Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 3068

Search results for: machine health monitoring.

3068 Empirical Process Monitoring Via Chemometric Analysis of Partially Unbalanced Data

Authors: Hyun-Woo Cho

Abstract:

Real-time or in-line process monitoring frameworks are designed to give early warnings for a fault along with meaningful identification of its assignable causes. In artificial intelligence and machine learning fields of pattern recognition various promising approaches have been proposed such as kernel-based nonlinear machine learning techniques. This work presents a kernel-based empirical monitoring scheme for batch type production processes with small sample size problem of partially unbalanced data. Measurement data of normal operations are easy to collect whilst special events or faults data are difficult to collect. In such situations, noise filtering techniques can be helpful in enhancing process monitoring performance. Furthermore, preprocessing of raw process data is used to get rid of unwanted variation of data. The performance of the monitoring scheme was demonstrated using three-dimensional batch data. The results showed that the monitoring performance was improved significantly in terms of detection success rate of process fault.

Keywords: Process Monitoring, kernel methods, multivariate filtering, data-driven techniques, quality improvement.

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3067 Bridge Health Monitoring: A Review

Authors: Mohammad Bakhshandeh

Abstract:

Structural Health Monitoring (SHM) is a crucial and necessary practice that plays a vital role in ensuring the safety and integrity of critical structures, and in particular, bridges. The continuous monitoring of bridges for signs of damage or degradation through Bridge Health Monitoring (BHM) enables early detection of potential problems, allowing for prompt corrective action to be taken before significant damage occurs. Although all monitoring techniques aim to provide accurate and decisive information regarding the remaining useful life, safety, integrity, and serviceability of bridges, understanding the development and propagation of damage is vital for maintaining uninterrupted bridge operation. Over the years, extensive research has been conducted on BHM methods, and experts in the field have increasingly adopted new methodologies. In this article, we provide a comprehensive exploration of the various BHM approaches, including sensor-based, non-destructive testing (NDT), model-based, and artificial intelligence (AI)-based methods. We also discuss the challenges associated with BHM, including sensor placement and data acquisition, data analysis and interpretation, cost and complexity, and environmental effects, through an extensive review of relevant literature and research studies. Additionally, we examine potential solutions to these challenges and propose future research ideas to address critical gaps in BHM.

Keywords: Structural health monitoring, bridge health monitoring, sensor-based methods, machine-learning algorithms, model-based techniques, sensor placement, data acquisition, data analysis.

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3066 Predictive Maintenance of Industrial Shredders: Efficient Operation through Real-Time Monitoring Using Statistical Machine Learning

Authors: Federico Pittino, Dominik Holzmann, Krithika Sayar-Chand, Stefan Moser, Sebastian Pliessnig, Thomas Arnold

Abstract:

The shredding of waste materials is a key step in the recycling process towards circular economy. Industrial shredders for waste processing operate in very harsh operating conditions, leading to the need of frequent maintenance of critical components. The maintenance optimization is particularly important also to increase the machine’s efficiency, thereby reducing the operational costs. In this work, a monitoring system has been developed and deployed on an industrial shredder located at a waste recycling plant in Austria. The machine has been monitored for several months and methods for predictive maintenance have been developed for two key components: the cutting knives and the drive belt. The large amount of collected data is leveraged by statistical machine learning techniques, thereby not requiring a very detailed knowledge of the machine or its live operating conditions. The results show that, despite the wide range of operating conditions, a reliable estimate of the optimal time for maintenance can be derived. Moreover, the trade-off between the cost of maintenance and the increase in power consumption due to the wear state of the monitored components of the machine is investigated. This work proves the benefits of real-time monitoring system for efficient operation of industrial shredders.

