This study investigates the use of vibration and strain measurements on machine tools in order to identify the propagating wear of the selected tools. Two case studies are considered, one of which was conducted in the plant of a South African piston manufacturer. The purpose of the ftrst case study was to investigate the feasibility of vibration monitoring to identify tool wear, before attempting to implement a monitoring system in the manufacturing plant. During this case study, data from a turning process was recorded using two accelerometers coupled to a PL202 real time FFT analyser. Features indicative of tool wear were extracted from the sensor signals, and then used as inputs to a Self-Organising Map (SOM). The SOM is a type of neural network based on unsupervised learning, and can be used to classify the input data into regions corresponding to new and worn tools. It was also shown that the SOM can also be used very efficiently with discrete variables. One of the main contributions of the second case study was the fact that a unique type of tool was investigated, namely a synthetic diamond tool specifically used for the manufacturing of aluminium pistons. Data from the manufacturing of pistons was recorded with two piezoelectric strain sensors and a single accelerometer, all coupled to a DSPT Siglab analyser. A large number of features indicative of tool wear were automatically extracted from different parts of the original signals. These included features from time and frequency domain data, time series model coefficients as features and features extracted from wavelet packet analysis. A correlation coefficient approach was used to auto-lJUltically select the best features indicative of the progressive wear of the diamond tools. The SOM was once again used to identify the tool state. Some of the advantages of using different map sizes on the SOM were also demonstrated. A near 100% correct classification of the tool wear data was obtained by training the SOM with two independent data sets, and testing it with a third independent data set. It was also shown that the monitoring strategy proposed in the second case study can be fully automated and can be implemented on-line if the manufacturer wishes to. Some of the contributions of this study are the use of the SOM for tool wear classification, and conclusions regarding the wear modes of the synthetic diamond tools. / Dissertation (M Eng (Mechanical Engineering))--University of Pretoria, 2006. / Mechanical and Aeronautical Engineering / unrestricted

The vibration of the railway superstructure is mainly influenced by its quality, by the operational technical conditions, climatic phenomena and above all by the dynamic load by the pair of wheels of the rail vehicles and also by the quality of railway subgrade. Simultaneously, the dynamic parameters also depend on the speed of rail vehicles, on the arrangement of axles, their spring mounting and on the spring mounting of the body casing or on the weight acting on the axle, and last but not least, also on the quality of the running surface of the wheel tyre. The dynamic effects of sets of wagons are transferred through the rails to the rail pads below the base of the rails, then to the sleepers or bearers and fastening system, then to the ballast bed and also to the superstructure construction. This fact applies especially for turnout structures. In turnout rigidity is changed and also there is a place where the wheel passes over a gap (in case of fixed crossings). In particular of above mentioned reasons, turnout is a place where high dynamic effects occurre and that is why often defects occurre. Dissertation thesis will be focused on measurement and analysis of the dynamic effects on turnout. The point of the thesis will be updating recent system (observing of the geometrical parameters and wear of the rails in turnouts) for dynamic effect observe. Methodology of the measurement and convenient mathematical apparatus for analysing dynamic effect will be proposed.

