2/16/24

ENGR-5696EL-01 Machinery
Condition Monitoring and
Diagnostics

Dr. Markus Timusk, PEng (F215C,

mtimusk@laurentian.ca)

Machinery Condition Monitoring and Diagnostics

Course Overview
§ Introduction to machine condition monitoring
§ basic maintenance philosophies and strategies,
§ vibration signal measurement and recording
instrumentation,
§ dynamic signal analysis, signal processing
techniques, and display,
§ bearings, gears and case studies,
§ non-vibration based methods of machine
condition monitoring,
§ advanced automatic fault diagnostic methods
and predictive maintenance.

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Machinery Condition Monitoring and Diagnostics

Paper Presentations
• Work in pairs
• Review the content of a paper and present to
class.
• Paper should be of sufficient length and detail
• Submit paper prior to beginning work
• 20 minutes
• Use powerpoint
• Provide handout for class summarizing the paper
• Provide a copy of the source article for the class

Machinery Condition Monitoring and Diagnostics

Last Name First Name

1 Young Stephen
2 Junkin William
3 McDonald Ethan
4 Alabi Ekundayo
5 Ibeneme Mnena
6 Akash Khan Mohammad
7 Patel Parthesh
8 Patel Jaykumar Sharadbhai
9 Vora Gnanesh Paresh
10 Patel Malav
11 Badresiya Jaimin Rajubhai
12 Patel Tirth
13 Akhtar Ali Raza
14 Talha .
15 Shah Mann Hetalbhai
16 Arora Sameer
17 Syed Aneeq
18 Khan Waseem

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Machinery Condition Monitoring and Diagnostics

Presentation Topics
• Topics for Case Studies Research Papers:
1. Condition monitoring of fans
2. Condition monitoring of pumping system
3. Condition monitoring of helicopter gearboxes
4. On-line lubricant analysis systems
5. Condition monitoring of wind turbines
6. Condition monitoring of a pipeline
7. A new type of sensor for CBM
8. Condition monitoring of a hydraulic system
9. Use of thermography in CBM
10. Use of deep learning and AI in fault detection
11. Condition monitoring of rail
12. Condition monitoring of structures

Or you can suggest a topic.

Machinery Condition Monitoring and Diagnostics

Paper Presentation
• Presentation Assignment
– If you have a preferred partner, please let me
know by 4pm this Friday.
– I will then assign rest of class to a partner

– You will find a couple of papers, send to me, and I

will upload
– Change the name of the paper that you upload to
the last name of you and your partner

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Machinery Condition Monitoring and Diagnostics

Machine Failure
• Last class we introduced the “bathtub
curve”

Wear In
Normal Wear Wear Out
Failure
Rate or
Likelihood (a)
of Failure
(b)

Time In Service

Figure 2.4 A typical bathtub curve showing the typically observed results (predominantly in the
wear out stage) of different operational conditions over the useful life of the machine a) under
designed for purpose and/or frequently overloaded b) over designed for purpose and/or
frequently lightly loaded.

Wear In Normal Wear Wear Out

7 Increasing Duty
Failure
Rate Wear In
Normal Wear Wear Out
Failure
Rate or
Likelihood (a)
of Failure Machinery Condition Monitoring and Diagnostics
Time in Service (b)

Machine Failure
Figure 2.5 A typical bathtub curve showing the true overall effects of different operational
conditions over the useful life of the machine.
Time In Service

