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24 pages, 3727 KiB

Open AccessArticle

Monitoring the Oil of Wind-Turbine Gearboxes: Main Degradation Indicators and Detection Methods

by Diego Coronado and Jan Wenske

Machines 2018, 6(2), 25; https://doi.org/10.3390/machines6020025 - 08 Jun 2018

Cited by 26 | Viewed by 6900

Oil condition monitoring is a common practice in the wind industry. However, the published research about oil degradation in wind turbine gearboxes is limited. This paper aims at providing new information on the oil degradation process by analyzing wind turbine gearbox oils aged [...] Read more.

Oil condition monitoring is a common practice in the wind industry. However, the published research about oil degradation in wind turbine gearboxes is limited. This paper aims at providing new information on the oil degradation process by analyzing wind turbine gearbox oils aged in the laboratory and in the field. Oil samples were analyzed in the laboratory and two sensors were used to determine the oil condition by means of dielectric constant and conductivity measurements. Additionally, micropitting tests were carried out for three oils with different base stocks. The results of this study show that viscosity changes of the oils from the field were not significant.Extreme pressure additives depletion and the increase of the iron content are among the most relevant degradation indicators. The oil sensors used in this study provided limited information on the oil degradation process. The accuracy of the sensors was affected by the oil type and its measurement range. The results of the micropitting tests showed that even aged oils exhibited a high micropitting resistance. Full article

(This article belongs to the Special Issue Machinery Condition Monitoring and Industrial Analytics)

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19 pages, 1186 KiB

Open AccessFeature PaperEditor’s ChoiceArticle

Development of a Methodology for Condition-Based Maintenance in a Large-Scale Application Field

by Marco Cocconcelli, Luca Capelli, Jacopo Cavalaglio Camargo Molano and Davide Borghi

Machines 2018, 6(2), 17; https://doi.org/10.3390/machines6020017 - 16 Apr 2018

Cited by 12 | Viewed by 6137

Abstract

This paper describes a methodology, developed by the authors, for condition monitoring and diagnostics of several critical components in the large-scale applications with machines. For industry, the main target of condition monitoring is to prevent the machine stopping suddenly and thus avoid economic [...] Read more.

This paper describes a methodology, developed by the authors, for condition monitoring and diagnostics of several critical components in the large-scale applications with machines. For industry, the main target of condition monitoring is to prevent the machine stopping suddenly and thus avoid economic losses due to lack of production. Once the target is reached at a local level, usually through an R&D project, the extension to a large-scale market gives rise to new goals, such as low computational costs for analysis, easily interpretable results by local technicians, collection of data from worldwide machine installations, and the development of historical datasets to improve methodology, etc. This paper details an approach to condition monitoring, developed together with a multinational corporation, that covers all the critical points mentioned above. Full article

(This article belongs to the Special Issue Machinery Condition Monitoring and Industrial Analytics)

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16 pages, 2663 KiB

Open AccessFeature PaperArticle

A Minimal-Sensing Framework for Monitoring Multistage Manufacturing Processes Using Product Quality Measurements

by Hossein Davari Ardakani and Jay Lee

Machines 2018, 6(1), 1; https://doi.org/10.3390/machines6010001 - 05 Jan 2018

Cited by 7 | Viewed by 4128

Abstract

For implementing data analytic tools in real-world applications, researchers face major challenges such as the complexity of machines or processes, their dynamic operating regimes and the limitations on the availability, sufficiency and quality of the data measured by sensors. The limits on using [...] Read more.