Keywords: predictive maintenance, circular economy, industrial shredder, cost optimization, statistical machine learning

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3065 States Estimation and Fault Detection of a Doubly Fed Induction Machine by Moving Horizon Estimation

Authors: A. T. Boum, L. Bitjoka, N. N. Léandre, S. Bennet

Abstract:

This paper presents the estimation of the key parameters of a double fed induction machine (DFIM) by the use of the moving horizon estimator (MHE) for control and monitoring purpose. A study was conducted on the behavior of this observer in the presence of some faults which can occur during the operation of the machine. In the first case a stator phase has been suppressed. In the second case the rotor resistance has been multiplied by a factor. The results show a good estimation of different parameters such as rotor flux, rotor speed, stator current with a very small estimation error. The robustness of the observer was also tested in the practical case of DFIM by using another model different from the real one at a constant close. The very small estimation error makes the MHE a good software sensor candidate for monitoring purpose for the DFIM. 

Keywords: Doubly fed induction machine, moving horizon estimator parameters’ estimation.

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3064 GSM Based Smart Patient Monitoring System

Authors: Ayman M. Mansour

Abstract:

In this paper, we propose an intelligent system that is used for monitoring the health conditions of patients. Monitoring the health condition of patients is a complex problem that involves different medical units and requires continuous monitoring especially in rural areas because of inadequate number of available specialized physicians. The proposed system will improve patient care and drive costs down comparing to the existing system in Jordan. The proposed system will be the start point to faster and improve the communication between different units in the health system in Jordan. Connecting patients and their physicians beyond hospital doors regarding their geographical area is an important issue in developing the health system in Jordan. The ability of making medical decisions, the quality of medical is expected to be improved.

Keywords: GSM, SMS, Patient, Monitoring system, Fuzzy Logic, Multi-agent system.

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3063 Envelope-Wavelet Packet Transform for Machine Condition Monitoring

Authors: M. F. Yaqub, I. Gondal, J. Kamruzzaman

Abstract:

Wavelet transform has been extensively used in machine fault diagnosis and prognosis owing to its strength to deal with non-stationary signals. The existing Wavelet transform based schemes for fault diagnosis employ wavelet decomposition of the entire vibration frequency which not only involve huge computational overhead in extracting the features but also increases the dimensionality of the feature vector. This increase in the dimensionality has the tendency to 'over-fit' the training data and could mislead the fault diagnostic model. In this paper a novel technique, envelope wavelet packet transform (EWPT) is proposed in which features are extracted based on wavelet packet transform of the filtered envelope signal rather than the overall vibration signal. It not only reduces the computational overhead in terms of reduced number of wavelet decomposition levels and features but also improves the fault detection accuracy. Analytical expressions are provided for the optimal frequency resolution and decomposition level selection in EWPT. Experimental results with both actual and simulated machine fault data demonstrate significant gain in fault detection ability by EWPT at reduced complexity compared to existing techniques.

Keywords: Envelope Detection, Wavelet Transform, Bearing Faults, Machine Health Monitoring.

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3062 A Multi-Agent Intelligent System for Monitoring Health Conditions of Elderly People

Authors: Ayman M. Mansour

Abstract:

In this paper, we propose a multi-agent intelligent system that is used for monitoring the health conditions of elderly people. Monitoring the health condition of elderly people is a complex problem that involves different medical units and requires continuous monitoring. Such expert system is highly needed in rural areas because of inadequate number of available specialized physicians or nurses. Such monitoring must have autonomous interactions between these medical units in order to be effective. A multi-agent system is formed by a community of agents that exchange information and proactively help one another to achieve the goal of elderly monitoring. The agents in the developed system are equipped with intelligent decision maker that arms them with the rule-based reasoning capability that can assist the physicians in making decisions regarding the medical condition of elderly people.

Keywords: Fuzzy Logic, Inference system, Monitoring system, Multi-agent system.

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3061 Condition Monitoring in the Management of Maintenance in a Large Scale Precision CNC Machining Manufacturing Facility

Authors: N. Ahmed, A.J. Day, J.L. Victory L. Zeall, B. Young

Abstract:

The manufacture of large-scale precision aerospace components using CNC requires a highly effective maintenance strategy to ensure that the required accuracy can be achieved over many hours of production. This paper reviews a strategy for a maintenance management system based on Failure Mode Avoidance, which uses advanced techniques and technologies to underpin a predictive maintenance strategy. It is shown how condition monitoring (CM) is important to predict potential failures in high precision machining facilities and achieve intelligent and integrated maintenance management. There are two distinct ways in which CM can be applied. One is to monitor key process parameters and observe trends which may indicate a gradual deterioration of accuracy in the product. The other is the use of CM techniques to monitor high status machine parameters enables trends to be observed which can be corrected before machine failure and downtime occurs. It is concluded that the key to developing a flexible and intelligent maintenance framework in any precision manufacturing operation is the ability to evaluate reliably and routinely machine tool condition using condition monitoring techniques within a framework of Failure Mode Avoidance.

