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Exploration of condition monitoring based on non-contact instantaneous angular speed measurement
Abstract
Recently, requirements for enhanced reliability of rotating equipment are more critical than ever before, and the demands continue to grow constantly. Due to the progress made in engineering and materials science, rotating machinery is becoming faster and lighter. They are also required to run for longer periods of time. All of these factors mean that the detection, location and analysis of faults play a vital role in the quest for highly reliable operations. Using vibration analysis, the condition of a machine can be constantly monitored. Angular Speed and vibration are related in the study of dynamics, but it is sometimes forgotten that Instantaneous Angular Speed (IAS) and vibration are much more interrelation, because the changes second by second could be expressed by the IAS changing. This paper is focused on the interrelation between the IAS and vibration, then the detailed analyses is able to show the conditions of a machine. Non-contact measurement engages aimed to detecting the health of a machine in real time without any stop. It is the latest requirement in industry. It then proceeds to present the comparison between Instantaneous Angular Speed data recorded and encoder data from induction motor operating with a representative range of healthy and incipient fault conditions. Finally, the capability of non-contact approach is compared to vibration spectra technique.
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This research presents the theory and implementation detail for the extraction of angular speed variations. In particular, band-pass filtering, frequency shifting and analytic representation are addressed with simple mathematical equations. Finally, some case studies on a 3kW induction motor are investigated for healthy and faulty conditions. Some vital key features and characteristics can be extracted from the angular speed variations. Pole pass speed side bands around the rotor speed can be used as a feature for broken rotor bar faults. The number of poles multiplied by the synchronous running speed cycles and the rise of 100 Hz components are key characteristics for voltage imbalance faults.
Gear manufacturers in all fields of industry are under increasing pressure to deliver products of high accuracy and which generate ever lower levels of vibration and noise. Over the past decades, transmission error (TE) measurement has become more popular as a means of measurement for research and quality control. However, dedicated measurement systems have often proved incapable of measuring TE under operating conditions.
This paper presents an overview of TE measurement techniques and their applications. In addition, an introduction to a versatile and portable method of measurement based on FFT analysis and demodulation is given. This method is easily implemented using current generation FFT analysers or signal analysis software, and is suitable for research, diagnostics, condition monitoring and quality control applications alike.