A big share of machinery failures (40÷50 %) is caused by the destruction of rolling bearings. To prevent sudden failures of rolling bearings a vibration diagnostics system for in-operation monitoring of bearings must be installed.
Virtually all methods of condition diagnostics of rolling bearings are based on the analysis of vibration-acoustic signals in time or frequency area. To increase the accuracy of diagnostic results, there is an urgent task aimed at developing new methods.
The paper dwells upon the problems of practical use of vibration characteristic function (CF) parameters for evaluation of rolling bearings’ condition. It describes an experimental system, system of diagnostic signs based on CF parameters, methods for obtaining experimental data, results of the data processing.
Kostyukov V.N., Kostyukov Al.V., Boychenko S.N. Application of characteristic function of vibration for condition diagnostics of rolling bearings // Proceedings of the XXI Russian NDT and Diagnostics Conference. - Moscow: "Spektr" Publishing House, 2017. - p. 155-162
The most critical part of a rolling stock, operability of which directly influences reliability of train operation and safety of transportation is a wheel-motor unit. The most loaded, liable to significant static and dynamic loads elements are bearing units of wheel-motor units. The most significant component of an operation cycle is a diagnostic system’s application. The widest acceptance in railway industry got systems of vibration diagnostics of wheel-motor units measuring vibration parameters, comparing them to critical values and using the results to determine the units’ condition. Level of diagnostic’s reliability that systems provide today is not enough, since the number of wheel-motor units failures is still pretty high. Today there are a variety of diagnostic means that differ in type of measurement means, data processing method and diagnostic task solution.
Zaytsev A.V., Kostyukov V.N., Kazarin D.V. Perfection of methods and means for vibration diagnostics of wheel-motor units of rolling stock // Proceedings of the XXI Russian NDT and Diagnostics Conference. - Moscow: "Spektr" Publishing House, 2017. - p. 155-162
The paper is aimed at increasing the reliability of diagnostics by creating an adaptive method of condition evaluation for typical mechanical assemblies of railway rolling stock in movement.
The condition of mechanical units of railway rolling stock has a great impact on transportation safety.
Using onboard systems for diagnosing mechanical units of railway rolling stock allows diagnostics with a minimum interval, due to which the dynamic error rate is acceptable, not more than 0.1%.
Basakin V.V., Kostyukov V.N., Kostyukov Al. V., Kazarin D.V. New method for diagnosing bearing units of railway rolling stock in movement // Proceedings of the XXI Russian NDT and Diagnostics Conference. - Moscow: "Spektr" Publishing House, 2017. - p. 145-152
The paper presents an algorithm for detecting exponential growth areas of acoustic emission activity based on approximation of saved values of informative parameters (hereinafter referred to as the trend) during continuous monitoring with the acoustic emission (AE) method. Besides, based upon parameters of exponential approximation of trends, a new method is suggested for predicting a time when AE parameters reach their critical (threshold) values.
This paper aimed at developing an algorithm for detecting hazardous developing defects during continuous monitoring with an AE method. The most important tasks are theoretical research of informative AE parameters studied as parameters for detecting hazardous developing defects, description of the algorithm for detecting exponential growths area, as well as analytical derivation of a formula to predict the critical condition of the monitoring object. The suggested algorithm is utilized in a stationary system for diagnostics and monitoring COMPACS (hereinafter referred to as the System) installed at a revivifier operating as a part of a reactor-revivifier unit of cat cracking section.
Application of the suggested approach can be found in systems of continuous monitoring of production facilities used for various purposes.
Kostyukov Al.V., Boychenko S.N., Bogomolov D.E. Detecting and predicting hazardous developing defects during continuous monitoring with an acoustic emission method // Proceedings of the XXI Russian NDT and Diagnostics Conference. - Moscow: "Spektr" Publishing House, 2017. - p.33-38
Implementation of the first stationary systems for automatic monitoring and diagnostics of machinery health – COMPACS in the early nineties of the last century, for the first time an opportunity to watch changes of machinery health in real operational conditions under deterioration and restoration factors was realized. The results of such systems implementation helped to solve several urgent problems of operational reliability and machinery operating life. It was established that about one-third of all machines decommissioned for repair had no need for the repair at all. More than 40% of machines after repair had the same high vibration rates as before. That meant they had to be dismounted and decommissioned once again to remove all defects and carry out another repair.