Keywords: Maintenance, Condition Monitoring, CNC, Machining, Accuracy, Capability, Key Process Parameters, Critical Parameters

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3060 Advance in Monitoring and Process Control of Surface Roughness

Authors: Somkiat Tangjitsitcharoen, Siripong Damrongthaveesak

Abstract:

This paper presents an advance in monitoring and process control of surface roughness in CNC machine for the turning and milling processes. An integration of the in-process monitoring and process control of the surface roughness is proposed and developed during the machining process by using the cutting force ratio. The previously developed surface roughness models for turning and milling processes of the author are adopted to predict the inprocess surface roughness, which consist of the cutting speed, the feed rate, the tool nose radius, the depth of cut, the rake angle, and the cutting force ratio. The cutting force ratios obtained from the turning and the milling are utilized to estimate the in-process surface roughness. The dynamometers are installed on the tool turret of CNC turning machine and the table of 5-axis machining center to monitor the cutting forces. The in-process control of the surface roughness has been developed and proposed to control the predicted surface roughness. It has been proved by the cutting tests that the proposed integration system of the in-process monitoring and the process control can be used to check the surface roughness during the cutting by utilizing the cutting force ratio.

Keywords: Turning, milling, monitoring, surface roughness, cutting force ratio.

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3059 Implementation of Security Algorithms for u-Health Monitoring System

Authors: Jiho Park, Yong-Gyu Lee, Gilwon Yoon

Abstract:

Data security in u-Health system can be an important issue because wireless network is vulnerable to hacking. However, it is not easy to implement a proper security algorithm in an embedded u-health monitoring because of hardware constraints such as low performance, power consumption and limited memory size and etc. To secure data that contain personal and biosignal information, we implemented several security algorithms such as Blowfish, data encryption standard (DES), advanced encryption standard (AES) and Rivest Cipher 4 (RC4) for our u-Health monitoring system and the results were successful. Under the same experimental conditions, we compared these algorithms. RC4 had the fastest execution time. Memory usage was the most efficient for DES. However, considering performance and safety capability, however, we concluded that AES was the most appropriate algorithm for a personal u-Health monitoring system.

Keywords: biosignal, data encryption, security measures, u-health

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3058 Machine Learning Methods for Environmental Monitoring and Flood Protection

Authors: Alexander L. Pyayt, Ilya I. Mokhov, Bernhard Lang, Valeria V. Krzhizhanovskaya, Robert J. Meijer

Abstract:

More and more natural disasters are happening every year: floods, earthquakes, volcanic eruptions, etc. In order to reduce the risk of possible damages, governments all around the world are investing into development of Early Warning Systems (EWS) for environmental applications. The most important task of the EWS is identification of the onset of critical situations affecting environment and population, early enough to inform the authorities and general public. This paper describes an approach for monitoring of flood protections systems based on machine learning methods. An Artificial Intelligence (AI) component has been developed for detection of abnormal dike behaviour. The AI module has been integrated into an EWS platform of the UrbanFlood project (EU Seventh Framework Programme) and validated on real-time measurements from the sensors installed in a dike.

Keywords: Early Warning System, intelligent environmentalmonitoring, machine learning, flood protection.

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3057 Automated Process Quality Monitoring with Prediction of Fault Condition Using Measurement Data

Authors: Hyun-Woo Cho

Abstract:

Detection of incipient abnormal events is important to improve safety and reliability of machine operations and reduce losses caused by failures. Improper set-ups or aligning of parts often leads to severe problems in many machines. The construction of prediction models for predicting faulty conditions is quite essential in making decisions on when to perform machine maintenance. This paper presents a multivariate calibration monitoring approach based on the statistical analysis of machine measurement data. The calibration model is used to predict two faulty conditions from historical reference data. This approach utilizes genetic algorithms (GA) based variable selection, and we evaluate the predictive performance of several prediction methods using real data. The results shows that the calibration model based on supervised probabilistic principal component analysis (SPPCA) yielded best performance in this work. By adopting a proper variable selection scheme in calibration models, the prediction performance can be improved by excluding non-informative variables from their model building steps.

