Condition Monitoring in Mechanical Domain

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Importance of condition monitoring in mechanical domain

Article in Materials Today: Proceedings · September 2021


DOI: 10.1016/j.matpr.2021.08.299

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Materials Today: Proceedings xxx (xxxx) xxx

Contents lists available at ScienceDirect

Materials Today: Proceedings


journal homepage: www.elsevier.com/locate/matpr

Importance of condition monitoring in mechanical domain


S.K. Nithin a,⇑, K. Hemanth a, V. Shamanth a, Rayappa Shrinivas Mahale a, P.C. Sharath b, Adarsh Patil c
a
School of Mechanical Engineering, REVA University, Bengaluru 560004, India
b
Department of Metallurgical and Materials Engineering, JAIN Deemed to be University, Bengaluru 562112, India
c
School of Mechanical Engineering, KLE Technological University, Hubballi 580031, India

a r t i c l e i n f o a b s t r a c t

Article history: This paper discusses the importance of condition Monitoring in the mechanical domain. Over the last few
Available online xxxx decades, researchers have been particularly interested in mechanical condition tracking. Automatic
machinery is susceptible to malfunction and progressive degradation from its initial state in harsh envi-
Keywords: ronments. For this, a suitable parameter that shows real-time internal conditions and mechanical device
Condition Monitoring fault incidence must be selected; as a result, continuous system monitoring is a more critical part of early
Vibration Analysis detection of failure that can trigger system shutdown, reducing system downtime and saving money.
Vibration Sensor/Transducers
Force imbalances, gearing system failures, bearing failures, shaft loading conditions, and incorrect
Gear and Bearing defects
Cutting tool Monitoring
machine selection for a particular job may all cause faults in mechanical systems. System parameters
such as efficiency, vibrations, noise, temperature, strain, wear on movables, and lubrication monitoring
are needed to detect the fault. Several early sensors are being used in this case to monitor the status
of device parameters in real time. Signal processing methods are used to convert the sensors’ signal to
an electrical signal, which is then processed and analyzed. The device’s smooth operation necessitates
parameter sensing and monitoring in-process. The use and benefits of sensors and transducers, as well
as advanced signal processing, each have their own set of benefits and drawbacks. The basics of various
condition monitoring techniques, approaches to condition monitoring, Condition Monitoring Types, and
other related topics will be covered in this article. The aim of this paper was to expand condition mon-
itoring to a variety of mechanical domains, including bearing defect detection, rotary machine vibration
monitoring, cutting tool monitoring, machine tool monitoring, electricity, vehicles, gear defect detection,
and bearing defect detection, to name a few.
Copyright Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 5th International Con-
ference on Advanced Research in Mechanical, Materials and Manufacturing Engineering-2021

1. Introduction which allows maintenance to be planned [5]. This is called predic-


tive maintenance and focuses on maintenance as it may cause
The process of measuring instrument parameters such as errors and you need to plan to prevent them. Condition monitoring
machine motion, temperature, oil condition, etc. is known as con- methods are widely used to track rotating devices (gearboxes,
dition monitoring, paying attention to visible changes that can sug- reciprocating machines, centrifuges, etc.), backup or auxiliary
gest impending errors. By continually tracking the health of your devices and compressors, turbines, electric motors, presses, and
device and taking ideal care that can usually shorten the life of other machines such as internal combustion engines [6]. For condi-
your assets, you can plan repairs or other precautions and fix prob- tion monitoring, there are two common methods.
lems before problems become more serious. Preventive mainte-
nance includes many condition managements [1-4]. Condition 1.1. Trend monitoring
monitoring data collected over hours provides valuable knowledge
of the current and past state of the asset. This machine evolution This is the process of regularly measuring and interpreting
can be used to predict how assets will work overtime and decline, trend monitoring data. Here, it is possible to determine when the
deterioration exceeds a critical threshold by selecting an appropri-
ate measurable of deterioration of a machine or part and analyzing
⇑ Corresponding author. the trend. For example, trend tracking is used to regularly track an

https://doi.org/10.1016/j.matpr.2021.08.299
2214-7853/Copyright Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 5th International Conference on Advanced Research in Mechanical, Materials and
Manufacturing Engineering-2021

