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Intelligent Condition Indices in Fault Diagnosis

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Automatic fault detection enables reliable condition monitoring even when long periods of continuous operation are required. Dimensionless indices provide useful information on different faults, and even more sensitive solutions can be obtained by selecting suitable features. These indices combine two or more features, e.g. root-mean-square values and peak values. Additional features can be introduced by analysing signal distributions, for example. The features are generated directly from the higher order derivatives of the acceleration signals, and the models can be based on data or expertise. Generalised moments and norms introduce efficient new features which even alone can provide good solutions with automation systems, but combining several easily calculated features is an efficient approach for intelligent sensors. The nonlinear scaling used in the linguistic equation approach extends the idea of dimensionless indices to nonlinear systems. Indices are obtained from these scaled values by means of linear equations. Indices detect differences between normal and faulty conditions and provide an indication of the severity of the faults. They can even classify different faults in case-based reasoning (CBR) type applications. Additional model complexity, e.g. response surface methods or neural networks, does not provide any practical improvements in these examples. The indices are calculated with problem-specific sample times, and variation with time is handled as uncertainty by presenting the indices as time-varying fuzzy numbers. The classification limits can also be considered fuzzy. Condition indices can be obtained from the degrees of membership which are produced by the reasoning system. Practical long-term tests have been performed e.g. for diagnosing faults in bearings, in supporting rolls of lime kilns and for the cavitation of water turbines. The indices obtained from short samples are aimed for use in the same way as the process measurements in process control. The new indices are consistent with the measurement index MIT and the health index SOL developed for condition monitoring.
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INTELLIGENT CONDITION INDICES IN FAULT DIAGNOSIS
Esko Juuso
Control Engineering Laboratory, Department of Process and Environmental Engineering,
P.O.Box 4300, FI-90014 University of Oulu, Finland
Phone: +358-8-5532463
E-mail: esko.juuso@oulu.fi
Sulo Lahdelma
Mechatronics and Machine Diagnostics Laboratory, Department of Mechanical
Engineering, P.O.Box 4200, FI-90014 University of Oulu, Finland
E-mail: sulo.lahdelma@oulu.fi
ABSTRACT
Automatic fault detection enables reliable condition monitoring even when long periods of
continuous operation are required. Dimensionless indices provide useful information on
different faults, and even more sensitive solutions can be obtained by selecting suitable
features. These indices combine two or more features, e.g. root-mean-square values and
peak values. Additional features can be introduced by analysing signal distributions, for
example. The features are generated directly from the higher order derivatives of the
acceleration signals, and the models can be based on data or expertise. Generalised
moments and norms introduce efficient new features which even alone can provide good
solutions with automation systems, but combining several easily calculated features is an
efficient approach for intelligent sensors. The nonlinear scaling used in the linguistic
equation approach extends the idea of dimensionless indices to nonlinear systems. Indices
are obtained from these scaled values by means of linear equations. Indices detect
differences between normal and faulty conditions and provide an indication of the severity
of the faults. They can even classify different faults in case-based reasoning (CBR) type
applications. Additional model complexity, e.g. response surface methods or neural
networks, does not provide any practical improvements in these examples. The indices are
calculated with problem-specific sample times, and variation with time is handled as
uncertainty by presenting the indices as time-varying fuzzy numbers. The classification
limits can also be considered fuzzy. Condition indices can be obtained from the degrees of
membership which are produced by the reasoning system. Practical long-term tests have
been performed e.g. for diagnosing faults in bearings, in supporting rolls of lime kilns and
for the cavitation of water turbines. The indices obtained from short samples are aimed for
use in the same way as the process measurements in process control. The new indices are
consistent with the measurement index MIT and the health index SOL developed for
condition monitoring.
1. INTRODUCTION
Attempts to detect different types of machine faults reliably at an early stage requires
improved signal processing methods and intelligent fault diagnosis. Vibration
measurements provide a good basis for condition monitoring. Dimensionless indices are
obtained by comparing each feature value with the corresponding value in normal
operation. These indices provide useful information on different faults, and even more
sensitive solutions can be obtained by selecting suitable features.(1) Generalised moments
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and norms include many well-known statistical features as special cases and provide
compact new features capable of detecting faulty situations (2).
Intelligent models extend the idea of dimensionless indices to nonlinear systems.
Operating conditions can be detected by means of a Case-Based Reasoning (CBR) type
application with linguistic equation (LE) models and Fuzzy Logic (3,4,5). The basic idea is
nonlinear scaling, which was developed to extract the meanings of variables from
measurement signals (6). The LE models are linear equations
0
1
=+
=
ij
m
j
ji BXA ................................................................................. (1)
where j
X is a linguistic level for the variable j, j=1...m. Each equation i has its own set of
interaction coefficients ....1, mjA ji = The bias term i
B was introduced for fault diagnosis
systems. Various fuzzy models can be represented by means of LE models, and neural
networks and evolutionary computing can be used in tuning. The first LE application in
condition monitoring was presented in (7). The condition monitoring applications are
similar to the applications intended for detecting operating conditions in the process
industry (8).
This paper deals with condition indices and fault models with special emphasis on
nonlinear scaling and linguistic equations.
2. FEATURE EXTRACTION
Feature extraction is based on velocity )1(
x, acceleration )2(
x and higher derivatives, )3(
x
and )4(
x. The other signals have been obtained from acceleration through analogue (9) or
numerical integration and derivation (10).
