Main Sector of relevance\IRC classification 8. Industrial Manufacturing, Material and Transport Technologies

8.40 Software-and-hardware unit for technical condition diagnosing “Watson”

Developers’ contact information

State Scientific Institution “Joint Institute of Mechanical Engineering of the National Academy of Sciences of Belarus”
12, Akademicheskaya Str., Minsk 220072
Tel/fax: +375 (17) 210-07-49; Web-site: http://oim.by

Summary

The software-and-hardware unit provides collection, storage and processing of measurement information received from sensors when investigating characteristics of mechanical engineering products.

Description

The software-and-hardware set makes it possible to carry out vibro-monitoring, diagnostics, presorting and comparative evaluation of quality characteristics of mechanical engineering products, to identify the causes of deviations from specified performance and perform their fine-tuning, to reduce the volume and timing of tests of developed and studied samples of complex technical systems.
The software-and-hardware unit includes a multi-channel vibro-acoustic measurement element, computing tools and software.
The vibro-acoustic measurement unit relies on the modular approach based on four measuring elements connected to one another and the CPU through SPI interface. The power supply of the measuring unit is provided by the 220 V network. The measuring unit houses a power supply and four printed circuit boards connected to one another via SPI interface:
- vibration detector module board;
- acoustic module board;
- tensometric module board;
- control module board.
The module operates with two piezoelectric vibration detectors, a half-inch condenser microphone, temperature sensor based on the chip from “ANALOG DEVISES” company and an optical rpm sensor. Another type of sensor can be used as the rpm sensor, i.e. an inductive one.
The software is designed for management and support of functioning of the vibro-acoustic module, its communications with a personal computer though a com-port (RS-232 interface), and it allows you to form and implement the modes of retrieving diagnostic information, measurement data processing, representing it as a data file or a print-out.
Microprocessor system software consists of three modules: “Communication”; “Vibration”; “Acoustics”.
The software communicates with the operator in a dialogue mode in Russian, and allows you to:
- display the information, which is necessary to operate the system;
- set the number of the sensor polled;
- enter the conversion factor for each sensor and store it in the memory of computational resources;
- specify the name of the file, which provides information;
- display the timetable of the original signal on the screen;
- generate an amplitude-frequency spectrum graph for the studied signal;
- determine the graph value of a point, which is selected using the marker location;
- record the results of measurements and processing on machine drives.

Technology type

• Other:
  Device.

Technical advantages and economic benefits

The software and hardware set performs functions of import substitution, reduces time and labour during bench tests of units and mechanisms, helps find new ways to improve the quality and competitiveness of products and features the following specifications:

• Number of analogue input signals channels - 7;
• ADC bits:
   strain sensor block - 12;
   acoustic block - 16;
   vibro-sensor block - 16.
• The sampling frequency is set via software:
   for the acoustic block and vibro-sensor block:
   - upper limit – 44100 Hz;
   - lower limit – 11025 Hz;
   for the strain sensor block:
   - upper limit –2756 Hz;
   - lower limit – 689 Hz;
  
• Dynamic input signals range:
   by vibration and noise – at least 80 dB;
   by strain metering – no less than 60 dB.
• The analyzed frequencies range:
   by vibration – 5 Hz ... 10 kHz;
   by noise – 20 Hz ... 20 kHz;
   by strain metering – 0 Hz …1 kHz.
• The capacity of built-in operational storage devices:
  64 Kbytes for each channel type.
• Range of temperatures:
  from minus 10 to plus 70 degrees by Celsius.
• Measured revolutions range:
  20 - 6000 min^-1.
• Module power supply:
  220VAC, 50 Hz.
• Power consumption:
  max. 40 W.

Technology differentiation and uniqueness

As a rule, the current diagnostics methods suggest full or partial dismantling of equipment, which is a laborious procedure, is expensive and, moreover, violates aging of units and reduces duration of their accident-free work. The software-and-hardware unit allows you to move from planning and preventive maintenance to non-dismantling control and maintenance according to the current state, to reduce labour costs for restoration of defective engineering products, to significantly increase the level of quality control.

Context in which technology was identified

• 3rd International Exhibition of Arms and Military eEuipment "MILEX 2005" (May 2005)
• Within the framework of the Belarusian Industrial Forum for International exhibitions “Belromekspo”, “Energy Saving”, “Welding and Cutting” (May 2005, May 2006.)
• 12th IFToMM World Congress, Besançon (France), June 18-21, 2007
• International Scientific-Technical Conference ZP-2008 “The Issues of Quality and Durability of Gears, Gearboxes, Parts and Assemblies”, August 28 - September 6, 2008, Sevastopol

Technological keywords

Means of control, microprocessor system, measuring information, software, and diagnostics.

Development Stage

• Prototype
• Currently in use/production

Intellectual property rights

• Patent pending
• Specific Patent Information:
  
  • Pat. No. 4261 C2 BY, MPЛG 01 M 13/02. The method of vibration diagnosis of loading stress on teeth of gears in the tests / O.V. Berestnev, N.N. Ishin, V.L. Basinyuk, Y.A. Berestnev, Y.V. Basinyuk – No. a 19980960; applied on 21.10.1998, issued on 30.12.2001 // Official bulletin / State Patent Committee of the Republic of Belarus. - 2001 .- No. 4 .- pp. 171-172.
  • Pat. No. 7366 C1 BY, MPK G 01 N 17/00. Device for diagnosing transmission gearing / V.L. Basinyuk, N.N. Ishin, M.G. Meleshko, I.N. Uss, Y.V. Basinyuk, E.I. Mardosevich – No. a 20030547; applied on 17.05.2001, issued on 30.09.2005 // Official bulletin / State Patent Committee of the Republic of Belarus. - 2005 .- No. 3 .- p.

Range of applications

Vibro-diagnostics and control of mechanical engineering products, bench-testing of units and mechanisms.

Classifier Used at the EU Innovation Relay Centres

• Industrial Manufacturing, Material and Transport Technologies

Preferable Regions

Practical experience

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Environmental impact

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Type of collaboration sought

Terms and restrictions

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Available technical assistance