Method and apparatus for analysing the condition of a machine having a rotating part

• US 8,762,104 B2
• Filed: 12/22/2009
• Issued: 06/24/2014
• Est. Priority Date: 12/22/2008
• Status: Active Grant

• Current Assignee: S.P.M. Instrument AB
• Original Assignee: S.P.M. Instrument AB
• Inventors: Hedin, Lars-Olov Elis
• Primary Examiner(s): Le, John H
• Application Number:
  US13/141,424
• Publication Number:
  US 20110295556A1
• Time in Patent Office: 1,645 Days
• Field of Search: 702/34, 702/35, 702/56, 702/77, 702/145, 702/182, 702/183, 702/185, 702/190, 700/110, 700/265, 735/93, 735/87
• US Class Current: 702/182
• CPC Class Codes: G01H 1/003 of rotating machines G01H1/10 takes precedence
• CPC Class Codes: G01H 17/00 Measuring mechanical vibrations or ultrasonic, sonic or infrasonic waves, not provided for in the preceding groups see provisionally also G01H1/00
• CPC Class Codes: G01M 13/045 Acoustic or vibration analysis
• CPC Class Codes: G05B 19/4069 Simulating machining process on screen G05B19/4068 takes precedence
• CPC Class Codes: G05B 19/416 characterised by control of velocity, acceleration or deceleration G05B19/19 takes precedence
• CPC Class Codes: G05B 2219/37228 Tool inspection, condition, dull tool
• CPC Class Codes: G06F 15/00 Digital computers in general details G06F1/00 – G06F13/00; Data processing equipment in general

Abstract

A method for analyzing a machine having a rotating shaft includes: generating an electric measurement signal dependent on vibrations emanating from the shaft; sampling the measurement signal at a sampling frequency to generate a digital measurement data signal; performing a decimation of the digital measurement data signal to achieve a digital signal having a reduced sampling frequency, the decimation including controlling the reduced sampling frequency such that the number of sample values per revolution of the shaft is kept at a substantially constant value; receiving the digital signal at an enhancer input; performing a correlation in the enhancer so as to produce an output signal sequence wherein repetitive signals amplitude components are amplified in relation to stochastic signal components; and performing a condition analysis function for analyzing the condition of the machine dependent on the digital signal having a reduced sampling frequency.

Claims

1. An apparatus for analysing the condition of a machine having a part rotating with a variable speed of rotation, comprising:

a first sensor adapted to generate an analogue electric measurement signal dependent on mechanical vibrations emanating from rotation of said part;

an analogue-to-digital converter for sampling said analogue electric measurement signal at a sampling frequency so as to generate a digital measurement data signal in response to said analogue electric measurement signal, said digital measurement data signal having a first Signal-to-Noise-Ratio level;

a digital filter for filtering said digital measurement data signal so as to produce a filtered digital measurement data signal;

a digital enveloper for generating a digital envelope signal in response to said filtered digital measurement data signal;

a decimator for performing a decimation of the digital envelope signal so as to achieve a decimated digital signal having a reduced sampling frequency dependent on a signal indicative of said variable speed of rotation, said decimator comprising

a first decimator adapted to reduce the sampling rate of the digital envelope signal by an integer factor so as to achieve a first digital signal having a first reduced sampling frequency, and

a second decimator adapted to generate said decimated digital signal such that it has a second reduced sampling frequency in response to said first digital signal,

wherein said second decimator is a fractional decimator having;

a first input for receiving said first digital signal as a sequence of data values,

a second input for receiving said signal indicative of said variable speed of rotation associated with said part,

a third input for receiving a signal indicative of an output sample rate setting signal,

a memory adapted to receive and store the data values as well as information indicative of said variable speed of rotation of the monitored rotating part,

a Finite Impulse Response filter having filter values,

said fractional decimator being adapted to generate said second digital signal in response to i) said first digital signal, ii) said signal indicative of said variable speed of rotation, and iii) said signal indicative of an output sample rate setting signal,

wherein said fractional decimator operates to record said data values in said memory, and associate each data value with a speed of rotation value,

wherein said memory is adapted to store each data value so that it is associated with a value indicative of the speed of rotation of the monitored part at the time of detection of the sensor signal value corresponding to the data value,

wherein said fractional decimator operates to analyze the recorded speed of rotation values, and divide the recorded data values into blocks of data dependent on the speed of rotation values so as to generate a number of blocks of data values, each block of data values being associated with a speed of rotation value,

wherein said fractional decimator operates to i) select a block of data values, and ii) determine a fractional decimation value corresponding to the associated speed of rotation value,