2.1 Statistical features
Signals )(
α
x can be analysed with standard deviation,
()
,)
1
(2/1
1
2
)()(
=
= N
i
ixx
N
αα
α
σ
........................................................ (2)
and kurtosis,
()
,
)(
1
1
4
)()(
4
2
=
= N
i
ixx
N
αα
α
α
σ
β
..................................................... (3)
where )(
α
x is the arithmetic mean of the signal values Nixi,...,1,
)( =
α
, and α is a real
number. Root-mean-square of )(
α
x, i.e. rms
x)(
α
is
α
σ
when .0
)( =
α
x
These features have been used for fault diagnosis in a test rig which consists of an
electric motor and a transmission between two axes with roller bearings (7). The rig was to
simulate different fault modes. Independent fault modes were rotor unbalance at two
levels, three coupling misalignment cases between the motor and input shaft, bent shaft,
and three bearings faults. One fault at time was simulated at five rotation speeds, and
vibration data were collected using seven acceleration sensors. The offset was removed
from the signals before calculating the features: rms and kurtosis of the acceleration )2(
x,
the average of the highest three values of the jerk )3(
x, and rms velocities rms
x)1( in two
frequency ranges, 10-1000 Hz and 20-85 Hz.
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The cavitation analysis for a Kaplan water turbine in (9) was based on two features: the
mean peak )(
α
mp
x and the fraction )(
α
h
F of the peaks exceeding the normal range
[]
αα
σ
σ
3,3 obtained from the signal )(
α
x, α = 1, 3 and 4. The feature values for )3(
x and
)4(
x are quite similar and give an indication of cavitation points. The velocity incorrectly
shows a high indication of cavitation in some cases. The power range, which is free of
cavitation, was taken as a basis for detecting an increase in the signal levels. The fractions
)(
α
h
F have low values in the low power range where the spikes are less frequent. The
values rise with increasing power as the number of small spikes grows. This can be heard
as an increasing noise.
The velocity )1(
x was replaced by the acceleration )2(
x in (10,11). The numerical
derivation and integration of the acceleration signals were performed with LabVIEW, and
all the signals were filtered by means of a sixth order Butterworth bandpass filter. The
frequency ranges were 10-1000 Hz, 10-2000 Hz, 10-3000 Hz and 10-4000 Hz. Signals
)(
α
x, α = 2, 3 and 4, were analysed in each frequency range by means of rms values,
kurtosis and peak values. As the peak values are based on the highest three peaks in the
discretised values, the three values may also originate from a single peak. The kurtosis is a
useful feature in the low power range but for the cavitation-free area and the high power
range, the kurtosis is close to value 3, which corresponds to a Gaussian signal, i.e. kurtosis
does not give an indication of cavitation in the high power range. An alternative feature for
kurtosis is peak value, which has fairly similar changes in the low power range and small
changes in the high power range.
Detecting bearing faults and unbalance in fast rotating bearings (12) was based on
standard deviations calculated for the signal )4(
xon three frequency ranges: 10-1000 Hz,
10-10000 Hz and 10-50000 Hz. Unbalance was clearly detected on the basis of the
standard deviations obtained from the lowest frequency range. Several signals had to be
combined for detecting the other faults. In this case the rotation frequency was in the range
65-525 Hz.
2.2 Signal distribution
The distributions of the signals )1(
x, )3(
x and )4(
x have been used in monitoring the
condition of the supporting rolls of a lime kiln (13,14). Fault situations were detected as a
large number of strong impacts. The bins )(
α
k
F of the histograms are based on the standard
deviation
α
σ
of the corresponding signal )(
α
x in the following way: (k=1)
α
ασ
2
)( x,
(k=2)
α
α
α
σσ
32 )( <x, (k=3)
α
α
α
σσ
43 )( <x, (k=4)
α
α
α
σσ
54 )( <x, and (k=5)
α
α
σ
5
)( x, where α is the order of derivative. The velocity signal only shows very small
differences between a serious surface problem and an excellent condition. For signals )3(
x
and )4(
x, large values for the features
α
σ
and the fractions )(
α
k
F, k=4 and 5 are related to
faulty situations, and large values for the fractions )(
α
k
F, k=1…3 are obtained in normal
conditions. Similar results can be obtained with bins defined by the absolute average of the
signals, and the resulting easier calculation is useful for developing intelligent sensors.
2.3 Generalised moments and norms
The generalised central moment can be normalised by means of the standard deviation
α
σ
of the signal )(
α
x:
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()
.
1)(
1
)( p
N
i
i
p
pxx
N
M
αα
α
α
τ
σ
σ
=
=
...................... (4)
which was presented in (15). The order of derivation ranges from 1 corresponding to
velocity to 4, which corresponds to the signal x(4). The moment 1
2=
α
τ
σ
M, and the moment
4
α
τ
σ
M correspond to the kurtosis of the signal. The norm defined by means of
,)
1
(/1
1
)( p
N
i
p
i
p
px
N
M
=
=
α
α
τ
............................................. (5)
was taken into use in (2).
Figure 1. Relative )max( p
M
α
τ
when α= 1, 3 and 4, τ = 3 s and p= 8, 3 and 2.75, and the
knowledge-based cavitation index *
C
I.
The knowledge-based cavitation index *
C
I (Figure 1) provides an indication of both clear
cavitation and clearly good operation. Values -2 and -1 indicate good operating conditions.
Value 1 corresponds to clear signs of cavitation, and value 2 means a very strong
indication of cavitation.
The relative )max( 75.2
4
3Mprovides a good indication for cavitation as explained in (2).
The relative )max( p
M
α
τ
is obtained by comparing )max( p
M
α
τ
at each power to the
)max( p
M
α
τ
at 15 MW. A slightly higher order of moment is needed for the signal )3(
x
than for )4(
x: The cavitation-free area and the cavitation cases at 2 and 10 MW are clearly
detected. However, the values of the relative )max( 3
3
3Mat 2 MW are slightly higher
than for the relative )max( 75.2
4
3M. A much higher order of moment is needed for the
signal )1(
x: the strongest cavitation at 2 MW is detected with the relative )max( 8
1
3M,
and also the cavitation-free area is recognised. However, all the other cavitation cases
would be classified as cases of short periods of cavitation.
