Time–frequency analysis for bearing fault diagnosis using multiple Q-factor Gabor wavelets

Rolling element bearings are key and also vulnerable machine elements in rotating machinery. Fault diagnosis of rolling element bearings is significant for guaranteeing machinery safety and functionality. To accurately extract bearing diagnostic information, a time–frequency analysis method based on continuous wavelet transform (CWT) and multiple Q-factor Gabor wavelets (MQGWs) (termed CMQGWT) is introduced in this paper. In the CMQGWT method, Gabor wavelets with multiple Q-factors are adopted and sets of the continuous wavelet coefficients for each Q-factor are combined to generate time–frequency map. By this way, the resolution of the CWT time–frequency map can be greatly increased and the diagnostic information can be accurately identified. Numerical simulation is carried out and verified the effectiveness of the proposed method. Case studies and comparisons with the continuous Morlet wavelet transform (CMWT) and the tunable Q-factor wavelet transform (TQWT) demonstrate the effectiveness and superiority of the CMQGWT for bearing diagnostic information extraction and fault identification.     

Hybrid time–frequency methods for non-stationary mechanical signal analysis

This paper presents a family of hybrid time–frequency methods to be used as a tool for transient signal analysis. These methods are based on autoregressive models of the signal, and on the maximum likelihood method. A classical Wigner–Ville distribution and a parametric time–frequency methods are used for comparison purposes. The characteristics, advantages and disadvantages, of non-parametric, parametric and hybrid methods are discussed and their performances are compared by analysing actual data. The superiority of time–frequency resolution of the hybrid methods is pointed out over that of the parametric and non-parametric ones. Three practical examples of transient signals illustrate the discussion: the vibration signal issued from a damaged gearbox, a signal from a pendular scratch test presenting beating phenomenon and the vibration signal measured in an electrical motor during start-up.     

Time–frequency approach to extraction of selected second-order cyclostationary vibration components for varying operational conditions

In this paper, the authors propose a method for extracting second-order cyclostationary components from a vibration signal. For a known cyclic frequency, the proposed algorithm allows to estimate the amount of energy of each cyclic component of interest in the time–frequency domain. In this way, the resulting representation contains only the chosen second-order cyclostationary component that manifests itself as a number of carrier frequencies modulated by the harmonic signal of selected frequency.     

Qualitative evaluation of the germination frequency in Zr–Fe binary alloy

Major thermo-physical properties data are of fundamental importance to accurate and reliable design of melting and casting processes. In this paper, we show that we can control the germination process using thermodynamics data. These data must be known for the entire period of time and temperature range of interest in any given condition. In addition, a kinetic approach is employed to predict the microstructure of alloys. Viscosity data for Zr₇₆Fe₂₄, are fitted with an empirical relation. The best fit allows to estimate, through the resistance to germination factor, thermodynamic proprieties of interest (i.e., namely the enthalpy of fusion, the surface tension, the molar volume and the glass temperature). From the values of these quantities, the parameters (T, t) can be estimated. The temperature T is found between 930 K and 1194 K and the time t can be derived from the plateau of the germination frequency–temperature profile.     

Non-stationary signal analysis based on general parameterized time–frequency transform and its application in the feature extraction of a rotary machine

With the development of large rotary machines for faster and more integrated performance, the condition monitoring and fault diagnosis for them are becoming more challenging. Since the time-frequency (TF) pattern of the vibration signal from the rotary machine often contains condition information and fault feature, the methods based on TF analysis have been widely-used to solve these two problems in the industrial community. This article introduces an effective non-stationary signal analysis method based on the general parameterized time–frequency transform (GPTFT). The GPTFT is achieved by inserting a rotation operator and a shift operator in the short-time Fourier transform. This method can produce a high-concentrated TF pattern with a general kernel. A multi-component instantaneous frequency (IF) extraction method is proposed based on it. The estimation for the IF of every component is accomplished by defining a spectrum concentration index (SCI). Moreover, such an IF estimation process is iteratively operated until all the components are extracted. The tests on three simulation examples and a real vibration signal demonstrate the effectiveness and superiority of our method.     

