Testing for detection of crack in rotor using vibration analysis: an experimental approach

2019 ◽  
Vol 36 (6) ◽  
pp. 999-1013
Author(s):  
Bhumi Ankit Shah ◽  
Dipak P. Vakharia
Keyword(s):  
Condition Monitoring ◽  
Vibration Analysis ◽  
Critical Speed ◽  
Energy Analysis ◽  
Wavelet Packet ◽  
Rotating Machinery ◽  
Wavelet Packets ◽  
Energy Component ◽  
Content Type ◽  
Analysis Technique

Purpose Many incidents of rotor failures are reported due to the development and propagation of the crack. Condition monitoring is adopted for the identification of symptoms of the crack at very early stage in the rotating machinery. Identification requires a reliable and accurate vibration analysis technique for achieving the objective of the study. The purpose of this paper is to detect the crack in the rotating machinery by measuring vibration parameters at different measurement locations. Design/methodology/approach Two different types of cracks were simulated in these experiments. Experiments were conducted using healthy shaft, crack simulated shaft and glued shaft with and without added unbalance to observe the changes in vibration pattern, magnitude and phase. Deviation in vibration response allows the identification of crack and its location. Initial data were acquired in the form of time waveform. Run-up and coast-down measurements were taken to find the critical speed. The wavelet packet energy analysis technique was used to get better localization in time and frequency zone. Findings The presence of crack changes the dynamic behavior of the rotor. 1× and 2× harmonic components for steady-state test and critical speed for transient test are important parameters in condition monitoring to detect the crack. To separate the 1× and 2× harmonic component in the different wavelet packets, original signal is decomposed in nine levels. Wavelet packet energy analysis is carried out to find the intensity of the signal due to simulated crack. Originality/value Original signals obtained from the experiment test set up may contain noise component and dominant frequency components other than the crack. Wavelet packets contain the crack-related information that are identified and separated in this study. This technique develops the condition monitoring procedure more specific about the type of the fault and accurate due to the separation of specific fault features in different wavelet packets. From the experiment end results, it is found that there is significant rise in a 2× energy component due to crack in the shaft. The intensity of a 1× energy component depends upon the shaft crack and unbalance orientation angle.

scholarly journals Low-Cost, High-Frequency, Data Acquisition System for Condition Monitoring of Rotating Machinery through Vibration Analysis-Case Study

Sensors ◽  
2020 ◽  
Vol 20 (12) ◽  
pp. 3493
Author(s):  
César Ricardo Soto-Ocampo ◽  
José Manuel Mera ◽  
Juan David Cano-Moreno ◽  
José Luis Garcia-Bernardo
Keyword(s):  
Data Acquisition ◽  
Condition Monitoring ◽  
Vibration Analysis ◽  
Low Cost ◽  
Data Acquisition System ◽  
Sampling Frequency ◽  
Rotating Machinery ◽  
Acquisition System ◽  
Raspberry Pi

Data acquisition is a crucial stage in the execution of condition monitoring (CM) of rotating machinery, by means of vibration analysis. However, the major challenge in the execution of this technique lies in the features of the recording equipment (accuracy, resolution, sampling frequency and number of channels) and the cost they represent. The present work proposes a low-cost data acquisition system, based on Raspberry-Pi, with a high sampling frequency capacity in the recording of up to three channels. To demonstrate the effectiveness of the proposed data acquisition system, a case study is presented in which the vibrations registered in a bearing are analyzed for four degrees of failure.

Wavelet Packet Analysis in the Condition Monitoring of Rotating Machinery

1998 ◽  
Vol 31 (29) ◽  
pp. 89-94
Author(s):  
Kevin Bossley ◽  
R. Mckendrick ◽  
C.J. Harris ◽  
C. Mercer
Keyword(s):  
Condition Monitoring ◽  
Wavelet Packet ◽  
Rotating Machinery ◽  
Wavelet Packet Analysis

A New Method for Real-Time Tool Condition Monitoring in Transfer Machining Stations1

2000 ◽  
Vol 123 (2) ◽  
pp. 339-347 ◽  
Author(s):  
Ya Wu ◽  
Philippe Escande ◽  
R. Du
Keyword(s):  
Decision Making ◽  
Condition Monitoring ◽  
Wavelet Packet ◽  
Signal Reconstruction ◽  
Spindle Motor ◽  
Tool Condition Monitoring ◽  
New Method ◽  
Wavelet Packets ◽  
Tool Condition ◽  
Threshold Crossing

This paper introduces a new method for tool condition monitoring in transfer machining stations. The new method is developed based on a combination of wavelet transform, signal reconstruction, and the probability of threshold crossing. It consists of two parts: training and decision making. Training is aimed at determining the alarm threshold and it is done in six steps: (1) Calculate the wavelet packet transform of the sensor signals (spindle motor current) obtained from normal tool conditions. (2) Select feature wavelet packets that represent the principal components of the signals. (3) Reconstruct the signals from the feature wavelet packets (this removes the unwanted noises). (4) Calculate the statistics of the reconstructed signals. (5) Calculate the alarm thresholds based on the statistics of the reconstructed signals, and (6) Calculate the probability of the threshold crossing (the number of threshold crossing conforms a Poisson distribution). The decision making is done in two steps: (1) Check the threshold crossing, and (2) Calculate the number of threshold crossing to determine whether an alarm shall be given. As demonstrated using a practical example from a drilling transfer station, the new method is effective with a success rate over 90 percent. Also, it is fast (the monitoring decision can be done in milliseconds) and cost-effective (the implementation cost shall be less than $500).

