Diagnostic Maintenance and Monitoring of Machines1
Diagnostic Maintenance and Monitoring of Machines1
Diagnostic Maintenance and Monitoring of Machines1
UG Course
UG Course
The desire and need for accurate diagnostic and real predictive prognostic capabilities have been around for as long as human beings have operated complex and expensive machinery.
The area of intelligent maintenance and diagnostic and prognosticenabled condition-based maintenance (CBM) of machinery, is a vital one for todays complex systems in industry, aerospace vehicles, military and merchant ships, the automotive industry, and elsewhere.
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For fault detection, the ability is specified to detect mechanical system degradation below required performance levels (incipient or impending failure) owing to physical property changes through detectable phenomena.
The industrial and military communities are concerned about critical system and component reliability and availability. The goals are both to maximize equipment up time and to minimize maintenance and operating costs.
1. Verify the fault 2. Collect further information 3. Evaluate the evidence 4. Carry out further tests in a logical sequence 5. Rectify the problem 6. Check all systems.
Diagnostics Routine
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2. Noise, vibration and harshness Noise, vibration and harshness (NVH) concerns have become more important as drivers have become more sensitive to these issues. Drivers have higher expectations of comfort levels. The main areas of the vehicle that produce NVH are: tyres; engine accessories; suspension; driveline.
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3. Noise conditions Noise is very difficult to describe. Gear noise is typically a howling or whining due to gear damage or incorrect bearing preload. It can occur at various speeds and driving conditions, or it can be continuous. Chuckle is a rattling noise that sounds like a stick held against the spokes of a spinning bicycle wheel. It usually occurs while decelerating. Knock is very similar to chuckle though it may be louder and occurs on acceleration or deceleration. Indian Institute of Technology Roorkee
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4. Vibration conditions Clicking, popping or grinding noises may be noticeable at low speeds and be caused by the following: inner or outer joints worn (often due to lack of lubrication so check for split gaiters); loose drive shaft; another component contacting a drive shaft; damaged or incorrectly installed wheel bearing, brake or suspension component. The following may cause vibration at normal road speeds: out-of-balance wheels; out-of-round tyres. Indian Institute of Technology Roorkee
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References
1. Sound and Vibration book, KTH, Stockholm, 2006. 2. Collacott, R.A., Mechanical fault diagnosis and condition
M., Handbook of condition monitoringTechniques and Methodology, Springer, 2006. Based Maintenance and Machine Diagnostics, Springer, 2006.
Science, 1998.
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Contents
Introduction Typical defects in gears and rolling element bearings Vibrations of gears and bearings Monitoring methods Vibration analysis Sound monitoring Discrete frequencies Machine condition indicators Measurement techniques Signal processing tools Case studies Indian Institute of Technology Roorkee
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Chapter 1: Introduction
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Maintenance Philosophies
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Corrective Maintenance: Run to failure The maintenance is done after some part breaks. Maintenance costs are low. Operating costs are high because of the downtime and damages.
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Preventive Maintenance: Scheduled maintenance action. Schedule is created from lifetime statistics of similar machines. High maintenance costs due unnecessary maintenance actions. Possibility to equipment failures.
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Condition Based Maintenance:
Maintenance when required Unnecessary maintenance is avoided. Availability of the equipment is guaranteed Overall cost of maintenance is reduced Monitoring creates costs. Indian Institute of Technology Roorkee
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Architecture for condition based maintenance Open System Architecture Maintenance (OSA-CBM) for Condition Based
ISO 13374-1&2 Condition monitoring and diagnostics of machines presentation Data processing, communication and
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Condition-based maintenance (CBM) is a methodology that strives to identify incipient faults before they become critical in order to enable more accurate planning of preventive actions.
By using efficient maintenance policies, a number of system improvements can be realized, including improvements to system performance, productivity, reliability metrics, cost, and cost-related metrics.
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Advantages of CBM
well-orchestrated
program
will
all
but
eliminate
catastrophic equipment failures. Maintenance activities can be scheduled to minimize or eliminate overtime costs. Additionally, inventory can be minimized because parts or equipment will not have to be ordered ahead of time to support anticipated maintenance needs.
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With equipment operating at an optimal level, energy costs are reduced and plant reliability is increased. Importantly, CBM not only reduces the amount of maintenance performed but also avoids maintenanceinduced failures. However, existing CBM models have many limitations that prevent them from effectively modeling all kinds of complex situations that arise in CBM decision-making.
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Categorization of application of CBM technologies Region I - High Cost / Low Effectiveness: Do not implement technology. For mission critical applications (e.g. as identified in RCM / FMECA analysis) use other approaches (e.g. time based maintenance) to ensure functionality / reliability of equipment. Region II - High Cost / High Effectiveness: Only implement technology on mission critical equipment and only if other more effective / lower cost CBM technologies are not available.
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Region III - Low Cost / Low Effectiveness: Only implement technology in mission critical applications as a confirmatory technology in conjunction with more effective technologies or where no other CBM technology is feasible. For non-critical applications, implement only if quantitative calculations indicate an acceptable return on investment can be achieved. Region IV - Low Cost / High Effectiveness: Implement technology failure. wherever practicable. Implement in all applications except those specifically identified as run-to
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