Please cite this article as: S.K. Nithin, K. Hemanth, V. Shamanth et al., Importance of condition monitoring in mechanical domain, Materials Today: Pro-
ceedings, https://doi.org/10.1016/j.matpr.2021.08.299
S.K. Nithin, K. Hemanth, V. Shamanth et al. Materials Today: Proceedings xxx (xxxx) xxx

airplane’s engine data to detect irregularities in engine perfor- To track the condition, ultrasound is commonly used in the
mance and to avoid diagnostic aids and more expensive damage. Impact Pulse Method (SPM), a monitoring device that uses the sig-
nal of a rotating bearing as a baseline. Think about what happens
1.2. Condition checking when you collide with a metal ball or metal rod. When colliding
with a ball bar, pressure waves are propagated through all materi-
Condition checking is performed on an equipment while it is in als. The pressure wave disappears rapidly (transition). When the
operation by performing periodic check measurements with an front of the pressure wave touches the shock pulse transducer,
accurate indicator. The information gathered during this process the mass of the converter swings back and forth, attenuating the
is then used to assess the current condition of the machine. Condi- front of the pressure wave. When the level of shock pulses is low
tion checking is the use of an oil inspection glass, such as a condi- (low peak), the oil film on the bearings is thickened. As the level
tion monitoring pod (CMP), to check the machine’s oil condition in rises, the film thickness decreases [16-20].
real time. [7-10].
2.4. Acoustic emissions

2. Condition monitoring techniques ISO 22,096 specifies how to regulate electricity using acoustic
emissions. Acoustic emission is a type of vibration analysis that
The most used techniques for collecting data on the current detects vibrations at much higher frequencies than conventional
state of the machine are: vibration analysis. Acoustic emission monitoring looks for high-
frequency signals caused by cracks or influences; not repetitive
2.1. Vibration analysis synchronized movements caused by vibrations. Acoustic emissions
are not affected by the position of the transducer, the speed of the
The method of measuring the vibration level and frequency of a system, or the composition of the entire body [21].
machine and evaluating the state of the machine based on the
information is called vibration analysis. Vibration analysis can 3. Condition monitoring types
detect imbalances, bearing defects, mechanical loosening,
misalignment, resonances and natural frequencies, electric motor Various formats and methods of monitoring the condition of
defects, bent shafts, and even cavitation. According to some esti- machines each serve a specific purpose in terms of data collection.
mates, vibration warnings can provide lead times of up to 3 months The most popular formats are:
before a malfunction occurs [11].
Use daily oil analysis to check machine lubricant status, oil
3.1. Offline condition monitoring
leaks and machine wear. Oil analysis methods include the use of
a Fourier transform infrared (FTIR) spectrometer to measure mois-
Offline status monitoring is generally used for properties that
ture analysis, particle coefficient, elemental analysis, peak / base
are less sensitive or semi-critical, and periodic inspections are
content, viscosity measurements, and some other parameters. I
appropriate to keep track of the status. Offline monitoring is most
will. Spectral oil analysis tests, for example, break down the chem-
often used when less sensitive devices are sufficient for periodic
ical structure of an oil to predict possible problems. Silicone and
inspection of pulses and when they are sent to the laboratory for
aluminum levels in the oil suggest soil and sand pollution (alu-
oil treatment. Some companies can use sampling kits to check
minum silicate), while high iron content indicates wear resistant
the viscosity and water content of a particular oil in the field for
components [12-14].
quick results in offline oil analysis. Semi-automatic in-house
research equipment measures wear metals, nitriding, oxidation,
2.2. Infrared thermography and additive depletion.

