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Article
Publication date: 31 January 2024

Tan Zhang, Zhanying Huang, Ming Lu, Jiawei Gu and Yanxue Wang

Rotating machinery is a crucial component of large equipment, and detecting faults in it accurately is critical for reliable operation. Although fault diagnosis methods based on…

Abstract

Purpose

Rotating machinery is a crucial component of large equipment, and detecting faults in it accurately is critical for reliable operation. Although fault diagnosis methods based on deep learning have been significantly developed, the existing methods model spatial and temporal features separately and then weigh them, resulting in the decoupling of spatiotemporal features.

Design/methodology/approach

The authors propose a spatiotemporal long short-term memory (ST-LSTM) method for fault diagnosis of rotating machinery. The authors collected vibration signals from real rolling bearing and gearing test rigs for verification.

Findings

Through these two experiments, the authors demonstrate that machine learning methods still have advantages on small-scale data sets, but our proposed method exhibits a significant advantage due to the simultaneous modeling of the time domain and space domain. These results indicate the potential of the interactive spatiotemporal modeling method for fault diagnosis of rotating machinery.

Originality/value

The authors propose a ST-LSTM method for fault diagnosis of rotating machinery. The authors collected vibration signals from real rolling bearing and gearing test rigs for verification.

Details

Industrial Lubrication and Tribology, vol. 76 no. 2
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 28 July 2023

Amit Kumar, Abhipsa P. Dash, Atul Kumar Ray, Priyabrata Sethy and Idamakanti Kasireddy

This study aims to examine the flow of unsteady mixed convective hybrid nanofluid over a rotating sphere with heat generation/absorption. The hybrid nanofluid contains different…

Abstract

Purpose

This study aims to examine the flow of unsteady mixed convective hybrid nanofluid over a rotating sphere with heat generation/absorption. The hybrid nanofluid contains different shapes of nanoparticles (copper [Cu] and aluminium oxide [Al2O3]) in the base fluid (water [H2O]). The influence of different shapes (sphere, brick, cylinder, platelets and blades) of nanoparticle in water-based hybrid nanofluid is also investigated.

Design/methodology/approach

To analyse the nanomaterial, the flow model is established, and in doing so, the Prandtl’s boundary layer theory is incorporated into the present model. The bvp4c approach, i.e. finite difference method, is used to find the numerical solution of differential equations that is controlling the fluid flow. The effect of relevant flow parameters on nanofluid temperature and velocity profile is demonstrated in detailed explanations using graphs and bar charts, whereas numerical results for Nusselt number and the skin’s coefficient for various form parameters are presented in tabular form.

Findings

The rate of heat transfer is least for spherical-shaped nanoparticle because of its smoothness, symmetricity and isotropic behaviour. The rate of heat transfer is highest for blade-shaped nanoparticles as compared to other shapes (brick, cylindrical and platelet) of nanoparticles because the blade-shaped nanoparticles causes comparatively more turbulence flow in the nanofluid than other shapes of nanoparticle. Heat generation affects the temperature distribution and, hence, the particle deposition rate. The absorption of heat extracts heat and reduce the temperature across the rotating sphere. The heat generation/absorption parameter plays an important role in establishing and maintaining the temperature around the rotating sphere.

Research limitations/implications

The numerical study is valid with the exception of the fluctuation in density that results in the buoyancy force and the functional axisymmetric nanofluid transport has constant thermophysical characteristics. In addition, this investigation is also constrained by the assumptions that there is no viscosity dissipation, no surface slippage and no chemically activated species. The hybrid nanofluid Al2O3–Cu/H2O is an incompressible and diluted suspension. The single-phase hybrid nanofluid model is considered in which the relative velocity of water (H2O) and hybrid nanoparticles (Al2O3–Cu) is the same and they are in a state of thermal equilibrium.

Practical implications

Study on convective flow across a revolving sphere has its applications found in electrolysis management, polymer deposition, medication transfer, cooling of spinning machinery segments, spin-stabilized missiles and other industrial and technical applications.

Originality/value

The originality of the study is to investigate the effect of shape factor on the flow of electrically conducting hybrid nanofluid past a rotating sphere with heat generation/absorption and magnetic field. The results are validated and provide extremely positive balance with the recognised articles. The results of the study provide many appealing applications that merit further study of the problem.

Details

International Journal of Numerical Methods for Heat & Fluid Flow, vol. 33 no. 11
Type: Research Article
ISSN: 0961-5539

Keywords

Article
Publication date: 26 March 2024

Anuj Kumar Goel and V.N.A. Naikan

The purpose of this study is to explore the use of smartphone-embedded microelectro-mechanical sensors (MEMS) for accurately estimating rotating machinery speed, crucial for…

Abstract

Purpose

The purpose of this study is to explore the use of smartphone-embedded microelectro-mechanical sensors (MEMS) for accurately estimating rotating machinery speed, crucial for various condition monitoring tasks. Rotating machinery (RM) serves a crucial role in diverse applications, necessitating accurate speed estimation essential for condition monitoring (CM) tasks such as vibration analysis, efficiency evaluation and predictive assessment.

Design/methodology/approach

This research explores the utilization of MEMS embedded in smartphones to economically estimate RM speed. A series of experiments were conducted across three test setups, comparing smartphone-based speed estimation to traditional methods. Rigorous testing spanned various dimensions, including scenarios of limited data availability, diverse speed applications and different smartphone placements on RM surfaces.

