Quantitative Index and Abnormal Alarm Strategy Using Sensor-Dependent Vibration Data for Blade Crack Identification in Centrifugal Booster Fans.

Centrifugal booster fans are important equipment used to recover blast furnace gas (BFG) for generating electricity, but blade crack faults (BCFs) in centrifugal booster fans can lead to unscheduled breakdowns and potentially serious accidents, so in this work quantitative fault identification and an abnormal alarm strategy based on acquired historical sensor-dependent vibration data is proposed for implementing condition-based maintenance for this type of equipment. Firstly, three group dependent sensors are installed to acquire running condition data. Then a discrete spectrum interpolation method and short time Fourier transform (STFT) are applied to preliminarily identify the running data in the sensor-dependent vibration data. As a result a quantitative identification and abnormal alarm strategy based on compound indexes including the largest Lyapunov exponent and relative energy ratio at the second harmonic frequency component is proposed. Then for validation the proposed blade crack quantitative identification and abnormality alarm strategy is applied to analyze acquired experimental data for centrifugal booster fans and it has successfully identified incipient blade crack faults. In addition, the related mathematical modelling work is also introduced to investigate the effects of mistuning and cracks on the vibration features of centrifugal impellers and to explore effective techniques for crack detection.

Fault Diagnosis of Demountable Disk-Drum Aero-Engine Rotor Using Customized Multiwavelet Method.

The demountable disk-drum aero-engine rotor is an important piece of equipment that greatly impacts the safe operation of aircraft. However, assembly looseness or crack fault has led to several unscheduled breakdowns and serious accidents. Thus, condition monitoring and fault diagnosis technique are required for identifying abnormal conditions. Customized ensemble multiwavelet method for aero-engine rotor condition identification, using measured vibration data, is developed in this paper. First, customized multiwavelet basis function with strong adaptivity is constructed via symmetric multiwavelet lifting scheme. Then vibration signal is processed by customized ensemble multiwavelet transform. Next, normalized information entropy of multiwavelet decomposition coefficients is computed to directly reflect and evaluate the condition. The proposed approach is first applied to fault detection of an experimental aero-engine rotor. Finally, the proposed approach is used in an engineering application, where it successfully identified the crack fault of a demountable disk-drum aero-engine rotor. The results show that the proposed method possesses excellent performance in fault detection of aero-engine rotor. Moreover, the robustness of the multiwavelet method against noise is also tested and verified by simulation and field experiments.

A comparative study of information-based source number estimation methods and experimental validations on mechanical systems.

This paper investigates one eigenvalue decomposition-based source number estimation method, and three information-based source number estimation methods, namely the Akaike Information Criterion (AIC), Minimum Description Length (MDL) and Bayesian Information Criterion (BIC), and improves BIC as Improved BIC (IBIC) to make it more efficient and easier for calculation. The performances of the abovementioned source number estimation methods are studied comparatively with numerical case studies, which contain a linear superposition case and a both linear superposition and nonlinear modulation mixing case. A test bed with three sound sources is constructed to test the performances of these methods on mechanical systems, and source separation is carried out to validate the effectiveness of the experimental studies. This work can benefit model order selection, complexity analysis of a system, and applications of source separation to mechanical systems for condition monitoring and fault diagnosis purposes.

Biaxial yield surface investigation of polymer-matrix composites.

This article presents a numerical technique for computing the biaxial yield surface of polymer-matrix composites with a given microstructure. Generalized Method of Cells in combination with an Improved Bodner-Partom Viscoplastic model is used to compute the inelastic deformation. The validation of presented model is proved by a fiber Bragg gratings (FBGs) strain test system through uniaxial testing under two different strain rate conditions. On this basis, the manufacturing process thermal residual stress and strain rate effect on the biaxial yield surface of composites are considered. The results show that the effect of thermal residual stress on the biaxial yield response is closely dependent on loading conditions. Moreover, biaxial yield strength tends to increase with the increasing strain rate.

LMD method and multi-class RWSVM of fault diagnosis for rotating machinery using condition monitoring information.