• Operational
2.4Figure
The History
2.4 A typical conditions
of Maintenance
bathtub Expectations
curve showingand can
the affect
Methods
typically the(predominantly in the
observed results
wear out stage) of different operational conditions over the useful life of the machine a) under
machinery
Over thedesigned
course offor failure
thepurpose
last 70 years rate
and/orthere has beenoverloaded
frequently an evolvingb)set of expectations
over designed forfrom
purpose and/or
maintenance activities in terms of what could be done and what the expected outcomes could
frequently lightly loaded.
achieve. Figure 2.6 shows a summary of how these expectations have changed over that time.
These changes can be group into three broad categories. Before the end of World War II
maintenance (apart from regular lubrication) was largely conducted only when a machine or
Wear In Normal Wearlimited to when
component actually broke. Failure detection was typically theOut
Wear machine could no
longer function. That is, only after catastrophic failure. Only in rare cases would a failure be
Increasing
detected before ultimate failure, usually by chance or byDuty
direct visual inspection. This
Failurethe machines of that time relatively well as they were typically over-
maintenance method served
Rate
designed to meet the required function and were generally relatively simple in design.

8 in Service
Time

Figure 2.5 A typical bathtub curve showing the true overall effects of different operational
conditions over the useful life of the machine.

2.4 The History of Maintenance Expectations and Methods

Over the course of the last 70 years there has been an evolving set of expectations from
8 maintenance activities in terms of what could be done and what the expected outcomes could
achieve. Figure 2.6 shows a summary of how these expectations have changed over that time.
These changes can be group into three broad categories. Before the end of World War II
maintenance (apart from regular lubrication) was largely conducted only when a machine or
component actually broke. Failure detection was typically limited to when the machine could no
longer function. That is, only after catastrophic failure. Only in rare cases would a failure be
detected before ultimate failure, usually by chance or by direct visual inspection. This
maintenance method served the machines of that time relatively well as they were typically over- 4
designed to meet the required function and were generally relatively simple in design.
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Machinery Condition Monitoring and Diagnostics

Basic Maintenance Strategies

There are three basic categories of maintenance
practise
• Run to failure
• Scheduled
• Condition Based

Two more:
4. Proactive maintenance
5. Redundancy

Basic Maintenance Strategies : Reactive

Philosophy: “ Fix it when it breaks”

Cost:
Reactive Benefit:
•Costly catastrophic
•Zero initial investment
breakdowns

Philosophy: “Change it out every ____ hours”

Benefit:
Scheduled Cost:
•Reduced catastrophic
•Premature work
breakdowns

Philosophy: “Does it need to be fixed?”

Condition Benefit: Cost:

•Maintenance done when •Requires effective use of
Based (CBM) information
needed
•Upfront cost

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Factors for considering Breakdown Maintenance

In general the following conditions apply:

• if equipment is redundant
• low cost spares available
• interruptible process, stockpiled product
• safe failure modes
• long MTTF/MTBF
• low cost secondary damage
• quick repair or replacement (low cost of
interruption to production)

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Basic Maintenance Strategies : Reactive

Run to failure (Breakdown) Maintenance
• maintenance performed only when machinery has failed.

•Example: Burnt out light bulb.

Machine Capacity (Est.)

Failures

Estimated
Capacity and
Load

Machine Duty (Load)

Time In Service Maintenance

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Basic Maintenance Strategies: Scheduled

Philosophy: “ Fix it when it breaks”

Cost:
Reactive Benefit:
•Costly catastrophic
•Zero initial investment
breakdowns

Philosophy: “Change it out every ____ hours”

Benefit:
Scheduled Cost:
•Reduced catastrophic
•Premature work
breakdowns

Philosophy: “Does it need to be fixed?”

Condition Benefit: Cost:

•Maintenance done when •Requires effective use of
Based (CBM) information
needed
•Upfront cost

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Basic Maintenance Strategies : Scheduled

Scheduled ( aka Preventative)

specific maintenance tasks performed at set

time intervals (or duty cycles)

• significant margin between machine capacity

and actual duty maintained.

Example: Oil changes on your car.

