On-line Condition Monitoring and Diagnostic Network System for Rotating Machine Set

Several industrial computers and a server are combined to set up the on-line monitoring and diagnostic system of turbo-generator sets. The main function of the system is to monitor machine sets' running condition. Through analyzing running data, technicians can detect whether there exist faults and where they occur. To share and transmit the dynamic information of the turbo-generator sets, a distributed network system is introduced. NetWare network operating system is used in the LAN (Local Area Network) system. The LAN is extended to realize the sharing of data and remote transmission of information. Furthermore, functions of monitoring and diagnostic clients are listed.

Evaluation of the Performance of Infrared Thermography for On-Line Condition Monitoring of Rotating Machines

This study evaluated the possibility of infrared thermography to measure accurately the temperature of elements of a rotating device, within the scope of condition monitoring. The tested machine was a blower coupled to a 500 kW electric motor, that operated in multiples regimes. The thermograms were acquired by a fixed thermographic camera and were processed and recorded every 15 minutes. Because the normal temperature variations could easily mask a drift caused by a failure, a corrected temperature was computed using autorecursive models. It was shown that an efficient temperature correction should compensate for the variations of the process, and for the ambient temperatures variations, either daily or seasonal. The standard deviation of the corrected temperature was of a few tenth of degree, making possible the detection of a drift of less than one degree and the prediction of potential failure.

Design, Implementation and Simulation of Non-Intrusive Sensor for On-Line Condition Monitoring of MV Electrical Components

Non-intrusive measurement technology is of great interest for the electrical utilities in order to avoid an interruption in the normal operation of the supply network during diagnostics measurements and inspections. Inductively coupled electromagnetic sensing provides a possibility of non-intrusive measurements for online condition monitoring of the electrical components in a Medium Voltage (MV) distribution network. This is accomplished by employing Partial Discharge (PD) activity monitoring, one of the successful methods to assess the working condition of MV components but often requires specialized equipment for carrying out the measurements. In this paper, Rogowski coil sensor is presented as a robust solution for non-intrusive measurements of PD signals. A high frequency prototype of Rogowski coil is designed in the laboratory. Step-by-step approach of constructing the sensor system is presented and performance of its components (coil head, damping component, integrator and data acquisition system) is evaluated using practical and simulated environments. Alternative Transient Program-Electromagnetic Transient Program (ATP-EMTP) is used to analyze the designed model of the Rogowski coil. Real and simulated models of the coil are used to investigate the behavior of Rogowski coil sensor at its different stages of development from a transducer coil to a complete measuring device. Both models are compared to evaluate their accuracy for PD applications. Due to simple design, flexible hardware, and low cost of Rogowski coil, it can be considered as an efficient current measuring device for integrated monitoring applications where a large number of sensors are required to develop an automated online condition monitoring system for a distribution network.

On-line Tool Condition Monitoring with Improved Fuzzy Neural Network

This paper presents an investigation of tool condition monitoring based on fuzzy neural network for drilling. In this study, five monitoring feature parameters, which will be used to monitor tool condition, are selected by means of vibration signal spectral analysis. In order to meet the need of the system real time, this paper presents a neural network with fuzzy inference. Fuzzy neural network requires less computation than backpropagation neural network, and can easily describe the relationship between the tool conditions and the monitoring indices. The experimental results indicate that the use of vibration signal for on--line drilling condition monitoring is feasible.

Improving autoencoder-based unsupervised damage detection in uncontrolled structural health monitoring under noisy conditions

Structural health monitoring is widely utilized in outdoor environments,especially under harsh conditions,which can introduce noise into the monitoring system.Therefore,designing an effective denoising strategy to enhance the performance of guided wave damage detection in noisy environments is crucial.This paper introduces a local temporal principal component analysis(PCA)reconstruction approach for denoising guided waves prior to implementing unsupervised damage detection,achieved through novel autoencoder-based reconstruction.Experimental results demonstrate that the proposed denoising method significantly enhances damage detection performance when guided waves are contaminated by noise,with SNR values ranging from 10 to-5 dB.Following the implementation of the proposed denoising approach,the AUC score can elevate from 0.65 to 0.96 when dealing with guided waves corrputed by noise at a level of-5 dB.Additionally,the paper provides guidance on selecting the appropriate number of components used in the denoising PCA reconstruction,aiding in the optimization of the damage detection in noisy conditions.