A thermal imaging camera is a method of detecting radiation 3.2. Online condition monitoring
(heat) emitted by an object using a thermal imaging device, con-
verting it to temperature, and displaying the temperature distribu- Online condition monitoring is the process of wirelessly attach-
tion in an image. It is commonly used to check the electrical and ing a machine-mounted sensor to integrated software to continu-
mechanical condition of the engine, the insulation of the bearing ously measure assets by providing real-time alerts for vibration
(abnormal friction) refractory and the level of gases, liquids, and analysis, acoustic emission, ultrasound, and infrared thermal
sludge. The primary purpose of infrared cameras is to ensure that images. Consider machine shape, bearing type, machine speed,
the machine is functioning properly by detecting abnormal ther- machine parts and machine elements when choosing an online
mal patterns in the device that may suggest malfunctions or inef- monitoring device [22,24]. Once the sensor is placed in the appro-
ficiencies [15]. priate location on the asset, it can wirelessly connect to a remote
condition monitoring system to display real-time data. Most
2.3. Ultrasound devices can use a variety of sensor data (vibration, thermograph,
acoustics, etc.) to provide a snapshot of the asset’s current state
Ultrasonic control is useful in slow and high-speed mechanical at any point in time. You can use online status monitoring to set
systems and high-pressure fluid environments. For example, a dig- up real-time notifications for remote devices or emails. The use
ital ultrasound instrument tracks the radio frequency signal emit- of portable devices that can read data from installed sensors is
ted by a bearing in real time and displays it in decibels (dBuV) per called ‘‘portable computer diagnostics”. The online condition mon-
microvolt. This metric produces historical images of friction, itoring device is also known as this.
scratches and other bearing defects that can be used to measure
improvements in friction, scratches, and other bearing defects. 3.3. Route-based condition monitoring
The dBuV metric is often used to calculate the proper lubrication
interval. Vibration measurements are often used in conjunction Route-based health monitoring is a technique in which a tech-
with ultrasonic monitoring. nician records daily data using a mobile device such as an infrared
2
S.K. Nithin, K. Hemanth, V. Shamanth et al. Materials Today: Proceedings xxx (xxxx) xxx

camera. This method is often used to identify a trend pattern and 6. Historical maintenance
determine if further analysis is needed [23].
Until the last 15–20 years, all machine tools were powered and
4. Condition monitoring maintenance technique operated by humans, and they are still regulated and operated by
humans for the most part. They have become more nuanced, but
Condition monitoring is a form of maintenance that monitors they have also become more successful in general because of better
the condition and condition of a machine or structure and notifies design and advancements in maintenance strategies. Fig. 1 depicts
when maintenance becomes necessary. Here, you can use sensor the benefits and drawbacks of these options. The techniques are
devices to collect data from the system and turn it into useful outlined in detail below.
information. Decision-making methods are used to determine
when maintenance is required. Health Control Center is a diagnos- 6.1. Unplanned (breakdown) maintenance
tic. The implemented method is used to distinguish between com-
plex system faults and detect fault conditions [25-30]. Three stages Maintenance before the emergence of CNC machines (and per-
of growth are used to categorize the maintenance strategy: haps that) was almost unexpected, and only occurred when a prob-
1. Breakdown maintenance lem occurred. This technique was applied due to several issues, as
2. Preventive maintenance shown in Fig. 1. The fact that machines generally have a full-time
3. Predictive maintenance operator who is good at predicting the onset of a failure has rein-
forced the failure maintenance case [35-38].
4.1. Break down maintenance

