scholarly journals Cross Correlation for Condition Monitoring of Variable Load and Speed Gearboxes

2014 ◽  
Vol 2014 ◽  
pp. 1-10
Author(s):  
Jordan McBain ◽  
Markus Timusk
Keyword(s):  
Cross Correlation ◽  
Complex Dynamics ◽  
Early Stage ◽  
Novelty Detection ◽  
Simple Algorithm ◽  
Operating Conditions ◽  
Physical Aspect ◽  
Variable Load ◽  
Problem Class ◽  
Constrained Environments

The ability to identify incipient faults at an early stage in the operation of machinery has been demonstrated to provide substantial value to industry. These benefits for automated, in situ, and online monitoring of machinery, structures, and systems subject to varying operating conditions are difficult to achieve at present when they are run in operationally constrained environments that demand uninterrupted operation in this mode. This work focuses on developing a simple algorithm for this problem class; novelty detection is deployed on feature vectors generated from the cross correlation of vibration signals from sensors mounted on disparate locations in a power train. The behavior of these signals in a gearbox subject to varying load and speed is expected to remain in a commensurate state until a change in some physical aspect of the mechanical components, presumed to be indicative of gearbox failure. Cross correlation will be demonstrated to generate excellent classification results for a gearbox subject to independently changing load and speed. It eliminates the need to analyze the highly complex dynamics of this system; it generalizes well across untaught ranges of load and speed; it eliminates the need to identify and measure all predominant time-varying parameters; it is simple and computationally inexpensive.

scholarly journals Process Engineering of the Acetone-Ethanol-Butanol (ABE) Fermentation in a Linear and Feedback Loop Cascade of Continuous Stirred Tank Reactors: Experiments, Modeling and Optimization

Fuels ◽  
2021 ◽  
Vol 2 (2) ◽  
pp. 108-129
Author(s):  
Katja Karstens ◽  
Sergej Trippel ◽  
Peter Götz
Keyword(s):  
Feedback Loop ◽  
Early Stage ◽  
Formation Rate ◽  
Abe Fermentation ◽  
Operating Conditions ◽  
Stirred Tank ◽  
Second Phase ◽  
Stirred Tank Reactors ◽  
Continuous Stirred Tank ◽  
Continuous Stirred Tank Reactors

The production of butanol, acetone and ethanol by Clostridium acetobutylicum is a biphasic fermentation process. In the first phase the carbohydrate substrate is metabolized to acetic and butyric acid, in the following second phase the product spectrum is shifted towards the economically interesting solvents. Here we present a cascade of six continuous stirred tank reactors (CCSTR), which allows performing the time dependent metabolic phases of an acetone-butanol-ethanol (ABE) batch fermentation in a spatial domain. Experimental data of steady states under four operating conditions—with variations of the pH in the first bioreactor between 4.3 and 5.6 as well as the total dilution rate between 0.042 h−1 and 0.092 h−1—were used to optimize and validate a corresponding mathematical model. Beyond a residence time distribution representation and substrate, biomass and product kinetics this model also includes the differentiation of cells between the metabolic states. Model simulations predict a final product concentration of 8.2 g butanol L−1 and a productivity of 0.75 g butanol L−1 h−1 in the CCSTR operated at pHbr1 of 4.3 and D = 0.092 h−1, while 31% of the cells are differentiated to the solventogenic state. Aiming at an enrichment of solvent-producing cells, a feedback loop was introduced into the cascade, sending cells from a later state of the process (bioreactor 4) back to an early stage of the process (bioreactor 2). In agreement with the experimental observations, the model accurately predicted an increase in butanol formation rate in bioreactor stages 2 and 3, resulting in an overall butanol productivity of 0.76 g L−1 h−1 for the feedback loop cascade. The here presented CCSTR and the validated model will serve to investigate further ABE fermentation strategies for a controlled metabolic switch.

Use of an Integrated Approach for Analysis and Design of Turbocharged Internal Combustion Engine

2021 ◽  
Author(s):  
Thiago Ebel ◽  
Mark Anderson ◽  
Parth Pandya ◽  
Mat Perchanok ◽  
Nick Tiney ◽  
...  
Keyword(s):  
Internal Combustion Engine ◽  
Combustion Engine ◽  
Early Stage ◽  
Pressure Ratio ◽  
Integrated Approach ◽  
Internal Combustion ◽  
Operating Conditions ◽  
Dynamics Simulation ◽  
Analysis And Design ◽  
Performance Requirements

