• 제어로봇시스템학회:학술대회논문집
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• 2005.06a
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• pp.1439-1444
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• 2005

Induction motors are the most commonly used electrical drives because they are rugged, mechanically simple, adaptable to widely different operating conditions, and simple to control. The most common faults in squirrel-cage induction motors are bearing, stator and rotor faults. Surveys conducted by the IEEE and EPRI show that the most common fault in induction motor is bearing failure (${\sim}$40% of failure). Thence, this paper addresses experimental results for diagnosing faults with different rolling element bearing damage via motor current spectral analysis. Rolling element bearings generally consist of two rings, an inner and outer, between which a set of balls or rollers rotate in raceways. We set the experimental test bed to detect the rolling-element bearing misalignment of 3 type induction motors with normal condition bearing system, shaft deflection system by external force and a hole drilled through the outer race of the shaft end bearing of the four pole test motor. This paper takes the initial step of investigating the efficacy of current monitoring for bearing fault detection by incipient bearing failure. The failure modes are reviewed and the characteristics of bearing frequency associated with the physical construction of the bearings are defined. The effects on the stator current spectrum are described and related frequencies are also determined. This is an important result in the formulation of a fault detection scheme that monitors the stator currents. We utilized the FFT, Wavelet analysis and averaging signal pattern by inner product tool to analyze stator current components. The test results clearly illustrate that the stator signature can be used to identify the presence of a bearing fault.

• Design & Manufacturing
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• v.15 no.4
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• pp.51-56
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• 2021

Piercing is the process of shearing a circular hole in sheet metal, whose high shear force makes it difficult to secure the durability of tools. In addition, uneven clearance between tools due to poor alignment of the piercing punch causes accelerated die wear and breakage of the tool. This study reviewed the feasibility of in-situ determining alignment failure during the piercing process by analyzing the signal deviation of a bolt-type piezo sensor installed inside the tool whose alignment level was controlled. Finite element analysis was performed to select the optimal sensor location on the piercing tool for sensitive detection of process signals. A well-aligned piercing process results in uniform deformation in the circumferential direction, and shearing is completed at a stroke similar to the sheet thickness. Afterward, a sharp decrease in shear load is observed. The misaligned piecing punch leads to a gradual decrease in the load after the maximum shear load. This gradual decrease is due to the progressive shear deformation that proceeds in the circumferential direction after the initial crack occurs at the narrow clearance site. Therefore, analyzing the stroke at which the maximum shear load occurs and the load reduction rate after that could detect the misalignment of the piercing punch in real-time.

• Transactions of the Korean Society for Noise and Vibration Engineering
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• v.12 no.4
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• pp.287-293
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• 2002

The unexpected failure of the induction motor makes the downtime of production, and the cost of the process cessation enormous. To reduce the downtime and increase the reliability of the motor, the vibration measurements for the fault detection have been used previously. Recently motor current signature analysis(MCSA) has been adapted for the fault detection and diagnosis of the motors. MCSA provides a powerful analysis tool for detecting the presence of mechanical and electrical faults in both the motor and driven equipment. In this paper, the fault severity of the rotor bar has been derived in terms of the resistance change which is calculated from the equivalent circuit model. Results show that the fault of the rotor can be easily detected and the measured value of the resistance change is verified by the detected fault from on-site tests using MCSA for the induction motors in an iron foundry.

• Journal of the Korean Society for Nondestructive Testing
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• v.14 no.1
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• pp.16-22
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• 1994

In contrast to the machineries using rolling element bearings, systems with journal bearings generally operate in large scale and under severe loading condition such as steam generator turbines and internal combustion engines. Failure of the bearings in these machineries can result in the system breakdown. To avoid the time consuming repair and considerable economic loss, the detection of incipient failure in journal bearings becomes very important. In this experimental approach, acoustic emission monitoring is applied to the detection of incipient failure caused by several types of abnormal operating condition most probable in the journal bearing systems. It has been known that the intervention of foreign materials, insufficient lubrication and misassembly etc. are principal factors to cause bearing failure and distress. The experiment was conducted under such designed conditions as hard particles in the lubrication layer, insufficient lubrication, and metallic contact in the simulated journal bearing system. The results showed that acoustic emission could be an effective tool to detect the incipient failure in journal bearings.