Keywords: Prediction, operation monitoring, on-line data, nonlinear statistical methods, empirical model.

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3056 Remote Operation of CNC Milling Through Virtual Simulation and Remote Desktop Interface

Authors: Afzeri, A.G.E Sujtipto, R. Muhida, M. Konneh, Darmawan

Abstract:

Increasing the demand for effectively use of the production facility requires the tools for sharing the manufacturing facility through remote operation of the machining process. This research introduces the methodology of machining technology for direct remote operation of networked milling machine. The integrated tools with virtual simulation, remote desktop protocol and Setup Free Attachment for remote operation of milling process are proposed. Accessing and monitoring of machining operation is performed by remote desktop interface and 3D virtual simulations. Capability of remote operation is supported by an auto setup attachment with a reconfigurable pin type setup free technology installed on the table of CNC milling machine to perform unattended machining process. The system is designed using a computer server and connected to a PC based controlled CNC machine for real time monitoring. A client will access the server through internet communication and virtually simulate the machine activity. The result has been presented that combination between real time virtual simulation and remote desktop tool is enabling to operate all machine tool functions and as well as workpiece setup..

Keywords: Remote Desktop, PC Based CNC, Remote Machining.

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3055 MIMCA: A Modelling and Simulation Approach in Support of the Design and Construction of Manufacturing Control Systems Using Modular Petri net

Authors: S. Ariffin, K. Hasnan, R.H. Weston

Abstract:

A new generation of manufacturing machines so-called MIMCA (modular and integrated machine control architecture) capable of handling much increased complexity in manufacturing control-systems is presented. Requirement for more flexible and effective control systems for manufacturing machine systems is investigated and dimensioned-which highlights a need for improved means of coordinating and monitoring production machinery and equipment used to- transport material. The MIMCA supports simulation based on machine modeling, was conceived by the authors to address the issues. Essentially MIMCA comprises an organized unification of selected architectural frameworks and modeling methods, which include: NISTRCS, UMC and Colored Timed Petri nets (CTPN). The unification has been achieved; to support the design and construction of hierarchical and distributed machine control which realized the concurrent operation of reusable and distributed machine control components; ability to handle growing complexity; and support requirements for real- time control systems. Thus MIMCA enables mapping between 'what a machine should do' and 'how the machine does it' in a well-defined but flexible way designed to facilitate reconfiguration of machine systems.

Keywords: Machine control, architectures, Petri nets, modularity, modeling, simulation.

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3054 Multiple-Points Fault Signature's Dynamics Modeling for Bearing Defect Frequencies

Authors: Muhammad F. Yaqub, Iqbal Gondal, Joarder Kamruzzaman

Abstract:

Occurrence of a multiple-points fault in machine operations could result in exhibiting complex fault signatures, which could result in lowering fault diagnosis accuracy. In this study, a multiple-points defect model (MPDM) is proposed which can simulate fault signature-s dynamics for n-points bearing faults. Furthermore, this study identifies that in case of multiple-points fault in the rotary machine, the location of the dominant component of defect frequency shifts depending upon the relative location of the fault points which could mislead the fault diagnostic model to inaccurate detections. Analytical and experimental results are presented to characterize and validate the variation in the dominant component of defect frequency. Based on envelop detection analysis, a modification is recommended in the existing fault diagnostic models to consider the multiples of defect frequency rather than only considering the frequency spectrum at the defect frequency in order to incorporate the impact of multiple points fault.

Keywords: Envelop detection, machine defect frequency, multiple faults, machine health monitoring.