Abstract When developing a turbocharged internal combustion engine, the choice of turbocharger is usually based on designer experience and existing hardware. However, proper turbocharger design relies on matching the compressor and turbine performance to the engine requirements so that parameters such as boost and back pressure, compressor pressure ratio, and turbine inlet temperatures meet the needs of the engine without exceeding its allowable operating envelope. Therefore, the ultimate measure of a successful turbocharger design is how well it is matched to an engine across various operating conditions. This, in turn, determines whether a new turbocharger is required, or an existing solution can be used. When existing turbocharger solutions are not viable, the engine designer is at a loss on how to define a new turbocharger that meets the desired performance requirements. A common approach in industry has been to scale the performance of an existing turbocharger (compressor and turbine maps) and take these requirements for Original Equipment Manufacturers to possibly match it with a real machine. However, the assumptions made in a basic scaling process are quite simplistic and generally not satisfactory in this situation. A better approach would be to use a validated meanline model for a compressor and turbine instead, allowing to perform an actual preliminary design of such components. Such approach allows to link the engine performance requirements in a very early stage of te component design project and it guides the designer for the design decisions, such as rotor size, variable geometry nozzles, diameter, or shroud trims and others. Therefore, a feasible solution is more likely with design less iterations. This paper describes a methodology for an integrated approach to design and analyze a turbocharged internal combustion engine using commercially available state-of-the-art 1D gas dynamics simulation tool linked to two powerful turbomachinery meanline programs. The outputs of this analysis are detailed performance data of the engine and turbocharger at different engine operating conditions. Two case studies are then presented for a 10-liter diesel truck engine. The first study demonstrates how the programs are used to evaluate an existing engine and reverse engineer an existing turbocharger based only on the available performance maps. Then a second study is done using a similar approach but redesigning a new turbocharger (based on the reverse engineered one) for an increased torque output of the same engine.

scholarly journals Analysis of Residual Current Flows in Inverter Based Energy Systems Using Machine Learning Approaches

Energies ◽  
2022 ◽  
Vol 15 (2) ◽  
pp. 582
Author(s):  
Holger Behrends ◽  
Dietmar Millinger ◽  
Werner Weihs-Sedivy ◽  
Anže Javornik ◽  
Gerold Roolfs ◽  
...  
Keyword(s):  
Machine Learning ◽  
Early Stage ◽  
Residual Current ◽  
Operating Conditions ◽  
Machine Learning Algorithms ◽  
Photovoltaic System ◽  
Detection Methods ◽  
Learning Approaches ◽  
Residual Currents ◽  
Current Flows

Faults and unintended conditions in grid-connected photovoltaic systems often cause a change of the residual current. This article describes a novel machine learning based approach to detecting anomalies in the residual current of a photovoltaic system. It can be used to detect faults or critical states at an early stage and extends conventional threshold-based detection methods. For this study, a power-hardware-in-the-loop approach was carried out, in which typical faults have been injected under ideal and realistic operating conditions. The investigation shows that faults in a photovoltaic converter system cause a unique behaviour of the residual current and fault patterns can be detected and identified by using pattern recognition and variational autoencoder machine learning algorithms. In this context, it was found that the residual current is not only affected by malfunctions of the system, but also by volatile external influences. One of the main challenges here is to separate the regular residual currents caused by the interferences from those caused by faults. Compared to conventional methods, which respond to absolute changes in residual current, the two machine learning models detect faults that do not affect the absolute value of the residual current.

scholarly journals Assessment of the technical condition of lift guides using a magnetic field

2021 ◽  
Vol 2130 (1) ◽  
pp. 012003
Author(s):  
P Lonkwic ◽  
T Krakowski ◽  
H Ruta
Keyword(s):  
Early Stage ◽  
Technical Condition ◽  
Operating Conditions ◽  
Measuring Head ◽  
Cross Sectional ◽  
Correct Operation ◽  
Emergency Braking ◽  
Wear And Tear ◽  
Equipment Failures ◽  
Novel Concept

Abstract The systems that monitor individual components of machines and devices are under constant development. The ability to detect damages at an early stage allows failures to be prevented, so any uncontrolled downtime can be predicted in a controlled manner. Continuous monitoring of technical condition is an activity that also helps to reduce the losses due to equipment failures. However, not all areas can be monitored continuously. Such areas include lift guides where wear and tear can occur naturally, i.e. through abrasion of the material layer due to interaction with moving guide shoes or after emergency braking. Emergency braking causes local damages to the guide through plastic deformation of its surface resulting from indentation of the knurled roller of the brake. Such places are cleaned mechanically, which results in local reduction of the cross-sectional area. In such a case, it is difficult to continuously assess the technical condition of guides due to the prevailing operating conditions. Therefore, a concept of a head enabling assessment of the technical condition of guides at every stage of their operation has been developed. This article presents the novel concept of a magnetic head used for assessing the technical condition of lift guide rails that are the running track of lifting equipment. The initial tests were performed on the original test setup. The concept of the developed measuring head was verified for correct operation on specially prepared flat bars with holes. The results obtained in the form of laboratory tests proved that the proposed measuring head concept can be applied to the measurements under real conditions.

