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Advanced Signal Processing for Machinery Fault DiagnosisA Practical Course on Advanced Vibration Analysis & Condition Monitoring taught by world recognized expert
-Professor Bob Randall, University of New South Wales, Australia and assisted by
-Dr. Suri Ganeriwala, SpectraQuest, Inc.
October 1 – 5, 2012
SpectraQuest offers a practical course on Machine Condition Monitoring and Diagnostics with an emphasis on signal processing techniques. The objective is to provide tools to prepare you to become an expert in analyzing machinery faults. Topics include overview of condition monitoring techniques, basic vibration theory, and advanced signal processing principles like FFT methods, Hilbert methods via FFT and related amplitude, phase and frequency demodulation, cepstrum, order tracking and time synchronous averaging. Rather than giving pure theory, it will be illustrated at all stages with diagnostic examples and demonstrations using SpectraQuest Machinery Fault Simulators and Drivetrain Diagnostics Simulators. The concept of cyclostationarity with principal application to bearing diagnostics will be presented. The course will cover a range of techniques for bearing diagnostics, as well as for gear diagnostics. It will also cover IC engines, and other reciprocating machines, by a number of techniques, including simple torsional vibration analysis by frequency demodulation of shaft encoder signals and will use SpectraQuest bearing wear and gearbox dynamics simulators, and a reciprocating compressor. The course will also stress the advantages and limitations of various signal analysis techniques and their relevance to specific applications and tasks. This unique course will provide a hands-on approach, with theory/lectures followed by real life examples as well as demonstration of novel techniques for fault diagnosis. The approach involves a classroom with several workstations set up for carrying out controlled exercises. Each workstation consists of Machinery Fault Simulator, Drive Train Diagnostics Simulator, Torsional Vibration Simulator/Calibrator, fully wired sensors, and a multi-channel data acquisition system. Different machine fault kits are used for demonstrating fault signatures using simulation and diagnosis software. Students perform each experiment, analyze the data and present results for group discussion. Other necessary accessories such as tachometer, strobe, etc are also provided. All the PCs are connected to a client-server type network for free exchange of data and enhanced discussion.
Date: October 1 – 5, 2012
Venue: SpectraQuest Corporate Headquarter, Richmond, VA.
Who Should Attend? • Vibration Analyst who wants to become expert in diagnostics.• Research and development professional working in diagnostics. • Vibration Analyst preparing for Category III or IV Exams
Cost: $1,950.00 if registering prior to September 15, 2012. $2,295.00 after September 15, 2012
The cost will cover all coffee breaks, lunches, and one dinner at a popular local restaurant. Attendees will receive a free copy of the ‘Signal Processing Fundamentals and Simulation’ software ($495 value) along with class notes. Participants will also have the opportunity to acquire Prof. Randall’s recently published book (Wiley) “Vibration-based Condition Monitoring: Industrial, Aerospace, and Automotive Applications” at a discount price. Classes will start at 8:30 am and end at 5:30 pm each day (except Friday where the course will end at noon). Continental breakfast will be provided from 8:00 to 8:30 am each day.
Download the registration form here or fill the online registration form.
All attendees must register and pay prior to attending the class.
Day 1 – AM Overview of Condition Monitoring and Vibration Analysis – Vibration signals produced by various machines and components – fault detection schemes and manifestation – typical diagnostics procedure – transducers and measurements
Signal Processing: Fourier analysis, continuous and discrete transforms, properties and computational aspects, spectral analysis uncertainties and their control,
Demonstration of using Signal Processing Simulation Software
Day 1 – PM Signal processing – Fourier analysis – Hilbert transforms – practical FFT analysis –CPB (constant percentage bandwidth), and demodulation
Hands-on experiments and analysis: Misalignment, balancing, cracked and bent shaft, and fault detection using CPB analysis
Day 2 – AM Signal Processing – cyclostationarity and spectral correlation – introduction to cepstrum analysis – time-frequency analysis, STFT, Wigner-Ville distribution, wavelets, and choice of method and parameters.
Rolling element bearing vibrations – fault diagnostics through envelope analysis – applications of cyclostationarity, local faults and extended faults – spectral kurtosis (SK) for determining optimum frequency band for demodulation– minimum entropy de-convolution (MED) to remove smearing effect of transmission path – combination for semi-automated process.