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3053 A Machine Learning Approach for Anomaly Detection in Environmental IoT-Driven Wastewater Purification Systems

Authors: Giovanni Cicceri, Roberta Maisano, Nathalie Morey, Salvatore Distefano

Abstract:

The main goal of this paper is to present a solution for a water purification system based on an Environmental Internet of Things (EIoT) platform to monitor and control water quality and machine learning (ML) models to support decision making and speed up the processes of purification of water. A real case study has been implemented by deploying an EIoT platform and a network of devices, called Gramb meters and belonging to the Gramb project, on wastewater purification systems located in Calabria, south of Italy. The data thus collected are used to control the wastewater quality, detect anomalies and predict the behaviour of the purification system. To this extent, three different statistical and machine learning models have been adopted and thus compared: Autoregressive Integrated Moving Average (ARIMA), Long Short Term Memory (LSTM) autoencoder, and Facebook Prophet (FP). The results demonstrated that the ML solution (LSTM) out-perform classical statistical approaches (ARIMA, FP), in terms of both accuracy, efficiency and effectiveness in monitoring and controlling the wastewater purification processes.

Keywords: EIoT, machine learning, anomaly detection, environment monitoring.

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3052 Time-Domain Stator Current Condition Monitoring: Analyzing Point Failures Detection by Kolmogorov-Smirnov (K-S) Test

Authors: Najmeh Bolbolamiri, Maryam Setayesh Sanai, Ahmad Mirabadi

Abstract:

This paper deals with condition monitoring of electric switch machine for railway points. Point machine, as a complex electro-mechanical device, switch the track between two alternative routes. There has been an increasing interest in railway safety and the optimal management of railway equipments maintenance, e.g. point machine, in order to enhance railway service quality and reduce system failure. This paper explores the development of Kolmogorov- Smirnov (K-S) test to detect some point failures (external to the machine, slide chairs, fixing, stretchers, etc), while the point machine (inside the machine) is in its proper condition. Time-domain stator Current signatures of normal (healthy) and faulty points are taken by 3 Hall Effect sensors and are analyzed by K-S test. The test is simulated by creating three types of such failures, namely putting a hard stone and a soft stone between stock rail and switch blades as obstacles and also slide chairs- friction. The test has been applied for those three faults which the results show that K-S test can effectively be developed for the aim of other point failures detection, which their current signatures deviate parametrically from the healthy current signature. K-S test as an analysis technique, assuming that any defect has a specific probability distribution. Empirical cumulative distribution functions (ECDF) are used to differentiate these probability distributions. This test works based on the null hypothesis that ECDF of target distribution is statistically similar to ECDF of reference distribution. Therefore by comparing a given current signature (as target signal) from unknown switch state to a number of template signatures (as reference signal) from known switch states, it is possible to identify which is the most likely state of the point machine under analysis.

Keywords: stator currents monitoring, railway points, point failures, fault detection and diagnosis, Kolmogorov-Smirnov test, time-domain analysis.

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3051 Low Cost Microcontroller Based ECG Machine

Authors: Muhibul H. Bhuyan, Md. T. Hasan, Hasan Iskander

Abstract:

Electrocardiographic (ECG) machine is an important equipment to diagnose heart problems. Besides, the ECG signals are used to detect many other features of human body and behavior. But it is not so cheap and simple in operation to be used in the countries like Bangladesh, where most of the people are very low income earners. Therefore, in this paper, we have tried to implement a simple and portable ECG machine. Since Arduino Uno microcontroller is very cheap, we have used it in our system to minimize the cost. Our designed system is powered by a 2-voltage level DC power supply. It provides wireless connectivity to have ECG data either in smartphone having android operating system or a PC/laptop having Windows operating system. To get the data, a graphic user interface has been designed. Android application has also been made using IDE for Android 2.3 and API 10. Since it requires no USB host API, almost 98% Android smartphones, available in the country, will be able to use it. We have calculated the heart rate from the measured ECG by our designed machine and by an ECG machine of a reputed diagnostic center in Dhaka city for the same people at the same time on same day. Then we calculated the percentage of errors between the readings of two machines and computed its average. From this computation, we have found out that the average percentage of error is within an acceptable limit.

Keywords: Low cost ECG machine, heart diseases, remote monitoring, Arduino microcontroller.

