Instrumentation and signal processing methods used for machine diagnostics

Transcription

1 International Carpathian Control Conference ICCC 2006 Rožnov pod Radhoštěm CZECH REPUBLIC May 29-31, 2006 Instrumentation and signal processing methods used for machine diagnostics VSB Technical University of Ostrava Faculty of Mechanical Engineering Department of Control Systems and Instrumentation Jiří Tůma Marek Babiuch, Radim Farana, David Fojtík, Petr Kočí, Petr Koňařík, Jiří Kulhánek, Petr Noskievič, Roman Pavlas, Lubomír Smutný, Pavel Smutný, Jaromír Škuta, Antonín Víteček, Miluše Vítečková, Renata Wagnerová

2 Outline Software and measurement equipments Software and signal processing methods Examples Angular Vibration Measurements Experimental Dynamics Mechatronic Systems Conclusion

3 Software and measurement equipments for machine diagnostics

4 Sensors for noise and vibration measurements Produced by BRÜEL&KJÆR (BK) ENDEVCO HEIDENHEIN TIRA dspace Charge amplifier NEXUS Deltatron Accelerometer 4396 & 4508, Triaxial Accelerometer Free-field ½ Microphone 4190 Photoelectric Tachometer Probe MM 0024 Exciter 100N (S521) & Power Amplifier 120 VA (A50112) Accelerometer 0.05 Hz 7745A 1000 Istron EE 0111 Delta Tron Impact Hammer Force sensor Istron MEDIATOR 2238, Incremental rotary encoders ERN and ERN ACE Kit with DS 1103 PPC Controller Board

5 Signal analyzers / Lasers PULSE, the BK Signal Analyzer 9-channel analyzer of the 25,6 khz frequency range 2-channel analyzer of the 102,4 khz frequency range OMETRON Laser vibrometer angular vibration linear vibration

6 Software Matlab-Simulink and Toolboxes dspace Support Code Generation PULSE LabShop ME scope VES (Operational Deflection Shapes, Modal Analysis) Indoor software (Signal Analyzer, PULSE Automation Programs)

7 Test Stands

8 Mechatronic Lab

9 Software and signal processing methods developed at the Department of Control Systems and Instrumentation

10 Signal Analyzer Time - Filtration in the Frequency Domain, Demodulation FFT - Fast Fourier Transform CPB - Constant Percentage Band Autospectrum Cross-Spectrum FRF - Frequency Response Function Overall Level Analysis Tachometer for Impulse Signals Resampling Correlation FIR Filters FIR Filter FRF Linear Combiner Autoregressive Model Autoregressive Spectrum Signal Detrend Eigenanalysis

11 PULSE Automation Program for Phase Demodulation

12 PULSE Automation Program and Database of Auxiliary Information Component data data Automation program (Visual Basic) Measurement control data Component data Measurement data Database client (MS Access) Data file (MS Access) Measurement software (PULSE) Data file definition, information about them Data file administration (MS Access)

13 Newly Developed Signal Processing Methods Methods for phase demodulation based on the Hilbert transform using digital filters Parametric methods for spectral analysis based on autoregressive modeling Order analysis methods Vold-Kalman order tracking filtering

14 Vold-Kalman order tracking filtration I First generation x y ( n) 2cos( ω t) x( n 1) + x( n 2) = ε( n) ( n) = x ( n) + η( n) n = 1,2,, N y(n) measured signal η(n) error term ω(n) angular frequency x(n) filter output Solution x = 2 T 1 ( r A A + E) y [-] [-] Time History : vyfuk_l_mono.wav 2 : Signal Time [s] Vold-Kalman : vyfuk_l_mono.wav 2 : Signal Time [s] 2 ord 4 ord 6 ord 8 ord

15 Vold-Kalman order tracking filtration II Second generation, 2-pole filter x y ( n) 2x( n 1) + x( n 2) = ε ( n) ( n) = x ( n) exp( jθ( n) ) + η ( n) n = 1,2,, N y(n) measured signal η(n) error term ω(n) angular frequency x(n) filter output Solution x = 2 T 1 H ( r A A + E) C y { exp( jθ( 1) ),..., ( jθ( N ))} C = diag exp [-] Ampl [-] Time History : vyfuk_l_mono.wav 2 : Signal Time [s] Vold-Kalman : vyfuk_l_mono.wav 2 : Signal Envelopes Time [s] 2 ord 4 ord 6 ord 8 ord

