Wind turbine gearbox oil filtration and condition monitoring. The perceived advantages, disadvantages, and the role each of these techniques may play in the diagnosis of safety critical failure modes is discussed. Survey of condition indicators for condition monitoring. Presented at the 8th international workshop on structural health.
Key component of the cooling tower fan is the gearbox. The question is, if one can influence the wear and degradation process,using condition monitoring. Condition monitoring of gear systems using vibration analysis. This paper deals with gear condition monitoring based on vibration analysis techniques. The various methods listed may or may not currently be linked within an iot network, but most are suitable for automatic data collection and analysis. Wind turbine gearbox condition monitoring round robin. Condition monitoring is the process of monitoring a parameter of condition in machinery vibration, temperature, etc. Several parameters have been proposed for monitoring gear condition locally gearbox casing including time, frequency, and joint timefrequency domain representation.
Review of condition monitoring and fault diagnosis. Wind turbine gearbox condition monitoring round robin study. The detection and diagnostic capability of some of the most effective techniques are discussed and compared on the basis of experimental results, concerning a gear pair affected by a. Investigation of various conditionmonitoring techniques.
Machine condition monitoring and fault diagnostics 25 5. Condition monitoring helps to identify the various type of deterioration in wind turbine gearbox. Jay huggins updated the dataset wind turbine gearbox condition monitoring vibration analysis benchmarking datasets over 5 years ago. Wind turbine gearbox oil filtration and condition monitoring shuangwen shawn sheng. Condition monitoring of mechanical and hydraulic plant. Page 1 condition monitoring tests and predictive maintenance can help pump operators determine when to overhaul pumps in a way that minimizes costs. Therefore, to improve upon the monitoring techniques and analysis tools for finding the gear ratios, gear faults, shaft misalignments in the gearbox and the current passing through the. Machine condition monitoring and fault diagnostics chris k. Techniques collectively referred to as vibration condition monitoring have a common objective of indicating early signs of deterioration, or malfunction in plant machinery through surveillance testing and analysis. Activity stream wind turbine gearbox condition monitoring. Woodley principles and methods as a starting point for any discussion on condition monitoring it is useful to define what is meant by the term, and to describe how it relates to other techniques used in the operation. Condition monitoring of cooling tower fan gearboxes by.
The gearbox of the test rig has the same structure as wind turbine gearbox. Several tasks have been outlined toward this objective and. These diagnostics techniques in gearbox condition monitoring are organized and. Condition monitoring is the process of monitoring conditions in machinery such as vibration and temperature to look for signs that a fault may be developing. The demerit of this technique lies in the fact that good. Army research laboratory glenn research center cleveland, ohio 445 ryan t. Fault andfailure are regarded as inevitable during the machine operation as the process of wear and theprocess of degradation. Planetary gearbox fault detection using vibration separation. Bearing faults that can be detected with vibration monitoring. While we run the motor and place the sensor on top of the gearbox the vibration, it will capture due to all system attached to the motor not just by gearbox and bearing. An investigation on gearbox fault detection using vibration. Wind turbine gearbox condition monitoring vibration analysis. Then it focused on fault diagnosis and monitoring techniques for the wind turbine gearbox.
Optimising sensor location for an enhanced gearbox condition. Lewicki national aeronautics and space administration glenn research center cleveland, ohio 445 kelsen e. Now it is one of the most important components of condition based maintenance cbm, a practice of assessing a machines condition by periodically gathering data on. An unexpected failure of the gear may cause significant economic losses. Photo by dennis schroeder, nrel 19018 nrelpr500065388. Research of condition monitoring and fault diagnosis.
Lubrication oil condition monitoring and remaining useful. During the dynamometer retest, various condition monitoring systems, e. The investigation on current state of the art lubrication oil monitoring techniques is reported in zhu et al. Establish good baseline data and know how the machines respond to the load and speed changes. Based on that research the same authors suggest a new feature for condition monitoring of planetary gearboxes in 9, taking advantage of the fact that a gearbox in bad condition is more likely to be influenced by load variation. Condition monitoring is more efficient than reactive maintenance since faults can generally be avoided, thus reducing machine downtime, saving money and prolonging the life of the machine. Gearbox condition monitoring through used oil analysis dave tiffany, pioneer engineering when the city of fort collins, colorado, purchased new planetary gearboxes for its wastewater sludge dewatering centrifuges, it decided to implement a proactive used oil analysis maintenance strategy. Jan 17, 2020 the monitoring techniques seem to have reached a mature level in case a machinery operates under steady speed and load. Vibration emanating from the transmission gearbox is a prime candidate for monitoring, as many. I am trying to do condition monitoring of gearbox and ball bearing. Condition monitoring of a wind turbine gearbox using the. The study contained in this report is a continuation of the 2009 paper and focuses on results obtained by various cm techniques from a damaged gearbox reliability collaborative test gearbox. Condition monitoring of gear systems using vibration. The use of condition monitoring allows maintenance to be scheduled.