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3050 Development of a Miniature and Low-Cost IoT-Based Remote Health Monitoring Device

Authors: Sreejith Jayachandran, Mojtaba Ghodsi, Morteza Mohammadzaheri

Abstract:

The modern busy world is running behind new embedded technologies based on computers and software meanwhile some people are unable to monitor their health condition and regular medical check-ups. Some of them postpone medical check-ups due to a lack of time and convenience while others skip these regular evaluations and medical examinations due to huge medical bills and hospital expenses. In this research, we present a device in the telemonitoring system capable of monitoring, checking, and evaluating the health status of the human body remotely through the internet for the needs of all kinds of people. The remote health monitoring device is a microcontroller-based embedded unit. The various types of sensors in this device are connected to the human body, and with the help of an Arduino UNO board, the required analogue data are collected from the sensors. The microcontroller on the Arduino board processes the analogue data collected in this way into digital data and transfers that information to the cloud and stores it there; the processed digital data are then instantly displayed through the LCD attached to the machine. By accessing the cloud storage with a username and password, the concerned person’s health care teams/doctors, and other health staff can collect these data for the assessment and follow-up of that patient. Besides that, the family members/guardians can use and evaluate these data for awareness of the patient's current health status. Moreover, the system is connected to a GPS module. In emergencies, the concerned team can be positioning the patient or the person with this device. The setup continuously evaluates and transfers the data to the cloud and also the user can prefix a normal value range for the evaluation. For example, the blood pressure normal value is universally prefixed between 80/120 mmHg. Similarly, the Remote Health Monitoring System (RHMS) is also allowed to fix the range of values referred to as normal coefficients. This IoT-based miniature system 11×10×10 cm3 with a low weight of 500 gr only consumes 10 mW. This smart monitoring system is manufactured for 100 GBP (British Pound Sterling), and can facilitate the communication between patients and health systems, but also it can be employed for numerous other uses including communication sectors in the aerospace and transportation systems.

Keywords: Embedded Technology, Telemonitoring system, Microcontroller, Arduino UNO, Cloud storage, GPS, RHMS, Remote Health Monitoring System, Alert system.

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3049 A Strategy to Optimize the SPC Scheme for Mass Production of HDD Arm with ClusteringTechnique and Three-Way Control Chart

Authors: W. Chattinnawat

Abstract:

Consider a mass production of HDD arms where hundreds of CNC machines are used to manufacturer the HDD arms. According to an overwhelming number of machines and models of arm, construction of separate control chart for monitoring each HDD arm model by each machine is not feasible. This research proposed a strategy to optimize the SPC management on shop floor. The procedure started from identifying the clusters of the machine with similar manufacturing performance using clustering technique. The three way control chart ( I - MR - R ) is then applied to each clustered group of machine. This proposed research has advantageous to the manufacturer in terms of not only better performance of the SPC but also the quality management paradigm.

Keywords: Three way control chart. I - MR - R , between/within variation, HDD arm.

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3048 Event Monitoring Based On Web Services for Heterogeneous Event Sources

Authors: Arne Koschel

Abstract:

This article discusses event monitoring options for heterogeneous event sources as they are given in nowadays heterogeneous distributed information systems. It follows the central assumption, that a fully generic event monitoring solution cannot provide complete support for event monitoring; instead, event source specific semantics such as certain event types or support for certain event monitoring techniques have to be taken into account. Following from this, the core result of the work presented here is the extension of a configurable event monitoring (Web) service for a variety of event sources. A service approach allows us to trade genericity for the exploitation of source specific characteristics. It thus delivers results for the areas of SOA, Web services, CEP and EDA.

Keywords: Event monitoring, ECA, CEP, SOA, Web services.

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3047 Monitoring the Fiscal Health of Taiwan’s Local Government: Application of the 10-Point Scale of Fiscal Distress

Authors: Yuan-Hong Ho, Chiung-Ju Huang

Abstract:

This article presents a monitoring indicators system that predicts whether a local government in Taiwan is heading for fiscal distress and identifies a suitable fiscal policy that would allow the local government to achieve fiscal balance in the long run. This system is relevant to stockholders’ interest, simple for national audit bodies to use, and provides an early warning of fiscal distress that allows preventative action to be taken.