The influence of a change in the electron trajectory in the vacuum-diode anode–cathode gap on the impedance

The analysis of the influence of the electron-trajectory curvature in the anode–cathode gap of a vacuum diode on its impedance during generation of high-current electron beams is performed, and the applicability of the one-dimensional Child–Langmuir formula for the electron-current calculation is evaluated. The results of an experimental study of a flat diode with explosive-emission graphite, copper, and carbon- fabric cathodes and also with a multipointed cathode are presented. These investigations were performed on the TEU-500 accelerator (350–500 kV, 60 ns). A strip diode with a graphite cathode was also studied in the mode of magnetic self-insulation of electrons. The experiments were performed on the TEMP-4М accelerators (150–200 kV, 400–600 ns). The investigation results showed that the satisfactory coincidence of the experimental values of the total current with those calculated from the one-dimensional Child–Langmuir formula (for the working area of the cathode) is observed in diodes not only in the absence of a change in the electron trajectory in the anode–cathode gap but also upon a deflection of the trajectory from the normal to the cathode surface by an angle of <90°. An increase in the electron current owing to a decrease in the anode–cathode gap and an increase in the emission area of the cathode during the cathode-plasma production and also at the expense of the presence of microirregularities on the cathode is properly described by the onedimensional Child-Langmuir formula, if the above factors are taken into account.     

An experimental study on real–time analysis of two–phase peristaltic slug flows in dialysis machines

Two–phase flows appear in many industrial and biomedical applications. One of the most vital biomedical applications of two–phase flows is in hemodialysis machines due to air embolism and heparin injection. Since these flows have a very complex and intermittent nature, studying their dynamics is a very challenging and fundamental problem. The purpose of this article is to present an experimental study on the dynamics of two–phase peristaltic slug flows. The measurement strategy is based on the image processing technology. The characteristic parameters of the two–phase pulsatile slug flows, including the slug length, as well as the translational velocity and frequency of the slug motion, are measured, and the effect of the liquid flow rate and liquid superficial velocity is investigated. The results show that the average and maximum slug velocities, and also the dominant amplitude of the slug velocity increase with the flow rate and liquid superficial velocity, while it is not possible to clearly predict a correlation between the liquid superficial velocity and the slug length. The measurement strategy presented in this article can be used in the control and alarm systems of smart dialysis machines.     

Adaptive time–frequency decomposition for transient vibration monitoring of rotating machinery

Monitoring the vibration behaviour of large rotating machinery is an effective way to reduce production losses and enhance safety, efficiency, reliability, availability and longevity in manufacturing processes. As large rotating machinery is increasingly employed in continuous operations at high speeds and with heavy loads, the vibration behaviour of the rotor systems is more and more complex. Focusing on the defects of different joint time–frequency representations, we present an adaptive time–frequency decomposition (ATFD) technique to describe transient vibration. This approach provides a precise interpretation of complex signals that consist of various time–frequency structures through decomposing it into paramedic, redundant and well-localised components in the time–frequency plane. Both computer simulation and an actual case show that this technique has high time–frequency resolution and no interference terms. The analysis results proved this approach could specify critical speed as well as acceleration rate accurately and is very effective in ensuring machinery passing through critical speed field safely.     

Real Time Control of pH in Fed‐Batch Process

Abstract

The objective of this work is to implement the linear, non linear model based and linear cascade controllers to control pH in a fed batch neutralisation process in real time and compare the performance with the simulation results. The control objective here is to make the process output pH to follow the given reference trajectory. This work aims at bringing out the best features of model‐based control and linear cascade control, when applied to highly non‐linear systems like pH‐controlled fed‐batch processes. For these processes, control of pH by a conventional Proportional Integral Derivative controller fails to provide satisfactory performance because of the extreme non‐linearity in the pH dynamics. Typical problems in control, e.g., uncertainty in model parameters, are addressed in this work. These controllers are implemented in real time using a lab scale setup and compared with the simulation. The results show the superior performance of the non linear model‐based and linear cascade controller over that of the conventional Proportional Integral controller.     

The Effect of Dwell Time on the Static Friction in Creeping Elastic–Plastic Polymer Spherical Contact

A theoretical model is developed to study the effect of dwell time on the junction growth and static friction of a creeping polymer sphere in contact with a rigid flat under full stick contact condition. A rapid normal loading into the elastic–plastic contact regime is followed by a rest period during which creep takes place causing contact area growth, and stress relaxation that can completely eliminate the plastic zone in the sphere. At the end of this rest time, an increasing tangential loading is applied to the flat till sliding inception occurs. During this loading step, further increase of the contact area and reappearing of a plastic zone in the sphere take place. An increase in static friction resulting from the dwell time during the creep stage is clearly demonstrated and explained.     

Experimental analysis of coating layer behavior of Al–Si-coated boron steel in a hot bending process for IT applications

The utilization of high-strength steel for automotive structural parts has increased since the oil crisis in the 1970s owing to its high strength and potential for weight reduction. Because of the limited formability of high-strength steels, automotive components are increasingly produced through hot press forming. In some instances, high-strength steel sheets are coated with an Al–Si layer in order to prevent scaling of components during hot press forming, and this can increase their reliability with a view to the dimensional accuracy and stress distribution when they are in service. In this contribution, the coating degradation mechanisms of Al–Si-coated boron steel after the hot bending process are reported. The issues related to coating degradation during hot press forming are critically reviewed at different positions on a part that was subject to hot bending. In addition, the hardness and friction coefficient were tested by a nano-indenter at various positions. The relationship between the experimental parameters and coating layer properties is also reported. It is concluded that the bending deformation affected the coating layer behavior the most.     