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2.4 Nonlinear scaling
The features described above are informative, some of them are dimensionless and
normalized. However, the analysis can be further improved by taking into account
nonlinear effects (7,9,12,13). Operating conditions can be detected with a Case-Based
Reasoning (CBR) application with linguistic equation (LE) models and Fuzzy Logic. The
basic idea of the linguistic equation (LE) methodology is the nonlinear scaling developed
to extract the meanings of variables from measurement signals. The scaling function scales
the real values of variables to the range of [-2, +2] which combines normal operation [-1,
+1] with the handling of warnings and alarms. The scaling function contains two
monotonously increasing functions: one for the values between -2 and 0, and one for the
values between 0 and 2. Both expertise and data can be used in developing the mapping
functions (membership definitions) (5).
The membership definition f consists of two second-order polynomials, i.e. the scaled
values, which are called linguistic levels j
X, are obtained by means of the inverse function
1
f:
+
+
=
+
+++
)min(2
)min(2
2
)(4
)max(2
2
)(4
)max(2
2
2
jj
jjj
j
jjjjj
jjj
j
jjjjj
jj
j
xxwith
cxxwith
a
xcabb
xxcwith
a
xcabb
xxwith
X
......................... (6)
where
j
a ,
j
b, +
j
a and +
j
b are coefficients of the corresponding polynomials, j
c is a
real value corresponding to the linguistic value 0 and j
x is the actual measured value.
Parameters )min( j
x and )max( j
x are minimum and maximum values corresponding to
the linguistic values –2 and 2. (5)
Nonlinear scaling has been used in previous studies for statistical features (7,9), and
features based on the signal distribution (13,14). The scaling functions shown in Figure 2
were obtained with a data-driven approach from the features obtained at ten power levels:
2, 3, 5, 8, 12, 25, 45, 57.5, 58.1 and 59.4 MW. For each feature, the level 0 was obtained as
a median of the values in the training set, and the levels -1 and 1 as medians of the lower
and higher halves of the values, respectively. A cavitation index can be obtained by scaling
the norm (5) with the function (6):
).max((
1p
CMrelativefI
α
τ
α
α
=......................................................... (7)
Figure 2. Scaling functions of the relative =
α
α
τ
),max( p
M1, 3 and 4, in a Kaplan water
turbine.
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Figure 3. Cavitation indices )(
α
C
I based on the scaled features
=
α
, 1, 3 and 4, in a Kaplan water
turbine.
The nonlinear scaling is based on functions shown in Figure 2. The indices =
α
α
,
C
I 1, 3
and 4, were compared to the knowledge-based cavitation index *
C
I at 29 power levels
varying from 1.5 to 59.4 MW (Figure 3). The coefficients of determination R2, calculated
as the square of the correlation coefficient are high for all the signals )1(
x, )3(
x and )4(
x
(Figure 3). The index 1
C
I based on the velocity signal has the lowest R2 value, and also the
classification result is the worst of these three. The index 3
C
I has the highest R2 value but
the index 4
C
I has the best classification result.
3. MODEL-BASED FAULT DIAGNOSIS
Operating conditions can be detected by combining several features in case-specific
models. Model-based cavitation indices are needed for a detailed analysis (10,11) .
3.1 Fault models
The machine condition monitoring application presented in (7) was based on models
developed for normal operation and nine fault cases. One fault at time was simulated at
five rotation speeds. In each case the model consists of seven LE models developed for a
sensor-specific variable group including the rotation speed and five features obtained from
the measurements of the sensor. The sequence of the LE models is case-specific, and each
equation has a weight factor ki
w. The error i
ε
, also called fuzziness, is calculated for each
LE model by means of
.
1
ij
m
j
jii BXA +=
=
ε
............................................................................... (8)
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The models of the normal case already provide useful information, as higher fuzziness is
detected in the fault cases, and each model has its own sensitivity profile (Figure 4):
The first four models detect very clearly the differences caused by the bearing
faults (data points 4001-5500).
Model 5 detects the stronger rotor unbalance (data points 1501-2000).
The bent shaft (data points 2001-2500) is detected with models 3 and 4.
The shaft misalignment (data points 2501-4000) is seen in the fuzziness of the
models 6 and 7.
The degree of membership of each equation, denoted as i
μ
, is based on the distribution
of error represented as a trapezoidal membership function developed on the basis of the
train case, see Figure 4. Since the degree of membership of the case is evaluated as the
weighted average of the degrees of membership of the individual equations, the condition
index k
C of each case k can be represented by means of
.24 7
1
7
1=
=
=
i
ki
i
i
ki
k
w
w
C
μ
........................................................................... (9)
Figure 4. Fuzziness of the LE models (or equations) of the normal case in the complete data set,
model numbers are from left to right (7).
For fast-rotating bearings, the condition index Ind is a sum of the scaled standard
deviations of the signal )4(
x calculated for three frequency ranges.
)()()( 43
1
4342
1
4241
1
41
σσσ
++= fffInd ............................................. (10)
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where 1
4
i
f is the scaling function of the standard deviation i4
σ
in three frequency ranges
10 –1000 Hz, 10 –10000 Hz, and 10 –50000 Hz. The faults are correctly detected by
means of the algorithm (12):
Calculating the condition index.
The condition is normal if Ind < -5…-4.
There is an outer race fault in the bearings if Ind < 0.
The condition is unbalance if the index for the low frequency range is very high,
Otherwise the condition is inner race fault in the bearings.
The minimum of the index Ind is -6 which is achieved when all the features are at the
lowest level.
The ranges of the Ind values in the cases, k = 1, 2, 3 and 4, as shown in Figure 5, can
also be represented as trapezoidal membership functions, and then the condition index of
an individual case is calculated from the corresponding degree of membership:
.24 = kk
C
μ
Unbalance is efficiently detected with the lowest frequency range )(41
1
41
σ
f
and inner race fault with the features )(42
1
42
σ
f and )(43
1
43
σ
f (12). However, the complete
index Ind is needed for detecting the outer race fault.
Figure 5. Condition index for fast-rotating bearings, the rotation frequencies were from 65 to 525
Hz (12).
