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

• US 9,213,671 B2
• Filed: 06/23/2014
• Issued: 12/15/2015
• 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:
  US14/311,369
• Publication Number:
  US 20140365176A1
• Time in Patent Office: 540 Days
• Field of Search: 702/34, 702/35, 702/56, 702/182, 702/185, 702/190, 700/110, 700/265, 735/87, 735/93
• US Class Current: 1/1
• 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 analyzing a machine having a rotating shaft includes generating an electric measurement signal dependent on mechanical vibrations from the shaft rotation; sampling the measurement signal 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, where the decimation includes controlling the reduced sampling frequency such that the number of sample values per revolution of the shaft is kept at a substantially constant value, and receiving the digital signal at an enhancer input performing a correlation in the enhancer so as to produce an output signal sequence where repetitive signals amplitude components are amplified in relation to stochastic signal components, and performing a condition analysis for analyzing the condition of the machine dependent on the digital signal having a reduced sampling frequency.

Claims

1. An apparatus for analyzing 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 a mechanical vibration emanating from rotation of said rotating part, wherein the analogue electric measurement signal includes at least one repetitive vibration signal component dependent on said mechanical vibration, said repetitive vibration signal component having a repetition frequency which depends on the speed of rotation of the rotating part;

an analogue-to-digital converter for sampling said analogue electric measurement signal at a first sampling frequency so as to generate a digital measurement data signal in response to said analogue electric measurement signal;

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

a first decimator for performing a first decimation of the digital envelope signal so as to achieve a first decimated digital envelope signal having a first reduced sampling frequency, the first reduced sampling frequency being reduced by an integer factor as compared to the first sampling frequency;

an evaluator adapted to perform a condition monitoring function for analyzing the condition of the machine;

a second decimator for performing a second decimation so as to generate a second decimated digital envelope signal;

said second decimator having

i) a first input for receiving said first decimated digital envelope signal,

ii) a second input for receiving a signal indicative of the variable speed of rotation associated with said rotating part, and

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

said second decimator being adapted to generate said second decimated digital envelope signal having a second reduced sampling frequency dependent on

i) said first decimated digital envelope signal,

ii) said signal indicative of the variable speed of rotation associated with said rotating part, and

iii) said signal indicative of an output sample rate setting signal,

such that the number of sample values per revolution of said rotating part is kept at a substantially constant value; and

an enhancer having an input for receiving said second decimated digital envelope signal, said enhancer being adapted to perform signal processing involving discrete autocorrelation of said second decimated digital envelope signal so as to produce an autocorrelated envelope signal sequence wherein a repetitive signal amplitude component, the repetition frequency of which is proportional to said speed of rotation, is amplified in relation to stochastic signal components,

wherein said evaluator is adapted to perform said condition monitoring function dependent on said autocorrelated envelope 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 first decimator has a port for receiving said integer factor, and

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

4. The apparatus according to claim 3,

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

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

5. The apparatus according to claim 1, wherein,

said enhancer is adapted to perform said autocorrelation so as to amplify a first repetitive signal amplitude component having a first repetition frequency and a second repetitive signal amplitude component having a second repetition frequency in relation to stochastic signal components,

the first repetition frequency and the second repetition frequency are proportional to the speed of rotation of the rotating part, and

the first repetition frequency is different from the second repetition frequency.

6. The apparatus according to claim 5, wherein,

the first repetition frequency is equal to a first factor multiplied by the speed of rotation of the rotating part,

the second repetition frequency is equal to a second factor multiplied by the speed of rotation of the rotating part,

the first factor and the second factor are positive real values greater than or equal to one, and

the first factor is different from the second factor.

7. The apparatus according to claim 1, wherein said enhancer is adapted to deliver said autocorrelated envelope signal sequence as a time domain signal.

8. The apparatus according to claim 1, wherein said enhancer is adapted to achieve said correlation by a method for producing autocorrelation data by performing successive Fourier Transform operations on said decimated digital envelope signal to provide said autocorrelated envelope signal.

9. The apparatus according to claim 1, wherein,

said second decimated digital envelope signal has a first signal-to-noise ratio value in respect of said repetitive signal amplitude component,

said autocorrelated envelope signal sequence has a second signal-to-noise ratio value in respect of said repetitive signal amplitude component, and

said enhancer is adapted to produce said autocorrelated envelope signal sequence so that said second signal-to-noise ratio value is higher than said first signal-to-noise ratio value;

and

said apparatus further comprising a user interface for setting a signal-to-noise ratio improver value,

wherein said enhancer is adapted to produce said autocorrelated envelope signal sequence so that said second signal-to-noise ratio value depends on said signal-to-noise ratio improver value.

10. The apparatus according to claim 1, wherein said condition monitoring function comprises a function for detection of whether the condition of the machine is normal or somewhat deteriorated or abnormal.

11. The apparatus according to claim 1, wherein said condition monitoring function comprises an evaluation function making it possible to establish the nature of, and/or cause for, an abnormal machine condition.