Experimental and theoretical analysis of friction stir welding of Al–Cu joints

This paper presents a study of friction stir welding of aluminium and copper using experimental work and theoretical modelling. The 5083-H116 aluminium alloy and pure copper were successfully friction-stir-welded by offsetting the pin to the aluminium side and controlling the FSW parameters. A theoretical analysis is presented along with key findings. The process temperatures are predicted analytically using the inverse heat transfer method and correlated with experimental measurements. The temperature distribution in the immediate surroundings of the weld zone is investigated together with the microstructures and mechanical properties of the joint. This was supported by a finite element analysis using COMSOL Multiphysics. In this study, two rotational speeds were used and a range of offsets was applied to the pin. The microstructure analysis of the joints was undertaken. This revealed some particles of Cu inclusion in the nugget zone. The energy dispersive spectroscopy showed a higher diffusion rate of aluminium towards the interface while copper maintained a straight base line.     

Experimental analysis on mechanical interlocking of metal–polymer direct joining

Injection molded direct joining (IMDJ) is a method for direct joining of metals and polymers. In this work, we identified the most influential parameter for IMDJ and explained the reasons for successful joining by considering mechanical interlocking. We prepared hybrid joints of 30% glass-fiber-reinforced polybutylene terephthalate and aluminum alloy (A5052) plates with laser-treated surface dimples via IMDJ under various injection parameters. We studied the effects of the packing and holding pressures and the polymer temperatures on the joining strength. We discussed the reasons for the observed effects by considering mechanical interlocking, including the infiltration depth and the contact between the metal and the polymer. We found the packing pressure to be the most influential parameter. Moreover, the interaction between the packing pressure and the polymer temperature also influenced the joining strength considerably. The increased joining strength under various combinations of injection parameters was a result of deeper infiltration depth and better contact. We anticipate that the findings of this study will aid better selection of injection parameters for IMDJ.     

Real‐Time Monitoring of Tool Fracture in Turning Using Sensor Fusion

The sensor fusion method using both an acoustic emission (AE) sensor and a built-in force sensor is introduced for on-line tool condition monitoring during turning. The cutting force was measured by a built-in piezoelectric force sensor, which was inserted in the tool turret housing of an NC lathe. FEM analysis was carried out to locate the most sensitive position for the sensor. A burst of AE signal was used as a triggering signal to inspect the cutting force. A significant drop in cutting force indicated tool breakage. The algorithm was implemented in a DSP board and the monitoring system was installed on a CNC lathe in an FMS line for in-process tool-breakage detection. The proposed system showed an excellent monitoring capability.     

Elastic–plastic contact analysis of an ellipsoid and a rigid flat

The work presents a finite element model (FEM) of the equivalent von-Mises stress and displacements that are formed for the different ellipticity contact of an ellipsoid with a rigid flat. The material is modeled as elastic perfectly plastic and follows the von-Mises yield criterion. The smaller the ellipticity of the ellipsoid is, the larger the depth of the first yield point from the ellipsoid tip happens. The FEM produces contours for the normalized normal and radial displacement as functions of the different interference depths. The evolution of plastic region in the asperity tip for a sphere (k_e=1) and an ellipsoid with different ellipticities $(k_e=\frac{1}{2}\mathrm{and}\frac{1}{5})$ is shown with increasing interferences. It is interesting to note the behavior of the evolution of the plastic region in the ellipsoid tip for different ellipticities, k_e, is different. The developments of the plastic region on the contact surface are shown in more details in Fig. 7. When the dimensionless contact pressure is up to 2.5, the uniform contact pressure distribution is almost prevailing in the entire contact area. It can be observed clearly that the normalized contact pressure ascends slowly from the center to the edge of the contact area for a sphere (k_e=1), almost has uniform distribution prevailing the entire contact area for an ellipsoid $(k_e=\frac{1}{2})$, and descends slowly from the center to the edge of the contact area for an ellipsoid $(k_e=\frac{1}{5})$.     