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Basic Maintenance Strategies : Scheduled

Factors which Influence Maintenance Strategy

In general the following rules apply.
Scheduled Maintenance
• statistical failure rate available
• narrow failure distribution (predictable
MTBF)
• maintenance restores full integrity
• single failure mode (known)
• low cost of regular
overhaul/replacement
• unexpected interruptions to production
expensive (scheduled interruptions
not so bad)
• low cost spares available
• reduced number of breakdowns
required
• costly secondary damage from failure

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Basic Maintenance Strategies : Scheduled

Scheduled Maintenance

Machine Capacity (Est.)

Estimated
Capacity and
Load
Margin
Margin

Machine Duty (Load)

Time In Service Maintenance

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Philosophy: “ Fix it when it breaks”

Cost:
Reactive Benefit:
•Costly catastrophic
•Zero initial investment
breakdowns

Philosophy: “Change it out every ____ hours”

Benefit:
Scheduled Cost:
•Reduced catastrophic
•Premature work
breakdowns

Philosophy: “Does it need to be fixed?”

Condition Benefit: Cost:

•Maintenance done when •Requires effective use of
Based (CBM) information
needed
•Upfront cost

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Basic Maintenance Strategies : Condition Based

Condition Based (on-condition, predictive, pro-

active) Maintenance

• actual condition of the machinery is assessed

• data used to optimally schedule maintenance
• maximum production and avoidance of catastrophic
failures is achieved

Example: Tire changes on your car.

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Basic Maintenance Strategies : Condition Based

Example: Tire changes on your car.

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Basic Maintenance Strategies : Condition Based

Note: margin between duty and capacity is never
allowed to reach zero - breakdown
avoidance.

• Results: longer time between maintenance tasks

than for scheduled maintenance.

Machine Capacity (Est.)

Reduced Load
Estimated
Capacity and
Load
Minimum Margin

Machine Duty (Load)

Time In Service Maintenance

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Basic Maintenance Strategies : Condition Based

In general the following rules apply.
• expensive/critical machinery
• long lead time for replacement (no spares)
• uninterruptible process (both regular and unexpected) –
costly
• large/complex machinery
• overhaul expensive/needs highly trained people
• reduced numbers of highly skilled maintenance people
• costs of monitoring program acceptable.
• safety is a priority (failures dangerous)
• remote, mobile equipment
• failure not indicated by operation degeneration
• costly secondary damage likely.
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Machinery Condition Monitoring and Diagnostics

Summary of maintenance strategies

Source: Noria corporation.

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Basic Maintenance Strategies

Advantages and disadvantages do exist.
Situations exist where one or the other would be
appropriate.
The maintenance engineer must decide and justify
action.
Combinations of strategies may also be required.
Examples:
- increased frequency of monitoring as the age of a
machine increases
- maximum time between overhauls with monitoring
looking for random failures

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Factors which Influence Maintenance Strategy

IN GENERAL:
• classification of machine
- critical to production?
- high cost of replacement?
- long lead time for replacement?
• manufacturers recommendations
• failure data (history), MTTF, MTBF, failure modes
• redundancy
• safety (plant personnel, community, environment)
• parts cost/availability
• costs (personnel, administrative, equipment)
• running costs

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Factors which Influence Maintenance Strategy

Finally:
• Each case must be evaluated individually.
• Principal considerations defined in economic terms.
• Company policy considerations.

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Machine Condition Monitoring

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Machinery Condition Monitoring and Diagnostics

Machine Condition Monitoring

The goal of machine condition monitoring and fault
diagnostics is to:
• Detect the onset of equipment deterioration.
• Diagnose the existing condition.
• Trend equipment condition or the progression of a
fault, over time.
• Prognose (predict) when ultimate failure will occur.