3.2 Case-based reasoning
A CBR type approach was used for the test rig (7): the degree of membership was
calculated as explained above for all nine cases, and the case with the highest degree of
membership was chosen. The classification results were very good. There are some faulty
classified measurements but the mistakes are very logical, e.g. small unbalance and normal
state. Misalignment increases when moving from class 5 to class 7. A small misalignment
and the normal state are also close to each other. In all the ten cases, mistakes only occur
between very similar classes. The system placed practically all the bearing faults into the
right classes. The fault models and the CBR system are necessary since the five features
obtained from the signals and the rotation speed need to be combined (Section 2.1). Since
the difference between the bearing faults was more prominent than the difference between
misalignment cases, there is more confusion in the misalignment categories.
4. CONDITION INDICES
The purpose with condition indices is to extract indirect measurements from the signal
samples. Possibility to use short samples is beneficial for automatic fault detection.
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4.1 Cavitation index
The intelligent cavitation indicator developed in (9) for a Kaplan water turbine is based on
the nonlinear scaling of two features: peak height and the fraction of the peaks exceeding
the normal limit. The classification results obtained from the experimental cases involving
the water turbine were very good and logical. Different cavitation types, some causing low
frequency vibration on structure and some only leading to fast impacts, can be identified.
The indicators detect the normal operating conditions, which are free of cavitation, and
also provide a clear indication of cavitation already at an early stage. The index obtained
from the signal )4(
x is the best alternative but also the index obtained from the signal )3(
x
provides good results throughout the power range. The cavitation indicator also provides
warnings of a possible risk on short periods of cavitation. Uncertainties can be taken into
account by extending the feature calculations and classification rules to fuzzy set systems.
Features of velocity )1(
x, acceleration )2(
x and higher derivatives, )3(
x and )4(
x were
compared in (10,11). The features of velocity had a very low correlation with the knowledge-
based cavitation index. Strong cavitation can be detected with the features of other signals
in the low frequency range, even in the range 10-1000 Hz. Kurtosis combined with rms
values was the best combination in the low frequency range, but widening the frequency
range makes the peak values better than kurtosis. Several model-based indicators based on
nonlinear scaling and linear equations provide a good fit to the cavitation index. In this
example, only higher derivatives can be used in the practical classification for cavitation,
short-term cavitation and cavitation-free operating conditions. The indices obtained from
)4(
x are the best alternatives.
Generalised moments and norms can also be used in the model-based cavitation indices.
The generalised moment (4) indicates possible cavitation but one moment value is not
enough for a detailed analysis (15): the moments should be combined with other features,
e.g. rms values used in (10). The norm (5) introduced in (2) can be used alone, see (7), if the
order p is chosen correctly. Combined indices, where several orders α are used, require
tuning of the scaling functions.
The healt index SOL can be calculated from the cavitation index by means of
),1(
4
2
1
*
δ
+
= C
I
SOL .................................................................... (11)
where
δ
is the value of SOL index when the cavitation index .2
*=
C
I The measurement
index MIT (2) is an inverse of the index SOL. If the parameter 2.0
=
δ
, the highest values
of the index MIT are 5 (Figure 6).
Figure 6. SOL and MIT indices obtained from the knowledge-based cavitation index in a Kaplan
water turbine.
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4.2 Condition index
In the lime kiln application, the features were combined with a linguistic equation, i.e.
1=iin (1). The condition index IC is a number between -2 and 2, and the interaction
coefficients ,6...1, =jA ji are based on expertise (13,14): A = [-2 1 1 1 -1 -1 -1] includes the
coefficients of the scaled features and the condition index. The same coefficients are used
for both signals )3(
x and )4(
x. Compared to (1), the index IC corresponds to i
B:
)()()()()()(2 )(
5
1
6
)(
4
1
5
)(
3
1
4
)(
2
1
3
)(
1
1
2
1
1
)(
ααααα
α
α
σ
FfFfFfFfFffI C
+++= ...... (12)
The condition index developed for the supporting rolls of a lime kiln provides an
efficient indication of faulty situations. Surface damage is clearly detected and friction
increase is indicated at an early stage. The features are generated directly from the higher
order derivates of the acceleration signals, and the model is based on expertise. All the
supporting rolls can be analysed using the same system. The index )4(
C
Iis very good and
logical for all the measurement points, which makes it already suitable for practical
applications. The index )3(
C
Irequires further tuning. (14)
The health index SOL and the measurement index MIT can be calculated from the
condition index, the only difference to the cavitation case is that the condition index is a
measure of good condition, i.e. value 2 corresponds to excellent condition. Figure 7 shows
the results of 6 cases for two measurement points from a period of three years: fault
situations include surface damage (case 1) and misalignment (cases 3 and 4).
(a) Measurement point 2 A. (b) Measurement point 2 B.
Figure 7. SOL and MIT indices obtained from the condition index of supporting rolls in a lime kiln.
5. TUNING
The parameters of the scaling functions can be tuned by means of neural networks or
genetic algorithms, for example: similar tuning approaches can be used for different LE
models and condition indices (5). For example, the cavitation indices )(
α
C
Iin Figure 3 can be
improved in this way. Additional model complexity, e.g. response surface methods or
neural networks, does not provide any practical improvements in these examples. Genetic
algorithms have also been used for selecting sensors and features in the test rig study.
Another possibility is to use artificial immune systems. The tuning and testing of the
condition indices will be continued with measurements available in a large database.
6. CONCLUSIONS
Fault diagnosis can be carried out with several alternative approaches. Thus feature
selection depends on the type of application: even a single feature can provide a good
solution with automation systems, but combining several easily calculated features is an
efficient approach for intelligent sensors. Nonlinear scaling and indices bring all the
features and faults to comparable ranges in analysis. The indices obtained from short
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samples are aimed for use in the same way as the process measurements in process control.
The new indices are consistent with the measurement index MIT and the health index SOL
developed for condition monitoring.