A test rig is designed to demonstrate condition monitoring of wind turbine gearbox. Condition monitoring systems based on vibration analysis can monitor all parts of gearboxes, for example gearing, bearings and shafts. The progress and changes over the past 30 years in failure detection techniques of rotating machinery including. The condition monitoring includes two major sources of vibration. Fundamentally different from fixedaxis gearboxes, planetary gearboxes refer to those including the transmission structure of. Condition monitoring of wind turbine planetary gearboxes. Basics of oil condition monitoring through oil analysis. Condition monitoring of a machine helps in retaining the efficiency and performance of a machine to its optimum level. Most investigations, however, focus on fixedaxis gearboxes in which all gears are designed to rotate around their own fixed centers,, see fig. Condition monitoring and fault diagnosis of gearboxes has been attracting considerably increasing attention. These datasets will benefit research, development, validation, verification, and advancement of vibrationbased wind condition monitoring techniques. Novel methodology for condition monitoring of gear wear. The following list of condition monitoring techniques, grouped by several category types, shows the extent technology has moved monitoring ahead.
The condition monitoring of a rotating machine is efficient, but often complex and labor intensive task for maintenance of the machine. Public interest statement condition monitoring is expected to assist in the prevention of machine failures and enhance. To improve the reliability and performance of wind turbine we apply condition monitoring systems which monitored key component of wind turbine like gearbox. Fusion techniques for vibration and oil debrisquality in gearbox failure testing.
Condition monitoring is a tool for detection of faults and failure prevention. Adaptive vibration condition monitoring techniques for local tooth. This technique is developed by integrating lubrication oil degradation physical models with the particle filtering algorithm. Condition monitoring techniques are used in wind turbine especially for gearbox. Condition monitoring of cooling tower fan gearboxes by wear. The capability of each technique to sense failure and damage in rotary equipments is addressed. Under abnormal conditions, contextual alerts are sent to a local visual indicator, your control system and the rexnord connect portal so your team knows what action to take and when. Moreover, most techniques used for monitoring the condition in gearboxes have their limitations, with the vibration and the. This means that condition monitoring of wind turbine gearboxes is a necessary practice. On the other hand, in case the operating conditions change, it is still unclear whether the change of the monitoring indicators is due to the change of the health of the machinery or due to the change of the operating parameters.
It is hoped that the tools presented in this article will help asset managers and engineers apply predictive maintenance approaches and condition monitoring to process pumps, as well as improve management of pump assets to provide. Even though, vibration monitoring has dominated successfully for several decades in many industrial applications. Introduction it has long been accepted that condition based maintenance is the most effective and costefficient approach to maximizing. Oil debris analysis is a very reliable method for detecting. The proposed technique could be used for continuous monitoring as well as online damage detection systems for gearbox maintenance. Healthy or fault, using conventional signal processing techniques such as timedomain. Maintenance of gearboxes is difficult and expensive, given the location and therefore condition monitoring techniques have been applied to detect common failure mechanisms.
The interest for applications using ae for condition monitoring systems has grown significantly over the past decade. Condition monitoring systems for manual transmissions based on vibration diagnostics are widely. Inservice oil analysis for condition based maintenance 7 the practice of inservice oil analysis or used oil analysis started over a century ago on locomotive engines. The fault on the gear tooth may be identified with this technique. Review article vibration analysis techniques for gearbox. The vibrationbased condition monitoring system and the test condition data enabled nrel to launch a wind turbine gearbox condition monitoring round robin project, as described in this report. Optimising sensor location for an enhanced gearbox.
Onsite condition monitoring for rotating machines abb ability condition monitoring for shaftlines is an onsite condition monitoring service that addresses the reliability of the complete shaftline, including motor, gearbox and driven load. The monitoring of a gearbox condition is a vital activity because of its importance in power transmission in any industry. Pdf data mining for gearbox condition monitoring researchgate. Condition monitoring is advance and useful tool of proactive technique. Condition monitoring of gearbox using experimental. It identifies electrical and mechanical issues related to the rotor, bearings, gearbox and. The vibration signal of a gearbox carries the signature of the fault in the gears, and early fault detection of the gearbox is possible by analyzing the vibration signal using different signal processing techniques.