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Machine Condition Monitoring and

Fault Diagnostics
Potential advantages
• increased machine availability and reliability
• improved operating efficiency
• improved risk management (less down time)
• reduced maintenance costs (better planning)
• reduced spare parts inventories
• improved safety
• improved knowledge of machine condition (safe overloading of
machine possible)

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Machine Condition Monitoring and

Fault Diagnostics

Potential advantages (cont’d)

• extended operational life of machine
• improved customer relations (less planned / unplanned downtime)
• elimination of chronic failures (root cause analysis and redesign)
• reduction of post overhaul failures due to improperly performed
maintenance or reassembly

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Machine Condition Monitoring and

Fault Diagnostics
Potential disadvantages
• monitoring equipment costs (high)
• operational costs (running the program)
• skilled personnel needed
• needs strong management commitment
• long run-in time to collect machine histories and set trends
• reduced costs are harder to sell as direct benefits to management
than increased profits

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MCMAD Philosophy

Get useful information on the condition of equipment to the people who need it.
- operators, maintenance, managers, etc.
- these groups need different information at different times
This means:
- collect useful data
- change data into information in a form
required by and useful to others
- timely reporting

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MCMAD Philosophy

Types of data collected:

- vibration severity, frequency analysis,
temperature, oil analysis, etc.
Types of information gleaned:
- existing condition
- trends
- expected time to failure at a given load
- type of fault existing or developing
- type of fault which caused failure

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MCMAD Tasks
• Detection
• Diagnosis
• Prognosis
• Post Mortem
• Prescription

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MCMAD Tasks
Detection
• data gathering
• comparison to standards
• comparison to limits set in-plant for specific
equipment
• trending over time

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MCMAD Tasks
Diagnosis
• recognizing the type of fault developing
(different fault types may be more or less
serious and require different action)
• severity of fault

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MCMAD Tasks

Prognosis
• expected time to failure
• trending
• forecasting
• maintenance planning/timing

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MCMAD Tasks

Post Mortem
• root cause failure analysis
• research, laboratory / field tests
• modeling of system and analysis

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MCMAD Tasks
Prescription (activity dictated by information
collected)
• may be applied at any stage
• alter operating conditions
• alter monitoring strategy (frequency, type)
• redesign process or equipment

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MCMAD Strategies
How much data to collect?
How much time to spend at data analysis?
These things dictate the MCMAD strategy
(cost will always be a factor)
Consider:
• equipment class, size, importance within
process, replacement cost and availability
• safety
• different pieces of equipment or processes may
require different monitoring strategies.

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MCMAD Strategies

No Monitoring
• inexpensive, non-critical equipment
• in stock equipment (or readily accessible)
• low load equipment
• low failure rate known
• failure modes well understood

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MCMAD Strategies

Periodic Monitoring
• non-critical equipment
• failure modes known
• historically dependable equipment
• trending and severity levels checks only
• problems trigger more rigorous investigations

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MCMAD Strategies
Continuous Monitoring
• permanently installed monitoring system
samples and analyses data automatically
• critical equipment (expensive to replace with
downtime (loss of production) being
expensive)
• changes in condition trigger more detailed
investigation or possibly automatic shutdown

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What to Measure
• vibration levels (displ., vel., accel.).
• oil analysis (lubricating quality contamination)
• wear particle monitoring and analysis
(number, size, shape, composition)
• force measurements
• sound level
• odour
• temperature
• output quantity
• product quality
• visual inspection, etc.

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The tasks listed above have relatively crisp definitions, but there is still considerable room for
adjustment within any machine condition monitoring and fault diagnostic program. There are
always questions concerning such things as how much data to collect and how much time to
spend on data analysis, that need to be considered before the final program is put in place. As
mentioned previously, things such as equipment class, size, importance within the process,
replacement cost, availability, and safety need to be carefully considered.
Machinery ConditionDifferent piecesand
Monitoring of Diagnostics
equipment or processes may require different monitoring strategies.

Approaches to MCM
Table 4.1 below shows several common fault types and the measurement parameter that could be
used to reveal the existence of such faults or changing overall machine condition. As can be seen
in this table, vibration based monitoring has the potential to provide moderate to excellent
condition assessment in most applications.