For implementing data analytic tools in real-world applications, researchers face major challenges such as the complexity of machines or processes, their dynamic operating regimes and the limitations on the availability, sufficiency and quality of the data measured by sensors. The limits on using sensors are often related to the costs associated with them and the inaccessibility of critical locations within machines or processes. Manufacturing processes, as a large group of applications in which data analytics can bring significant value to, are the focus of this study. As the cost of instrumenting the machines in a manufacturing process is significant, an alternative solution which relies solely on product quality measurements is greatly desirable in the manufacturing industry. In this paper, a minimal-sensing framework for machine anomaly detection in multistage manufacturing processes based on product quality measurements is introduced. This framework, which relies on product quality data along with products’ manufacturing routes, allows the detection of variations in the quality of the products and is able to pinpoint the machine which is the cause of anomaly. A moving window is applied to the data, and a statistical metric is extracted by comparing the performance of a machine to its peers. This approach is expanded to work for multistage processes. The proposed method is validated using a dataset from a real-world manufacturing process and additional simulated datasets. Moreover, an alternative approach based on Bayesian Networks is provided and the performance of the two proposed methods is evaluated from an industrial implementation perspective. The results showed that the proposed similarity-based approach was able to successfully identify the root cause of the quality variations and pinpoint the machine that adversely impacted the product quality. Full article

(This article belongs to the Special Issue Machinery Condition Monitoring and Industrial Analytics)

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5268 KiB

Open AccessArticle

The Decision making System for Condition Monitoring of Induction Motors Based on Vector Control Model

by Abdullah Alwadie

Machines 2017, 5(4), 27; https://doi.org/10.3390/machines5040027 - 12 Nov 2017

Cited by 10 | Viewed by 4498

Abstract

Induction motors are mainly used for variable load applications and it is vital to have a condition monitoring system with capabilities to diagnose motor faults in variable load conditions. The environment noise varies has non-linear relation with motor load and it challenges the [...] Read more.

Induction motors are mainly used for variable load applications and it is vital to have a condition monitoring system with capabilities to diagnose motor faults in variable load conditions. The environment noise varies has non-linear relation with motor load and it challenges the decision making capability of the condition monitoring system. This paper addresses the issue of reliable decision making on the existence of bearing faults in variable load conditions. Two type of threshold schemes have been proposed to reliably diagnose bearing faults in Park vector modulus spectrum. The performance of the developed threshold based condition monitoring system has been analyzed theoretically and experimentally. Full article

(This article belongs to the Special Issue Machinery Condition Monitoring and Industrial Analytics)

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3380 KiB

Open AccessArticle

Drilling Rig Hoisting Platform Security Monitoring System Design and Application

by Junjiang He and Min Luo

Machines 2017, 5(3), 19; https://doi.org/10.3390/machines5030019 - 22 Aug 2017

Cited by 1 | Viewed by 10254

Abstract

Drilling rig hoisting platform security monitoring system has played a very important role in oil exploration. And drilling parameters and working condition of workers are particularly important, because these parameters indicate that whether the drilling work is safe and effective directly. A security [...] Read more.

Drilling rig hoisting platform security monitoring system has played a very important role in oil exploration. And drilling parameters and working condition of workers are particularly important, because these parameters indicate that whether the drilling work is safe and effective directly. A security monitoring system is established to provide the real-time parameters for drilling safety is the purpose of this study. The monitoring system includes a top drive, a traveling block hook, an oil derrick and a driller room, and the controller of the system is programmable logic controller PLC. The procedure of the system is written by the RSLogix5000 software, the PC configuration is used force control monitor configuration software. According to the system, top drive, driller room and environment wind speed parameters in real-time are collected and displayed in the configuration of upper computer, the collected parameters can be used to determine the working conditions of the top drive and to send timely warnings for inspection maintenance to avoid drilling safety accidents. Work fatigue remind of driller and regularly remind of derrick check can be as much as possible to reduce safety accidents. And automatic operation of traveling block hook reached the default point faster and more smoothly than manual operation given the other uncontrollable factors in manual operation. The application of the system is successfully working in the drilling work site. Full article

(This article belongs to the Special Issue Machinery Condition Monitoring and Industrial Analytics)

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3223 KiB

Open AccessArticle

An Ensemble-Boosting Algorithm for Classifying Partial Discharge Defects in Electrical Assets

by Abdullahi Abubakar Mas’ud, Jorge Alfredo Ardila-Rey, Ricardo Albarracín and Firdaus Muhammad-Sukki

Machines 2017, 5(3), 18; https://doi.org/10.3390/machines5030018 - 08 Aug 2017

Cited by 14 | Viewed by 5018

Abstract

This paper presents an ensemble-boosting algorithm (EBA) for classifying partial discharge (PD) patterns in the condition monitoring of insulation diagnosis applied for electrical assets. This approach presents an optimization technique for creating a sequence of artificial neural network (ANNs), where the training data [...] Read more.

