MACHINE CONDITION MONITORING

E SIVASIDHARTH
(19BEC0721)

BACHELOR OF ENGINEERING

Electronics and Communication Engineering

Vellore Institute of Technology,

Vellore – 632 014
OVERVIEW:
When designing the physical experiments, the one takes into account is the mechanical
vibrations which may occur and affect the results, so utmost importance must be given for
the mechanical vibrations. Vibration analysis is one of the oldest and the most successful
techniques used for condition monitoring of rotating machines. To measure mechanical
vibrations there are several ways and this project look closer on how to measure the
vibrations using MEMS based accelerometer. In condition based monitoring (CBM) process,
the state of machinery is determined while in operation through a three step data
management process. This includes data collection, processing, and analysis which includes
fault diagnosis and predictive maintenance. The aim of this project is to show that vibration
analysis is a very efficient and convenient tool for diagnosing mechanical and
electromagnetic problems in motors.

NEED FOR VIBRATION ANALYSIS:

The vibration analysis is a significant tool to diagnose mechanical vibrations in machines. It is

based on the high information content provided by the machine vibration signals that are
used for indicating the machine condition and diagnosis of faults. Vibration analysis is a
predictive maintenance programme, being widely used for detection and monitoring
incipient and severe faults in machinery parts, like bearings, shafts, couplings, rotors, motors
etc. Some problems that are usually detected by vibration analysis are: unbalance,
misalignment, bent shaft, rolling bearing faults, eccentricity, resonance, looseness, rotor
rub, fluid-film bearing instabilities, gear faults and belt/sheave damages.

OBJECTIVE:

Condition monitoring of electrical motors is a high-priority task due to the prevalent and
continually extended use of electric motors around the world. The accelerometer sensor is
placed above the motor. Improvisation Scope: The values collected from the sensor can be
sent to the data acquisition module and the digital values can be sent to the personal
computer and the evaluated data can be sent to a cloud storage.

INTRODUCTION:

One of the oldest and the most successful techniques used for condition monitoring of
rotating machines is vibration analysis. In combination with other non-invasive techniques,
it is used in all types of industry. Machine condition monitoring and fault diagnostics may be
defined as the field of technical activity in which selected physical parameters, associated
with machinery operation, are observed for the purpose of determining machinery integrity.
In industrial domain, a system similar with that presented in this project allows the
continuous monitoring of a various machinery and provides information essential to the
early detection of faults or malfunctions under all service conditions. In this way further
serious damage or even failures can be prevented, which may impair the machine
performance or endanger the plant and the operating personnel.

CONDITION MONITORING:

The objective of maintenance function is to optimize maintenance cost and improve

reliability. A maintenance task is effective when (i) Increases the Mean Time between
Failures (MTBF) of the equipment. (ii) Reduces the consequence of failure. (iii) Reduces the
risk of multiple failures. To maintain the equipment correctly at the right time, condition
based maintenance (CBM) is introduced. CBM is based on using real-time data to prioritize
and optimize maintenance resources. Observing the state of the system is known as
condition monitoring. Such a system will determine the equipment's health, and act only
when maintenance is actually necessary,
Condition Based Maintenance (CBM) practices, such as vibration monitoring of machine tool
spindle units, are therefore becoming a very attractive, but still challenging, method for
companies operating high-value machines and components. CBM is being used to plan for
maintenance action based on the condition of the machines and to prevent failures by
solving the problems in advance as well as controlling the accuracy of the machining
operations.

VIBRATION ANALYSIS:

(About 3 different researcher papers)

Hunter Barksdale in his paper described in a motor engineers needs to monitor the
electromagnetic field within and around the machine, along with motor current,
temperature, and noise measurements to detect faults within the machine. For condition
monitoring, the data from industrial devices is routed to secondary controllers connected to
a secondary data bus.

Laurence Maregedze in his paper described that vibration analysis is a measurement tool
used to identify, predict, and prevent failures in machine tools. It involves the analysis of
machinery performance parameters to detect and identify problems before failure and
extensive damage can occur. The vibration which occurs in most machines, vehicles,
structures, buildings and dynamic systems is undesirable, not only because of the resulting
unpleasant motions and the dynamic stresses which may lead to fatigue and failure of the
structure or machine, but also because of the energy losses, reduction in performance and
the noise produced. Since the vibration frequency and amplitude cannot be measured by
sight or touch, a means must be employed to convert the vibration into a usable product
that can be measured and analysed.
Mikhail Tsypkin in his paper described the process of vibration analysis, the first of these
tasks is called fault detection and the second one is fault diagnosis. Fault detection is when a
measurement parameter exceeds a normal operating range. Fault diagnosis is often
associated with condition monitoring, and focuses on specific changes and symptoms in
order to determine a cause, severity, and corrective action.
From a practical standpoint, simple harmonic vibration functions are related to the circular
frequencies of the rotating or moving components. Therefore, these frequencies are some
multiple of the basic running speed of the machine-train, which is expressed in revolutions
per minute (rpm) or cycles per minute (cpm). Determining these frequencies is the first
basic step in analysing the operating condition of the machine-train, are proposed by Ioan
Lita.