6.2. Planned schedule maintenance


This allows us to replace defective parts or systems after the
device is no longer able to function. The simplest solution is to
The invention of CNC machines with unmanned manufacturing
use breakdown repair. This will reduce initial costs such as
capabilities was one of the issues that spurred the study of main-
employee training and other related expenses.
tenance strategies. However, there is no doubt that the most effi-
cient users of all types of machine tools have sought to improve
4.2. Preventive maintenance
maintenance (breakdowns) beyond the previously mentioned
plan. As a result, maintenance was carried out on a regular basis.
Preventive maintenance is done regardless of the machine’s
The system works in this way until the maintenance is carried
state and is scheduled on a calendar or by hours.
out in a certain (i.e., scheduled) period. This strategy has the
advantage of being able to schedule maintenance resources, timing
4.3. Predictive maintenance of downtime, and planning for replacement (Fig. 1). The main
drawback is the focus on established intervals between mainte-
By trending and measuring machinery parameters, this can nance phases.
identify emerging problems in their early stages. As a result,
repairs can be completed before a computer breaks down [31].
The following are the most used condition control techniques: 6.3. Condition based maintenance
1. Vibration Measurement and Analysis
2. Acoustic Emissions Detection Most machine tool users continue to perform routine mainte-
3. IR Thermography nance. Few customers, on the other hand, may be willing to imple-
4. Corrosion Monitoring ment condition-based maintenance due to perceived
5. Lubricant Sampling and Analysis disadvantages. This is preventative maintenance that focuses on
6. Process control equipment (measurement and trends) determining the state of all device components when the computer
7. Trend of process parameters (e.g., flow, speed, pressure, tem- is in service. These calculations should allow for the estimation of
perature, etc.) all elements’ time to failure, allowing maintenance to be scheduled
8. Visual Inspection before any of them fail [39].
9. Motor Current Analysis

5. Machine tools

Machine tools are an important area for a repairman. Unsched-


uled repairs and faulty machine tools have a direct impact on the
productivity of every manufacturer. Therefore, the prospective
company ensured that the purchased machine tool had a good rep-
utation for maintenance and / or ensured that the service techni-
cians repaired quickly and / or had a spare machine available for
service. Not everyone can promise to avoid costly or downtime.
In addition, in today’s competitive environment, arbitrary break-
down is inevitable. As a result, there has been a concerted effort
in the last 10 to 15 years to combine planning and maintenance.
A more well-developed fault log and related parameter control
have been implemented, but what is really needed is an automated
system that predicts faults before they occur or occur, or in any
order. his treatise examines historical and traditional commercial
methods and focuses on an overview of recent research activities
and recent efforts [32-34]. Fig. 1. Turning Operation.

3
S.K. Nithin, K. Hemanth, V. Shamanth et al. Materials Today: Proceedings xxx (xxxx) xxx

7. Gears and bearings condition monitoring: a literature review


and discussion

Condition monitoring is a modern tool that allows operators to


minimize the number of scheduled inspections and reduce down-
time, saving money and effort. Changing data while working con-
ditions is a research priority.

7.1. Bearings

In most rotating machinery, bearings are one of the most critical Fig. 2. Frequency of Failure.

