monitoring the health of rotating machinery. In this study, a new benchmark for endurance gear vibration signals is presented and made publicly available. The new dataset was used in the HUMS 2023 conference data challenge to test anomaly detection algorithms. A survey of the suggested techniques is provided, demonstrating that traditional signal processing techniques interestingly outperform deep learning algorithms in this case. Of the 11 participating groups, only those that used traditional approaches achieved good results on most of the channels. Additionally, we introduce a signal processing anomaly detection algorithm and meticulously compare it to a standard deep learning anomaly detection algorithm using data from the HUMS 2023 challenge and simulated signals. The signal processing algorithm surpasses the deep learning algorithm on all tested channels and also on simulated data where there is an abundance of training data. Finally, we present a new digital twin that enables the estimation of the remaining useful life of the tested gear from the HUMS 2023 challenge.

Digital Twin of a Gear Root Crack Prognosis.

Digital twins play a significant role in Industry 4.0, offering the potential to revolutionize machinery maintenance. In this paper, we introduce a new digital twin designed to address the open problem of predicting gear root crack propagation. This digital twin uses signal processing and model fitting to continuously monitor the condition of the root crack and successfully estimate the remaining time until immediate maintenance is required for the physical asset. The functionality of this new digital twin is demonstrated through the experimental data obtained from a planetary gear, where comparisons are made between the actual and estimated severity of the fault, as well as the remaining time until maintenance. It is shown that the digital twin addresses the open problem of predicting gear root crack propagation.

Probability-Based Algorithm for Bearing Diagnosis with Untrained Spall Sizes.

Bearing spall detection and predicting its size are great challenges. Model-based simulation is a well-known traditional approach to physically model the influence of the spall on the bearing. Building a physical model is challenging due to the bearing complexity and the expert knowledge required to build such a model. Obviously, building a partial physical model for some of the spall sizes is easier. In this paper, we propose a machine-learning algorithm, called Probability-Based Forest, that uses a partial physical model. First, the behavior of some of the spall sizes is physically modeled and a simulator based on this model generates scenarios for these spall sizes in different conditions. Then, the machine-learning algorithm trains these scenarios to generate a prediction model of spall sizes even for those that have not been modeled by the physical model. Feature extraction is a key factor in the success of this approach. We extract features using two traditional approaches: statistical and physical, and an additional new approach: Time Series FeatuRe Extraction based on Scalable Hypothesis tests (TSFRESH). Experimental evaluation with well-known physical model shows that our approach achieves high accuracy, even in cases that have not been modeled by the physical model. Also, we show that the TSFRESH feature-extraction approach achieves the highest accuracy.

Enhanced algorithm for predictive maintenance to detect turbocharger overspeed in diesel engine rail vehicles.

The reliability and safety of locomotives is crucial for efficient train operation. Repeated turbocharger failures in Israel Railways locomotive fleet have raised serious safety concerns. An investigation into the failures revealed that the uncontrolled acceleration and overspeed transients of the turbocharger shaft occurred before the failure. Early detection of potential turbocharger failures by predicting overspeed conditions is critical to the safety and reliability of locomotives. In this study, an enhanced novel algorithm for estimating the Instantaneous Angular Speed (IAS) of the turbocharger and diesel engines is presented to overcome the challenges of transient operating conditions of diesel engines. Using adaptive dephasing, the algorithm effectively isolates critical asynchronous vibration components that are crucial for the early detection of turbocharger failures. This algorithm is suitable for non-stationary speeds and is applicable to any range of rotational speed and rate of change. The algorithm requires the input of the basic parameters of the system, while all other parameters that control the process are determined automatically. The algorithm was developed specifically for the special operating conditions of diesel engines and improves predictive maintenance and operational reliability. The method is robust as it correlates between several characteristic frequencies of the rotating parts of the system. The algorithm was verified and validated with simulated and experimental data.

Development of an Operational Digital Twin of a Locomotive Parking Brake for Fault Diagnosis.

In recent years, a growing role in digital technologies has been filled by model-based digital twinning. A digital twin produces a one-to-one mapping of a physical structure, operating in the digital domain. Combined with sensor technology and analytics, a digital twin can provide enhanced monitoring, diagnostic, and optimization capabilities. This research harnesses the significant capabilities of digital twining for the unmitigated challenge of fault type classification of a locomotive parking brake. We develop a digital twin of the locomotive parking brake and suggest a method for fault type classification based on the digital twin. The diagnostic ability of the method is demonstrated on a large experimental dataset.

New Damage Accumulation Model for Spall Propagation Mechanism in Bearing Raceways.