Structure, uses, issues, and types of maintenance, machine fault signature. The paper will present technology which demonstrates that the use ofthe proper method can. New focus on gearbox condition monitoring for failure. For that reason, fault diagnosis in gears has been the subject of. Jay huggins updated the dataset wind turbine gearbox condition monitoring vibration analysis benchmarking. We offer torque monitoring for all gear unit types either independently or as an addon option to vibrationbased analysis gear units for tube mills extruder gear units planurex gear units. The need for improved performance of the huge investment in industrial plant particularly electrical generating machinery in recent times necessitates the application of condition monitoring techniques in its maintenance.
In this work, the ae is assessed to identify the presence of the crack at the root of gear tooth. Pdf conditioning monitoring of gearbox using different. Vibration condition monitoring helps reduce the possibility of catastrophic failures, increasing safety and machine performance. Abb ability condition monitoring for shaftlines onsite. This paper outlines our approach to devising such a monitoring system. Jian shuai 0 1 0 edited by yanhua sun 1 school of electrical and electronic engineering, nanyang technological university, singapore 639798, singapore vibration and oil debris analysis are widely. The present paper proposes a methodology for placing sound sensor on a fixedaxis gearbox to obtain highquality information regarding the dynamic characteristics of machine. When you find a unusual change in the vibration signature, analysis will indicate what areas to investigate.
Gearbox in wind turbines has the greatest share of downtime among all other components affecting directly the cost of operation and maintenance. Index terms condition monitoring, failure mechanisms, gearbox, lubricant. Master of engineering abstract vibration monitoring is widely used to determine the condition of various mechanical systems. Condition monitoring condition monitoring requires that you know your equipment and understand what is normal for it. In particular, current research focuses on implementing onboard condition monitoring systems to detect and diagnose failures in rotorcraft transmissions 1. With these oil analysis and vibration techniques, monitoring has been done and gear box failures has been detected. The challenges and future research directions were presented, and the simulator rig of wind turbine gearbox was designed to develop condition monitoring and fault diagnosis techniques for wind turbine gearbox. Survey of condition indicators for condition monitoring systems junda zhu, tom nostrand, cody spiegel, and brogan morton. Hence, the gear conditions were considered to be normal gearbox and worn and broken teeth gears faults with the aim of fault detection and identification.
Panda gears are used to transmit power and motion in mechanical, electrical and chemical process industries. This case study summarizes continuing cost saving benefits to the city of ft. Future condition monitoring may be possible using low cost online techniques. The results show that traditional signal processing techniques were insufficient for revealing fault detection information due to the low signal to noise ratio snr.
Furthermore, various methods and techniques in the literature will be presented in. Vibration analysis is a commonly used method for condition monitoring, and is based on the idea that the rotating machinery have a specific vibration signature for their standard condition that changes with the. Fft analysis is used to correlate the components of steady vibration and current signatures. Condition monitoring or, colloquially, cm is the process of monitoring a parameter of condition in machinery vibration, temperature etc. Gearbox condition monitoring through used oil analysis demonstration in proven reliability and continued cost savings by dave tiffany, reliability specialist with pioneer engineering. Our smart condition monitoring system uses proprietary algorithms to continuously compare sensor data against models of healthy drive operating conditions. Rules for survey after construction part 7 or the abs. Integrating vibration and oil analysis for machine condition. Dynamic datasets were analyzed to diagnose the condition of the gear.
Gears are important element in a variety of industrial applications such as machine tool and gearboxes. Gearbox condition monitoring through used oil analysis. The present paper proposes a methodology for placing sound sensor on a fixedaxis gearbox to obtain. Acoustic emission ae is a non destructive testing for the condition monitoring of rotating machines such as gearboxes. Proceedings of the international conference on condition monitoring. Fault detection of gearbox from inverter signals using. Condition monitoring of wind turbine gearbox by vibration. Nowadays the demands for condition monitoring and vibration analysis are no more limited trying to. Vibration analysis is a technique used for condition monitoring of the machine. Even though, vibration monitoring has dominated successfully for several decades in. Virtual sensing for gearbox condition monitoring based on kernel factor analysis jinjiang wang 0 1 yinghao zheng 0 1 laibin zhang 0 1 lixiang duan 0 1 rui zhao 0 1 handling editor. Planetary gearbox fault detection using vibration separation techniques david g.
Virtual sensing for gearbox condition monitoring based on. Sensors technologies have received great attention within the industrial community and they are key component in any condition monitoring system. Guidance notes on equipment condition monitoring techniques. Condition indicators for gearbox condition monitoring systems. Siemensmachine protectionand gear unit condition monitoringincluding. The second purpose is to identify the status of the gearbox, to distinguish the good and the faulty gear and to indicate the defective components. Wind turbine gearbox condition monitoring vibration. Wind turbine gearbox condition monitoring system based on. Condition monitoring and fault diagnosis of planetary. Condition monitoring has a great potential for enhancement in the reliability of operation. Optimization of sound sensor placement for condition. Condition monitoring of gear box by using motor current.