Timely and accurate condition monitoring and fault diagnosis of rotating machinery are very important to maintain a high degree of availability, reliability and operational safety. This paper presents a novel intelligent method based on local mean decomposition (LMD) and multi-class reproducing wavelet support vector machines (RWSVM), which is applied to diagnose rotating machinery faults. First, the sensor-based vibration signals measured from the rotating machinery are preprocessed by the LMD method and product functions (PFs) are produced. Second, statistic features are extracted to acquire more fault characteristic information from the sensitive PF. Finally, these features are fed into a multi-class RWSVM to identify the rotating machinery health conditions. The experimental results validate the effectiveness of the proposed RWSVM method in identifying rotating machinery fault patterns accurately and effectively and its superiority over that based on the general SVM.

Customized multiwavelets for planetary gearbox fault detection based on vibration sensor signals.

Planetary gearboxes exhibit complicated dynamic responses which are more difficult to detect in vibration signals than fixed-axis gear trains because of the special gear transmission structures. Diverse advanced methods have been developed for this challenging task to reduce or avoid unscheduled breakdown and catastrophic accidents. It is feasible to make fault features distinct by using multiwavelet denoising which depends on the feature separation and the threshold denoising. However, standard and fixed multiwavelets are not suitable for accurate fault feature detections because they are usually independent of the measured signals. To overcome this drawback, a method to construct customized multiwavelets based on the redundant symmetric lifting scheme is proposed in this paper. A novel indicator which combines kurtosis and entropy is applied to select the optimal multiwavelets, because kurtosis is sensitive to sharp impulses and entropy is effective for periodic impulses. The improved neighboring coefficients method is introduced into multiwavelet denoising. The vibration signals of a planetary gearbox from a satellite communication antenna on a measurement ship are captured under various motor speeds. The results show the proposed method could accurately detect the incipient pitting faults on two neighboring teeth in the planetary gearbox.

A method based on multi-sensor data fusion for fault detection of planetary gearboxes.

Studies on fault detection and diagnosis of planetary gearboxes are quite limited compared with those of fixed-axis gearboxes. Different from fixed-axis gearboxes, planetary gearboxes exhibit unique behaviors, which invalidate fault diagnosis methods that work well for fixed-axis gearboxes. It is a fact that for systems as complex as planetary gearboxes, multiple sensors mounted on different locations provide complementary information on the health condition of the systems. On this basis, a fault detection method based on multi-sensor data fusion is introduced in this paper. In this method, two features developed for planetary gearboxes are used to characterize the gear health conditions, and an adaptive neuro-fuzzy inference system (ANFIS) is utilized to fuse all features from different sensors. In order to demonstrate the effectiveness of the proposed method, experiments are carried out on a planetary gearbox test rig, on which multiple accelerometers are mounted for data collection. The comparisons between the proposed method and the methods based on individual sensors show that the former achieves much higher accuracies in detecting planetary gearbox faults.

Method for vibration response simulation and sensor placement optimization of a machine tool spindle system with a bearing defect.

Bearing defects are one of the most important mechanical sources for vibration and noise generation in machine tool spindles. In this study, an integrated finite element (FE) model is proposed to predict the vibration responses of a spindle bearing system with localized bearing defects and then the sensor placement for better detection of bearing faults is optimized. A nonlinear bearing model is developed based on Jones' bearing theory, while the drawbar, shaft and housing are modeled as Timoshenko's beam. The bearing model is then integrated into the FE model of drawbar/shaft/housing by assembling equations of motion. The Newmark time integration method is used to solve the vibration responses numerically. The FE model of the spindle-bearing system was verified by conducting dynamic tests. Then, the localized bearing defects were modeled and vibration responses generated by the outer ring defect were simulated as an illustration. The optimization scheme of the sensor placement was carried out on the test spindle. The results proved that, the optimal sensor placement depends on the vibration modes under different boundary conditions and the transfer path between the excitation and the response.

A monotonic degradation assessment index of rolling bearings using fuzzy support vector data description and running time.