The aim of this study was to investigate the spall propagation mechanism in ball bearing raceways using physics-based models. Spalling is one of the most common types of bearing failures that can lead to catastrophic failure. This research takes a step forward toward developing a prognostic tool for ball bearings. It is first necessary to understand the spall progression process in order to formulate a constitutive law of spall deterioration and to estimate the amount of remaining useful life. Fragment formation in the vicinity of the spall edge was found to consist of surface and sub-surface cracks that eventually coalesce, and a fragment is released from the raceway, based on naturally-developed spalls. Here, we describe a physics-based model, integrating a dynamic model with a finite element one to simulate this process. A continuum damage mechanics (CDM) approach and fracture mechanics tools were embedded into the finite element model to simulate the damage propagation. The formation of cracks in the vicinity of the spall (surface and sub-surface cracks) were studied using this effective stress CDM model, and the propagation of the cracks was examined using two approaches: a fracture mechanics approach and an accumulated inelastic hysteresis energy CDM approach. The latter also predicts the overall process of a single fragment release. The simulation results of the spall propagation models are supported by experimental results of spalls from both laboratory experimental bearings and an in-service Sikorsky CH-53 helicopter swashplate bearing. The results obtained show that the impact of the ball on the spall edge affects the crack propagation and the appearance of the surface and sub-surface cracks. Both release the residual stresses and cause crack propagation until a fragment is released.

Experimental Investigation of the Spall Propagation Mechanism in Bearing Raceways.

This article investigates the spall propagation mechanism for ball bearing raceways by focusing on an experimental investigation of cracks that evolve in the vicinity of the spall edge. Understanding the spall propagation mechanism is an important step towards developing a physics-based prognostic tool for ball bearings. This research reflects an investigation of different spall sizes that propagate naturally both in laboratory experiments and in the field. By using a combined model of a rigid body dynamic model and a finite element model that simulates the rolling element-spall edge interaction, our results shed light on the material behavior (displacements, strains, and stresses) that creates an environment for crack formation and propagation. With the support of the experimental results and the rolling element-spall edge interaction model results, three stages of the mechanism that control fragment release from the raceway were identified. In Stage one, sub-surface cracks appear underneath the spall trailing edge. In Stage two, cracks appear in front of the trailing edge of the spall and, in Stage three, the cracks propagate until a fragment is released from the raceway. These stages were observed in all the tested bearings. In addition, other phenomena that affect the propagation of the cracks and the geometry of the fragment were observed, such as blistering and plastic deformation. We include an explanation of what determines the shape of the fragments.

Transfer Across Different Machines by Transfer Function Estimation.

A digital twin is a promising evolving tool for prognostic health monitoring. However, in rotating machinery, the transfer function between the rotating components and the sensor distorts the vibration signal, hence, complicating the ability to apply a digital twin to new systems. This paper demonstrates the importance of estimating the transfer function for a successful transfer across different machines (TDM). Furthermore, there are few algorithms in the literature for transfer function estimation. The current algorithms can estimate the magnitude of the transfer function without its original phase. In this study, a new approach is presented that enables the estimation of the transfer function with its phase for a gear signal. The performance of the new algorithm is demonstrated by measured signals and by a simulated transfer function.

Restoring the biophysical properties of decellularized patches through recellularization.

Various extracellular matrix (ECM) scaffolds, isolated through decellularization, were suggested as ideal biomimetic materials for 'Functional tissue engineering' (FTE). The decellularization process comprises a compromise between damaging and preserving the ultrastructure and composition of ECM-previously shown to affect cell survival, proliferation, migration, organization, differentiation and maturation. Inversely, the effects of cells on the ECM constructs' biophysical properties, under physiological-like conditions, remain still largely unknown. We hypothesized that by re-cellularizing porcine cardiac ECM (pcECM, as a model scaffold) some of the original biophysical properties of the myocardial tissue can be restored, which are related to the scaffold's surface and the bulk modifications consequent to cellularization. We performed a systematic biophysical assessment of pcECM scaffolds seeded with human mesenchymal stem cells (MSCs), a common multipotent cell source in cardiac regenerative medicine. We report a new type of FTE study in which cell interactions with a composite-scaffold were evaluated from the perspective of their contribution to the biophysical properties of the construct surface (FTIR, WETSEM™) and bulk (DSC, TGA, and mechanical testing). The results obtained were compared with acellular pcECM and native ventricular tissue serving as negative and positive controls, respectively. MSC recellularization resulted in an inter-fiber plasticization effect, increased protein density, masking of acylated glycosaminoglycans (GAGs) and active pcECM remodelling which further stabilized the reseeded construct and increased its denaturation resistance. The systematic approach presented herein, therefore, identifies cells as "biological plasticizers" and yields important methodologies, understanding, and data serving both as a reference as well as possible 'design criteria' for future studies in FTE.