Analysis on the Steady-state Performance and Losses of a Bent-axis Type Hydraulic Motor Used in Heavy Earth Moving Machinery

2021 ◽  
Author(s):  
Ajit Kumar Pandey ◽  
Amit Kumar ◽  
Nitish Kumar
Keyword(s):  
Steady State ◽  
Electric Motor ◽  
Underground Mining ◽  
Operating Conditions ◽  
Constant Speed ◽  
Working Environment ◽  
Variable Load ◽  
Mining Equipment ◽  
Mining Operations ◽  
Design Guideline

Hydraulic components play a significant role in the mining and construction equipment. It is responsible for smooth change in the output speed, torque, and power of the machine. The hydrostatic drive powered by a constant speed electric motor is widely used in the propel system of the mining equipment. Regulation of the displacements of the pump and the hydro-motor of the drive facilitates the control of the straight running and steering of the machines. In the present scenario, better efficiency and ease of control are the critical aspects to be considered in the design and selection of the hydraulic pump and motor used in underground mining operations. The bent axis hydro-motor is one such equipment that is an electro-hydraulic component that can work in an adverse working environment. The present study deals with the performance analysis of fixed displacement bent axis hydro-motor at different operating parameters such as different temperatures, sizes, viscosity at different loads, and drive speed. For analysis, the hydraulic drive consists of a variable displacement pump rotated by a constant speed electric motor and a fixed displacement hydro-motor. The regulation of the pump displacement controls the speed of the drive. Manually controlled hydrostatic drive propels the said machine against variable load demands. The present work investigates the performances of the hydro-motor used in the mining and construction machine through detailed modeling and experimentations. The steady-state performances are analyzed in terms of slip, torque losses and efficiency of the hydro-motor. The study finds the design guideline to operate the hydrostatic drive using such motors in a reasonable efficiency zone. The model is validated for various operating conditions of the equipment by comparing the predicted results with the test results. The outcome of the present work will be expedient for the preliminary design and assortment of similar hydraulic component used in the mobile, mining equipment.

scholarly journals New State Identification Method for Rotating Machinery under Variable Load Conditions Based on Hybrid Entropy Features and Joint Distribution Adaptation

Complexity ◽  
2020 ◽  
Vol 2020 ◽  
pp. 1-17
Author(s):  
Xiaoming Xue ◽  
Nan Zhang ◽  
Suqun Cao ◽  
Wei Jiang ◽  
Jianzhong Zhou ◽  
...  
Keyword(s):  
Joint Distribution ◽  
Operating Conditions ◽  
Variable Load ◽  
Rolling Element Bearings ◽  
Time Frequency ◽  
Identification Method ◽  
State Identification ◽  
Rolling Element ◽  
Load Conditions ◽  
Testing Set

Fault identification under variable operating conditions is a task of great importance and challenge for equipment health management. However, when dealing with this kind of issue, traditional fault diagnosis methods based on the assumption of the distribution coherence of the training and testing set are no longer applicable. In this paper, a novel state identification method integrated by time-frequency decomposition, multi-information entropies, and joint distribution adaptation is proposed for rolling element bearings. At first, fast ensemble empirical mode decomposition was employed to decompose the vibration signals into a collection of intrinsic mode functions, aiming at obtaining the multiscale description of the original signals. Then, hybrid entropy features that can characterize the dynamic and complexity of time series in the local space, global space, and frequency domain were extracted from each intrinsic mode function. As for the training and testing set under different load conditions, all data was mapped into a reproducing space by joint distribution adaptation to reduce the distribution discrepancies between datasets, where the pseudolabels of the testing set and the final diagnostic results were obtained by the k-nearest neighbor algorithm. Finally, five cases with the training and testing set under variable load conditions were used to demonstrate the performance of the proposed method, and comparisons with some other diagnosis models combined with the same features and other dimensionality reduction methods were also discussed. The analysis results show that the proposed method can effectively recognize the multifaults of rolling element bearings under variable load conditions with higher accuracies and has sound practicability.