LABVIEW: (Machine Condition Analysis)

The application software, developed in LABVIEW graphical environment, conducted data
measurement and true vibration analysis. To recognize the faults, remove the analytical
value features from the vibration signals. The developed LabVIEW program can be easily
configured and used to monitor online vibration condition and quickly process large
amounts of data to highlight new or unusual events such as high vibration level that can
pose a problem. The user interface is simple and does not require that the user has
extensive knowledge of the process and a thorough technical understanding of the code
used, are proposed by Heta S. Shah From the developed LABVIEW’s graphical environment,
data measurement and real vibration analysis are taken. Remove the analytical value
characteristics from the vibration signals to recognize the faults. The developed LabVIEW
program can be easily configured and used to monitor the condition of online vibration and
process large amounts of data quickly to highlight new or unusual events such as high
vibration levels that may pose a problem. Asan Gani proposes a user interface that is simple
and does not require the user to have extensive process knowledge and a through technical
understanding of the code used.

BLOCK DIAGRAM OF THE PROPOSED SYSTEM:

The proposed block diagram consists of an accelerometer sensor which is placed above the
motor and data collected from the accelerometer is sent to the data acquisition module and
in the data acquisition module the analog values are converted into digital values. The
digital values are send to the PC for data evaluation and the evaluated data is send to the
cloud for storage. The proposed block diagram is shown in Fig. 3.1.
ACCELEROMETER:

In a smartphone an accelerometer is used to measure frequencies. As the name indicates

the acceleration to which it is subject, the accelerometer measures. The model is mounted
on a breakout board of Spark Fun using the 3-axis accelerometer ADXL335 Analog Devices. It
measures ±3 g of three orthogonal axes in the direction of X, Y and Z. It can read from 0.5 Hz
to 1600 Hz for the X and Y axis while the Z axis ranges from0.5Hzto550Hz.However, the
Spark Fun model comes with 0.1 μF capacitors that act as a low pass filter and limit the
bandwidth of each axis to 50Hz.
The operation of the accelerometer takes between 1.8 V and 3.6 V so that it is not possible
to use the 5 V output on the Arduino and have to use the 3 V. This also means that simply
plugging one of the axes into one of the Arduinos analog input pins will cause complications
as it expects a maximum value of 5 V. To solve this, we connect the supply voltage to the
Arduino AREF pin as well as to the Arduino AREF pin. The breakout board of the ADXL335
accelerometer is shown in Fig. 3.2.
The sensor in the ADXL335 is a sensor based on a silicon wafer based on micro-machined
polysilicon surface. The sensor contains a proof mass called a seismic mass that is bound to
deflectable plates. When accelerated, the mass deflects the plates and a differential
condenser measures this deflection. The differential condenser consists of separately fixed
plates and seismic mass-connected plates. The fixed plates are driven by 180° out of phase
square waves and when the plates are deflected the differential capacitor becomes
unbalanced and gives a square wave output signal whose amplitude is proportional to the
acceleration.
ARDUINO UNO:

Arduino is an open source microcontroller that has become popular with students,
hobbyists and professionals alike. It has a very active community and the low purchase cost
makes it a great tool to test and deploy ideas quickly. We chose to work with the Arduino
Uno Rev. 3 reference model, which can be seen in Fig. 3.3. It has a weight of 68.6x 53.4 mm
and 25 g. It is based on the 8-bit microcontroller ATmega328. It has a 16 MHz clock
frequency and a flash memory of 32 KB. It operates at 5 V and can be powered by an
external power supply or USB. There are six analog pins on the board and a total of 14
digital I / O pins, of which 6 provide PWM output. Power management pins are also
available.
The analog pins with which we work mostly in this project have a 10-bit resolution meaning
that they can handle 1024 different values. This is usually done by having each value
correspond to a voltage between ground and 5 V, but by using the AREF pin (analog
reference pin) this can be changed. UART TTL (5V) serial communication is used to
communicate with the Arduino. It is also possible to use the digital pins0 (RX) and 1 (TX) to
send and receive serial data. There is an integrated serial monitor in the IDE which can be
used for sending and receiving information. The Arduino appears as a virtual COM - port
when connected to a computer via USB and any software capable of serial communication
can be used.
ESP8266 Wi-Fi MODULE:

Due to its low price but packed with a bunch of hardware capabilities, the ESP8266 has
attracted attention of many developers, especially in the open source community. Currently
there are numbers of manufacturers which produce ready-to-use ESP8266 modules. Over
time each manufacturer has designed and launched numerous versions of modules, each of
which offers different added features and configurations. Some modules feature bigger flash
memory, while others have more number of exposed I/O pins. Some are equipped with an
external antenna, while some are not. Fig. 3.4 depicts some of ESP8266 modules available in
the market. external antenna, while some are not. Fig. 3.4 depicts some of ESP8266 modules
available in the market
ESP8266 is a system on chip (SOC) and Wi-Fi network that can carry software applications. It
also has TCP/IP protocol that permits to access Wi-Fi network. The ESP8266 is efficient to
host an application or remove all Wi-Fi networking functions from another application
processor. The flash memory can be started straight from an external move. In-built cache
memory will help upgrade system performance and curtail memory requirements. Another
condition is when wireless Internet access considers the task of Wi-Fi adapter, you can
integrate it to any microcontroller-based design, and the connection is uncomplicated, just
by SPI / SDIO interface. The module has fast processing and high storage capability. This
allows it to integrate via GPIO ports sensors and other application specific machine with the
lowest development in early and least loading during runtime. The ESP8266 allows very less
external circuitry due to the highly integrated chip. It includes antenna switch and front-end
module, including the entire designed to minimize PCB area. The system of ESP8266
supports the following features: energy saving VoIP applications and Bluetooth interference.
It has self-generated RF allow it to work on the operating condition with no external RF
parts. The input voltage of the module is 3.3 V, with 8 pins, which have two pins of 1 TXD
and 1 RXD, 2 GPIO pins i.e. GPIO 0 and GPIO 2, RST is Reset, VCC and GND is Ground. The
module is very cheap and transforming it into an IoT solution is a unique thing.
Although it is not the only factor, antenna is a critical one that determines the coverage
distance of a wireless transceiver. Among the ESP8266 modules with integrated antenna, it
can be recognized that there are three distinctive types, which in this paper will be refer to
as model A, B, and C. For ease of use, we employ modules with integrated USB to serial
converter, like shown in Fig. 3.5. Model A employs the ESP-12 module, which is integrated
with a meandered PCB antenna. Model B, also called Wemos D1 Mini, is using the ESP-12F
module and incorporated with another type of meandered Inverted-F PCB antenna.
Meanwhile module C is known as Wemos D1 Mini Pro, which uses a ceramic antenna. In
fact, model C also has an IPX RF plug for connecting additional antenna. We also try model C
coupled with a dipole antenna, which is referred to as model D. It is worth to mention that
for model D to work properly, the 0-ohm resistor on the board should be rerouted to the
dipole antenna. By default, the resistor is connected to the ceramic antenna.
RSSI is a parameter used by Wi-Fi transceivers to adapt its modulation and coding scheme so
that the optimum data rate can be achieved. Modulation scheme supporting high speed
transmission requires high SNR, which is correlated to strong RSSI. Otherwise, error rate will
be high, and a lot of time wasted for correction and retransmission. Therefore, a Wi-Fi
transceiver will dynamically change its modulation scheme according to the actual RSSI. In
ESP8266 relation between data rate and signal strength is shown in Table 3.1

Table 3.1 Relation DATA RATE SIGNAL

Between Data STRENGHT
Rate and Signal
Strength
MODULATION
DSSS 1Mbps -98 dBm
CCK 11 Mbps -91 dBm
1\2BPSK 6 Mbps -93 dBm
3\4 64-QAM 54 Mbps -75 dBm
HT20,MCS 7 72.2 Mbps -72 dBm
LABVIEW FOR DATA ACQUISITION:

LabVIEW (Laboratory Virtual Instrument Engineering Workbench) is a type ofopening

platform for virtual instruments VI. The system's software unit can acquire, manage and
interface data. The measured signals can also be analysed and processed. LabVIEW
significantly reduces the software development period due to its influential function module
and communication protocol. It can acquire and analyse data, particularly in measuring and
controlling systems.
System programs software by Lab VIEW's powerful VISA. VISA (Virtual Instrument Software
Architecture) is a standard instrument program input / output API. It can make appropriate
driver calls based on the instrument type used by the user, such that VISA can control gpib,
serial, usb, Ethernet, pxi or vxi instruments, so that the user does not need to specifically
study the instrument's communication protocol. Lab VIEW has 5 serial VIs and can be found
through the "I / O Serial Function Instrument" path.

ARDUINO IDE:

The Arduino microcontroller is coded using the C / C++ based Arduino language and has an
Integrated Development Environment (IDE) that is user-friendly. To make an executable
development program, the user only has to define two functions: a setup and a loop
function. Only once is the setup function executed and used to initialize variables, pin
modes, etc. The loop function is essentially an infinite loop that is repeatedly called until the
device is decided to switch off, where your code is implemented. These types of programs
are called executive cyclic programs.

CIRCUIT:
HARDWARE SETUP:
CONCLUSION AND FUTURE WORK:

SPM and SKF Modules are used for Machine Condition monitoring and analysis which take a
long time to process and cost in lakhs. This Module which uses ADXL 335B and LM35 Can
detect their respective reading with an ample amount of accuracy and doing the same
function of those other modules.

In future work, the collected data can be sent to the LabVIEW for applying Fast Fourier
Transform and for faster data optimisation. The accuracy of the vibration velocity measured
can be improved by using accelerometer sensor which operates at higher frequency so that
the vibration values would be more accurate.