wherein said fractional decimator is adapted to generate said fractional decimation value dependent on said speed of rotation value,

wherein said fractional decimator operates to associate said fractional decimation value with the selected block of data values,

wherein said fractional decimator operates to select a block of data values and the associated fractional decimation value,

wherein said fractional decimator operates to generate a block of output values in response to the selected block of input values and the associated fractional decimation value such that the number of sample values per revolution of said rotating part is kept at a substantially constant value, generating the block of output values including said fractional decimator operating to adapt said Finite Impulse Response filter in response to said fractional value and to generate said block of output values corresponding to that associated fractional decimation value; and

an enhancer having an input for receiving said decimated digital signal, said enhancer being adapted to receive a first plurality of sample values, wherein said decimated digital signal represents mechanical vibrations emanating from rotation of said part for a duration of time,

said enhancer being adapted to perform discrete autocorrelation of the decimated digital signal so as to produce an output signal sequence in the time domain wherein repetitive signal amplitude components are amplified in relation to stochastic signal components; and

an evaluator for performing a condition analysis function for analysing the condition of the machine, said evaluator being adapted to perform said condition analysis function dependent on said output signal sequence.

2. The apparatus according to claim 1, wherein said integer factor is settable to a value adapted for measuring conditions in a measuring session, said integer factor being kept constant for the duration of a measuring session.

3. The apparatus according to claim 1, wherein,

said second digital signal represents mechanical vibrations emanating from rotating said shaft so far as to cause occurrence of a vibration having a period of repetition,

said enhancer is adapted to divide said second digital signal into a first signal portion and a second signal portion, and

said enhancer is adapted to generate a digital output signal having a second plurality of samples, said second plurality being a positive integer and lower than said first plurality, said digital output signal being generated in response to the first signal portion (2070) and the second signal portion.

4. The apparatus according to claim 1, wherein,

the received digital input signal includes signal components emanating from a deteriorated condition, said deterioration signal components being repetitive with said period of repetition.

5. The apparatus according to claim 1, wherein,

said first decimator has a port for receiving said integer factor, and

said integer factor is settable in dependence on a detected speed of rotation.

6. The apparatus according to claim 5, wherein,

said first decimator includes plural low pass Finite Impulse Response Filters,

said first decimator is adapted to perform said integer decimation in plural steps using said plural low pass Finite Impulse Response Filters, and

each low pass Finite Impulse Response Filter is settable to a desired degree of decimation.

7. The apparatus according to claim 6, wherein said first decimator is adapted to perform said integer decimation in four steps using four low pass Finite Impulse Response Filters having individual integer decimation factors Ml, M2, M3 and M4 such that a total integer decimation M of said first decimator equals

M=M1*M2*M3*M4.

8. The apparatus according to claim 7, wherein said first decimator includes a bank of mutually different Finite Impulse Response Filters which are combinable in plural combinations to achieve the total integer decimation.

9. The apparatus according to claim 7, wherein the maximum degree of decimation in the fourth step is five, rendering a filter having 201 taps.

10. The apparatus according to claim 9, wherein the Finite Impulse Response Filters in said first step, said second step and said third step have fewer than 201 taps.

11. The apparatus according to claim 10, wherein the Finite Impulse Response Filters in said first step, said second step and said third step have 71 taps each or less than 71 taps.

12. The apparatus according to claim 11, wherein,

said Finite Impulse Response Filter in said first step has 71 taps,

the Finite Impulse Response Filter in said second step has 71 taps,

the Finite Impulse Response Filter in said third step has 71 taps, and

the Finite Impulse Response Filter in said fourth step has 201 taps so that these four Finite Impulse Response Filter have a total of 414 taps.

13. The apparatus according to claim 7, wherein,

the Finite Impulse Response Filter in said first step is adapted to provide a first decimation factor M1=10,

the Finite Impulse Response Filter in said second step is adapted to provide a second decimation factor M2=10,

the Finite Impulse Response Filter in said third step is adapted to provide a third decimation factor M3=10, and

the Finite Impulse Response Filter in said fourth step is adapted to provide a fourth decimation factor M4=4, so that a total decimation of M=4000 is achieved.