REFERENCES
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CM 2008 – MFPT 2008, 12 pp, July 2008.
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UK, pp 943-952, Coxmoor Publishing, Oxford, UK, June 2007.
11. S Lahdelma, P Vähäoja, and E Juuso, ’Detection of cavitation in Kaplan water
turbines’, Proceedings of 2007 Arctic Summer Conference on Dynamics, Vibrations
and Control, Ivalo, Finland, pp 80–87, Tampere University Press, Tampere, Finland,
August 2007.
12. S Lahdelma, E Juuso and J Strackeljan, ‚Neue Entwicklungen auf dem Gebiet der
Wälzlagerüberwahung, in A Seeliger and P Burgwinkel (Ed.) Tagungsband zum
AKIDA 2006, Aachen, Germany, pp 447-460, ASRE, Band 63, 2006, RWTH
Aachen, November 2006.
13. S Lahdelma and E K Juuso, ’Intelligent condition monitoring for lime kilns’, in A
Seeliger and P Burgwinkel (Ed.) Tagungsband zum AKIDA 2006, Aachen,
Germany, pp 399-408, ASRE, Band 63, RWTH Aachen, November 2006.
14. E Juuso and S Lahdelma, ‘Advanced condition monitoring for lime kilns’.
Proceedings of WCEAM-CM 2007, Harrogate, UK, pp 931-942, Harrogate, UK.
Coxmoor, June 2007.
15. S Lahdelma and E Juuso, ‘Vibration Analysis of Cavitation in Kaplan Water
Turbines’, IFAC World Congres, Seoul, Korea, 6 pp, July 2008.
The Fifth International Conference on Condition Monitoring & Machinery Failure Prevention Technologies
708
... The knowledge-based cavitation index * C I provides an indication of both clear cavitation and clearly good operation (20) . Values -2 and -1 indicate good operating conditions. ...
... Before the l p norm, kurtosis combined with rms values was the best combination in the low frequency range, but widening the frequency range makes the peak values better than kurtosis. The scaling functions shown in Figure 1 were obtained with a data-driven approach from the features obtained at ten power levels: The coefficients of determination R 2 , calculated as the square of the correlation coefficient, was compared in (20) for all the signals x . The index 1 C I based on the velocity signal had the lowest R 2 value, and also the classification result wer the worst of these three. ...
... The index 1 C I based on the velocity signal had the lowest R 2 value, and also the classification result wer the worst of these three. The index 3 C I has the highest R 2 value but the index 4 C I has the best classification result (20) , when p = 2.75. Absolute averages and rms values, too, have a high correlation in the cavitation-free area and high power range 50-59.4 ...
Conference Paper
Full-text available
Cavitation is harmful to water turbines and may cause shutdowns for several weeks. The real-time detection of cavitation risk is increasingly important, and even narrow cavitation-free power ranges can be utilised in load optimisation. Higher derivative signals x(α), α = 3 or 4, calculated from acceleration signals x(2) are very suitable for detecting impacts. Generalised moments and their lp norms, ‖τMαp‖, detect the normal operating conditions, which are free of cavitation, and also provide an early indication of cavitation risk. On-line cavitation monitoring is based on cavitation indices calculated from a moving maximum of the lp norms obtained from samples. Data compression is very efficient, as the detailed analysis only requires feature values with a short sample time, τ = 3s. The absolute mean, i.e. the order of moment p = 1, is very good in normal operating conditions and in the high power range. The cavitation indicator also provides warnings on short periods of cavitation if the power is not too low. This is readily suitable for intelligent sensors where a good solution is to use analogue signals x(4). The optimal norm (p = 2.75) is only needed in the low power range. Power control minimises the cavitation risk by dividing the load between three turbines, whose conditions are normal, bad and very good. Each turbine has three operating modes: low, normal and high power. In the normal area, a cavitation free power level is taken as an operating point. The low and high operating areas are defined by local minima of the cavitation indices. The control system has a feedforward controller, which allocates the load to the turbines by means of knowledge-based cavitation indices, and a feedback controller, which is based on the linguistic equation (LE) approach. Each turbine has a P type LE controller which is adapted to the operating conditions by the scaling functions. The cumulative time in the strong cavitation provides an indication of possible damage to be used in selecting the turbine for low power operation. The characteristic curves are adapted to the recent indices in order to handle the changes in the condition of the turbines. For power stations with many turbines, alternatives to reduce cavitation risks are evaluated by simulation to optimise maintenance actions.
... Different approaches have been reviewed in [7,8]. Vibration indices based on several higher derivatives in different frequency ranges were already introduced in 1992 [2, 8,9]. Higher and real order derivatives in processing vibration measurements and feature extraction by generalised moments and l p norms have been discussed in [6,8,10]. ...
... On the other hand it is well known that the early detection of bearing faults, as well as cavitation can be detected more efficiently with the acceleration signal. Often higher order derivatives provide more sensitive solutions, i.e. the ratios of calculated features between the faulty and nonfaulty cases become higher [7,9,11]. ...
Conference Paper
Full-text available
Advanced signal processing methods combined with automatic fault detection enable reliable condition monitoring for long periods of continuous operation. Any attempt to detect different types of machine faults reliably at an early stage requires the development of improved signal processing methods. Vibration measurements provide a good basis for condition monitoring. In some cases the simple calculation of root-mean-square and peak values obtained from vibration signals are useful features for detecting various faults. Unbalance, misalignment, bent shaft, mechanical looseness and some electrical faults, for example, can be detected using features of displacement and velocity. Higher order derivatives provide additional possibilities for detecting faults that introduce high-frequency vibrations or impacts. New generalised moments and norms related to lp space have been used for diagnosing faults in a roller contact on a rough surface. This paper extends the field of possible applications from roller bearing fault detection to more complex faults situations where different kinds of fault occur simultaneously. In consequence, feature calculation and signal processing have to be adopted and optimized for each fault type on the basis of one measured signal. The features of x(4) indicate well the intact case and the outer race fault. Velocity x(1) is needed for detecting unbalance. This approach also works for the combined case, outer race fault and unbalance. Derivation reduced the effect of noise by amplifying higher frequency components from bearing faults more than the added noise components.
