Statistical Vibration Analysis For Predictive Maintenance of Machines Working Under Large Variation of Speed and Load
Statistical Vibration Analysis For Predictive Maintenance of Machines Working Under Large Variation of Speed and Load
ABSTRACT 1. INTRODUCTION
Prognosis of defects for machines working under large Vibration analysis has been implemented and studied in
variation of speed and load conditions is a topic still rotating machinery for many years, and it is widely
under development. Wind turbines are recent examples accepted as one of the main techniques for condition
of such kind of machines that need reliable diagnosis based maintenance (Hameed, 2009). With the advance
methods. Vibration analysis can be of very limited use of technology, more complex machines that operate
when the speed variation is too high. An effective under more severe conditions have been developed; an
angular resampling method can be very valuable as the example of these conditions are those who operate
first step of vibration signal processing but it is under varying loads and speeds like wind turbines,
important to know what are the appropriate variables to excavators and helicopters (Barszcz, 2009; Blunt, 2006;
be monitored. Combet, 2009; Bartelmus, 2009). In these kinds of
machines, gear transmissions play a crucial role in
The authors present a statistical analysis method terms of their reliability.
consisting of a linear model based on the parameters
that characterize the system, in our case the variable The initial research in the area of transmission damage
speed and load, and the fault condition to which the detection was focused on vibration signal analysis
system is subjected. With this method can be (Davies, 1998). At first, as discussed in (Samuel, 2005),
determined if the variable analyzed is significant, that is the statistical characteristics of the signal in the time
to say if are sensitive to these parameters and hence can domain were the primary focus of study. However, the
detect the fault faster. The aim of implementing this field quickly expanded to include spectral analysis,
method is to reduce the number of variables to be time-frequency analysis, wavelet analysis, neural
monitored, resulting in a savings not only in measuring networks and mathematical modeling. This field is
equipment but also in times of processing and continuing to grow. As new signal processing
analyzing information. techniques emerge, they are applied to the transmission
damage detection problem and must be accommodated
The results of vibration analysis of a test-bed working to the needs and specificities of each mechanical
under large variation of speed and load are shown. system.
Different tests with increasing level of defects are tried
and the corresponding vibration is analyzed and For systems which work under variable speed and load
modeled so an effective detection and prognosis can be conditions one of the most appropriate signal
done. Taking in to account such variation of speed and processing method is angular resampling, however,
load for the vibration modeling can lead to a very using this method is only the fisrt step because it is
sensitive detection of incipient defects.* necessary to analyze the information obtained and it is
also important to determine that the variables that are
being analyzed are those that provide the best
* information on fault diagnosis. For the selection of
This is an open-access article distributed under the terms of
the Creative Commons Attribution 3.0 United States License,
these variables, the authors present in this paper a
which permits unrestricted use, distribution, and reproduction statistical method based on a linear model to determine
in any medium, provided the original author and source are the sensitivity of each variable with respect to the
credited. failure and system operating conditions.
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The main motivation for this work is the diagnosis of For the above reasons, the vibration monitoring
wind turbines, so the test bed that will be shown, is systems require signal processing procedures to
used to approach the phenomenon and failures of a real compensate for the fluctuations in shaft speed and the
wind turbine. amplitude modulation caused by the variable load
(UpWind, 2006; Stander, 2002; Stander, 2005).
2. VARIABLE SPEED AND LOAD In the fluctuating load research many studies have been
RESERARCH developed using various methods of signal analysis,
among these studies are those by Stander, Heyns, Zhan
For the analysis of systems that operate under variable and Bartelmus (Stander, 2006; Zhan, 2006; Bartelmus,
speed conditions, efforts were made to find techniques 2009). However, until now no studies have been
that allow for better processing and analysis of the developed in an extended work range of speed and
signals captured from these systems. A theory of load, and that is where our research focuses.
interpolation applied to time domain averaging was
presented in (McFadden, 1989; McFadden, 1991) as an
alternative to averaging when there is no rotational 3. ANGULAR RESAMPLING ALGORITHM
reference signal.
FOR LARGE SPEED VARIATION
Due to the fact that many systems are working under Due to the speed variations caused by the operating
variable speed, the technique known as order tracking conditions itself, and load variations, as is the case of
is very common in vibration analysis. Each of the steps wind turbines, it is necessary to process the vibration so
that comprise the order tracking method are explained its frequency content can be analyzed. The angular
in (Fyfe, 1997). In this method the main algorithm is resampling technique can be used to solve this problem.
the angular resampling, which repositions the samples
of vibration to be equivalents to a signal measured at The works that have been developed previously on the
constant speed. In this article comparisons are made at issue of angular resampling are applicable to cases in
each step and the best alternatives for each are given. which the speed fluctuations are small (Bonnardot,
Later, (Bossley, 1999) presented a hybrid, computed 2005; McFadden, 1989; Fyfe, 1997; Bossley, 1999).
order tracking method to perform angular resampling The application of this kind of signal processing to the
which was compared with two previously proposed vibration analysis of machines like wind turbines is
methods by comparing the results. limited, because the angular speed and hence
acceleration variations experienced in a wind turbine
A method to perform angular resampling was presented are high and are not predictable as they depend on the
in (Bonnardot, 2005) using the acceleration signals wind.