14. A method for analyzing a condition of a machine having a part rotating with a variable speed of rotation, the method comprising the steps of:

(I) providing an apparatus comprising;

a first sensor adapted to generate an analogue electric measurement signal dependent on mechanical vibrations emanating from rotation of said part;

an analogue-to-digital converter for sampling said analogue electric measurement signal at a sampling frequency so as to generate a digital measurement data signal in response to said analogue electric measurement signal, said digital measurement data signal having a first Signal-to-Noise-Ratio level;

a digital filter for filtering said digital measurement data signal so as to produce a filtered digital measurement data signal;

a digital enveloper for generating a digital envelope signal in response to said filtered digital measurement data signal;

a decimator for performing a decimation of the digital envelope signal so as to achieve a decimated digital signal having a reduced sampling frequency dependent on a signal indicative of said variable speed of rotation, said decimator comprising

a first decimator adapted to reduce the sampling rate of the digital envelope signal by an integer factor so as to achieve a first digital signal having a first reduced sampling frequency, and

a second decimator adapted to generate said decimated digital signal such that it has a second reduced sampling frequency in response to said first digital signal,

wherein said second decimator is a fractional decimator having;

a first input for receiving said first digital signal as a sequence of data values,

a second input for receiving said signal indicative of said variable speed of rotation associated with said part,

a third input for receiving a signal indicative of an output sample rate setting signal,

a memory adapted to receive and store the data values as well as information indicative of said variable speed of rotation of the monitored rotating part, and

a Finite Impulse Response filter having filter values,

said fractional decimator being adapted to generate said second digital signal in response to i) said first digital signal, ii) said signal indicative of said variable speed of rotation, and iii) said signal indicative of an output sample rate setting signal,

wherein said fractional decimator operates to record said data values in said memory, and associate each data value with a speed of rotation value,

wherein said memory is adapted to store each data value so that each data value is associated with a value indicative of the speed of rotation of the monitored part at the time of detection of the sensor signal value corresponding to the data value,

wherein said fractional decimator operates to analyze the recorded speed of rotation values, and divide the recorded data values into blocks of data dependent on the speed of rotation values so as to generate a number of blocks of data values, each block of data values being associated with a speed of rotation value,

wherein said fractional decimator operates i) to select a block of data values, and ii) to determine a fractional decimation value corresponding to the associated speed of rotation value,

wherein said fractional decimator is adapted to generate said fractional decimation value dependent on said speed of rotation value, and

wherein said fractional decimator operates to associate said fractional decimation value with the selected block of data values,

wherein a) said fractional decimator operates to select a block of data values and the associated fractional decimation value, and b) said fractional decimator operates to generate a block of output values in response to the selected block of input values and the associated fractional decimation value such that the number of sample values per revolution of said rotating part is kept at a substantially constant value, and

wherein generating a block of output values includes b1) said fractional decimator operating to adapt said Finite Impulse Response filter in response to said fractional value and to generate said block of output values corresponding to that associated fractional decimation value; and

an enhancer having an input for receiving said decimated digital signal, said enhancer being adapted to receive a first plurality of sample values,

wherein said decimated digital signal represents mechanical vibrations emanating from rotation of said part for a duration of time, and

wherein said enhancer is adapted to perform discrete autocorrelation of the decimated digital signal so as to produce an output signal sequence in the time domain wherein repetitive signal amplitude components are amplified in relation to stochastic signal components; and

an evaluator for performing a condition analysis function for analyzing the condition of the machine, said evaluator being adapted to perform said condition analysis function dependent on said output signal sequence;

(II) applying the sensor to a measuring point on the machine; and

(III) generating the machine condition from the evaluator,

wherein the rotating part has a rotational speed of less than 50 revolutions per minute.

15. A method for analyzing a condition of a machine having a part rotating with a variable speed of rotation, the method comprising the steps of:

(I) providing an apparatus comprising;

a first sensor adapted to generate an analogue electric measurement signal dependent on mechanical vibrations emanating from rotation of said part;

an analogue-to-digital converter for sampling said analogue electric measurement signal at a sampling frequency so as to generate a digital measurement data signal in response to said analogue electric measurement signal, said digital measurement data signal having a first Signal-to-Noise-Ratio level;

a digital filter for filtering said digital measurement data signal so as to produce a filtered digital measurement data signal;

a digital enveloper for generating a digital envelope signal in response to said filtered digital measurement data signal;

a decimator for performing a decimation of the digital envelope signal so as to achieve a decimated digital signal having a reduced sampling frequency dependent on a signal indicative of said variable speed of rotation, said decimator comprising

a first decimator adapted to reduce the sampling rate of the digital envelope signal by an integer factor so as to achieve a first digital signal having a first reduced sampling frequency, and

a second decimator adapted to generate said decimated digital signal such that it has a second reduced sampling frequency in response to said first digital signal, wherein