Keywords: Fiscal distress, fiscal health, monitoring signals, 10-point scale.

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3046 Symmetrical Analysis of a Six-Phase Induction Machine Under Fault Conditions

Authors: E. K.Appiah, G. M'boungui, A. A. Jimoh, J. L. Munda, A.S.O. Ogunjuyigbe

Abstract:

The operational behavior of a six-phase squirrel cage induction machine with faulted stator terminals is presented in this paper. The study is carried out using the derived mathematical model of the machine in the arbitrary reference frame. Tests are conducted on a 1 kW experimental machine. Steady-state and dynamic performance are analyzed for the machine unloaded and loaded conditions. The results shows that with one of the stator phases experiencing either an open- circuit or short circuit fault the machine still produces starting torque, albeit the running performance is significantly derated.

Keywords: Performance, fault conditions, six-phase induction machine.

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3045 Quality Classification and Monitoring Using Adaptive Metric Distance and Neural Networks: Application in Pickling Process

Authors: S. Bouhouche, M. Lahreche, S. Ziani, J. Bast

Abstract:

Modern manufacturing facilities are large scale, highly complex, and operate with large number of variables under closed loop control. Early and accurate fault detection and diagnosis for these plants can minimise down time, increase the safety of plant operations, and reduce manufacturing costs. Fault detection and isolation is more complex particularly in the case of the faulty analog control systems. Analog control systems are not equipped with monitoring function where the process parameters are continually visualised. In this situation, It is very difficult to find the relationship between the fault importance and its consequences on the product failure. We consider in this paper an approach to fault detection and analysis of its effect on the production quality using an adaptive centring and scaling in the pickling process in cold rolling. The fault appeared on one of the power unit driving a rotary machine, this machine can not track a reference speed given by another machine. The length of metal loop is then in continuous oscillation, this affects the product quality. Using a computerised data acquisition system, the main machine parameters have been monitored. The fault has been detected and isolated on basis of analysis of monitored data. Normal and faulty situation have been obtained by an artificial neural network (ANN) model which is implemented to simulate the normal and faulty status of rotary machine. Correlation between the product quality defined by an index and the residual is used to quality classification.

Keywords: Modeling, fault detection and diagnosis, parameters estimation, neural networks, Fault Detection and Diagnosis (FDD), pickling process.

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3044 Data Analysis Techniques for Predictive Maintenance on Fleet of Heavy-Duty Vehicles

Authors: Antonis Sideris, Elias Chlis Kalogeropoulos, Konstantia Moirogiorgou

Abstract:

The present study proposes a methodology for the efficient daily management of fleet vehicles and construction machinery. The application covers the area of remote monitoring of heavy-duty vehicles operation parameters, where specific sensor data are stored and examined in order to provide information about the vehicle’s health. The vehicle diagnostics allow the user to inspect whether maintenance tasks need to be performed before a fault occurs. A properly designed machine learning model is proposed for the detection of two different types of faults through classification. Cross validation is used and the accuracy of the trained model is checked with the confusion matrix.

Keywords: Fault detection, feature selection, machine learning, predictive maintenance.

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3043 Design Optimization of a Double Stator Cup- Rotor Machine

Authors: E. Diryak, P. Lefley, L. Petkovska, G. Cvetkovski

Abstract:

This paper presents the optimum design for a double stator, cup rotor machine; a novel type of BLDC PM Machine. The optimization approach is divided into two stages: the first stage is calculating the machine configuration using Matlab, and the second stage is the optimization of the machine using Finite Element Modeling (FEM). Under the design specifications, the machine model will be selected from three pole numbers, namely, 8, 10 and 12 with an appropriate slot number. A double stator brushless DC permanent magnet machine is designed to achieve low cogging torque; high electromagnetic torque and low ripple torque.

Keywords: Permanent magnet machine, low- cogging torque, low- ripple torque, high- electromagnetic torque, design optimization.

