Practical Application of Condition Monitoring and Fault Diagnosis Techniques in Modern Equipment Management

Thread Content

Images: A Brief Analysis of Condition Monitoring and Fault Diagnosis Techniques 1. Condition Monitoring: During the operation of modern equipment, its overall operational status is monitored continuously through condition monitoring techniques. It can be said that these techniques constitute a fundamental element in the process of diagnosing equipment faults. In terms of condition monitoring technology, it is capable of detecting and converting various signals generated during the operation of equipment, analyzing the characteristics of these signals, and recording various operational data of the equipment. By analyzing this data, it is possible to determine whether there are any abnormalities in the equipment’s operating condition. When signal detection and conversion are carried out using condition monitoring techniques, these signals can manifest in various forms, such as sound, vibration, pressure, flow rate, or temperature. Through these forms of signals, it is possible to extract specific signal characteristics using condition monitoring techniques, thereby accurately determining the operating condition of the equipment. Condition monitoring techniques also enable the analysis of changes in these signals. For example, changes in sound volume, variations in vibration frequency, or shifts in temperature. By capturing these characteristics of signal changes and comparing them with the normal standard values of such signals, it is possible to determine whether there are any abnormalities in the equipment’s operating condition. This enables technicians to take appropriate actions based on the actual operating status of the equipment. 2 Diagnostic Analysis In modern equipment management, fault diagnosis techniques are also frequently utilized. The diagnostic analysis of modern equipment using these techniques involves two main aspects: the processing of equipment operation signals and the diagnosis of equipment faults. In the process of analyzing and processing the signals related to equipment operation, it is necessary to collect the information generated during equipment operation, perform appropriate conversions and processing on it, and present this information in various forms, so as to assist staff in making accurate and intuitive judgments based on this information. In signal analysis and processing, various methods can be employed, as well as computers or different specialized instruments, to carry out analysis and processing from different approaches, perspectives, and fields; of course, the results of such analysis and processing also vary. With the continuous advancement in signal analysis and processing in our country, fault diagnosis technology has also emerged. By using the data obtained from system monitoring and diagnosis as a basis and comparing it with normal performance indicators, it is possible to determine whether there are operational faults in the equipment. Once a fault occurs, fault diagnosis technology can be employed to conduct further analysis, thereby identifying the location of the fault. 3 Governance and Prevention After performing fault diagnosis on modern equipment, governance and prevention are also required. Generally speaking, when a device fails, it is necessary to take preventive measures to avoid such failures from occurring again. Based on the causes of failures, the locations where they occur, and the level of risk they pose, it is necessary to implement preventive measures of varying degrees to ensure that such failures do not occur again. In preventive maintenance, measures such as adjustment, inspection, replacement, or improvement are typically involved. After analysis, there are usually two possible outcomes: the first is that although there are some issues with the equipment’s operation, it can still function properly; in this case, it is necessary for the company to monitor the equipment’s operating conditions and the trends in its failures more closely, to ensure that the use of the equipment does not affect normal production. Another consequence is that the equipment is more likely to fail during operation, which can severely impact normal production; in such cases, companies need to carry out immediate repairs on the equipment to prevent failures from occurring. In governance and prevention, three methods—immediate shutdown, supervised operation, and periodic monitoring—can be employed to carry out the relevant tasks. Image: Discussion on the technical aspects involved in condition monitoring. In modern equipment management, monitoring the operating condition of equipment requires the use of various sensors, signal collectors, analysis and processing software, as well as computers; it also involves the use of instruments such as vibration detectors and infrared temperature detectors. In the process of monitoring the operating condition of equipment, vibration analysis is an important monitoring method. During vibration analysis, both time-domain spectrum analysis and frequency-domain spectrum analysis can be employed. Through these analyses, it is possible to conduct reliable diagnosis and treatment of various faults that may occur in modern equipment, such as shaft misalignment, gearbox failures, sliding bearing failures, mechanical looseness, rotor imbalance, rolling bearing failures, and motor failures. By observing the fault characteristics shown in the diagrams, it helps technicians quickly diagnose the root causes of equipment failures. For the time-domain spectrum, it is capable of objectively reflecting the kurtosis index of the equipment in a vibrating state, as well as the rubbing condition between the rotating and