Skanska driver cirka 30 asfaltverk i Sverige. Något alla dessa verk har gemensamt är att driftsäkerheten är viktig då ett driftstopp på asfaltverket kan leda till höga kostnader ifallbeläggningsarbetet blir stillastående. Syftet med examensarbetet är att undersöka olika teknikersom används inom tillståndsbaserat underhåll och hur de kan appliceras på ett av Skanskas asfaltverk.Datainsamling skedde genom litteratursökning, dokumentstudier, observationer och intervjuer. Resultatet av litteratursökningen visade att det finns flera tekniker inom tillståndsbaserat underhåll. Några av de vanligaste teknikerna är mätning av vibrationer, temperatur och ultraljud. Alla inrapporterade driftstörning på Skanskas asfaltverk i region väst under 2022 kategoriserades efter vilken utrustning som orsakat stoppet. Analysen av störningarna visade att siktutrustningen stod för den största procentuella andelen av driftstoppstimmarna. Vid observationer och intervjuer framkom att haveri av sikten ofta leder till långa driftstopp och att det är svårt att upptäcka felen innan de inträffar. För att undersöka sikten på komponentnivå genomfördes en FEMA som visade att sprickbildning i plåtar, motorhaveri och felmonterade såll är de mest kritiska felorsakerna. För att mäta dessa fel valdes vibrationsmätning då denna metod ansågs ha störst sannolikhet att upptäcka de kritiska felen. Tre företag som arbetar med vibrationsmätning kontaktades för att diskutera olika lösningskoncept. Utifrån dessa tre lösningsförslag rekommenderades två koncept för fortsatt arbete. Det som skiljer lösningarna från varandra är att den ena innebär en större investering ekonomiskt och kompetensmässigt men ger möjlighet till mer detaljerad information. / Skanska operates approximately 30 asphalt plants in Sweden. One thing all these plants have in common is that operational reliability is important, as unplanned downtime at the asphalt plant can lead to high costs if asphalt paving work is interrupted. The purpose of the thesis is to investigate various techniques used in condition-based maintenance and how they can be applied to one of Skanska's asphalt plants.Data was collected through literature searches, document studies, observations, and interviews.The literature search showed that there are many technologies used in condition-basedmaintenance. Some of the most common techniques are vibration measurement, temperature measurement, and ultrasonic testing. All reported equipment failures at Skanska's asphalt plants in the west region in 2022 were categorized by the equipment that caused the downtime. Analysis of the failures showed that the screening equipment accounted for the largest percentage of downtime. Observations and interviews revealed that shutdowns of the screens are often long and that it is difficult to detect faults before they occur.To investigate the screen at the component level, a FMEA was carried out, which showed that cracking in plates, motor failures, and incorrectly installed screens are the most critical causes of failure. Vibration measurement was chosen to measure these faults as this method was considered to have the highest probability of detecting the critical faults. Three companies working with vibration measurement were contacted to discuss different solution concepts. Based on these three proposals, two concepts were recommended for further study. What differentiates the solutions from each other is that one entails a greater investment both financially and in terms of expertise but provides the opportunity for more detailed information.

This dissertation presents a self-tuning regulator (STR) design method developed based upon a state-space linear quadratic Gaussian (LQG) control strategy for rejecting a disturbance in a flexible structure in the face of model uncertainty. The parameters to be tuned are treated as additional state variables and are estimated recursively together with the system state that is needed for feedback. Also, the feedback gains are designed in the LQ framework based upon the estimated model parameters. Two problems concerning the uncertainty of model parameters are recognized. First, we consider the uncertainty in the system matrix of the state space model. The self-tuning regulator is implemented by computer and the control law is obtained based upon a discrete-time model; however, only selected continuous-time parameters with physical meanings to which the controller is highly sensitive are tuned. It is formulated as a nonlinear filtering problem such that both the estimated state and the unknown parameters can be obtained by an extended Kahman filter. The capability of this design method is experimentally demonstrated by applying it to the rejection of a disturbance in a simply supported plate. The other problem considered is that the location where the disturbance enters the system is unknown. This corresponds to an unknown disturbance influence matrix. Under the assumption that the system matrix is known and the disturbance can be measured, it is formulated as a linear filtering problem with an approximate discrete-time design model. Similarly, the estimated state for feedback and the unknown parameters are identified simultaneously and recursively. Also, the feedback gains are calculated approximately by recursively solving the discrete-time control Riccati equation. The effectiveness of the controller is shown by applying it to a simply-supported plate, when the location of the disturbance is assumed unknown. Since implementing LQG self-tuning controllers for vibration control systems requires significant real-time computation, methods that can reduce the computing load are examined. In addition, the possibility of extending the self tuning to disturbance model parameters is explored. / Ph. D.

This thesis presents the design and simulation of a digital frequency demodulator applied to a Michelson interferometer-based scanning laser vibrometer. The laser vibrometer is a velocity transducer that produces frequency-modulated signals that have traditionally been optically or electronically frequency shifted from baseband to an intermediate frequency. This shifting produces a narrow band modulation that may be demodulated with standard analog frequency demodulators. This thesis proposes replacing these traditional optics or electronic circuits with a digital frequency demodulator. The optics of a laser vibrometer can be constructed such that a near-perfect baseband quadrature representation is available for the frequency modulation. It will be seen that this representation is well suited for use by a digital frequency demodulator. This thesis applies the arctangent-type digital frequency demodulator to a laser vibrometer and demonstrates its superiority over other digital demodulation techniques. In addition some specialized signal processing to handle the special case of sine-dwell vibration tests is presented. / Master of Science