Effect of Plasma Nitriding Environment and Time on Plain Fatigue and Fretting Fatigue Behavior of Ti–6Al–4V

Plasma nitriding was performed on Ti–6Al–4V fatigue test samples at 520°C in two environments (nitrogen and nitrogen–hydrogen mixture in a ratio of 3:1) for two time periods (4 and 18 h). Plain fatigue and fretting fatigue tests were conducted on unnitrided and plasma nitrided samples. Plasma nitriding degraded lives under both plain fatigue and fretting fatigue loadings. The samples nitrided in nitrogen exhibited superior lives compared with the samples nitrided in the nitrogen–hydrogen mixture, possibly due to the relatively higher hardness (and presumably lower toughness) of the nitrided layer of the samples nitrided in the nitrogen–hydrogen mixture environment. For those samples nitrided in the nitrogen–hydrogen mixture, those nitrided for 18 h exhibited superior lives compared with those nitrided for 4 h. This trend was observed for samples nitrided in nitrogen gas at lower stress levels only; the converse was true at higher stress levels of 550 MPa and 700 MPa under plain fatigue loading. However, under fretting fatigue loading, the plasma nitriding time did not influence the lives significantly.     

Measurement of electromagnetic radiation with respect to the hours and days of a week at 100kHz–3GHz frequency band in a turkish dwelling

In this paper, the electromagnetic (EM) radiation to which we are exposed in our life is aimed to be observed during a week. The measurements are carried out in a randomly selected apartment during 24 h a day at 4 s sampling period for all days of a week. Due to the result of the study, we can see whether any radiation above specified limits occurs during a day and week or not and also we can determine how an ordinary instantaneous measurement represents the usual radiation level in related area. Measurement results showed that EM radiation levels in 100 kHz–3 GHz frequency band were considerably below specified limit values. There is statistically no difference between measured values in Monday and Saturday with respect to days. However, it is observed that the measured values in other days except for Monday and Saturday are statistically considerably different.     

Wear analysis of Cu–Al coating on Ti–6Al–4V substrate under fretting condition

Fretting behavior of Cu–Al coating on Ti–6Al–4V substrate was investigated with and without fatigue load. Soft and rough Cu–Al coating resulted in abrasive wear and a large amount of debris remained at the contact surface, which caused an increase in tangential force during the fretting test under gross slip condition. Fretting in the partial slip condition also showed the wear of coating. To characterize wear, dissipated energies during fretting were calculated from fretting loops and wear volumes were obtained from worn surface profiles. Energy approach of wear analysis showed a linear relationship between wear volume and accumulated dissipated energy. This relationship was independent of fatigue loading condition and extended from partial slip to gross slip regimes. As an alternate but simple approach for wear analysis, accumulated relative displacement range was correlated with the wear volume. This also resulted in a linear relationship as in the case of accumulated dissipated energy suggesting that the accumulated relative displacement range can be used as an alternative parameter for dissipated energy to characterize the wear. When the maximum wear depth was equal to the thickness of Cu–Al coating, harder Ti–6Al–4V substrate inhibited further increase in wear depth. Only when a considerable energy was supplied through a large value of the applied displacement, wear in the substrate material could occur beyond the thickness of coating.     

Modeling and analysis of the effects of processing parameters on the performance characteristics in the high pressure die casting process of Al–SI alloys

The high pressure die casting (HPDC) process has achieved remarkable success in the manufacture of aluminum–silicon (Al–SI) alloy components for the modern metal industry. Mathematical models are proposed for the modeling and analysis of the effects of machining parameters on the performance characteristics in the HPDC process of Al–SI alloys which are developed using the response surface methodology (RSM) to explain the influences of three processing parameters (die temperature, injection pressure and cooling time) on the performance characteristics of the mean particle size (MPS) of primary silicon and material hardness (HBN) value. The experiment plan adopts the centered central composite design (CCD). The separable influence of individual machining parameters and the interaction between these parameters are also investigated by using analysis of variance (ANOVA). With the experimental values up to a 95% confidence interval, it is fairly well for the experimental results to present the mathematical models of both the mean particle size of primary silicon and its hardness value. Two main significant factors involved in the mean particle size of primary silicon are the die temperature and the cooling time. The injection pressure and die temperature also have statistically significant effect on microstructure and hardness.     

Determination of a Mobile-Ion Concentration in the Dielectric Films of Metal–Insulator–Semiconductor Structures

An experimental technique for determining the surface concentration N _Sof mobile ions in dielectric films of metal–insulator–semiconductor (MIS) structures is described. The technique is based on synchronous recording of the dynamic volt–ampere and low-frequency capacity–voltage characteristics of a sample under investigation. These experimental dependences are shown to ensure accurate extraction of the ion current peaks whose areas are proportional to N _S. These characteristics also allow the relaxation of the surface semiconductor potential to be found, which is needed for reconstructing the dependence of the convection ion current on the voltage drop across the insulation gap of the MIS capacitor. A comparative analysis with other known methods for determining N _Sis carried out. The proposed technique helps find a mobile-ion concentration from a 5 × 10⁹to 10¹³-cm^–2range, including the case when ion current peaks do not appear on the current–voltage characteristics.