Statistical Models for Condition Monitoring and State of Health Estimation of Lithium-Ion Batteries for Ships

Battery systems are increasingly being used for powering ocean going ships,and the number of fully electric or hybrid ships relying on battery power for propulsion is growing.To ensure the safety of such ships,it is important to monitor the available energy that can be stored in the batteries,and classification societies typically require the state of health(SOH)to be verified by independent tests.This paper addresses statistical modeling of SOH for maritime lithium-ion batteries based on operational sensor data.Various methods for sensor-based,data-driven degradation monitoring will be presented,and advantages and challenges with the different approaches will be discussed.The different approaches include cumulative degradation models and snapshot models,models that need to be trained and models that need no prior training,and pure data-driven models and physics-informed models.Some of the methods only rely on measured data,such as current,voltage,and temperature,whereas others rely on derived quantities such as state of charge.Models include simple statistical models and more complicated machine learning techniques.Insight from this exploration will be important in establishing a framework for data-driven diagnostics and prognostics of maritime battery systems within the scope of classification societies.

Temporally Preserving Latent Variable Models:Offline and Online Training for Reconstruction and Interpretation of Fault Data for Gearbox Condition Monitoring

Latent variable models can effectively determine the condition of essential rotating machinery without needing labeled data.These models analyze vibration data via an unsupervised learning strategy.Temporal preservation is necessary to obtain an informative latent manifold for the fault diagnosis task.In a temporalpreserving context,two approaches exist to develop a condition-monitoring methodology:offline and online.For latent variable models,the available training modes are not different.While many traditional methods use offline training,online training can dynamically adjust the latent manifold,possibly leading to better fault signature extraction from the vibration data.This study explores online training using temporal-preserving latent variable models.Within online training,there are two main methods:one focuses on reconstructing data and the other on interpreting the data components.Both are considered to evaluate how they diagnose faults over time.Using two experimental datasets,the study confirms that models from both training modes can detect changes in machinery health and identify faults even under varying conditions.Importantly,the complementarity of offline and online models is emphasized,reassuring their versatility in fault diagnostics.Understanding the implications of the training approach and the available model formulations is crucial for further research in latent variable modelbased fault diagnostics.

Development and Application of On-Line Corrosion Monitoring Device for Condenser Tube

This paper introduces the development and industrial application of an on-line corrosion monitoring device for condenser tubes. Corrosion sensors are made up of representative condenser tubes chosen by eddy current test, which enable the monitoring result to be consistent with the corrosion of actual condenser tubes. Localized corrosion rate of condenser tubes can be measured indirectly by a galvanic couple made up of tube segments with and without pits. Using this technology, corrosion problems can be found in time and accurately, and anticorrosive measures be made more economic and effective. Applications in two power plants showed the corrosion measurements are fast and accurate.

AN INTELLIGENT TOOL CONDITION MONITORING SYSTEM USING FUZZY NEURAL NETWORKS

Reliable on line cutting tool conditioning monitoring is an essential feature of automatic machine tool and flexible manufacturing system (FMS) and computer integrated manufacturing system (CIMS). Recently artificial neural networks (ANNs) are used for this purpose in conjunction with suitable sensory systems. The present work in Norwegian University of Science and Technology (NTNU) uses back propagation neural networks (BP) and fuzzy neural networks (FNN) to process the cutting tool state data measured with force and acoustic emission (AE) sensors, and implements a valuable on line tool condition monitoring system using the ANNs. Different ANN structures are designed and investigated to estimate the tool wear state based on the fusion of acoustic emission and force signals. Finally, four case studies are introduced for the sensing and ANN processing of the tool wear states and the failures of the tool with practical experiment examples. The results indicate that a tool wear identification system can be achieved using the sensors integration with ANNs, and that ANNs provide a very effective method of implementing sensor integration for on line monitoring of tool wear states and abnormalities.

On-Line Monitoring of Cutting Tool Fracture & Wear

A technique of detecting cutting tool fracture and ultimate wear by si- multaneously monitoring both the spindle motor current and cutting process related acoustic emission(AE)in the cutting process is reported.The technique can detect breakage of drills having diameter over 0.8mm,turning cutter crack of area over 0.2mm,and the ultimate wear.The principle,system construction,experimental method and result of the technique are discussed.The ratio of success in detection approaches 96% or higher.

Working Condition Real-Time Monitoring Model of Lithium Ion Batteries Based on Distributed Parameter System and Single Particle Model

Lithium ion batteries are complicated distributed parameter systems that can be described preferably by partial differential equations and a field theory. To reduce the solution difficulty and the calculation amount, if a distributed parameter system is described by ordinary differential equations （ODE） during the analysis and the design of distributed parameter system, the reliability of the system description will be reduced, and the systemic errors will be introduced. Studies on working condition real-time monitoring can improve the security because the rechargeable LIBs are widely used in many electronic systems and electromechanical equipment. Single particle model （SPM） is the simplification of LIB under some approximations, and can estimate the working parameters of a LIB at the faster simulation speed. A LIB modelling algorithm based on PDEs and SPM is proposed to monitor the working condition of LIBs in real time. Although the lithium ion concentration is an unmeasurable distributed parameter in the anode of LIB, the working condition monitoring model can track the real time lithium ion concentration in the anode of LIB, and calculate the residual which is the difference between the ideal data and the measured data. A fault alarm can be triggered when the residual is beyond the preset threshold. A simulation example verifies that the effectiveness and the accuracy of the working condition real-time monitoring model of LIB based on PDEs and SPM.