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3042 Condition Monitoring System of Mine Air Compressors Based on Wireless Sensor Network

Authors: Sheng Fu, Yinbo Gao, Hao Lin

Abstract:

In the current mine air compressors monitoring system, there are some difficulties in the installation and maintenance because of the wired connection. To solve the problem, this paper introduces a new air compressors monitoring system based on ZigBee in which the monitoring parameters are transmitted wirelessly. The collecting devices are designed to form a cluster network to collect vibration, temperature, and pressure of air cylinders and other parameters. All these devices are battery-powered. Besides, the monitoring software in PC is developed using MFC. Experiments show that the designed wireless sensor network works well in the site environmental condition and the system is very convenient to be installed since the wireless connection. This monitoring system will have a wide application prospect in the upgrade of the old monitoring system of the air compressors.

Keywords: Condition monitoring, wireless sensor network, air compressor, ZigBee, data collecting

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3041 A Combined Practical Approach to Condition Monitoring of Reciprocating Compressors using IAS and Dynamic Pressure

Authors: M. Elhaj, M. Almrabet, M. Rgeai, I. Ehtiwesh

Abstract:

A Comparison and evaluation of the different condition monitoring (CM) techniques was applied experimentally on RC e.g. Dynamic cylinder pressure and crankshaft Instantaneous Angular Speed (IAS), for the detection and diagnosis of valve faults in a two - stage reciprocating compressor for a programme of condition monitoring which can successfully detect and diagnose a fault in machine. Leakage in the valve plate was introduced experimentally into a two-stage reciprocating compressor. The effect of the faults on compressor performance was monitored and the differences with the normal, healthy performance noted as a fault signature been used for the detection and diagnosis of faults. The paper concludes with what is considered to be a unique approach to condition monitoring. First, each of the two most useful techniques is used to produce a Truth Table which details the circumstances in which each method can be used to detect and diagnose a fault. The two Truth Tables are then combined into a single Decision Table to provide a unique and reliable method of detection and diagnosis of each of the individual faults introduced into the compressor. This gives accurate diagnosis of compressor faults.

Keywords: Condition Monitoring, Dynamic Pressure, Instantaneous Angular Speed, Reciprocating Compressor.

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3040 Oil Debris Signal Detection Based on Integral Transform and Empirical Mode Decomposition

Authors: Chuan Li, Ming Liang

Abstract:

Oil debris signal generated from the inductive oil debris monitor (ODM) is useful information for machine condition monitoring but is often spoiled by background noise. To improve the reliability in machine condition monitoring, the high-fidelity signal has to be recovered from the noisy raw data. Considering that the noise components with large amplitude often have higher frequency than that of the oil debris signal, the integral transform is proposed to enhance the detectability of the oil debris signal. To cancel out the baseline wander resulting from the integral transform, the empirical mode decomposition (EMD) method is employed to identify the trend components. An optimal reconstruction strategy including both de-trending and de-noising is presented to detect the oil debris signal with less distortion. The proposed approach is applied to detect the oil debris signal in the raw data collected from an experimental setup. The result demonstrates that this approach is able to detect the weak oil debris signal with acceptable distortion from noisy raw data.

Keywords: Integral transform, empirical mode decomposition, oil debris, signal processing, detection.

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3039 Real Time Remote Monitoring and Fault Detection in Wind Turbine

Authors: Saad Chakkor, Mostafa Baghouri, Abderrahmane Hajraoui

Abstract:

In new energy development, wind power has boomed. It is due to the proliferation of wind parks and their operation in supplying the national electric grid with low cost and clean resources. Hence, there is an increased need to establish a proactive maintenance for wind turbine machines based on remote control and monitoring. That is necessary with a real-time wireless connection in offshore or inaccessible locations while the wired method has many flaws. The objective of this strategy is to prolong wind turbine lifetime and to increase productivity. The hardware of a remote control and monitoring system for wind turbine parks is designed. It takes advantage of GPRS or Wi-Max wireless module to collect data measurements from different wind machine sensors through IP based multi-hop communication. Computer simulations with Proteus ISIS and OPNET software tools have been conducted to evaluate the performance of the studied system. Study findings show that the designed device is suitable for application in a wind park.

Keywords: Embedded System, Monitoring, Wind Turbine, Faults Diagnosis, TCP/IP Protocol, Real Time, Web.

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