The Effect of Geometrical Features on Air-Side Heat Transfer and Friction Characteristics, and Optimization of a Large-Size Plain Fin-and-Tube Heat Exchanger by 3-D Numerical Simulation

2009 ◽  
Author(s):  
M. Izadi ◽  
D. K. Aidun ◽  
P. Marzocca ◽  
H. Lee
Keyword(s):  
Heat Transfer ◽  
Numerical Modeling ◽  
Heat Exchanger ◽  
Heat Exchangers ◽  
Simple Algorithm ◽  
Operating Conditions ◽  
Friction Characteristics ◽  
Tube Heat Exchanger ◽  
Large Size ◽  
Geometrical Features

The effect of geometrical features on the air-side heat transfer and friction characteristics of an industrial plain fin-and-tube heat exchanger is investigated by 3-D numerical modeling and simulations. The heat exchanger has been designed and employed as an intercooler in a gas power plant and is a large-size compact heat exchanger. Most of the available design correlations developed so far for plain fin–and–tube heat exchangers have been prepared for small-size exchangers and none of them fits completely to the current heat exchanger regarding the geometrical limitations of correlations. It is shown that neglecting these limitations and applying improper correlations may generate considerable amount of error in the design of such a large-size heat exchanger. The geometry required for numerical modeling is produced by Gambit® software and the boundary conditions are defined regarding the real operating conditions. Then, three-dimensional simulations based on the SIMPLE algorithm in laminar flow regime are performed by FLUENT™ code. The effect of fin pitch, tube pitch, and tube diameter on the thermo-hydraulic behavior of the heat exchanger is studied. Some variations in the design of the heat exchanger are suggested for optimization purposes. It is finally concluded that the current numerical model is a powerful tool to design and optimize of large-size plain fin-and-tube heat exchangers with acceptable accuracy.

A predictive combustion model for one-dimensional gasoline engine simulation

2020 ◽  
pp. 146808742094590
Author(s):  
Yoshihiro Nomura ◽  
Seiji Yamamoto ◽  
Makoto Nagaoka ◽  
Stephan Diel ◽  
Kenta Kurihara ◽  
...  
Keyword(s):  
Gasoline Engine ◽  
Early Stage ◽  
Burning Velocity ◽  
Turbulent Flame ◽  
Operating Conditions ◽  
Combustion Model ◽  
One Dimensional ◽  
Turbulent Reynolds Number ◽  
Proposed Model ◽  
Wide Range

A new predictive combustion model for a one-dimensional computational fluid dynamics tool in the multibody dynamics processes of gasoline engines was developed and validated. The model consists of (1) a turbulent burning velocity model featuring a flame radius–based transitional function, steady burning velocity that considers local quenching using the Karlovitz number and laminarization by turbulent Reynolds number, as well as turbulent flame thickness and its quenching model near the liner wall, and (2) a knock model featuring auto-ignition by the Livengood–Wu integration and ignition delay time obtained using a full-kinetic model. The proposed model and previous models were verified under a wide range of operating conditions using engines with widely different specifications. Good agreement was only obtained for combustion characteristics by the proposed model without requiring individual calibration of model constants. The model was also evaluated for utilization after prototyping. Improved accuracy, especially of ignition timing, was obtained after further calibration using a small amount of engine data. It was confirmed that the proposed model is highly accurate at the early stage of the engine development process, and is also applicable for engine calibration models that require higher accuracy.

scholarly journals Measurements Based Analysis of the Proton Exchange Membrane Fuel Cell Operation in Transient State and Power of Own Needs

Energies ◽  
2020 ◽  
Vol 13 (2) ◽  
pp. 498
Author(s):  
Andrzej Wilk ◽  
Daniel Węcel
Keyword(s):  
Fuel Cells ◽  
Fuel Cell ◽  
Proton Exchange Membrane ◽  
Transient State ◽  
Experimental Tests ◽  
Cell System ◽  
Proton Exchange ◽  
Operating Conditions ◽  
Variable Load ◽  
Exchange Membrane

Currently, fuel cells are increasingly used in industrial installations, means of transport, and household applications as a source of electricity and heat. The paper presents the results of experimental tests of a Proton Exchange Membrane Fuel Cell (PEMFC) at variable load, which characterizes the cell’s operation in real installations. A detailed analysis of the power needed for operation fuel cell auxiliary devices (own needs power) was carried out. An analysis of net and gross efficiency was carried out in various operating conditions of the device. The measurements made show changes in the performance of the fuel cell during step changing or smooth changing of an electric load. Load was carried out as a change in the current or a change in the resistance of the receiver. The analysis covered the times of reaching steady states and the efficiency of the fuel cell system taking into account auxiliary devices. In the final part of the article, an analysis was made of the influence of the fuel cell duration of use on obtained parameters. The analysis of the measurement results will allow determination of the possibility of using fuel cells in installations with a rapidly changing load profile and indicate possible solutions to improve the performance of the installation.

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