Day 2 – PM Exercises: Rolling element bearing faults: inner race, outer race, and rolling element defects with varying degrees of faults and complexities.
Day 3 – AM Gear vibrations – separation of gear and bearing signals by self adaptive noise cancellation (SANC), discrete/random separation (DRS), linear prediction and cepstrum – order tracking (angular sampling) – synchronous averaging of individual gear signals – residual analysis – cepstrum analysis – amplitude and phase demodulation of gear mesh signal – transmission error (TE) measurement using shaft encoders and its use for diagnostics.
Day 3 – PM Exercises: Gear diagnostics: Different types of faults, effects of loadings and complexities.
Day 4 – AM Reciprocating machine vibrations – time (crank angle) vs. frequency representations – spectrogram comparison for detecting change – torsional vibration (angular velocity) measurement for irregular combustion – determination of angular velocity by phase demodulation of encoder signal followed by differentiation in the frequency domain (simultaneously removing irrelevant high and low frequency noise) – determination of angular velocity by encoder pulse timing with a high frequency clock – benefits of instantaneous (Wigner-Ville) spectrum after removal of periodic components – determination of cylinder pressure (or pressure torque) from external acceleration and/or torsional vibration measurements.
Day 4 – PM Exercises: Reciprocating compressor, torsional vibration, and induction motor faults.
Day 5 – AM Dynamic structural response – introduction to experimental modal analysis (EMA) and operational deflection shape (ODS) – simple structural response measurements with a single accelerometer, first used to measure and adjust force frequency range by changing impact pad, then responses at different locations – determination of excited frequency range from mass of hammer and stiffness of impact pad – ODS using a fixed and a roving accelerometer
Demonstration of the above topics including ODS and closure at noon.
Previous Course Attendees Comments
“Excellent coverage of diagnostic tools with applications to important classes of machinery. Professor was knowledgeable and insightful.” – Mitchell Wlodawski, DSPcon Inc. ” Excellent overview, wide palette of techniques and case studies” – Gianluca Nicchiotti, Vibro-Meter SA “A very good advanced course. I would recommend this course to my colleagues” – Alberto Ordonez, Universidad Carlos III de Madrid
Professor R. B. Randall, University of New South Wales, Australia
is a world-recognized expert on machinery fault diagnostics and prognostics, especially bearings and gearboxes. He has pioneered numerous signal processing techniques for analyzing complex machinery signals such as helicopter gearboxes, gas turbines, IC engines, reciprocating machines etc. He has published extensively on signal processing and diagnostics. Professor Randall is a frequent invited keynote speaker at conferences and symposia. He worked in industry for over 10 years in Australia, Canada, and Europe before becoming a senior fellow at Brüel & Kjær for 17 years. He taught at the University of New South Wales, Australia for the last 23 years, and since his recent retirement still supervises a number of PhD students. Bob is well known all over the world for introducing innovative signal processing techniques for complex machinery fault diagnosis and prognosis. He is the author of the recently published book “Vibration-based Condition Monitoring: Industrial, Aerospace, and Automotive Applications” and the widely used “Frequency Analysis” by B&K.
Dr. Suri Ganeriwala - Founder and President of SpectraQuest, Inc.
Suri has expertise in signal processing and diagnostics, modal analysis, finite element modeling, and constitutive modeling of amorphous (polymer) materials. He has been invited speaker in several international conferences around the world. Dr. Ganeriwala has implemented successful condition monitoring and diagnostics program in industrial settings. Suri has developed unique products for education and research in wind energy, machine fault diagnosis, teaching fundamentals of vibration, controls, and dynamics and kinematics of machines. SpectraQuest’s flagship products Machinery Fault Simulators (MFS) and Drivetrain Diagnostics/Prognostics Simulators are his brainchild from concept to completion. These devices have been sold in over forty five countries around the world for research and teaching. He has over thirty years of industrial and academic experience in machinery fault diagnosis, signal processing, vibration analysis and control. He has authored over seventy papers, technical reports and articles in journals, magazines, and books. He obtained a Ph.D. in Mechanical Engineering from The University of Texas at Austin.
SpectraQuest regularly offers the following courses, though no time have been set at this time. Please contact us if interested.