... Vibration indices based on several higher derivatives in different frequency ranges were already introduced in 1992 [2]. Fractional integrals and derivatives are discussed in [7]. Higher and real order derivatives in processing vibration measurements and feature extraction by generalised moments and l p norms have been discussed in [8,9,10,11]. ...
Conference Paper
Full-text available
Advanced signal processing methods combined with automatic fault detection enable reliable condition monitoring for long periods of continuous operation. Root-mean-square and peak values obtained from vibration signals are useful features for detecting various faults. Unbalance, misalignment, bent shaft, mechanical looseness and some electrical faults, for example, can be detected using features of displacement and velocity. Higher order derivatives provide additional possibilities for detecting faults that introduce high-frequency vibrations or impacts. Real order derivatives increase the number of signal alternatives. New generalised moments and norms related to lp space have been used for diagnosing faults in a roller contact on a rough surface. Kurtosis provides a strong indication if the order of derivation, α, is at least 4. For peak values, the change is smaller but already starts at α = 3. The generalised moment and norm can be defined by the order of derivation, the order of the moment, p, and sample time, τ. Reliable results can be obtained by relative norms if α and p are in the range between 4 and 6. For the impact of a small scratch, sensitivity is further improved with short sample times, but several sequential samples are required to guarantee the detection of impacts. Then the order p can also be reduced.
... Bearing fault [26] Paste pump A piece missing from a stator [76] Coating machine Gear fault [67] Pulp washer Bearing fault [72,73] Lime kiln Uneven surface of a supporting roll [67,68,75,[77][78][79] Misalignment [68,[77][78][79] Friction [77][78][79] Large gear Gear wheel fault [26] Kaplan water turbine Cavitation [24,[68][69][70][71]74,78,[80][81][82][83][84] ...
Article
Full-text available
The time derivatives of acceleration offer a great advantage in detecting impact-causing faults at an early stage in condition monitoring applications. Defective rolling bearings and gears are common faults that cause impacts. This article is based on extensive real-world measurements, through which large-scale machines have been studied. Numerous laboratory experiments provide additional insight into the matter. A practical solution for detecting faults with as few features as possible is to measure the root mean square (RMS) velocity according to the standards in the frequency range from 10 Hz to 1000 Hz and the peak value of the second time derivative of acceleration, ie snap. Measuring snap produces good results even when the upper cut-off frequency is as low as 2 kHz or slightly higher. This is valuable information when planning the mounting of accelerometers.
... It has been shown in a number of studies (1,2,6,7,8) that applying real order derivatives to signals can be a very effective way to extract shock-like events. This kind of events are normally expected in vibration measurement from a faulty roller bearing. ...
Conference Paper
Full-text available
Roller bearing faults are a common fault type in machines. There are several condition monitoring handbooks which describe ways of detecting these faults by means of vibration measurements. Handbooks on neither condition monitoring nor vibration analysis usually mention real order derivatives or cyclostationary technique. These methods have rarely been applied to vibration analysis in industrial condition monitoring , although plenty of studies on both of them have been published. In this study, these methods are applied on the fault detection of a roller bearing.
... The coefficients of determination R 2 , calculated as the square of the correlation coefficient, was compared in (Lahdelma and Juuso, 2008a) for all the signals x (1) , x (3) and x (4) . The index I ...
Conference Paper
Full-text available
Cavitation is harmful to water turbines and may cause shutdowns for several weeks. The real-time detection of cavitation risk is increasingly important, and even narrow cavitation-free power ranges can be utilised in load optimisation. Higher derivative signals calculated from acceleration signals and their lp norms detect the normal operating conditions, which are free of cavitation, and also provide an early indication of cavitation risk. On-line cavitation monitoring is based on cavitation indices calculated from a moving maximum of the lp norms obtained from samples. Data compression is very efficient, as the detailed analysis only requires feature values with a short sample time. Power control minimises the cavitation risk by dividing the load between three turbines, whose conditions are normal, bad and very good. Each turbine has three operating modes: low, normal and high power. In the normal area, a cavitation free power level is taken as an operating point. The low and high operating areas are defined by local minima of the cavitation indices. The control system has a feedforward controller, which allocates the load to the turbines by means of the cavitation indices, and a linguistic equation (LE) feedback controller. Each turbine has a P type controller which is adapted to the operating conditions by the scaling functions. The cumulative time in the strong cavitation provides an indication of possible damage to be used in selecting the turbine for low power operation.The characteristic curves are adapted to the recent indices in order to handle the changes in the condition of the turbines. For power stations with many turbines, alternatives to reduce cavitation risks are evaluated by simulation to optimise maintenance actions.
Chapter
Fatigue mechanisms proceeding through the formation and growing of cracks are well-known but the progress is not easy to detect with measurements during the operation. The localised structural damage is caused by repeated loading and unloading when the load exceeded certain thresholds. The effect of the loading is highly nonlinear and structures fracture suddenly when a crack reaches a critical size. This research focuses on the advanced data analysis aimed at detecting effective stress impacts by using generalised norms and intelligent stress indices based on nonlinear scaling to provide good severity indicators. Digital twin type solutions can help in detecting changes in fatigue risk analysis. Contributions of the stress are calculated in each sample time, which is taken as a fraction of the cycle time. The Wöhler curve is represented by a linguistic equation (LE) model where the stress part is represented by the intelligent stress indices. The cumulative sum of the contributions indicates the deterioration of the condition, and the simulated sums can be used to predict failure time. Scheduling the maintenance actions can be extended to avoiding risky stress levels. The generalised statistical process control (GSPC) is a feasible solution to demonstrating in real time these risky levels during the operation. The analysis is adapted to changing operating conditions by updating recursively the parameters of the scaling functions. Algorithms of the model and digital twin remain unchanged. In a rolling mill, torque measurements are collected and analysed with a combination of two norms scaled with the nonlinear scaling approach.KeywordsFatigue risk detectionNonlinear scalingIntelligent stress indicesCondition monitoring
Book
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The papers published in these proceedings are presented in the Third International Seminar on Maintenance, Condition Monitoring and Diagnostics, to be arranged in Oulu, Finland, in 29th – 30th September, 2010. Arranged by the University of Oulu and POHTO – The Institute for Management and Technological Training, the present seminar is supported by a variety of Finnish industrial enterprises.
