An advanced real-time predictive maintenance framework for large scale machine systems

This thesis introduces and develops a novel real-time predictive maintenance system to estimate the machine system parameters using the motion current signature. Recently, motion current signature analysis has been addressed as an alternative to the use of sensors for monitoring internal faults of a motor. A maintenance system based upon the analysis of motion current signature avoids the need for the implementation and maintenance of expensive motion sensing technology. By developing nonlinear dynamical analysis for motion current signature, the research described in this thesis implements a novel real-time predictive maintenance system for current and future manufacturing machine systems. A crucial concept underpinning this project is that the motion current signature contains infor­mation relating to the machine system parameters and that this information can be extracted using nonlinear mapping techniques, such as neural networks. Towards this end, a proof of con­cept procedure is performed, which substantiates this concept. A simulation model, TuneLearn, is developed to simulate the large amount of training data required by the neural network ap­proach. Statistical validation and verification of the model is performed to ascertain confidence in the simulated motion current signature. Validation experiment concludes that, although, the simulation model generates a good macro-dynamical mapping of the motion current signature, it fails to accurately map the micro-dynamical structure due to the lack of knowledge regarding performance of higher order and nonlinear factors, such as backlash and compliance. Failure of the simulation model to determine the micro-dynamical structure suggests the pres­ence of nonlinearity in the motion current signature. This motivated us to perform surrogate data testing for nonlinearity in the motion current signature. Results confirm the presence of nonlinearity in the motion current signature, thereby, motivating the use of nonlinear tech­niques for further analysis. Outcomes of the experiment show that nonlinear noise reduction combined with the linear reverse algorithm offers precise machine system parameter estimation using the motion current signature for the implementation of the real-time predictive maintenance system. Finally, a linear reverse algorithm, BJEST, is developed and applied to the motion current signature to estimate the machine system parameters.

Some aspects of the dynamic performance of machine tool structural joints

The work presented in this thesis is concerned with the dynamic behaviour of structural joints which are both loaded, and excited, normal to the joint interface. Since the forces on joints are transmitted through their interface, the surface texture of joints was carefully examined. A computerised surface measuring system was developed and computer programs were written. Surface flatness was functionally defined, measured and quantised into a form suitable for the theoretical calculation of the joint stiffness. Dynamic stiffness and damping were measured at various preloads for a range of joints with different surface textures. Dry clean and lubricated joints were tested and the results indicated an increase in damping for the lubricated joints of between 30 to 100 times. A theoretical model for the computation of the stiffness of dry clean joints was built. The model is based on the theory that the elastic recovery of joints is due to the recovery of the material behind the loaded asperities. It takes into account, in a quantitative manner, the flatness deviations present on the surfaces of the joint. The theoretical results were found to be in good agreement with those measured experimentally. It was also found that theoretical assessment of the joint stiffness could be carried out using a different model based on the recovery of loaded asperities into a spherical form. Stepwise procedures are given in order to design a joint having a particular stiffness. A theoretical model for the loss factor of dry clean joints was built. The theoretical results are in reasonable agreement with those experimentally measured. The theoretical models for the stiffness and loss factor were employed to evaluate the second natural frequency of the test rig. The results are in good agreement with the experimentally measured natural frequencies.

Design methodology for the servo control of high speed multi-axis machinery (BL): decoupling and synchronisation of a generic machine by blockwise decentralised MIMO control

Traditional machinery for manufacturing processes are characterised by actuators powered and co-ordinated by mechanical linkages driven from a central drive. Increasingly, these linkages are replaced by independent electrical drives, each performs a different task and follows a different motion profile, co-ordinated by computers. A design methodology for the servo control of high speed multi-axis machinery is proposed, based on the concept of a highly adaptable generic machine model. In addition to the dynamics of the drives and the loads, the model includes the inherent interactions between the motion axes and thus provides a Multi-Input Multi-Output (MIMO) description. In general, inherent interactions such as structural couplings between groups of motion axes are undesirable and needed to be compensated. On the other hand, imposed interactions such as the synchronisation of different groups of axes are often required. It is recognised that a suitable MIMO controller can simultaneously achieve these objectives and reconciles their potential conflicts. Both analytical and numerical methods for the design of MIMO controllers are investigated. At present, it is not possible to implement high order MIMO controllers for practical reasons. Based on simulations of the generic machine model under full MIMO control, however, it is possible to determine a suitable topology for a blockwise decentralised control scheme. The Block Relative Gain array (BRG) is used to compare the relative strength of closed loop interactions between sub-systems. A number of approaches to the design of the smaller decentralised MIMO controllers for these sub-systems has been investigated. For the purpose of illustration, a benchmark problem based on a 3 axes test rig has been carried through the design cycle to demonstrate the working of the design methodology.

Control integrated finite state machine design for photovoltaic module integrated converter

The operation state of photovoltaic Module Integrated Converter (MIC) is subjected to change due to different source and load conditions, while state-swap is usually implemented with flow chart based sequential controller in the past research. In this paper, the signatures for different operational states are evaluated and investigated, which lead to an effective control integrated finite state machine (CIFSM), providing real-time state-swap as fast as the local control loop. The proposed CIFSM is implemented digitally for a boost type MIC prototype and tested under a variety of load and source conditions. The test results prove the effectiveness of the proposed CIFSM design.

Double machine operation and psychological strain

This study examines the effects of double machine operation on psychological strain. CNC drilling machine operators' reactions to their job were monitored as they rotated between three different work conditions; single machine operation, double machine operation, and double machine operation with additionally high responsibility for products. Results show no effect of double machine operation on strain where responsibility was low. Double machine operation under the condition of high responsibility, however, was found to increase strain.

Investigation of uncoordinated coexisting IEEE 802.15.4 networks with sleep mode for machine-to-machine communications

The low-energy consumption of IEEE 802.15.4 networks makes it a strong candidate for machine-to-machine (M2M) communications. As multiple M2M applications with 802.15.4 networks may be deployed closely and independently in residential or enterprise areas, supporting reliable and timely M2M communications can be a big challenge especially when potential hidden terminals appear. In this paper, we investigate two scenarios of 802.15.4 network-based M2M communication. An analytic model is proposed to understand the performance of uncoordinated coexisting 802.15.4 networks. Sleep mode operations of the networks are taken into account. Simulations verified the analytic model. It is observed that reducing sleep time and overlap ratio can increase the performance of M2M communications. When the networks are uncoordinated, reducing the overlap ratio can effectively improve the network performance. © 2012 Chao Ma et al.

Uncoordinated coexisting IEEE 802.15.4 networks for machine to machine communications

IEEE 802.15.4 standard has been proposed for low power wireless personal area networks. It can be used as an important component in machine to machine (M2M) networks for data collection, monitoring and controlling functions. With an increasing number of machine devices enabled by M2M technology and equipped with 802.15.4 radios, it is likely that multiple 802.15.4 networks may be deployed closely, for example, to collect data for smart metering at residential or enterprise areas. In such scenarios, supporting reliable communications for monitoring and controlling applications is a big challenge. The problem becomes more severe due to the potential hidden terminals when the operations of multiple 802.15.4 networks are uncoordinated. In this paper, we investigate this problem from three typical scenarios and propose an analytic model to reveal how performance of coexisting 802.15.4 networks may be affected by uncoordinated operations under these scenarios. Simulations will be used to validate the analytic model. It is observed that uncoordinated operations may lead to a significant degradation of system performance in M2M applications. With the proposed analytic model, we also investigate the performance limits of the 802.15.4 networks, and the conditions under which coordinated operations may be required to support M2M applications. © 2012 Springer Science + Business Media, LLC.