Unexpected bearing failures in agricultural equipment can result in considerable inconvenience, potential hazard, and monetary loss. Continuous bearing condition monitoring using vibration and audio spectrum analysis can detect imminent bearing failures before dangerous situations develop. Current application of bearing condition monitoring using vibration signature analysis has focused on fixed industrial applications involving high cost equipment and high shaft speeds. The feasible application of current technology on mobile agricultural equipment requires a lower-cost method of signal sensing and processing. Lower shaft speeds and the use of neural-net based pattern recognition techniques can allow the use of lower-cost transducers necessary for practical adoption on mobile equipment. A test apparatus was developed and constructed to test the feasibility of using a electret microphone as a sensor for monitoring bearing condition through vibration signature analysis. Laboratory experiments designed to evaluate the sensors with test bearings at both an advanced and an early stage of wear were developed. A field-worn bearing that had been removed from a unit of farm machinery was obtained and examined. Twelve new bearings identical in type to the field worn bearing were also examined, altered to simulate an early stage of wear, and re-examined. Identical experiments were conducted on both the field-worn and altered bearings. The signal acquired from a field-worn bearing was compared with the signal acquired from a new bearing using a two-sample, paired t-test for means at an alpha level of 0.05 and a graphical defect frequency analysis. The signals acquired from the altered bearings were compared with the signals acquired from the new bearings using the same statistical and graphical test performed on the field-worn bearings. The goal of the analysis was to evaluate the performance of the microphone by attempting to identify significant frequency patterns that could be used to determine the condition of the test bearing while in operation. Duplicate experiments conducted using the accelerometer provided a comparison of sensor performance. The microphone performed well for bearings at an advanced stage of wear. The sensitivity of the accelerometer resulted in better performance when used with bearings at an early stage of wear. / Master of Science

Wood pallets serve as interfaces between packaged products and transport vehicles. vertical vibrations are transmitted through pallets into unit-loads. Pallet response to forced vibration affects forces experienced by products. A study was conducted to determine how pallet design influenced the resonant response of a uniformly distributed case goods unit-load. other studies were conducted to develop a pallet section model to emulate the response of three stringer wood pallets to forced vibration. This model was used to investigate the effects of joint stiffness, deckboard EI, and uniformly distributed load level on the resonant response of pallet decks. Pallets were found to lower unit-load resonant frequencies and increase transmissibilities at resonance. Pallet sections constructed with stiff decks and joints were found to have higher resonant frequencies and lower transmissibilities than sections constructed with less stiff deck components. To prevent pallets from elevating acceleration transmitted through unit-loads, pallets should be constructed with the stiffest decks and joints that are economically feasible. / Master of Science

A technique to determine the three-dimensional velocity of a point on a vibrating structure is developed. This technique uses a reference-beam type laser-doppler velocimeter in three independent positions to determine the target velocity in a non orthogonal coordinate system. The transformation from non-orthogonal to orthogonal coordinate systems is analyzed. The sensitivities of the resulting velocity to measurement noise and position errors are also analyzed. Recommendations are made for future testing and applications of this technique. / Master of Science