12. The apparatus according to claim 1, wherein,

said enhancer is adapted to receive a first plurality of samples of said second decimated digital envelope signal, said second decimated digital envelope signal representing mechanical vibrations emanating from rotating said rotating part so far as to cause occurrence of a vibration having a period of repetition;

and

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

said enhancer is adapted to generate said autocorrelated envelope signal sequence so that it has a second plurality of samples, said second plurality being a positive integer and lower than said first plurality, said autocorrelated envelope signal sequence being generated in response to the first signal portion and the second signal portion.

13. The apparatus according to claim 1, wherein said first sensor is a shock pulse sensor.

14. The apparatus according to claim 1, wherein said first sensor is a vibration sensor having a substantially linear response in a frequency range up to around 10 kHz.

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 according to claim 1;

(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.

16. 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 according to claim 1;

(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.

17. The method according to claim 16, wherein,

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

the first sensor is adapted to generate the analogue electric measurement signal so that it includes at least one repetitive vibration signal component dependent on said mechanical vibrations such that the repetitive vibration signal component 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:

(IIIA) indicating the rotating part from which the repetitive vibration signal component originates;

said indication being generated in dependence on the repetition frequency of the repetitive signal amplitude component.

18. The method according to claim 16, wherein,

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

the first sensor is adapted to generate the analogue electric measurement signal so that it includes at least one repetitive vibration signal component dependent on said mechanical vibrations such that the repetitive vibration signal component 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 amplitude component.

19. The method according to claim 16, wherein,

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

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

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

detecting the repetition frequency of the repetitive signal amplitude component, and

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

wherein the detected repetition frequency is indicative of at least one deteriorated condition selected from a group comprising;

a Bearing Inner Race damage, a Bearing Outer Race damage, and a teeth engagement error.

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

generating, with a first sensor, an analogue electric measurement signal dependent on a mechanical vibration emanating from rotation of said rotating part, wherein the analogue electric measurement signal includes at least one repetitive vibration signal component dependent on said mechanical vibration, said repetitive vibration signal component having a repetition frequency which depends on the speed of rotation of the rotating part;

sampling, with an analogue-to-digital converter, said analogue electric measurement signal at a first sampling frequency so as to generate a digital measurement data signal in response to said analogue electric measurement signal;

generating, with a digital enveloper, a digital envelope signal in response to said digital measurement data signal;

performing a first decimation of the digital envelope signal, with a first decimator, so as to achieve a first decimated digital envelope signal having a first reduced sampling frequency, the first reduced sampling frequency being reduced by an integer factor as compared to the first sampling frequency;

performing a condition monitoring function, with an evaluator, for analyzing the condition of the machine;

performing a second decimation, with a second decimator, so as to generate a second decimated digital envelope signal;

said second decimation including

i) receiving said first decimated digital envelope signal,

ii) receiving a signal indicative of the variable speed of rotation associated with said rotating part, and

iii) receiving a signal indicative of an output sample rate setting signal;

generating, with said second decimator, said second decimated digital envelope signal having a second reduced sampling frequency dependent on

i) said first decimated digital envelope signal,

ii) said signal indicative of the variable speed of rotation associated with said rotating part, and

iii) said signal indicative of an output sample rate setting signal,

such that the number of sample values per revolution of said rotating part is kept at a substantially constant value; and

receiving said second decimated digital envelope signal in an enhancer;

performing, with said enhancer, signal processing involving discrete autocorrelation of said second decimated digital envelope signal so as to produce an autocorrelated envelope signal sequence wherein a repetitive signal amplitude component, the repetition frequency of which is proportional to said speed of rotation, is amplified in relation to stochastic signal components,

wherein said condition monitoring function is performed, with said evaluator, dependent on said autocorrelated envelope signal sequence.

21. A computer program stored on a non-transitory computer readable medium for causing a computer to analyze the condition of a machine having a rotating part, the computer program comprising:

computer readable code means which, when run on a computer, causes the computer to receive a digital measurement data signal having a first sampling frequency from an analogue-to-digital converter, said digital measurement data signal including at least one repetitive vibration signal component dependent on a mechanical vibration emanating from rotation of said rotating part, said repetitive vibration signal component having a repetition frequency which depends on the speed of rotation of the rotating part;

computer readable code means which, when run on a computer, causes the computer to generate a digital envelope signal in response to said digital measurement data signal;

computer readable code means which, when run on a computer, causes the computer to perform a first decimation of the digital envelope signal so as to achieve a first decimated digital envelope signal having a first reduced sampling frequency, the first reduced sampling frequency being reduced by an integer factor as compared to the first sampling frequency;

computer readable code means which, when run on a computer, causes the computer to perform a second decimation so as to generate a second decimated digital envelope signal having a second reduced sampling frequency dependent on

i) said first decimated digital envelope signal,

ii) a signal indicative of the variable speed of rotation associated with said rotating part, and

iii) a signal indicative of an output sample rate setting signal,

such that the number of sample values per revolution of said rotating part is kept at a substantially constant value;

computer readable code means which, when run on a computer, causes the computer to perform signal processing involving discrete autocorrelation of said second decimated digital envelope signal so as to produce an autocorrelated envelope signal sequence wherein a repetitive signal amplitude component, the repetition frequency of which is proportional to said speed of rotation, is amplified in relation to stochastic signal components; and

computer readable code means which, when run on a computer, causes the computer to perform a condition monitoring function for analyzing the condition of the machine dependent on said autocorrelated envelope signal sequence.