• Journal of the Korean Institute of Illuminating and Electrical Installation Engineers
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• v.20 no.1
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• pp.132-137
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• 2006

The second part of paper related rotor failure is to evaluate that the axial magnetic flux measurement could be used as a tool of the condition monitoring system for the induction motor and to develope the diagnostic algorithm for the various fault in the electric motors. The magnetic leakage flux signal is captured by the flux coil located at the end of motor without the disturbance of the operation. And the signal is analyzed both time and frequency domain to detect the failure of the motor. Specific signature can be described in tin and frequency domain for each fault of the motor. The experimental test found that the rotor failures - broken rotor bar, broken end ing and rotor eccentricity, could be detected from the spectrum with high resolution. The method of detecting the rotor fault was found by analysing the specific frequency and the sideband of the rotor bar pass frequency from axial leakage flux spectrum. In addition the optimal flux coil and measuring equipment for the axial leakage flux measurement was verified and the diagnostic method for the detection of the rotor related failure was developed.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.12 no.6
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• pp.22-28
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• 2003

We should maintain the maximum operation capacity for production facilities and find properly out the fault of each equipment rapidly in order to decrease a loss caused by its failure. The acoustic signals of a machine always carry the dynamic information of the machine. These signals are very useful for the feature extraction and fault diagnosis. We performed a fundamental study which develops a system of fault diagnosis for a pump. We obtained noises by a microphone, analysed and compared the signals converted to Sequency range for normal products, artificially deformed products. We tried to search a change of noise signals according to machine malfunctions and analyse the type of deformation or failure. The results showed that acoustic signals as well as vibration signals can be used as a simple method for a detection of machine malfunction or fault diagnosis.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2003.04a
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• pp.99-104
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• 2003

We should maintain the minimum operation capacity for production facilities and find properly out the fault of each equipment rapidly in order to decrease a loss caused by its failure. The acoustic signals of a machine always carry the dynamic information of the machine. These signals are very useful for the feature extraction and fault diagnosis. We performed a fundamental study which develops a system of fault diagnosis for a pump. We obtained noises by a microphone, analysed and compared the signals converted to frequency range for normal products, artificially deformed products. We tried to search a change of noise signals according to machine malfunctions and analyse the type of deformation or failure. The results showed that acoustic signals as well as vibration signals can be used as a simple method for a detection of machine malfunction or fault diagnosis.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2014.10a
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• pp.745-750
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• 2014

The chatter vibration in the machining process plays bad role in machining quality such as high roughness as well as tool life and machine failure. And the grinding process under this risk in the fully automated factory is exposed to the unexpected mass machining quality problem. Studying the vibration signal of the hub bearing grinding process, the reason of chatter vibration was explained with the specific machining pattern of chatter. And this study suggests the chatter detecting method in the production line, which is monitoring the peak acceleration level around the natural frequencies of the specimen, and calculating kurtosis value by assuming the chatter is related to the resonance of the specimen. The suggested method was applied to the vehicle hub bearing grinding process and proved good to detecting the chatter induced machining quality problem.

• Journal of the Institute of Convergence Signal Processing
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• v.14 no.1
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• pp.1-5
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• 2013

The two major problems related to the blood flow in replaced prosthetic heart valve are thrombus formation and hemolysis. Reliability of prosthetic valve is very important because its failure means the death of patient. There are many factors affecting the valvular failures and their representatives are mechanical failure and thrombosis, so early noninvasive detection is essentially required. The purpose of this study is to detect the various thromboses formation by using acoustic signal acquisition and its spectral analysis on the frequency domain. We made the thrombosis models using Polydimethylsiloxane (PDMS) and they are thrombosis model on the disc, around the sewing ring and fibrous tissue growth across the orifice of valve. Using microphone and amplifier, we measured the acoustic signal from the prosthetic valve, which is attached to the pulsatile mock circulation system. A/D converter sampled the acoustic signal and the spectral analysis is the main algorithm for obtaining spectrum. Then the spectrum of normal and 5 different kinds of abnormal valve were obtained. Each spectrum waveform shows a primary and secondary peak. The secondary peak changes according to the thrombus model. To quantitatively distinguish the frequency peak of the normal valve from that of the thrombosed valves, analysis using a neural network was employed. Acoustic measurement has been used as a noninvasive diagnostic tool and is thought to be a good method for detecting possible mechanical failure or thrombus.

• Journal of the Korea Safety Management & Science
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• v.16 no.4
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• pp.229-236
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• 2014

Failure modes and effects analysis (FMEA) is a widely used engineering tool in the fields of the design of a product or a process to improve its quality or performance by prioritizing potential failure modes in terms of three risk factors-severity, occurrence, and detection. In a classical FMEA, the risk priority number is obtained by multiplying the three values in 10 score scales which are evaluated for the three risk factors. However, the drawbacks of the classical FMEA have been mentioned by many previous researchers. As a way to overcome these difficulties, this paper suggests the ELECTRE III that is a representative technique among outranking models. Furthermore, fuzzy linguistic variables are included to deal with ambiguous and imperfect evaluation process. In addition, when the importances for the three risk factors are obtained, the entropy method is applied. The numerical example which was previously studied by Kutlu and Ekmekio$\breve{g}$lu(2012), who suggested the fuzzy TOPSIS method along with fuzzy AHP, is also adopted so as to be compared with the results of their research. Finally, after comparing the results of this study with that of Kutlu and Ekmekio$\breve{g}$lu(2012), further possible researches are mentioned.