Acoustic condition monitoring for cold metal forming

One of the most important objectives of cold metal forming research is to develop techniques that enable better manufacturing efficiencies. Within this monitoring of tooling condition is vital to providing high quality manufacturing. The objective of this research is to determine the signature derived from Acoustic Emission (AE) sensors, in order to establish the current condition of a machine tool, as applied to bolt-making. From here we aim to develop and implement an on-line condition monitoring tool for the cold forming process. A review of the literature has shown that much research into AE has been successfully applied in metal cutting operations; such as milling, drilling and turning, but little research has been done related to metal forming. This appears to be due to the complexity of obtaining consistent signals using Acoustic Emission systems, because the presence of noise in many forms. This paper will detail many of the AE signals acquired and analysed through our research. The extensive results indicate this form of condition monitoring is not suitable for metal forming in its current configuration. Further tests are proposed to enable such research to move forward, so a condition monitoring system can be established.

On-line tool condition monitoring and control system in forging processes

Cold bulk metal forming has made large-scale production of small complex solid parts economically feasible. Tooling used in metal forming poses many uncertainties in the preliminary cost estimation and production process and continual tool replacement and maintenance dramatically reduces productivity and raises manufacturing cost. In order to tackle this, an on-line tool condition monitoring system using artificial neural network (ANN) to integrate information from multiple sensors for forging process has been developed. Together with the force, acoustic emission signals and process conditions, information developed from theoretical models is integrated into the ANN tool monitoring system to predict tool life and provide the maintenance schedule.

A brief review on offshore wind turbine fault detection and recent development in condition monitoring based maintenance system

Offshore wind turbine requires more systematized operation and maintenance strategies to ensure systems are harmless, profitable and cost-effective. Condition monitoring and fault diagnostic systems ominously plays an important role in offshore wind turbine in order to cut down maintenance and operational costs. Condition monitoring techniques which describing complex faults and failure mode types and their generated traceable signs to provide cost-effective condition monitoring and predictive maintenance and their diagnostic schemes. Continuously monitor the condition of critical parts are the most efficient way to improve reliability of wind turbine. Implementation of Condition Based Maintenance (CBM) strategy provides right time maintenance decisions and Predictive Health Monitoring (PHM) data to overcome breakdown and machine downtime. Fault detection and CBM implementation is challenging for off shore wind farm due to the complexity of remote sensing, components health and predictive assessment, data collection, data analysis, data handling, state recognition, and advisory decision. The rapid expansion of wind farms, advanced technological development and harsh installation sites needs a successful CM approach. This paper aims to review brief status of recent development of CM techniques and focusing with major faults takes place in gear box and bearing, rotor and blade, pitch, yaw and tower system and generator and control system.

Emission-based condition monitoring technique for ZnO surge arrester

In this paper, electromagnetic emission at the frequency range of 30MHz to 300MHz is used to detect physical defects on the 22kV outdoor zinc-oxide (ZnO) surge arresters. Different weather conditions combining with artificially created pollution were produced in a laboratory environment and measurements were recorded over a fixed period of time. Pollution due to fine dust particles has been created according to IEC standard under both wet and dry conditions. The aim is to detect the defects (bushing damage) when the surge arrester is subjected to various weather and surface condition. The collected electromagnetic signals were sampled and analyzed using analysis tools such as the autocorrelation coefficient and Wigner-Ville distribution. The results from the present paper indicate that electromagnetic radiation from the defects on surge arrester combining with the adequate analysis tools can be used as a valuable diagnostic tool for power system operator.

Productive on-line student support : developing a system for primary mathematics trainee teachers

This paper outlines the development project for the 'Productive on-line student support system', a student "self-help" system, at Deakin University. The aim of this project was to provide Deakin primary teacher education students with a web-based learning tool that allowed them to assess and diagnose their strengths and weaknesses in mathematics, and supports students in their mathematics learning, and in so doing produce mathematically competent graduates. This project was, like similar programs, a development of peer or cross-age tutoring common in primary and secondary schools. A grant under the Deakin University Strategic Teaching and Learning Grant Scheme enabled a staff team from the mathematics education group, to develop a sophisticated and well-designed system that catered for a wide range of student needs, provided useful feedback, and was engaging and easy to use. The under-pinning software for the system was WebCT, available to staff through the Deakin Studies On-line system, to which students are connected also. The 'Productive on-line student support system' enabled students to determine their own mathematical needs, and have these addressed whenever they wished, as often as they wished, and allowed self-monitoring of progress. An outline of the system and examples of the assessment materials will be presented.