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The papers published in these proceedings are presented in the International Conference on Maintenance, Condition Monitoring and Diagnostics, and Maintenance Performance Measurement and Management, MCMD 2015 and MPMM 2015, to be arranged in Oulu, Finland, in 30th September – 1st October, 2015. Arranged by the University of Oulu and POHTO – The Institute for Management and Technological Training, the present conference is supported by a variety of Finnish industrial enterprises.
Conference Paper
A consistent representation is needed to understand meanings of the measurement values and use them together with knowledge-based information. The nonlinear scaling approach is used for any numeric values, including measurements, features, indices and indicators. The scaled values in the range [-2, 2] are interpreted in natural language labels, e.g. very low, low, normal, high, very high. Also the expert knowledge is represented in the same range. Parameters of the functions are obtained from the numeric values and modified to ensure the monotonic increase. Intelligent condition and stress indices are calculated from consecutive samples of the waveform signals by using generalized norms and the nonlinear scaling approach. Uncertainty, fluctuations and confidence in results are estimated by a difference of norms of high positive and negative order, respectively. Temporal analysis is based on the scaled values: trend indices are calculated by comparing the averages in the long and short time windows, a weighted sum of the trend index and its derivative detects the trend episodes and severity of the trend is estimated by including also the variable level in the sum. Risk indices are obtained from stress contributions. All indices are in the range [-2, 2] and represented in natural language.
Conference Paper
Full-text available
Machine condition monitoring enables reliable and economical way of action for maintenance operations in modern industrial plants. Increasing number of measurement points and more demanding problems require automatic fault detection. Advanced signal processing methods exposed failures earlier and then it's possible to plan more operating time and less shutdowns. Intelligent methods have been increasingly used in model based fault diagnosis and intelligent analysers. Intelligent methods provide various techniques for combining a large number of features. A test rig was used to simulate different fault types and changes in operating conditions. Linguistic equation (LE) models were developed for the normal operation and nine fault cases including rotor unbalance, bent shaft, misalignment and bearing faults. Classification is based on the degrees of membership developed for each case from the fuzziness of the LE models. The classification results of the experimental cases are very good and logical. As even very small faults are detected by a slight increase of membership, the results are very promising for early detection of faults. Together with the compact implementation and the operability of the normal model, this makes the extension to real world problems feasible.
Conference Paper
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Advanced signal processing methods combined with automatic fault detection enable reliable condition monitoring even when long periods of continuous operation are required. Intelligent techniques for combining features have been studied in a lime kiln. Lime kilns are essential parts in the chemical recovery cycle of a pulp mill. These large machines with very slow rotation speeds must run at different production capacities and speeds. Alignment problems of the kiln are severe because of the high weight affecting on the supporting rolls. Problems may lead to serious damage or even fire. A large set of previously collected measurements has been analysed with intelligent models based on new features. The set of data covers surface problems, good conditions after grinding, misalignment after grinding, stronger misalignment, very good conditions after repair work, and good conditions one year later. The condition indices developed for the supporting rolls provide an efficient indication of failure situations also in new cases without any changes in the calculation system. Faulty cases are clearly detected and even an early indication of the friction increase is achieved. The features are directly generated from the higher order derivates of the acceleration signals, and the model is based on expertise. All the supporting rolls can be analysed using the same system. The detection of the faulty situation is the most important step. An indication of the fault types, surface damage and alignment problems, can be achieved with a more detailed analysis.
Conference Paper
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Early detection of fluctuations in operating conditions are important in maintaining smooth production in process industry. Detecting can be done with similar method as fault detection although the classes do not necessarily correspond to any fault. Case-based reasoning (CBR) is used for same purpose for finding out the solution to a new problem by remembering a previous similar situation. Model-based approaches, especially intelligent methods, provide useful extensions for these approaches. Linguistic equations (LE) are suitable for modelling multivariable nonlinear systems. Indicators have been built for several applications by combining LE models wit fuzzy logic. The same methodology provides good results in detecting fluctuations of flavour ingredients in brewing, in predicting web break sensitivity in paper machines and in condition monitoring of machines.
Conference Paper
Full-text available
Several intelligent cavitation indicators obtained from vibration measurements have been compared in a Kaplan turbine. The indicators are based on the nonlinear scaling of features: one of the features is rms value and the other is either kurtosis or peak value. Indicators obtained from acceleration x(2) and higher derivatives x(3) and x(4) were tested by comparing the calculated indices with the sound of the recorded acceleration signals and analysing the signals with an oscilloscope in a wide power range. The results were compared in four frequency ranges with the knowledge-based cavitation index and previous studies. The indicators detect the normal operating conditions, which are free of cavitation, and also provide a clear indication of cavitation already at an early stage. The indices obtained from x(4) are the best alternative though also the index obtained from x(3) provides good results throughout the power range. Acceleration provided a good fit with the data but was less sensitive than higher derivatives. Automatic monitoring can be based on steps: detecting normal conditions, cavitation and the type of cavitation. The indicator also provides warnings of possible risk on short periods of cavitation. Uncertainties can be taken into account by extending the feature calculations and classification rules to fuzzy set systems.