16 Truck Pass-By Noise Measurements [Pa] 1,5 1,0 0,5 0,0-0,5-1,0-1,5 Time History : 3r : Left Time [s] RPM RPM 3r : Inst Speed Time [s] c/(c-v) c/(c-v) Vold-Kalman : 3r : Left 1,02 1,01 1,00 0,99 0,98 0, Position [m] RMS db(a)/ref 2E-5 [Pa] Vold-Kalman : 3r : Left Position [m] 27 ord 54 ord 81 ord

17 Angular Vibration Measurements Using a principle based on the phase demodulation of impulse signals

18 Phase and Frequency Modulation Real phase modulated signal x(t) = A cos(ω P t+ φ M (t)) 1,5 1,0 0,5 0,0-0,5-1,0-1,5 Modulation signal Phase 0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1 Revolution ω P Analytic signal Carrying componen t Sideband componen ts

19 Uniformity of Electric Drill Angular Velocity Laser Encoder Angular velocity [deg/s] ,0 0,2 0,4 0,6 0,8 Nominal Revolution [-] Laser Encoder

20 Gear Angular Vibration 0,0016 Time : Time (Enhanced Time(Encoder)) deg deg/s^2 0,0000-0,0016 0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 Nominal Revolution [-] Time : Time (Time (Enhanced Time(Encoder))) - 0 to 100 ord 0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 Nominal Revolution [-] Difference between actual and nominal rotation angle Double differentiation Angular acceleration m/s^ Time : Order Analyzer : Enhanced Time(Vibrace H) Linear acceleration on the gearbox housing 0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 Nominal Revolution [-]

21 Instrumentation for Transmission Error (TE) Measurements 21 V Car gearbox I REV II III IV 21 Engine E 1 E 2 4/2 channels PULSE Order Analysis & Special software Heidehain encoders of the ERN type Axle

22 Phase Modulation Effect TE Measurement Result RMS db/ref 1 V Enhanced Spectrum, 21-Tooth Gear TE [micron] Transmission Error Order [-] Tooth pitch rotation Pinion 21 T 500 RPM, +40 Nm 500 RPM, +80 Nm

23 Measurements of Car Engine Crankshaft Angular Acceleration Impulse signals crankshaft 4/2 channels PULSE Order Analysis & tacho (Divider) camshaft

24 Source of Impulse Signals

25 Angular Acceleration During Two Complete Engine Revolutions 4-cylinder // 4-stroke engine combustion cycles rad/s ,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8 2 Revolution compression cycles

26 Experimental Dynamics

27 Vehicle Structure Vibration Time based Operational Deflection Shapes

28 Vehicle Structure Vibration Modal analysis 2 Hz Mode

29 Vehicle Structure Vibration Modal analysis 6 Hz Mode

30 Vehicle Structure Vibration Modal analysis 9 Hz Mode

31 Sound Intensity Measurement

32 Gearbox Noise and Vibration Measurements Semi-unechoic room at the TATRA Company Drop Gearbox Main Gearbox

33 Effect of Teeth Surface Modification on Noise Level Noise db S Gear train S RPM Torque Nm Noise db Gear train T RPM Torque Nm T1 On-road operation Gear trains of Drop Gearbox T2 Off-road operation

34 Mechatronic Systems

35 Multirate Digital Filters for a Stand to Test Rolling Bearings Test Stand designed by Diagnostika Brno Tacho DSP 44,1 khz A/D Amplitudový filtr 1 Výpočet RPM RS 232 PC Left Amplitudový filtr 2 Počet špiček Vibrace Right A/D Frekvenční filtr 1,8-10 khz Výpočet RMS Nábojový zesilovač Frekvenční filtr Hz Výpočet RMS Snímač vibrací ložiska Tachosonda Frekvenční filtr Hz Výpočet RMS Antiimaging filtr D/A 44,1 khz Připoslech/ Analyzátor Functional Block Diagram Input IIR1 20 Hz FIR64 10 khz 2 1k8 FIR64 Hz 6 FIR64 10 khz 2 Output 1 Output FIR64 Hz 6 FIR64 50 Hz xi 2 Multirate filters FIR64 1k8 Hz FIR Hz xi 2 xi 2 Analog Devices DSP

36 Inertial measurement units Platform stabilization Analog Devices angular rate sensor ADXRS300 crio - Compact Reconfigurable I/O LabView

37 Conclusion The paper reviews instrumentation and software for diagnostics of machines and some of results of research work done for industry Equipments enable to do noise and vibration measurements of machines Special interest is focused at angular vibration during rotation Development of measurement methods is supported by software design