This paper presents an ensemble-boosting algorithm (EBA) for classifying partial discharge (PD) patterns in the condition monitoring of insulation diagnosis applied for electrical assets. This approach presents an optimization technique for creating a sequence of artificial neural network (ANNs), where the training data for each constituent of the sequence is selected based on the performance of previous ANNs. Four different PD faults scenarios were manufactured in the high-voltage (HV) laboratory to simulate the PD faults of cylindrical voids in methacrylate, point-air-plane configuration, ceramic bushing with contaminated surface and a transformer affected by the internal PD. A PD dataset was collected, pre-processed and prepared for its use in the improved boosting algorithm using statistical techniques. In this paper, the EBA is extensively compared with the widely used single artificial neural network (SNN). Results show that the proposed approach can effectively improve the generalization capability of the PD patterns. The application of the proposed technique for both online and offline practical PD recognition is examined. Full article

(This article belongs to the Special Issue Machinery Condition Monitoring and Industrial Analytics)

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Review

Jump to: Research

1110 KiB

Open AccessReview

Rotating Electrical Machine Condition Monitoring Automation—A Review

by Mallikarjun Kande, Alf J. Isaksson, Rajeev Thottappillil and Nathaniel Taylor

Machines 2017, 5(4), 24; https://doi.org/10.3390/machines5040024 - 19 Oct 2017

Cited by 43 | Viewed by 10410

Abstract

We review existing machine condition monitoring techniques and industrial automation for plant-wide condition monitoring of rotating electrical machines. Cost and complexity of a condition monitoring system increase with the number of measurements, so extensive condition monitoring is currently mainly restricted to the situations [...] Read more.

We review existing machine condition monitoring techniques and industrial automation for plant-wide condition monitoring of rotating electrical machines. Cost and complexity of a condition monitoring system increase with the number of measurements, so extensive condition monitoring is currently mainly restricted to the situations where the consequences of poor availability, yield or quality are so severe that they clearly justify the investment in monitoring. There are challenges to obtaining plant-wide monitoring that includes even small machines and non-critical applications. One of the major inhibiting factors is the ratio of condition monitoring cost to equipment cost, which is crucial to the acceptance of using monitoring to guide maintenance for a large fleet of electrical machinery. Ongoing developments in sensing, communication and computation for industrial automation may greatly extend the set of machines for which extensive monitoring is viable. Full article

(This article belongs to the Special Issue Machinery Condition Monitoring and Industrial Analytics)

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5781 KiB

Open AccessReview

A Review of Feature Extraction Methods in Vibration-Based Condition Monitoring and Its Application for Degradation Trend Estimation of Low-Speed Slew Bearing

by Wahyu Caesarendra and Tegoeh Tjahjowidodo

Machines 2017, 5(4), 21; https://doi.org/10.3390/machines5040021 - 27 Sep 2017

Cited by 311 | Viewed by 15575

Abstract

This paper presents an empirical study of feature extraction methods for the application of low-speed slew bearing condition monitoring. The aim of the study is to find the proper features that represent the degradation condition of slew bearing rotating at very low speed [...] Read more.

This paper presents an empirical study of feature extraction methods for the application of low-speed slew bearing condition monitoring. The aim of the study is to find the proper features that represent the degradation condition of slew bearing rotating at very low speed (≈ 1 r/min) with naturally defect. The literature study of existing research, related to feature extraction methods or algorithms in a wide range of applications such as vibration analysis, time series analysis and bio-medical signal processing, is discussed. Some features are applied in vibration slew bearing data acquired from laboratory tests. The selected features such as impulse factor, margin factor, approximate entropy and largest Lyapunov exponent (LLE) show obvious changes in bearing condition from normal condition to final failure. Full article

(This article belongs to the Special Issue Machinery Condition Monitoring and Industrial Analytics)

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