A mutation-based evolving neural network model and its application to condition monitoring

Data analysis using intelligent systems is a key solution to many industrial problems. In this paper, a mutation-based evolving artificial neural network, which is based on an integration of the Fuzzy ARTMAP (FAM) neural network and evolutionary programming (EP), is proposed. The proposed FAMEP model is applied to detect and classify possible faults from a number of sensory signals of a circulating water system in a power generation plant. The efficiency of FAM-EP is assessed and compared with that of the original FAM network in terms of classification accuracy as well as network complexity. In addition, the bootstrap method is used to quantify the performance statistically. The results positively demonstrate the usefulness of FAM-EP in tackling data classification problems.

Condition monitoring and fault prediction via an adaptive neural network

This paper describes the application of an adaptive neural network, called Fuzzy ARTMAP (FAM), to handle fault prediction and condition monitoring problems in a power generation station. The FAM network, which is supplemented with a pruning algorithm, is used as a classifier to predict different machine conditions, in an off-line learning mode. The process under scrutiny in the power plant is the Circulating Water (CW) system, with prime attention to monitoring the heat transfer efficiency of the condensers. Several phases of experiments were conducted to investigate the `optimum' setting of a set of parameters of the FAM classifier for monitoring heat transfer conditions in the power plant.

Condition monitoring of induction motors : A review and an application of an ensemble of hybrid intelligent models

In this paper, a review on condition monitoring of induction motors is first presented. Then, an ensemble of hybrid intelligent models that is useful for condition monitoring of induction motors is proposed. The review covers two parts, i.e.; (i) a total of nine commonly used condition monitoring methods of induction motors; and (ii) intelligent learning models for condition monitoring of induction motors subject to single and multiple input signals. Based on the review findings, the Motor Current Signature Analysis (MCSA) method is selected for this study owing to its online, non-invasive properties and its requirement of only single input source; therefore leading to a cost-effective condition monitoring method. A hybrid intelligent model that consists of the Fuzzy Min-Max (FMM) neural network and the Random Forest (RF) model comprising an ensemble of Classification and Regression Trees is developed. The majority voting scheme is used to combine the predictions produced by the resulting FMM-RF ensemble (or FMM-RFE) members. A benchmark problem is first deployed to evaluate the usefulness of the FMM-RFE model. Then, the model is applied to condition monitoring of induction motors using a set of real data samples. Specifically, the stator current signals of induction motors are obtained using the MCSA method. The signals are processed to produce a set of harmonic-based features for classification using the FMM-RFE model. The experimental results show good performances in both noise-free and noisy environments. More importantly, a set of explanatory rules in the form of a decision tree can be extracted from the FMM-RFE model to justify its predictions. The outcomes ascertain the effectiveness of the proposed FMM-RFE model in undertaking condition monitoring tasks, especially for induction motors, under different environments. © 2014 Elsevier Ltd. All rights reserved.

An audio signal based model for condition monitoring of sheet metal stamping process

Tool condition monitoring is an important factor in ensuring manufacturing efficiency and product quality. Audio signal based methods are a promising technique for condition monitoring. However, the influence of interfering signals and background noise has hindered the use of this technique in production sites. Blind signal separation (BSS) has the potential to solve this problem by recovering the signal of interest out of the observed mixtures, given that the knowledge about the BSS model is available. In this paper, we discuss the development of the BSS model for sheet metal stamping with a mechanical press system, so that the BSS techniques based on this model can be developed in future. This involves conducting a set of specially designed machine operations and developing a novel signal extraction technique. Also, the link between stamping process conditions and the extracted audio signal associated with stamping was successfully demonstrated by conducting a series of trials with different lubrication conditions and levels of tool wear.