Kostyukov Al.V., Tarasov E.V., Dvuhzhilov D.V., Averyanov S.A., Mayorov V.I. Practical application of the COMPACS bench systems at AO Omsk Refinery Machinery and Repair Plant // Himicheskaya tehnika. - 2017. -No1. - p.17-20
Implementation of the Technology of safe resource-saving operation of machinery deals with a problem of a variety of machines and devices used in common production facility which requires different methods of condition monitoring. The paper describes the experience of using a comprehensive condition monitoring system providing safe resource-saving operation by means of its software and hardware solutions.
Boychenko S.N., Sititsyn A.A Experiencing safe resource-saving operation provided by the COMPACS stationary system // Proceedings of the VI School-Seminar RISKOM. - Omsk. - Publishing house "Zolotoy tirazh" (ООО "Omskblankizdat"). - 2016. - p.158-169
The paper describes the main causes of higher accident risk and lower reliability of power facilities (PF) which became apparent recently in power and other industries. Poor reliability of equipment imported to RF to solve power industry tasks is noticed. Our study is aimed at suggesting new ways of improving reliability and decreasing accident risks. One of the main paths is the implementation of modern automatic monitoring systems COMPACS. We also suggest modern tasks for monitoring and break-through technologies aimed at maximum satisfaction of all maintenance, repair and operational needs. The paper describes the necessity in improving the regulatory environment having an impact on power facility operation. It is also noted, that the implementation of modern automatic systems not only reduces the risk of PF operation but also contributes to personnel qualification level.
Kumenko A.I. Ways of reducing operational risks of power facilities // Proceedings of the VI School-Seminar RISKOM. - Omsk. - Publishing house "Zolotoy tirazh" (ООО "Omskblankizdat"). - 2016. - p.107-117
Improvement of the system of criteria for defects of machines and mechanisms by vibration-acoustic signal parameters is an urgent task of technical diagnostics. Our study is aimed at finding peculiarities and approaches towards the assessment of standard diagnostic signal parameters corresponding to various conditions of a diagnostic object. A classic approach is based on the fact that faultless condition is characterized by a certain diagnostic sign which rate increases when the machine turns faulty. Non-classic approach – condition worsening is characterized by lower rates of certain diagnostic signs. Both situations require determining correct rates of possible defect skipping and false alarm. The paper shows the methods of a correct rating of defect skipping and false alarms for various conditions of a machine and the nature of diagnostic sign changes. As an example of a diagnostic sign let us consider a module of the characteristic function of instantaneous values of a vibroacoustic signal for a set parameter of the characteristic function. This diagnostic sign is an example of the non-classic approach of rating. We used statistical methods of decision-making to rate the characteristic function module’s limiting values showing the diagnostic state. The results prove that methods of statistical decision making can be used to rate limiting values of diagnostic signs for “classic” and “non-classic” cases of probability distribution functions. That allows setting certain conditions of a diagnostic sign rating and making correct calculation of possible defect skipping and false alarm rates.
Kostyukov V.N., Naumenko A.P., Kudryavtseva I.S. Assessment of quantitative criteria for diagnostic signal parameters and limiting conditions of a diagnostic object // Proceedings of the VI School-Seminar RISKOM. - Omsk. - Publishing house "Zolotoy tirazh" (ООО "Omskblankizdat"). - 2016. - p.137-147
The paper describes a scientifically grounded system-based approach towards scientific monitoring of natural-engineering systems (NES) based on fundamental principles, laws and patterns of classic continuum and elastic-media mechanics , theory of stress-strain states, methods and instruments of condition monitoring, analysis, assessment, expertise and prediction of homeostasis in operational resource of structural integrity for such tasks as prevention of accidents, and man-made and natural-engineering disasters.
Speranksy A.A., Kosyukov A.V. Modern tools for real-time monitoring of mechanical systems // Proceedings of the VI School-Seminar RISKOM. - Omsk. - Publishing house "Zolotoy tirazh" (ООО "Omskblankizdat"). - 2016. - p.47-59
The paper provides background on vibration diagnostics in Russia, and, also, gives the reader perception on modern health monitoring system COMPACS, examples of its work and production risk matrix.
Kostyukov V.N., Kostyukov A.V. Real-time health monitoring of equipment – a breakthrough innovative technology for Russia // Proceedings of the VI School-Seminar RISKOM. - Omsk. - Publishing house "Zolotoy tirazh" (ООО "Omskblankizdat"). - 2016. - p.28-39