directly without the need for an encoder signal, but this
method has the limitation that it can only be used when The method of angular resampling algorithm proposed
speed variations are small and it requires a sufficient by (Fyfe, 1997) is valid for linear profile of speed. The
number of harmonics. authors in (Villa, 2011) presented an evolution of this
method, an angular resampling algorithm for a general
An extension to the algorithm proposed by Bonnardot case of variable speed and a generic number of
was presented by Combet. However, it is not advisable keyphasors.
for use in the case of very large speed variations, such
as during acceleration (Combet, 2007; Combet, 2009). The method proposed by (Fyfe, 1997) includes the
following steps; first records the data at constant ∆t
Another factor affecting the variability of the speed is increments, and them resamples this signal to provide
the fluctuating load that modulates the amplitude of the the desired data at constant ∆θ increments, based on a
vibration signal measurement and causes changes in the
keyphasor signal. To determine the resample times, it is
rotational speed of the system. Changes in the system
assumed that the shaft is undergoing constant angular
speed cause a modulation in the characteristic
frequencies of the mechanical elements of the system acceleration, the shaft angle; θ is described by the
(Stander, 2005). following quadratic equation:
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Figure 3. Test-bed
Figure 1. Spectrum before and after angular resampling
for a simulated signal
For the acquisition of vibration signals we used four
accelerometers distributed in axial and radial position
The angular resampling method developed by the in the gearboxes located on the right side of the test-
authors (Villa, 2011) was also tested with experimental bed.
data with satisfactory results. The data shown
corresponds to a bearing with damage in the inner ring
of the fast Shaft (figure 2). 5. EXPERIMENTATION
The failures simulated on the test bed were unbalance
and misalignment, starting with small values of defects
and increasing with each new set of measurements to
simulate a progressive failure (table 1). The table shows
the value of the weight in grams and the equivalent
percentage of the total weight of the rotor test bed, and
the thickness of the sheet used to misalign and their
respective angle of misalignment.
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These profiles were generated to cover a full day of 6.1 Unbalance analysis
measurements (24h), with constant intervals of speed
and load every 100 sec. Speed measurements were First of all an analysis of the radial vibration level (first
generated starting at 1000 rpm because this is the harmonic) for the different defects was made. It is
approximately equivalent speed in the slow axis when a presented the vibration for the 4 levels of unbalance
wind turbine begins to generate energy. compared with the vibration without defect, and can be
clearly seen that the defects cannot be distinguished
Captures were made of 72 seconds with each of the directly (figure 5) and are not statistically different
four accelerometers mentioned in section 4 with a (figure 6) due to the fact that the amount of unbalance
sampling frequency of 25600 Hz. The speed signal and the speed shaft are very low.
captured in the slow axis used for angular resampling
was sampled at a frequency of 6400 Hz.
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4).
0.00015
Y = (b0 + b3 F ) + b1 S + b2 L (2)
Figure 7. Vibration level harmonic 6X planetary radial
(unbalance)
Where Y is the vibration dependent on the speed, load
and defect, b0 + b3 F is the intercept, b1 S is the
slope as a function of speed and b2 L is the slope as a
function of load.
Signif. codes: 0 ‘***’ 0.001 ‘**’ 0.01 ‘*’ 0.05 ‘.’ 0.1 ‘ ’ 1
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variables
Statistical variables 1
Electrical variables 0
Order 1X to 10X 10
8e-05
Gears 5
Vibration (g)
accelerometers
Planetary Axial 0
Planetary Radial 1
4e-05
Parallel Axial 0
Parallel Radial 2
2e-05
5e-04
Signif. codes: 0 ‘***’ 0.001 ‘**’ 0.01 ‘*’ 0.05 ‘.’ 0.1 ‘ ’ 1
4e-04
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Figure 10. Vibration level harmonic 1X planetary axial Figure 12. Vibration level harmonic 1X planetary radial
(misalignment) (misalignment)
4e-04
0.00035
3e-04
Vibration (g)
Vibration (g)
0.00025
2e-04
0.00015
1e-04
0 0.75 2 0 0.75 2
Figure 11. Box-plot harmonic 1X planetary radial Figure 13. Box-plot harmonic 2X planetary axial
(misalignment) (misalignment)
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Figure 14. Vibration level harmonic 2X planetary axial Figure 16. Vibration level harmonic 2X planetary radial
(misalignment) (misalignment)
0.00008
0 0.75 2
F=0.75 -5.325e-05 4.190e-06 -12.709 <2e-16 ***
Signif. codes: 0 ‘***’ 0.001 ‘**’ 0.01 ‘*’ 0.05 ‘.’ 0.1 ‘ ’ 1
Figure 15. Box-plot harmonic 2X planetary radial
(misalignment)
Table 7: Coefficients modeling harmonic 2X planetary
axial (misalignment)
Estimate Std. Error t value Pr(>|t|)
b0 2.713e-04 3.826e-06 70.923 <2e-16 ***
b1 -2.378e-04 8.690e-06 -27.365 <2e-16 ***
b2 -4.248e-06 2.012e-06 -2.112 0.0348 *
F=0.75 -2.818e-05 1.266e-06 -22.264 <2e-16 ***
F=2 -3.300e-05 1.276e-06 -25.867 <2e-16 ***
Signif. codes: 0 ‘***’ 0.001 ‘**’ 0.01 ‘*’ 0.05 ‘.’ 0.1 ‘ ’ 1
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Table 10. Selected variables to be monitored for Special thanks to Roberto Arnanz for his work in the
misalignment data recording and processing during the project.
Type of variable Number of
variables REFERENCES
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