Conference Paper
Full-text available
Cavitation causes excessive pressure pulsations, which damage the surfaces of the runner and channels of a turbine. As a result, the overall operating efficiency of the water turbine decreases and repair costs increase. Traditionally, there have been efforts to detect cavitation using vibration, pressure and acoustic emission measurements. For instance, extensively used vibration velocity measurements are not effective enough to detect all cavitation areas so more sensitive and accurate signal processing methods are still demanded. This study concentrates on vibration measurements in the real operating environment of a Kaplan turbine. Altogether 29 measurement periods were carried out at different power levels from 1.5 to 59.4 MW. The vibration analysis was based on the use of traditional velocity and acceleration signals and novel higher order derivatives: x(3) and x(4). The features used were rms, peak, kurtosis and crest factor. Normal accelerometers could be used and the upper cut-off frequency did not have to be high in order to detect all cavitation areas reliably. The sample length has to be over 30 seconds in order to detect all cavitation areas accurately. The rms value works sufficiently well at high powers, whereas kurtosis and crest factor are effective at low powers only. The feature working well throughout the whole power range is peak value.
Conference Paper
Full-text available
Advanced signal processing methods combined with automatic fault detection enable reliable condition monitoring for long periods of continuous operation. The signals x(3) and x(4) are very suitable for the condition monitoring of slowly rotating bearings since rapid changes in acceleration become emphasised upon the differentiation of the signal x(2). Real order derivatives x(α) provide additional possibilities, e.g. in a bearing fault case the sensitivities of some features have been found to reach a maximum when α = 4.75. In earlier cavitation indicators, the rms values were combined with either kurtosis or peak values. Generalised moments τMαp can be defined by the order of derivation (α), the order of the moment (p) and sample time (τ). The moment normalised by standard deviation can be used as kurtosis in the model-based analysis. This paper introduces a new norm ‖τMαp‖p = (τMαp)1/p = [1/NΣi=1N|xi(α)|p]1/p, where the orders α and p are real numbers. The number of signal values s N =τ N where Ns is the number of samples per second. The new norm has the same dimensions as the corresponding signals x(α ) . The cavitation of a Kaplan water turbine was analysed in the power range 1.5…59.4 MW based on measurements collected with sampling frequency 12800 Hz. The order p was compared in the range from 0.25 to 8 with a step 0.25, and a total of 11 sample times were used: τ = 1, 2,…, 6, 8, 10, 20, 30, and 40 seconds. An optimum order p was detected for each sample time τ. The relative max(‖3^M_4^2.75‖) compared to a cavitation-free case is alone a good indicator for cavitation: strong cavitation and cavitation-free cases are clearly detected, and the power ranges for shortterm cavitation are only slightly wider than in the previously developed knowledge-based cavitation index. Short sample times and relatively small requirements for the frequency ranges make this approach feasible for on-line analysis and power control. The weighted sums of features on a different order of derivation form fault-specific measurement indices MIT, and several indices MIT define the health index SOL. The sensitivity increases with the order of derivation to some limit of α. For faults causing impacts, high MIT values for lower orders of derivation indicate an increase in the severity of the fault.
Article
A Linguistic Equation Framework developed for expert systems provides a flexible environment for fault diagnosis applications. The reasoning is based on matrix equations or on the aggregated sets of linguistic relations obtained by solving the equations. The expert system consists of two parts: Symptom Generation System is based on process modelling knowledge (analytical or heuristic) and measurements provided by other systems; Fault Diagnosis System evaluates the linguistic symptoms obtained from the Symptom Generation System via an inference mechanism. The system is adaptive since the meaning of the linguistic values depends on the working point of the process.
Chapter
Expert systems are developed for the multilayer simulation system in order to improve the application facilities. The combined system contains procedures for developing simplified fuzzy models on the basis of deterministic simulation experiments. Since these models, together with rule-based linguistic models, are embedded in the expert systems, there are a total of five levels of simulation. The linguistic models developed from the fuzzy models are used together with qualitative relations to define suitable meaning for each linguistic variable.
Article
Advanced signal processing methods combined with automatic fault detection enable reliable condition monitoring even when long periods of continuous operation are required. The parameters x(3) and x(4) are very suitable for the condition monitoring of slowly rotating bearings, as although the acceleration pulses are weak and occur at long intervals, the changes in acceleration are rapid and become emphasised upon differentiation of the signal x(2). Grounds for the need of x(-n) signals, ie integration of displacement n times with respect to time, have been indicated. In addition, derivatives where the order is a real number or a complex number + i have been developed. These signals can be utilised in process or machine operation by combining the features obtained from the derivatives. The importance of each derivative is defined by weight factors. Dimensionless indices are obtained by comparing each feature value with the corresponding value in normal operation. These indices provide useful information on different faults, and even more sensitive solutions can be obtained by selecting suitable features. Widely used root-mean-square values are important in many applications, but the importance of the peak values increases in slowly rotating machines. Further details can be introduced by analysing the distributions of the signals. The features are generated directly from the higher order derivatives of the acceleration signals, and the model can be based on data or expertise. The intelligent models extend the idea of dimensionless indices to nonlinear systems. Variation with time can be handled as uncertainty by presenting the indices as time-varying fuzzy numbers. The classification limits can also be considered fuzzy. The reasoning system will produce degrees of membership for different cases. Practical long-term tests have been performed e.g. for fault diagnosis in bearings, cogwheels, gear boxes, electric motors and supporting rolls, and for cavitation in turbines and pumps.
Article
The process industries face considerable control challenges, especially in the consistent production of high quality products, more efficient use of energy and raw materials, and stable operation on different conditions. The processes are nonlinear, complex, multivariable and highly interactive. Usually, the important quality variables can be estimated only from other measured variables. Constraints, e.g. physical limitations of actuators must be taken into account. Significant interactions between process variables cause interactions between the controllers. Various time-delays depend strongly on operating conditions and can dramatically limit the performance and even destabilize the closed loop system. Uncertainty is an unavoidable part of the process control in real world applications.