Condition Monitoring Using

Thermography For Preventive

And Predictive Maintenance

Prepared By:-Guided By:-

Prof Prashant Bagga
INDEX
 Thermography
 Principle of black body radiation
 Advantage of thermography
 Limitation of thermography
 Application of thermography
 Literature review
 Experiment setup
 Experiment procedure
 Results
 conclusion
Thermography
 Thermography is a process where by using thermal and
Infrared camera’s the temperature of and object is visually
observed.[1]
 Thermography can be used in various application such as
research and development, optimization, inspection of
mechanical and electrical equipment’s, medical, building
inspection, maintenance, automation.
Black Body Radiation Law
 According to the principle of black body radiation law, when a
body is heated above the absolute zero temperature the
produce radiation and this radiation can be seen under
thermal imaging camera more the temperature more will be
radiation and more it will differ from its environment.[2]
 And this law is the based of thermal analysis as every object
in nature radiate heat and this can be measured using
thermal cameras
Advantages
 Temperature of a large area can be known
 Moving targets can also be analyzed
 It’s able to find deterioration of machine components due to
higher temperature
 Hazardous area can be also analyzed
 It’s a non-destructive testing method
 Nearly every type of material can be analyzed
Limitation
 Quality cameras often have a high price range so it’s termed
as an expensive method
 Frequent calibration is needed and also information could be
lost if proper maintenance is done of the equipment
 Images can be difficult to interpret accurately when based
upon certain objects, specifically objects with erratic
temperatures
 By different emissivity’s and reflections there may be a
change in results
 Only surface temperature can be measured
Application
 Condition monitoring
 Roofing inspection
 Building diagnostics
 Thermal mapping
 Medical imaging
 Non-contact thermography
 Archaeological Aerial Thermography
 Veterinary Thermal Imaging
 Veterinary Thermal Imaging
 Night vision and Targeting
Ambient Temperature For Defect Free System
Literature review
 We have studied 20 research papers related to condition
monitoring of machines with the help of Thermal Imaging.
 Thermal Imaging picks up the surface temperature of a machine
while running.
 Most of the techniques for condition monitoring with thermal
imaging requires huge data collection and data processing to
obtain various working condition of the machine.
 Once the data is collected the software can easily decide
whether the machine is at optimum or not. Most of the common
post processing of the data is FFT (Fast Fourier
Transformation), it is a mathematical model of the machine that
is calculated under various limits such that we can know at what
condition the machine gets damaged.
Setup
 Our experiment consists of a motor and rotating disk
mounted on a shaft with bush bearing. The shafts are
mounted on a frame by helical springs on 4 corners.
 The motor rotates the disk, when the disk rotates on the shaft
it oscillates the system as it is supported on springs.
 In order to reduce the vibration the system needs to balance.
We have selected the motor to be the subject of our
experiment. The motor is 1 BHP, 1500 rpm, V Belt type
transmission from motor to shaft.
Procedure:-  We considered two different
condition when the system
is balanced and when the
system is unbalanced.
 The unbalanced condition
of the motor duplicates the
condition failure of shaft of
the motor. We then
measured the temperature
of the system in this two
different conditions.
 We were provided with a
Fluke TiS40 infrared
camera with 160x120 mega
pixel resolution and IR
Fusion with blending and
PIP mode.
 ( Balanced Condition ( Balanced Condition motor
motor run for 1 minute) run for 10 Minutes)

we run the motor initially with balanced condition and recorded the
temperature via thermal camera. We run the motor in balanced condition for
10 minutes and then recorded the temperature of the motor once again with
the thermal camera.
Unbalanced condition

( Unbalanced condition ( Unbalanced condition

motor run for 15 minute) motor run for 20 minutes)
Result
 We run the motor in balanced and unbalanced condition for
stable conditions and recorded temperature of both condition
at both time in beginning and in stable state.
 We found a significant increase in temperature of the motor
when it was unbalanced. The unbalanced motor is the
condition that duplicates the condition of shaft failure of the
motor. Thus we have data of the motor at shaft failure.
Maintenance table
Conclusion
 Thermography has changes a lot from its invention to the
current state it have evolved a lot and there are also many
further scope where it can evolve and effect our life’s.
 By understanding various properties of thermal images we
are able to predict various conditions prior they happen which
saves our cost as well as time and also .
 many innovations are to be done in thermography to make it
a close loop system so that computer can directly read the
thermal images and predict the output via using artificial
intelligence.
References
1. Thermal image based fault diagnosis for rotating machinery
2. Research on Insulator Fault Diagnosis and Remote Monitoring system based on IR images
3. Scheme for predictive fault diagnosis in photo voltaic modules using thermal imaging
4. Monitoring of MMCs grinding process by means of IR thermography
5. Application of infrared thermography for predictive/preventive maintenance of thermal defect in
electrical equipment
6. An intelligent approach for cooling radiator fault diagnosis based on infrared thermal image
processing technique
7. Shaft misalignment detection by thermal imaging of support bearings
8. Intelligent fault diagnosis of rotating machinery using infrared thermal image
9. Fault detection in induction motors and the impact on the kinematic chain through thermographic
analysis
10. Comprehensive diagnosis methodology for faults detection and identification, and performance
improvement of Air-Cooled Polymer Electrolyte Fuel Cells
11. Evaluation of Thermography image data for machine fault diagnosis
12. Confirmation of thermal images and vibrations signals for Intelligent machine fault diagnostics.
13. Diagnosis of a three phase induction motor using thermal imaging
14. Fault detection using thermal imaging based on soft computing methods.
15. Thermal image based fault diagnostics for rotating machinery
16. A Thermograph Image Extraction Based On Color Features For Induction Motor Bearing Fault
Diagnosis
17. Low-Cost Thermographic Analysis For Bearing Fault Detection On Induction Motors
18. Detection Of Short-Circuits Of Dc Motor Using Thermographic Images Binarization And K-Nn
Classifier.
19. Detection Of Hot Spots By Thermal Imaging To Protect Power Equipments.
20. An Approach To Fault Diagnosis Of Rotating Machinery Using The Second-Order Statistical
Features Of Thermal Images And Simplified Fuzzy Artmap.