stationary parts of the rotor. In addition to providing an objective representation of all the elements in the time-domain waveform, the frequency-domain spectrum can also visually display various abnormal operating conditions that occur during the equipment’s operation. This helps technicians to diagnose equipment failures more accurately, understand the types of failures, their locations, and their severity, thereby providing important data support and quantitative criteria for the maintenance of modern equipment. By collecting and analyzing the current spectrum during the operation of the equipment, it is possible to accurately diagnose faults in AC motors, as well as determine whether there are issues such as high-resistance joints in the rotor or cracks in the end rings. With the help of equipment operation status monitoring systems, automated diagnosis of equipment failures can be achieved. These systems assist employees in diagnosing equipment faults based on their own work experience. Technicians can use handheld infrared thermography cameras or other infrared detection devices to carry out non-contact fault diagnosis and status monitoring of modern equipment; these instruments enable the analysis of the temperature of friction pairs, the temperature of the medium used in equipment operation, and the temperature of key bearings. Equipment maintenance personnel can also use simple vibration monitors to regularly assess the vibration levels of equipment. These simple vibration monitors can collect vibration data in real time, and by analyzing this data, conclusions can be drawn regarding the operating condition of the equipment. Images: Development Trends in Condition Monitoring and Fault Diagnosis Techniques 1. Trends toward Intelligence. In recent years, various types of sensors have been increasingly applied in the field of condition monitoring and fault diagnosis, which has led to the emergence of many more advanced new methods and techniques in this area, such as expert-based real-time diagnosis and neural network diagnosis. In the processes of condition monitoring and fault diagnosis, the gradual integration of artificial intelligence technologies has led to an increasing level of its application, and this field is also moving in the direction of intelligence. Guided by theories related to artificial intelligence, state monitoring and fault diagnosis techniques will also have a stronger theoretical foundation. At the same time, the degree of application of these techniques in various complex systems will gradually increase, thereby leading to a closer integration between them and more significant improvements in their performance. 2 Development trends toward networking and real-time operation: It has become imperative to apply networking to fault diagnosis and condition monitoring tasks. Through networked applications, fault diagnosis and condition monitoring technologies enable online, real-time monitoring of large-scale critical units, ensuring continuous tracking of all types of data generated during their operation. This helps to keep the units in normal operating condition at all times. Companies can also use information such as the actual operating status of the units and their maintenance history to flexibly plan and adjust equipment repairs, thereby preventing serious failures and avoiding unnecessary economic losses resulting from interruptions in unit operation. 3. Development directions toward integration and informatization: In previous equipment management practices, different professionals were required to monitor the operating status of various production equipment. At the same time, this operational status information for these devices is also stored in different locations. For example, when managing equipment, enterprises need to follow the principles of electrical engineering, process engineering, and mechanical engineering, and assign management staff, operators, technicians, and other personnel according to these different fields, in order to monitor and diagnose the operating condition of the equipment. The data stored in storage devices is also relatively dispersed, which prevents these stored data from being fully utilized. Through status monitoring and fault diagnosis technologies, a highly unified and integrated equipment management information system can be created, ensuring that these independently stored data points are effectively connected together. This enables centralized information detection and storage, meeting the requirements for monitoring the operational status of modern equipment and conducting fault diagnosis. It can be said that the application of condition monitoring and fault diagnosis technologies has made equipment information management more comprehensive and centralized. 4. A direction toward greater refinement and specialization: With the advancement of science and technology, China is placing increasing emphasis on the training of scientific and technical talents, which leads to a more refined division of labor among such professionals. Monitoring equipment is also evolving toward a networked format, and the level of specialization in condition monitoring and fault diagnosis continues to improve. Rapid technological advancements are driving state monitoring and fault diagnosis toward a more regional and industry-specific approach. This also enables companies and equipment manufacturers to establish closer connections with equipment condition monitoring, allowing them to provide diagnostic services by expert teams located in different locations. The rapid spread of the Internet also enables companies located in different regions to engage in real-time communication, discussion, and knowledge sharing regarding certain equipment failures.