scholarly journals Condition monitoring of PARR-1 rotating machines by vibration analysis technique

2014 ◽  
Vol 29 (3) ◽  
pp. 249-252 ◽  
Author(s):  
Javed Qadir ◽  
Hameed Qaiser ◽  
Mehar Ali ◽  
Masood Iqbal
Keyword(s):  
Condition Monitoring ◽  
Preventive Maintenance ◽  
Vibration Analysis ◽  
Research Reactor ◽  
Vibration Spectrum ◽  
Experimental Setup ◽  
Performance Parameters ◽  
Vibration Data ◽  
Analysis Technique ◽  
Vibration Signatures

Vibration analysis is a key tool for preventive maintenance involving the trending and analysis of machinery performance parameters to detect and identify developing problems before failure and extensive damage can occur. A lab-based experimental setup has been established for obtaining fault-free and fault condition data. After this analysis, primary and secondary motor and pump vibration data of the Pakistan Research Reactor-1 were obtained and analyzed. Vibration signatures were acquired in horizontal, vertical, and axial directions. The 48 vibration signatures have been analyzed to assess the operational status of motors and pumps. The vibration spectrum has been recorded for a 2000 Hz frequency span with a 3200 lines resolution. The data collected should be helpful in future Pakistan Research Reactor-1 condition monitoring.

scholarly journals Condition monitoring for airport baggage handling in the era of industry 4.0

2019 ◽  
Vol 25 (3) ◽  
pp. 435-451 ◽  
Author(s):  
Frank Koenig ◽  
Pauline Anne Found ◽  
Maneesh Kumar
Keyword(s):  
Condition Monitoring ◽  
Industry 4.0 ◽  
High Speed ◽  
Rotating Machinery ◽  
Condition Based Maintenance ◽  
Vibration Monitoring ◽  
Vibration Velocity ◽  
Clear Trend ◽  
Content Type ◽  
Stationary Structure

Purpose The purpose of this paper is to present the findings of a recent study conducted with the objective of addressing the problem of failure of baggage carts in the high-speed baggage tunnel at Heathrow Terminal 5 by the development of an innovative condition-based maintenance system designed to meet the requirements of twenty-first century airport systems and Industry 4.0. Design/methodology/approach An empirical experimental approach to this action research was taken to install a vibration condition monitoring pilot test in the north tunnel at Terminal 5. Vibration data were collected over a 6-month period and analysed to find the threshold of good quality tires and those with worn bearings that needed replacement. The results were compared with existing measures to demonstrate that vibration monitoring could be used as a predictive model for condition-based maintenance. Findings The findings demonstrated a clear trend of increasing vibration velocity with age and use of the baggage cart wheels caused by wheel mass unbalanced inertia that was transmitted to the tracks as vibration. As a result, preventative maintenance is essential to ensure the smooth running of airport baggage. This research demonstrates that a healthy wheel produces vibration of under 60 mm/s whereas a damaged wheel measures up to 100 mm/s peak-to-peak velocity and this can be used in real-time condition monitoring to prevent baggage cart failure. It can also run as an autonomous system linked to AI and Industry 4.0 airport logic. Originality/value Whilst vibration monitoring has been used to measure movement in static structures such as bridges and used in rotating machinery such as railway wheels (Tondon and Choudhury, 1999) this is unique as it is the first time it has been applied on a stationary structure (tracks) carrying high-speed rotating machinery (baggage cart wheels). This technique has been patented and proven in the pilot study and is in the process of being rolled out to all Heathrow terminal connection tunnels. It has implications for all other airports world-wide and, with new economic sensors, to other applications that rely on moving conveyor belts.

Wavelet Packet Analysis in the Condition Monitoring of Rotating Machinery

1998 ◽  
Vol 31 (29) ◽  
pp. 37-39
Author(s):  
K.M. Bossley ◽  
R.J. Mckendrick ◽  
C. Mercer ◽  
C.J. Harris
Keyword(s):  
Condition Monitoring ◽  
Wavelet Packet ◽  
Rotating Machinery ◽  
Wavelet Packet Analysis

Practical Applications of Vibration Analysis Software for Diagnosis and Condition Monitoring of Turbomachinery

2007 ◽  
Author(s):  
Norman Remedios ◽  
Ningsheng Feng ◽  
Eric J. Hahn
Keyword(s):  
Condition Monitoring ◽  
Vibration Analysis ◽  
Operating Parameter ◽  
Rotating Machinery ◽  
System Stability ◽  
Practical Application ◽  
Analysis Software ◽  
Significant Cost ◽  
Practical Applications ◽  
Vibration Problems

The benefits of modelling turbomachinery for diagnostic and condition monitoring purposes have not been fully appreciated by the power generation industry or the consultants who service the industry. This paper describes the capabilities and practical application of vibration analysis software for analysing rotor bearing systems of rigidly coupled rotors supported on several hydrodynamic bearings of various bearing profiles. The software has two distinct components — the measurement component and the modelling component. The combination of the two provides access to existing rotating machinery and machinery in the commissioning stage in order to identify the cause of vibration problems and the corrective action required. The modelling software evaluates the effects of bearing alignment changes and operating parameter changes on system stability and vibration response. The data collection analysis software that links with the modelling results provides valuable information about the measured shaft performance at the bearings. The combination of the two components provides an efficient and valuable tool that yields significant cost benefits. The application of the software to a 360Mw and 450Mw unit is evaluated.

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