and widely used components. Failures of rotating elements cost


time and money. From power plants to aerospace, bearing fault
operative conditions, are established to confirm that the instru-
detection is important in many industries. Since the displayed
mentation is operated safely which the instrumentation or device’s
defects are present unstable, many errors occur. Some of the vibra-
style specifications are not exceeded. they are typically pro-
tion parameters were compared to determine defects in rolling
grammed to maximise product performance and outturn (load)
bearings. The total rms value, peak component, crest factor, power
whereas reducing instrumentation tension. This implies that the
and acceleration character spectrum of bearing vibration were
hardware can just work inside a specific speed range. This guide-
measured and compared to good bearings in a sound pressure
line applies to both consistent state (steady speed) and variable-
microphone capability test to evaluate various machine conditions
speed machines, which can run over a more extensive scope of
in noisy situations. To cut back noise, AN adaptative filtering rou-
paces however are yet restricted by plan limits. Machines are infre-
tine was combined.
quently expected to work outside of these cut-off points for brief
These system diagnostics seem to be less sensitive to sound
timeframes (during fire up, closure, and arranged over-burdens).
pressure microphones. A logical model was proposed for foresee-
There are several different types of failure, just as there are many
ing moving bearing vibration frequencies and amplitudes of recur-
different reasons for failure. In this segment, the forms will be
rence parts because of a restricted imperfection on the inward race,
divided into just two groups. Catastrophic failures strike without
external race, or one of the moving segments, rather than different
notice and with no warning. Incipient failures occur partially and
strategies, for example, accelerometer estimations under out-
naturally over time. In all but a few instances, there is some fore-
spread and hub loads. An examination of vibration and acoustic
warning of the impending failure; that is, most failures go through
estimation techniques has been proposed for the discovery of
a distinct incipient phase. Computer fault diagnosis and health
deformities in moving component heading. Both grouped and dis-
monitoring are used to find and diagnose the cause of a problem,
sipated deformity structures have been considered for recognition.
and to track its progress over time. After that, better planning is
The Wavelet Packet Transform (WPT) has been proposed as a tech-
possible to avoid the possibility of fatal consequences, since the
nique for considering vibration signals delivered by orientation
time until the eventual failure can be more accurately estimated.
with limited imperfections. In the wake of creating a period recur-
Of course, failure due to external control force is not included.
rence deterioration of vibration flags, the segments conveying the
To summarize the anecdotal data and the statistics describing
basic indicative data were picked for additional preparing [40-42].
the frequency of errors, a ‘‘bath curve” can be used. Fig. 2 shows
a typical bathtub curve that can be used on a single machine or a
7.2. Gears group of similar machines. A high rate of failure is typical within
the first few years of a machine’s useful life. ‘‘Wear-in” failures
Condition control of rotating machine fundamental components are the name for these types of failures. The most common triggers
like gearboxes aids in the reduction of costly unscheduled machine are design flaws, manufacturing flaws, assembly defects, installa-
downtime. There are three sections to a gearbox vibration: a period tion problems, and commissioning flaws. If the cause of these fail-
sinusoidal part, an occasional transient segment actuated by disfig- ures is established and addressed, the level of damage will be
urement, and arbitrary clamor. The vibrations are managed by the reduced. The machine then undergoes a relatively long period of
sinusoidal components, bringing about a tough gearbox. In any operation, during which a failure very rarely occurs. Failures do
case, a blemish is embedded into the circuit, causing modulation happen, but they often happen haphazardly. The era of ‘‘normal
and amplitude variety in the sinusoidal variable. Checking the wear and tear” in the life of a machine is called the epoch, and it
soundness of a gearbox is a huge errand due to its situation in generally constitutes the bulk of the life of a machine. When work-
power transmission in each industry. Utilizing ferromagnetic ing according to design requirements, a relatively low failure rate
examination and vibration investigation innovation, the pinion is required under normal wear [43-45].
wheels condition was checked. In a period, space investigation of
three sorts of spall gears, difference, mean square worth, top
worth, and kurtosis all expanded all together. By giving extra 8. Conclusions
understanding into the wear rate and system of the stuff, ferro-
magnetic examination may give fast and exact data on its condi- Vibration analysis is an important part of many predictive
tion. To characterize and evaluate hurt, the Wigner-Ville maintenance programs and is one of the most effective methods
Distribution (WVD) and wavelet change were utilized. Progressed of condition maintenance. Vibration analysis for machine health
signal preparing procedures like Acoustic Emission (AE) and vibra- monitoring is a simple, inexpensive, and effective method for early
tion estimation were utilized to explore the lab-sized, single-stage fault detection, avoiding unplanned downtime and high repair
gearbox. For recognizing early crack propagation, Acoustic Emis- costs. This method assumes that most machine failures are accom-
sion beat vibration, and stuff issues were grouped and researched panied by a change in the way the computer vibrates. The vibration
utilizing artificial neural networks. probe detects the machine’s vibrations (mainly the accelerometer).
Most of the instrumentation is predicted to control inside a Vibrating signals can be analysed in different signal domains after
selected set of parameters. These limitations, additionally called data pre-processing (involving data normalization and noise
4
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