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Condition Monitoring in Mechanical Domain
Condition Monitoring in Mechanical Domain
Condition Monitoring in Mechanical Domain
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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
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
5. Machine tools
3
S.K. Nithin, K. Hemanth, V. Shamanth et al. Materials Today: Proceedings xxx (xxxx) xxx
7.1. Bearings
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