said second decimator is a fractional decimator having;

a first input for receiving said first digital signal as a sequence of data values,

a second input for receiving said signal indicative of said variable speed of rotation associated with said part,

a third input for receiving a signal indicative of an output sample rate setting signal,

a memory adapted to receive and store the data values as well as information indicative of said variable speed of rotation of the monitored rotating part, and

a Finite Impulse Response filter having filter values,

said fractional decimator being adapted to generate said second digital signal in response to i) said first digital signal, ii) said signal indicative of said variable speed of rotation, and iii) said signal indicative of an output sample rate setting signal,

wherein said fractional decimator operates to record said data values in said memory, and associate each data value with a speed of rotation value,

wherein said memory is adapted to store each data value so that each data value is associated with a value indicative of the speed of rotation of the monitored part at the time of detection of the sensor signal value corresponding to the data value,

wherein said fractional decimator operates to analyze the recorded speed of rotation values, and divide the recorded data values into blocks of data dependent on the speed of rotation values so as to generate a number of blocks of data values, each block of data values being associated with a speed of rotation value,

wherein said fractional decimator operates to i) select a block of data values, and ii) determine a fractional decimation value corresponding to the associated speed of rotation value,

wherein said fractional decimator is adapted to generate said fractional decimation value dependent on said speed of rotation value,

wherein said fractional decimator operates to associate said fractional decimation value with the selected block of data values,

wherein a) said fractional decimator operates to select a block of data values and the associated fractional decimation value, and b) said fractional decimator operates to generate a block of output values in response to the selected block of input values and the associated fractional decimation value such that the number of sample values per revolution of said rotating part is kept at a substantially constant value, and

wherein generating a block of output values includes b1) said fractional decimator operating to adapt said Finite Impulse Response filter in response to said fractional value and to generate said block of output values corresponding to that associated fractional decimation value; and

an enhancer having an input for receiving said decimated digital signal;

said enhancer being adapted to receive a first plurality of sample values,

wherein said decimated digital signal represents mechanical vibrations emanating from rotation of said part for a duration of time, and

wherein said enhancer is adapted to perform discrete autocorrelation of the decimated digital signal so as to produce an output signal sequence in the time domain wherein repetitive signal amplitude components are amplified in relation to stochastic signal components; and

an evaluator for performing a condition analysis function for analysing the condition of the machine, said evaluator being adapted to perform said condition analysis function dependent on said output signal sequence;

(II) applying the sensor to a measuring point on the machine; and

(III) generating the machine condition from the evaluator,

wherein the rotating part is part of a gear system, and the machine condition is a condition of the gear system.

16. The method according to claim 15, wherein,

the gear system includes a plurality of rotating parts which are rotating at mutually different rotational speed,

the sensor is adapted to generate the analogue electric measurement signal so that it includes at least one repetitive signal signature dependent on said mechanical vibrations such that the repetitive signal signature has a repetition frequency which depends on the speed of rotation of a part which is the origin of the repetitive signal signature, and

in the step of generating the machine condition includes the step of:

(IIIA) indicating the rotating part from which repetitive signal signature originates, said indication being generated in dependence on the repetition frequency of the repetitive signal signature.

17. The method according to claim 15, wherein,

the gear system includes a plurality of rotating parts which are rotating at mutually different rotational speed,

the sensor is adapted to generate the analogue electric measurement signal so that it includes at least one repetitive signal signature dependent on said mechanical vibrations such that the repetitive signal signature has a repetition frequency which depends on the speed of rotation of a part which is the origin of the repetitive signal signature, and

the step of generating the machine condition includes the step of:

(IIIB) indicating a type of deteriorated condition from among a plurality of different types of deteriorated conditions;

said indicating step being performed in dependence on the repetition frequency of the repetitive signal signature.

18. The method according to claim 15, wherein,

the gear system includes a plurality of rotating parts which are rotating at mutually different rotational speed,

the sensor is adapted to generate the analogue electric measurement signal so that it includes at least one repetitive signal signature dependent on said mechanical vibrations such that the repetitive signal signature has a repetition frequency which depends on the speed of rotation of a part which is the origin of the repetitive signal signature,

the step of generating the machine condition includes the step of:

detecting the repetition frequency of the repetitive signal signature, and

indicating a type of deteriorated condition in dependence on the detected repetition frequency, and

the repetitive signal signature is indicative of at least one deteriorated condition selected from a group consisting of a Bearing Inner Race damage, a Bearing Outer Race damage, and a teeth engagement error.