On-line Monitoring for Phosphorus Removal Process and Bacterial Community in Sequencing Batch Reactor

For efficient energy consumption and control of effluent quality, the cycle duration for a sequencing batch reactor (SBR) needs to be adjusted by real-time control according to the characteristics and loading of waste-water. In this study, an on-line information system for phosphorus removal processes was established. Based on the analysis for four systems with different ecological community structures and two operation modes, anaerobic-aerobic process and anaerobic-anaerobic process, the characteristic patterns of oxidation-reduction potential (ORP) and pH were related to phosphorous dynamics in the anaerobic, anoxic and aerobic phases, for determination of the end of phosphorous removal. In the operation mode of anaerobic-aerobic process, the pH profile in the anaerobic phase was used to estimate the relative amount of phosphorous accumulating organisms (PAOs) and glycogen accumulat-ing organisms (GAOs), which is beneficial to early detection of ecology community shifts. The on-line sensor val-ues of pH and ORP may be used as the parameters to adjust the duration for phosphorous removal and community shifts to cope with influent variations and maintain appropriate operation conditions.

Turbopump Condition Monitoring Using Incremental Clustering and One-class Support Vector Machine

Turbopump condition monitoring is a significant approach to ensure the safety of liquid rocket engine （LRE）.Because of lack of fault samples,a monitoring system cannot be trained on all possible condition patterns.Thus it is important to differentiate abnormal or unknown patterns from normal pattern with novelty detection methods.One-class support vector machine （OCSVM） that has been commonly used for novelty detection cannot deal well with large scale samples.In order to model the normal pattern of the turbopump with OCSVM and so as to monitor the condition of the turbopump,a monitoring method that integrates OCSVM with incremental clustering is presented.In this method,the incremental clustering is used for sample reduction by extracting representative vectors from a large training set.The representative vectors are supposed to distribute uniformly in the object region and fulfill the region.And training OCSVM on these representative vectors yields a novelty detector.By applying this method to the analysis of the turbopump＇s historical test data,it shows that the incremental clustering algorithm can extract 91 representative points from more than 36 000 training vectors,and the OCSVM detector trained on these 91 representative points can recognize spikes in vibration signals caused by different abnormal events such as vane shedding,rub-impact and sensor faults.This monitoring method does not need fault samples during training as classical recognition methods.The method resolves the learning problem of large samples and is an alternative method for condition monitoring of the LRE turbopump.

Online Condition Monitoring of Gripper Cylinder in TBM Based on EMD Method

The gripper cylinder that provides braced force for Tunnel Boring Machine （TBM） might fail due to severe vibration when the TBM excavates in the tunnel. Early fault diagnosis of the gripper cylinder is important for the safety and efficiency of the whole tunneling project. In this paper, an online condition monitoring system based on the Empirical Mode Decomposition （EMD） method is estab- lished for fault diagnosis of the gripper cylinder while TBM is working. Firstly, the lumped mass parameter model of the gripper cylinder is established considering the influence of the variable stiffness at the rock interface, the equivalent stiffness of the oil, the seals, and the copper guide sleeve. The dynamic performance of the gripper cylinder is investigated to provide basis for its health condition evaluation. Then, the EMD method is applied to identify the characteristic frequencies of the gripper cylinder for fault diagnosis and a field test is used to verify the accuracy of the EMD method for detection of the characteristic frequencies. Furthermore, the contact stiff- ness at the interface between the barrel and the rod is calculated with Hertz theory and the relationship between the natural frequency and the stiffness varying with the health condition of the cylinder is simulated based on the dynamic model. The simulation shows that the character- istic frequencies decrease with the increasing clearance between the barrel and the rod, thus the defects could be indicated by monitoring the natural frequency. Finally, a health condition management system of the gripper cylin- der based on the vibration signal and the EMD method is established, which could ensure the safety of TBM.

Sparsity-Assisted Intelligent Condition Monitoring Method for Aero-engine Main Shaft Bearing

Weak feature extraction is of great importance for condition monitoring and intelligent diagnosis of aeroengine.Aimed at achieving intelligent diagnosis of aero-engine main shaft bearing,an enhanced sparsity-assisted intelligent condition monitoring method is proposed in this paper.Through analyzing the weakness of convex sparse model,i.e.the tradeoff between noise reduction and feature reconstruction,this paper proposes an enhanced-sparsity nonconvex regularized convex model based on Moreau envelope to achieve weak feature extraction.Accordingly,a sparsity-assisted deep convolutional variational autoencoders network is proposed,which achieves the intelligent identification of fault state through training denoised normal data.Finally,the effectiveness of the proposed method is verified through aero-engine bearing run-to-failure experiment.The comparison results show that the proposed method is good at abnormal pattern recognition,showing a good potential for weak fault intelligent diagnosis of aero-engine main shaft bearings.