Table 4.1 Machine Condition Evaluation

4.1 Periodic Monitoring

44 Periodic monitoring involves intermittent data gathering and analysis with portable, removable
monitoring equipment. On occasion, permanent monitoring hardware may be used for this type

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Automated Machine Condition

Monitoring Case Study

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Automated Machine Condition

Monitoring Case Study

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Problem of Unsteady Machinery

Problem:
– Operation of a large proportion of machinery is unsteady
(operates in a range of “Modes”)
– This can have a profound influence on parameters.
– Unaccounted for mode shift can result in false alarms
Factors influencing modes:
– Duty (speed, loading, operator, time etc.)
– environmental characteristics (Ambient temp etc.)
– Machine age

Page 47

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Problem of Unsteady Machinery

Some Possible Approaches:
1. Ignore: System attempts to model all modes
– Resulting in a generalized model
– Risk losing fault detection sensitivity
– Or risk false alarms
– Precludes application to unsteady machinery
2. Data Normalization
– Identify governing parameter (system
identification)
– Applicable to influence which is predictable
and
– Multiple Classifier Method
– Identify modes and associated parameters
– Design system to recognize modes
– Dispatch optimal classifier (must be present for
training and operation)
Page 48

» Approach used in following case study…

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Machinery Condition Monitoring and Diagnostics

Case Study

This case study reports on the

computational approach of an
autonomous condition
monitoring system for a large
hydraulic system.
Project involved:
• Experimental Development
• Practical Implementation

49

Machinery Condition Monitoring and Diagnostics

Application
• Double Roll Crusher At Syncrude
Description
Ltd. Ft. McMurray Alberta
• Subsystem: Apron Feeder
Hydraulic System

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Machinery Condition Monitoring and Diagnostics

Process Flow for Oil Sand Mining

Operation

51

Schematic of Operation

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Apron Feeder

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Machinery Condition Monitoring and Diagnostics

Apron Feeder Hydraulic System

• 3 9 piston variable
displacement hydraulic
pumps.
• Parallel pump configuration,
pump into common manifold
• System Control: Apron feeder
speed
– Speed controlled by pump
swash plate angles which is
in turn regulated by
displacements of pumps

55

Machinery Condition Monitoring and Diagnostics

Justification for Condition Monitoring System

Maintenance history of pumps: The apron feeder

Justificatio hydraulic drives have been subject to various

sporadic and unpredictable failures

n for Unique machinery, no off the shelf solutions are

available

Condition Remote Location: Access to the crusher for

Monitoring
maintenance staff difficult, especially in winter or
wet conditions.

System Condition monitoring via Manual Data Collection

and Plant Information System (PI) has yielded little
insight into the causes of the failures

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Machinery Condition Monitoring and Diagnostics

Justification for Condition Monitoring System

Due to the serial nature of the operation, a failure in the

crusher results in production stoppage in that line until

System the problem is rectified.

Justificatio Difficult Monitoring Application: Due to the highly

n cont.
irregular nature of ore load on the conveyor and the
stop and go nature of its duty, the hydraulic system is
subject impulsive shock loading. The effect of this duty
is twofold. Firstly, it results in unpredictable premature
failures. The second effect is that this impulsive loading
would plague a simple limit based condition monitoring
system.

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Machinery Condition Monitoring and Diagnostics

System Requirements

System should capitalize Modular and

on past experience and
expertise of
System maintenance staff
Requirements
Must be able to detect
faults with little or no
previous fault data
expandable to be able
to accommodate
additional machines
All hardware and
software used must be
mainstream and easily
implemented

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Machinery Condition Monitoring and Diagnostics

• DedicatedProposed Solution
PC Based Online Condition
monitoring system incorporating an expert
system and Artificial Neural Network based
Novelty Detector

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Monitoring System
Hardware Configuration
HYDRAULIC SYSTEM ELECTRICAL ROOM

