Instrumentation and signal processing methods used for

Instrumentation and signal processing methods used for

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
Outline
Software and measurement equipments
„ Software and signal processing methods
„ Examples
„
… Angular
Vibration Measurements
… Experimental Dynamics
… Mechatronic Systems
„
Conclusion
Software and measurement
equipments for machine
diagnostics
Sensors for noise and vibration
measurements
Produced by BRÜEL&KJÆR (BK)
ENDEVCO
HEIDENHEIN
TIRA
dSPACE
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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
2302-5
Force sensor 2311-10 Istron
MEDIATOR 2238,
Incremental rotary encoders ERN
460-500 and ERN 460-1024
ACE Kit with DS 1103 PPC
Controller Board
Signal analyzers / Lasers
PULSE, the BK Signal Analyzer
OMETRON Laser vibrometer
‰ 9-channel analyzer of the
25,6 kHz frequency range
‰ angular vibration
‰ linear vibration
‰ 2-channel analyzer of the
102,4 kHz frequency range
Software
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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)
Test Stands
Mechatronic Lab
Software and signal processing
methods developed at the
Department of Control Systems
and Instrumentation
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
PULSE Automation Program for
Phase Demodulation
PULSE Automation Program and
Database of Auxiliary Information
Automation program
(Visual Basic)
Component data
data
Database client
(MS Access)
Component data
Measurement data
Data file
(MS Access)
Measurement control
data
Measurement software
(PULSE)
Data file definition,
information about them
Data file administration
(MS Access)
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
„
Vold-Kalman order tracking filtration I
First generation
24000
x(n ) − 2 cos(ω ∆ t ) x(n − 1) + x(n − 2 ) = ε (n )
[-]
y (n ) = x (n ) + η (n )
(
x = r A A+E
2
T
8000
0
-16000
-24000
0
y
5
10
15
Time [s]
Vold-Kalman : vyfuk_L_mono.wav 2 : Signal
24000
16000
[-]
)
−1
16000
-8000
n = 1,2, …, N
y(n) – measured signal
η(n) – error term
ω(n) – angular frequency
x(n) – filter output
Solution
Time History : vyfuk_L_mono.wav 2 : Signal
8000
2 ord
0
4 ord
6 ord
-8000
8 ord
-16000
-24000
0
5
10
Time [s]
15
Vold-Kalman order tracking filtration II
Second generation, 2-pole filter 24000
x(n ) − 2 x(n − 1) + x(n − 2) = ε (n )
16000
8000
[-]
y (n ) = x (n ) exp( jΘ(n )) + η (n )
T
)
H
C = diag {exp( jΘ(1)),..., exp( jΘ( N ))}
-16000
-24000
0
5
10
15
Time [s]
Vold-Kalman : vyfuk_L_mono.wav 2 : Signal
24000
20000
Ampl [-]
(
−1
x = r A A+E C y
2
0
-8000
n = 1,2, …, N
y(n) – measured signal
η(n) – error term
ω(n) – angular frequency
x(n) – filter output
Solution
Time History : vyfuk_L_mono.wav 2 : Signal
Envelopes
16000
12000
8000
2 ord
4 ord
6 ord
8 ord
4000
0
0
5
10
Time [s]
15
[Pa]
Truck Pass-By Noise Measurements
Time History : 3r : Left
1,5
1,0
0,5
0,0
-0,5
-1,0
-1,5
0
c/(c-v)
3r : Inst Speed
2500
c/(c-v)
RPM
2000
1500
1000
500
0
2
4
Time [s]
6
1,02
1,01
1,00
0,99
0,98
0,97
Vold-Kalman : 3r : Left
-10
0
Position [m]
2
10
3
Time [s]
4
5
6
Vold-Kalman : 3r : Left
80
RM S dB(A)/ref 2E -5
[P a]
RPM
1
70
60
50
40
30
20
-10
-5
27 ord
0
Position [m]
54 ord
5
10
81 ord
Angular Vibration Measurements
Using a principle based on the
phase demodulation of impulse
signals
Phase and Frequency Modulation
Real phase modulated
signal
x(t) = A cos(ωPt+∆φM(t))
Modulation
signal
Analytic
signal
Carrying
componen
t
Sideband
componen
ts
ωP
Phase
1,5
1,0
0,5
0,0
-0,5
-1,0
-1,5
0
0,1
0,2
0,3
0,4
0,5
Revolution
0,6
0,7
0,8