This thesis presents fundamental research in the field of laser vibrometry for the application to vibration measurements. A key concern for laser vibrometry is the effect of laser speckle which appears when a coherent laser beam scatters from an optically rough surface. The laser vibrometer is sensitive to changes in laser speckle which result from surface motions not in the direction of the incident beam. This adds speckle noise to the vibrometer output which can be indistinguishable from the genuine surface vibrations. This has been termed ‘pseudo-vibration' and requires careful data interpretation by the vibration engineer. This research has discovered that measurements from smooth surfaces, even when no identifiable speckle pattern is generated, can produce noise and therefore reference to speckle noise, in such circumstances, is inappropriate. This thesis has, therefore, adopted the more general term of pseudo-vibration to include noise generated from any surface roughness or treatment, i.e. including but not limited to speckle noise. This thesis develops and implements novel experimental methods to quantify pseudovibration sensitivities (transverse, tilt and rotation sensitivity) with attention focussed on commercially available laser vibrometers and consideration is given to a range of surface roughnesses and treatments. It investigates, experimentally, the fundamental behaviour of speckles and attempts to formulate, for the first time, a relationship between changes in intensity to pseudo-vibration sensitivity levels. The thesis also develops and implements models for computational simulation of pseudo-vibrations using the fundamental behaviour of speckles. The combination of experimentation and simulation improves current understanding of the pseudo-vibration mechanisms and provides the vibration engineer with a valuable resource to improve data interpretation. Two experimental methods of quantifying pseudo-vibration sensitivity are developed and successfully applied in the evaluation of transverse, tilt and rotation sensitivity for two models of commercial laser vibrometer. These evaluations cover both single beam (translational vibration measurement) and parallel beam (for angular vibration measurement) modes. The first method presented requires correction of the vibrometer measurement with an independent measurement of genuine velocity to produce an iii apparent velocity dominated by the required noise components. The second method requires a differential measurement using two vibrometers to cancel common components such as genuine velocity, leaving only uncorrelated noise from each measurement in the resulting apparent velocity. In each case, a third measurement is required of the surface motion component causing pseudo-vibration and this is used to normalise the apparent velocity. Pseudo-vibration sensitivity is then presented as a map showing the spectral shape of the noise, as a mean and standard deviation of harmonic peaks in the map and as a total rms level across a defined bandwidth. The simulations employ a novel and effective approach to modelling speckle evolution. Transverse and tilt sensitivity are predicted for the first time and are verified by the experimental study. They provide the vibration engineer with the potential to estimate pseudo-vibrations using a simple piece of software. The laser beam spot diameter has a large influence on the pseudo-vibration sensitivity. Transverse sensitivity has been quantified as around 0.03% and 0.01% (per order) of the transverse velocity of the surface for beam spot diameters of 100 μm and 600 μm respectively. Larger beam spots have been shown to significantly reduce transverse sensitivity and measurements from smoother surfaces have also shown a reduced level of transverse sensitivity. Tilt sensitivity has been quantified at about 0.1 μms-1/degs-1 and 0.3 μms-1/degs-1 (per order) of angular velocity of the surface for beam spot diameters of 100 μm and 600 μm respectively. Smaller beam spot diameters significantly reduce tilt sensitivity. The surface roughness or treatment has been shown to have little effect on the level of tilt sensitivity. Rotation sensitivity has been quantified at approximately 0.6 μms- 1/rads-1 and 1.9μms-1/rads-1 (per order) of rotation velocity of the rotor for 90 μm and 520 μm. Smaller beam spot diameters have shown a significant reduction in rotation sensitivity and measurements on smoother surfaces have shown a reduced rotation sensitivity. Focussing the laser beam approximately on the rotation axis has also shown a significant reduction in rotation sensitivity. Parallel beam rotation sensitivity has been quantified at 0.016 degs-1/rads-1 and it is demonstrated that this can adequately be estimated using the single beam rotation sensitivity.

From 2000 to 2015, the cost of operation and maintenance (including reinvestment) and traffic control has increased from approximately three billion to over nine billion Swedish kronor annually. By making more frequent measurements of track irregularities and identifying trends earlier, accurate and effective maintenance can be performed. Therefore, in the industry and academy, different measurement solutions are tested to measure the state of railroad tracks in a simple and more frequent manner. One of the solutions is to use measuring systems mounted on trains in regular traffic. By using regular scheduled services, a higher cost effectiveness regarding inspection frequency can be achieved. When the measuring equipment is mounted on freight trains, a measurement with considerably higher axle load can also be performed. In the course of this work, a literature study have been conducted and a number of scientific articles and reports have been studied at depth. There is a number of different systems that have been manufactured to be mounted on rolling stock in regular service. Different solutions are applied to perform the measurements. Acceleration sensors are robust and reliable, which is necessary because they will be mounted in an exposed environment. A difference that has been identified is the installation of accelerometer sensors that are either mounted before or after the primary suspension. Before suspension the sensors are mounted on the axle box and, after suspension the sensors are mounted on the train bogie. The engineering company Damill is working within monitoring solutions and has developed equipment for mounting on trains in regular traffic called Tracklogger. Earlier evaluations of the equipment have been made with focus on comparison with machine inspections. There is a difference between the technology used in track recording vehicles and the technology that Tracklogger uses, such comparison is not entirely appropriate. In discussion with Damill the focus of this work has been to see if recordings of switches can be linked to maintenance actions. Since the equipment is in the development stage it is important that the measurement data collected is critically reviewed with regard to what information it delivers. The measurements have been carried out on switches in the main train track on track number 119 between Luleå and Boden and the mining company LKAB's ore wagon has been a tool carrier.  Five out of eight cases, a maintenance action can be linked to reduced measured values of switches with fixed crossing points. In one case, maintenance action has increased the measured value. In two cases, there is no signifcant difference in the measured value associated with maintenance actions. In previous evaluation, it was determined that it is good repeatability in the measured position, but not as high repeatability in the measured size. A number of switches have been studied to check the repeatability of the measurement. As the train runs in acircle run in Luleå harbor, there will be a limited number of occasions the equipment is running in the same direction in combination with the sensors on the same axle in the bogie, which may effect the measurement results. When analyzing the repeatability of five passages where the direction of travel is not taken into account, it is determined that three out of five passages show a good repeatability. The repeatability of the measurement is suspected of being related to the condition, as significantly greater differences in the measured signal are obtained just before a maintenance action has been taken.