Swarm-LSTM: Condition Monitoring of Gearbox Fault Diagnosis Based on Hybrid LSTM Deep Neural Network Optimized by Swarm Intelligence Algorithms

Nowadays,renewable energy has been emerging as the major source of energy and is driven by its aggressive expansion and falling costs.Most of the renewable energy sources involve turbines and their operation and maintenance are vital and a difficult task.Condition monitoring and fault diagnosis have seen remarkable and revolutionary up-gradation in approaches,practices and technology during the last decade.Turbines mostly do use a rotating type of machinery and analysis of those signals has been challenging to localize the defect.This paper proposes a new hybrid model wherein multiple swarm intelligence models have been evaluated to optimize the conventional Long Short-Term Memory(LSTM)model in classifying the faults from the vibration signals data acquired from the gearbox.This helps to analyze the performance and behavioral patterns of the system more effectively and efficiently which helps to suggest for replacement of the unit with higher precision.The results have demonstrated that the proposed hybrid modeling approach is effective in classifying the faults of the gearbox from the time series data and achieve higher diagnostic accuracy in comparison to the conventional LSTM methods.

A system for underground road condition monitoring

Poor road conditions in underground mine tunnels can lead to decreased production efficiency and increased wear on production vehicles. A prototype system for road condition monitoring is presented in this paper to counteract this. The system consists of three components i.e. localization, road monitoring, and scheduling. The localization of vehicles is performed using a Rao-Blackwellized extended particle filter, combining vehicle mounted sensors with signal strengths of Wi Fi access points. Two methods for road monitoring are described: a Kalman filter used together with a model of the vehicle suspension system, and a relative condition measure based on the power spectral density. Lastly, a method for taking automatic action on an ill-conditioned road segment is proposed in the form of a rescheduling algorithm.The scheduling algorithm is based on the large neighborhood search and is used to integrate road service activities in the short-term production schedule while minimizing introduced production disturbances.The system is demonstrated on experimental data collected in a Swedish underground mine.

Virtual sensing for gearbox condition monitoring based on kernel factor analysis

Vibration and oil debris analysis are widely used in gearbox condition monitoring as the typical indirect and direct sensing techniques. However, they have their own advantages and disadvantages. To better utilize the sensing information and overcome its shortcomings, this paper presents a virtual sensing technique based on artificial intelligence by fusing low-cost online vibration measurements to derive a gearbox condition indictor, and its performance is comparable to the costly offline oil debris measurements. Firstly, the representative features are extracted from the noisy vibration measurements to characterize the gearbox degradation conditions. However, the extracted features of high dimensionality present nonlinearity and uncertainty in the machinery degradation process. A new nonlinear feature selection and fusion method,named kernel factor analysis, is proposed to mitigate the aforementioned challenge. Then the virtual sensing model is constructed by incorporating the fused vibration features and offline oil debris measurements based on support vector regression. The developed virtual sensing technique is experimentally evaluated in spiral bevel gear wear tests,and the results show that the developed kernel factor analysis method outperforms the state-of-the-art featureselection techniques in terms of virtual sensing model accuracy.

Bio-inspired computational techniques based on advanced condition monitoring

The application of bio-inspired computational techniques to the field of condition monitoring is addressed. First, the bio-inspired computational techniques are briefly addressed; the advantages and disadvantages of these computational methods are made clear. Then, the roles of condition monitoring in the predictive maintenance and failures prediction and the development trends of condition monitoring are discussed. Finally, a case study on the condition monitoring of grinding machine is described, which shows the application of bio-inspired computational technique to a practical condition monitoring system.

Massive Power Device Condition Monitoring Data Feature Extraction and Clustering Analysis using MapReduce and Graph Model

Effective storage,processing and analyzing of power device condition monitoring data faces enormous challenges.A framework is proposed that can support both MapReduce and Graph for massive monitoring data analysis at the same time based on Aliyun DTplus platform.First,power device condition monitoring data storage based on MaxCompute table and parallel permutation entropy feature extraction based on MaxCompute MapReduce are designed and implemented on DTplus platform.Then,Graph based k-means algorithm is implemented and used for massive condition monitoring data clustering analysis.Finally,performance tests are performed to compare the execution time between serial program and parallel program.Performance is analyzed from CPU cores consumption,memory utilization and parallel granularity.Experimental results show that the designed framework and parallel algorithms can efficiently process massive power device condition monitoring data.