0,9
1
Uniformity of Electric Drill Angular
Velocity
Laser
Angular velocity
[deg/s]
Encoder
300
200
100
Laser
0
Encoder
-100
-200
0,0
0,2
0,4
0,6
Nominal Revolution [-]
0,8
Gear Angular Vibration
Time : Time (Enhanced Time(Encoder))
deg
0,0016
0,0000
-0,0016
0,0
0,2
0,3
0,4
0,5
0,6
0,7
Nominal Revolution [-]
0,8
0,9
1,0
Double differentiation
Time : Time (Time (Enhanced Time(Encoder))) - 0 to 100 ord
60000
30000
Angular
acceleration
0
-30000
-60000
0,0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1,0
Nominal Revolution [-]
m/s^2
deg/s^2
0,1
Difference between
actual and nominal
rotation angle
Time : Order Analyzer : Enhanced Time(Vibrace H)
10
5
0
-5
-10
0,0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
Nominal Revolution [-]
0,8
0,9
Linear acceleration
on the gearbox
housing
1,0
Instrumentation for Transmission
Error (TE) Measurements
Car gearbox
V
I
REV II
21
21
44
44
III
IV
Engine
E1
E2
4/2 channels PULSE
Order Analysis
&
Special software
Heidehain encoders
of the ERN 460-500 type
Axle
Phase Modulation Effect
TE Measurement Result
Enhanced Spectrum, 21-Tooth Gear
Transmission Error
4
3
-10
T E [m icro n ]
RMS dB/ref 1 V
10
-30
-50
-70
2
1
0
-1
-2
-3
-90
-4
374
416
458
500
542
Order [-]
Pinion 21 T
584
626
0
1
2
Tooth pitch rotation
500 RPM, +40 Nm
500 RPM, +80 Nm
3
Measurements of Car Engine
Crankshaft Angular Acceleration
Impulse
signals
crankshaft
4/2 channels PULSE
Order Analysis
tacho
&
(Divider)
camshaft
Source of Impulse Signals
Angular Acceleration During Two
Complete Engine Revolutions
4-cylinder
4-cylinder//4-stroke
4-strokeengine
engine
combustion
combustioncycles
cycles
300
250
+
200
150
100
rad/s2
50
0
-50
-100
-
-150
-200
0
0,2
0,4
0,6
0,8
1
1,2
1,4
1,6
1,8
2
Revolution
compression
compressioncycles
cycles
Experimental Dynamics
Vehicle Structure Vibration
Time based
Operational
Deflection
Shapes
Vehicle Structure Vibration
Modal analysis
2 Hz Mode
Vehicle Structure Vibration
Modal analysis
6 Hz Mode
Vehicle Structure Vibration
Modal analysis
9 Hz Mode
Sound Intensity Measurement
Gearbox Noise and Vibration
Measurements
Semi-unechoic
room at the
TATRA
Company
Drop
Gearbox
Main
Gearbox
Effect of Teeth Surface Modification
on Noise Level
Noise dB
Torque
Nm
805
Gear train T2
Noise dB
1001
88-92
1245
84-88
80-84
76-80
72-76
68-72
1549
80-84
1968
76-80
2448
72-76
3080
68-72
64-68
60-64
3831
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
88-92
84-88
S
T1
Torque
Nm
1771
2203
2740
3408
4330
64-68
60-64
RPM
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
22005
Gear train S
RPM
On-road operation
Off-road operation
T2
Gear trains of Drop Gearbox
386
Mechatronic Systems
Multirate Digital Filters for a Stand
to Test Rolling Bearings
Test Stand designed by Diagnostika Brno
DSP
Tacho
RS 232
A/D
Left
Vibrace
Snímač vibrací ložiska
Amplitudový
filtr 1
Výpočet
RPM
Amplitudový
filtr 2
Počet
špiček
Frekvenční filtr
1,8-10 kHz
Výpočet
RMS
Frekvenční filtr
300-1800 Hz
Výpočet
RMS
Frekvenční filtr
50-300 Hz
Výpočet
RMS
Right
A/D
Nábojový zesilovač
PC
44,1 kHz
Tachosonda
Antiimaging
filtr
D/A
44,1 kHz
Připoslech/
Analyzátor
Functional Block Diagram
Output 1
FIR64 2
10 kHz
Output 2
Input
IIR1
20 Hz
FIR64 2
10 kHz
Multirate
filters
FIR64 6
1k8 Hz
FIR64 6
300 Hz
FIR64
300 Hz
FIR64
1k8 Hz
FIR64
50 Hz
∑x
2
i
∑x
2
i
∑x
2
i
Analog Devices DSP
Inertial measurement units
Platform stabilization
cRIO - Compact
Reconfigurable
I/O
Analog Devices
angular rate
sensor
ADXRS300
LabView
Conclusion
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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