PENTIUM III PC
ANALOG
SIGNALS

ANALOG TRANSDUCERS
-Case Drain x3 PC
-Pump Output x3 Analog I/O RS232 Cable Matlab Neural
-Swashplate Ðx3 Network
-Charge Pressure Network LabVIEW
-Drive Speed Interface

Multifunction
I/O Data
Acquisition
Card
PROGRAMMABLE
LOGIC CONTROLLER

Ethernet Card
or MODEM
HYDRAULIC PUMP#1
ACCELEROMTERS

Shielded
Connector
Signal Conditioning

HYDRAULIC PUMP#2
ACCELEROMTERS SH100100
Block Cable

HYDRAULIC PUMP#3
ACCELEROMTERS

Client PC
Company LAN or
Imminent failure Phone Line
VIBRATION SIGNALS report

Web enabled mobile device

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Machinery Condition Monitoring and Diagnostics

Advantages of PC Based System

Relatively inexpensive (when compared to dedicated
standalone systems)

Advantage
Hardware and Software more easily supported by company IT
department

s of PC System easily upgraded and expanded

Based Inexpensive and reliable data storage

System PC platform allows many separate software types to work in

unison

Adequate computing power for advanced signal processing

and computing applications

Familiar interfaces for operators

Easily integrated into existing company network

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Machinery Condition Monitoring and Diagnostics

Instrumented Parameters
Parameter Transducer
Pump Vibration (9 total, 1 per ICP Piezoelectric
pump axis x 3 pumps) Accelerometers
Pump Output Flow (3) Inline Flowmeters
Swash Plate Angles (3) Potentiometer
Motor Current Draw (3) Inline
Apron Feeder Speed (1) RVDT via PLC
System Charge Pressure (1) Inline Pressure Transducer
Manifold Pressure (1) Inline Pressure Transducer
Pump Case Drain Flow (3) Inline Flowmeters

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Machinery Condition Monitoring and Diagnostics

Instrumented Pump

63

Monitoring System

• National Instruments
LabVIEW used for data
acquisition hardware
control, expert system
routines and user interface
development
• MATLAB used for Neural
Network Development and
execution of Neural Network
Routines

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Machinery Condition Monitoring and Diagnostics

Expert System
• Expert rulebase developed from
• Input from maintenance staff
• Knowledge of behavior of machine
• Measured data

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Expert System Rulebase Development

• Sample of
machine data Pump Output vs. Swash Plate Angle
trendline y = 5.5499x - 37.427

used to
16.00

14.00

develop
Pump Output

12.00

rulebase 10.00

• Easily
8.00

6.00

correlated 4.00

parameters 8.00 8.20 8.40 8.60 8.80 9.00

Swash Plate Angle
9.20 9.40 9.60

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Machinery Condition Monitoring and Diagnostics

Sample 2 Expert System Rulebase Development

•Since the swash plate angles for the three pumps are linked
together, they have identical loading and the motors driving them
are always at synchronous speed
•the current draw for the pumps should be identical (within an
allowable tolerance). If one current goes out of the tolerance: it
could signify a failure.
Simultanious Motor Current Measurements
DRC7 Apron Feeder (normal operation)
35.00
Current (Amps @ 600VAC)

30.00
25.00
Motor 11
20.00
Motor 12
15.00
Motor 13
10.00
5.00
0.00
1
8
15
22
29
36
43
50
57
64
71
78
85
92
99
Sample Number

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Neural Network Based Novelty Machinery Condition Monitoring and Diagnostics

Detector
Autoencoder General Structure

• Due to fact that Hidden Layer

there was no failure

data to work with,
novelty detector was
chosen as a suitable
approach
• Autoencoder Neural
Network used
Input Layer Output Layer

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Challenges Encountered

1. Multiple operating states

– Wide range of “normal operating
behaviour”
– Difficult for single network to model without
compromising sensitivity
2. Transient behaviour
– Spikes and transient behavior lead to high
novelty scores and false alarms
– During mode changes and shock loading of
hydraulic system
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69