Performance degradation assessment based on condition monitoring plays an important role in ensuring reliable operation of equipment, reducing production downtime and saving maintenance costs, yet performance degradation has strong fuzziness, and the dynamic information is random and fuzzy, making it a challenge how to assess the fuzzy bearing performance degradation. This study proposes a monotonic degradation assessment index of rolling bearings using fuzzy support vector data description (FSVDD) and running time. FSVDD constructs the fuzzy-monitoring coefficient ε⁻ which is sensitive to the initial defect and stably increases as faults develop. Moreover, the parameter ε⁻ describes the accelerating relationships between the damage development and running time. However, the index ε⁻ with an oscillating trend disagrees with the irreversible damage development. The running time is introduced to form a monotonic index, namely damage severity index (DSI). DSI inherits all advantages of ε⁻ and overcomes its disadvantage. A run-to-failure test is carried out to validate the performance of the proposed method. The results show that DSI reflects the growth of the damages with running time perfectly.

Operation reliability assessment for cutting tools by applying a proportional covariate model to condition monitoring information.

The reliability of cutting tools is critical to machining precision and production efficiency. The conventional statistic-based reliability assessment method aims at providing a general and overall estimation of reliability for a large population of identical units under given and fixed conditions. However, it has limited effectiveness in depicting the operational characteristics of a cutting tool. To overcome this limitation, this paper proposes an approach to assess the operation reliability of cutting tools. A proportional covariate model is introduced to construct the relationship between operation reliability and condition monitoring information. The wavelet packet transform and an improved distance evaluation technique are used to extract sensitive features from vibration signals, and a covariate function is constructed based on the proportional covariate model. Ultimately, the failure rate function of the cutting tool being assessed is calculated using the baseline covariate function obtained from a small sample of historical data. Experimental results and a comparative study show that the proposed method is effective for assessing the operation reliability of cutting tools.

Simulation and experimental investigation of structural dynamic frequency characteristics control.

In general, mechanical equipment such as cars, airplanes, and machine tools all operate with constant frequency characteristics. These constant working characteristics should be controlled if the dynamic performance of the equipment demands improvement or the dynamic characteristics is intended to change with different working conditions. Active control is a stable and beneficial method for this, but current active control methods mainly focus on vibration control for reducing the vibration amplitudes in the time domain or frequency domain. In this paper, a new method of dynamic frequency characteristics active control (DFCAC) is presented for a flat plate, which can not only accomplish vibration control but also arbitrarily change the dynamic characteristics of the equipment. The proposed DFCAC algorithm is based on a neural network including two parts of the identification implement and the controller. The effectiveness of the DFCAC method is verified by several simulation and experiments, which provide desirable results.

An adaptive stochastic resonance method based on grey wolf optimizer algorithm and its application to machinery fault diagnosis.

Stochastic resonance (SR) is widely used as an enhanced signal detection method in machinery fault diagnosis. However, the system parameters have significant effects on the output results, which makes it difficult for SR method to achieve satisfactory analysis results. To solve this problem and improve the performance of SR method, this paper proposes an adaptive SR method based on grey wolf optimizer (GWO) algorithm for machinery fault diagnosis. Firstly, the SR system parameters are optimized by the GWO algorithm using a redefined signal-to-noise ratio (SNR) as optimization objective function. Then, the optimal SR output matching the input signal can be adaptively obtained using the optimized parameters. The proposed method is validated on a simulated signal detection and a rolling element bearing test bench, and then applied to the gear fault diagnosis of electric locomotive. Compared with the conventional fixed-parameter SR method, the adaptive SR method based on genetic algorithm (GA-SR) as well as the well-known fast kurtogram method, the proposed method can achieve a greater accuracy. The results indicated that the proposed method has great practical values in engineering.

A hybrid fault diagnosis method based on second generation wavelet de-noising and local mean decomposition for rotating machinery.

In order to extract fault features of large-scale power equipment from strong background noise, a hybrid fault diagnosis method based on the second generation wavelet de-noising (SGWD) and the local mean decomposition (LMD) is proposed in this paper. In this method, a de-noising algorithm of second generation wavelet transform (SGWT) using neighboring coefficients was employed as the pretreatment to remove noise in rotating machinery vibration signals by virtue of its good effect in enhancing the signal-noise ratio (SNR). Then, the LMD method is used to decompose the de-noised signals into several product functions (PFs). The PF corresponding to the faulty feature signal is selected according to the correlation coefficients criterion. Finally, the frequency spectrum is analyzed by applying the FFT to the selected PF. The proposed method is applied to analyze the vibration signals collected from an experimental gearbox and a real locomotive rolling bearing. The results demonstrate that the proposed method has better performances such as high SNR and fast convergence speed than the normal LMD method.