1. Multiple Operating Modes

Proposed Solution
• Single governing parameter found to influence modes of operation
•swash plate angle
• Expert system dispatches appropriate specialized network
•Leads to better modeling

Implementation
• Data sorted by governing parameter
• Histogram sorts data while ensuring minimum amount for effective
training
• Automatically decides how many modes to model and
corresponding networks to create / train

February 16, 2024 System Dynamics Research Group Page 70

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1. Multiple Operating Modes

February 16, 2024

71

Diagnostic Routine Data

• Combination of Expert
Flow DATA
ACQUISITION Slowly Changing
Parameters from
Raw Vibration
Signal from High
ROUTINE
System and Neural FieldPoint Module Speed DAQ Board

Network Based Novelty

Detector DIAGNOSTIC
ROUTINE
Crest
Factors
Frequency
Spectrum
RMS
Values

• Novelty detector is input Redundant

data
Feature Vector
Assembled

to expert system removed

Vectors Normalized

Vectors sorted into groups of

common operating parameters

Autoencoder Autoencoder Autoencoder

Mode 1 Mode 2 Mode N

Expert System
Inference Engine

User Interface And Diagnostic

Communications Result
Routine

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2. Transient Problem: Fault

discrimination
Proposed Solution:
• Design system to discriminate between faults and momentary
transient behaviour
• Only persistent behavior occurring during stable operation
considered for fault detection

Implementation:
• Moving average transient filter used to detect transient
behavior
• Novelty score and duration passed on to expert system

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2. Transient Problem: Fault

Discrimination

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Novelty Detector Validation

Known faults:
• Simply caught by expert system

Progressive Unknown Faults:

• Not described in expert rule-base

•Overlooked by expert system
• Resulted in high novelty score in novelty detector

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Novelty Detector Validation

Novlety Detection Errors on Progressive Simulated

Faults

80.0
70.0 Progressive Fault 1
Mean Square Error

60.0
(Novelty Score)

50.0 Progressive Fault 2

40.0
Mean Fault Free
30.0 Error
20.0 Above + 1 stdv
10.0
0.0
1

13

17

21

25

29

Fault Progression

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Novelty Detection using Auto-Encoders

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Novelty Detection using Auto-Encoders

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Novelty Detection using Auto-Encoders

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Novelty Detection using Auto-Encoders

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Conclusions

Based on preliminary results and offline testing:

• System was able to detect known and unknown
(previously unseen) faults
• Novelty detection is an effective approach, if the
proper steps are taken to implement it
• To be truly useful: must address integration of system
into overall decision support
• Approach merits further investigation, refinement and
development

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Problem of Unsteady Machinery

Problem:
– Operation of a large proportion of machinery is unsteady
(operates in a range of “Modes”)
– This can have a profound influence on parameters.
– Unaccounted for mode shift can result in false alarms
Factors influencing modes:
– Duty (speed, loading, operator, time etc.)
– environmental characteristics (Ambient temp etc.)
– Machine age

Page 82

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Problem of Unsteady Machinery

Some Possible Approaches:
1. Ignore: System attempts to model all modes
– Resulting in a generalized model
– Risk losing fault detection sensitivity
– Or risk false alarms
– Precludes application to unsteady machinery
2. Data Normalization
– Identify governing parameter (system
identification)
– Applicable to influence which is predictable
and
– Multiple Classifier Method
– Identify modes and associated parameters
– Design system to recognize modes
– Dispatch optimal classifier (must be present for
training and operation)
Page 83

» Approach used in following case study…

83

Reading
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CO N N EC TED A SS E T LI FEC YCLE M A N AG EM ENT

Taking the first steps towards

condition-based maintenance
in the rail industry

84

42
 2/16/24

STOPPED Jan 18 … Did paper ABB

discussion

85

43