Findings

The methodology demonstrated exceptional performance across low and high-speed contexts. Smartphones-MEMS accurately estimated speed regardless of their placement on surfaces like metal and fiber, presenting promising outcomes with a mere 6 RPM maximum error. Statistical analysis, using a two-sample t-test, compared smartphone-derived speed outcomes with those from a tachometer and high-quality (HQ) data acquisition system.

Research limitations/implications

The research limitations include the need for further investigation into smartphone sensor calibration and accuracy in extremely high-speed scenarios. Future research could focus on refining these aspects.

Social implications

The societal impact is substantial, offering cost-effective CM across various industries and encouraging further exploration of MEMS-based vibration monitoring.

Originality/value

This research showcases an innovative approach using smartphone-embedded MEMS for RM speed estimation. The study’s multidimensional testing highlights its originality in addressing scenarios with limited data and varied speed applications.

Details

Sensor Review, vol. 44 no. 2
Type: Research Article
ISSN: 0260-2288

Keywords

Article
Publication date: 3 November 2022

Vinod Nistane

Rolling element bearings (REBs) are commonly used in rotating machinery such as pumps, motors, fans and other machineries. The REBs deteriorate over life cycle time. To know the…

Abstract

Purpose

Rolling element bearings (REBs) are commonly used in rotating machinery such as pumps, motors, fans and other machineries. The REBs deteriorate over life cycle time. To know the amount of deteriorate at any time, this paper aims to present a prognostics approach based on integrating optimize health indicator (OHI) and machine learning algorithm.

Design/methodology/approach

Proposed optimum prediction model would be used to evaluate the remaining useful life (RUL) of REBs. Initially, signal raw data are preprocessing through mother wavelet transform; after that, the primary fault features are extracted. Further, these features process to elevate the clarity of features using the random forest algorithm. Based on variable importance of features, the best representation of fault features is selected. Optimize the selected feature by adjusting weight vector using optimization techniques such as genetic algorithm (GA), sequential quadratic optimization (SQO) and multiobjective optimization (MOO). New OHIs are determined and apply to train the network. Finally, optimum predictive models are developed by integrating OHI and artificial neural network (ANN), K-mean clustering (KMC) (i.e. OHI–GA–ANN, OHI–SQO–ANN, OHI–MOO–ANN, OHI–GA–KMC, OHI–SQO–KMC and OHI–MOO–KMC).

Findings

Optimum prediction models performance are recorded and compared with the actual value. Finally, based on error term values best optimum prediction model is proposed for evaluation of RUL of REBs.

Originality/value

Proposed OHI–GA–KMC model is compared in terms of error values with previously published work. RUL predicted by OHI–GA–KMC model is smaller, giving the advantage of this method.

Article
Publication date: 1 November 2023

Sanjay Kumar, Kushal Sharma, Oluwole Daniel Makinde, Vimal Kumar Joshi and Salman Saleem

The purpose of this study is to investigate the entropy generation in different nanofluids flow over a vertically moving rotating disk. Unlike the classical Karman flow…

Abstract

Purpose

The purpose of this study is to investigate the entropy generation in different nanofluids flow over a vertically moving rotating disk. Unlike the classical Karman flow, water-based nanofluids have various suspended nanoparticles, namely, Cu, Ag, Al2O3 and TiO2, and the disk is also moving vertically with time-dependent velocity.

Design/methodology/approach

The Keller box technique numerically solves the governing equations after reduction by suitable similarity transformations. The shear stress and heat transport features, along with flow and temperature fields, are numerically computed for different concentrations of the nanoparticles.

Findings

This study is done comparatively in between different nanofluids and for the cases of vertical movement of the disk. It is found that heat transfer characteristics rely not only on considered nanofluid but also on disk movement. Moreover, the upward movement of the disk diminishes the heat-transfer characteristics of the fluid for considered nanoparticles. In addition, for the same group of nanoparticles, an entropy generation study is also performed, and an increasing trend is found for all nanoparticles, with alumina nanoparticles dominating the others.

Originality/value

This research is a novel work on a vertically moving rotating surface for the water-conveying nanoparticle fluid flow with entropy generation analysis. The results were found to be in good agreement in the case of pure fluid.

Details

International Journal of Numerical Methods for Heat & Fluid Flow, vol. 34 no. 2
Type: Research Article
ISSN: 0961-5539

Keywords

Article
Publication date: 6 November 2023

Qing Liu, Li Wang and Ming Feng

This paper aims to study the clearance compatibility of active magnetic bearing (AMB) and gas bearing (GB) to achieve a single-structured hybrid gas-magnetic bearing (HGMB), which…

Abstract

Purpose

This paper aims to study the clearance compatibility of active magnetic bearing (AMB) and gas bearing (GB) to achieve a single-structured hybrid gas-magnetic bearing (HGMB), which uses a single bearing structure to realize both the functions of gas bearing and magnetic bearing.

Design/methodology/approach

Because the radial clearance size of the AMB is typically ten times larger than that of the GB, radial clearance compatibility of GB and AMB needs to maximize the radial clearance of GB by adjusting structural parameters. Parametric analysis of structural parameters of GB is explored. Furthermore, a general structural design principle based on static analysis, rotordynamic performance and system stability is established for the single-structured HGMB.

Findings

Load capacity is vastly reduced due to the enlarged radial clearance of the GB. A minimum clearance needs to be ensured by increasing the bearing diameter or width to compensate for the reduced load capacity, yet indirectly raising the bearing load. Increased bearing load is conducive to stability, yet it raises the risk of rotor abrasion. In addition, excessively large bearing diameter leads to system instability, and inappropriate bearing width affects critical speeds. A general structural design principle is established and the designed HGMB–rotor processes optimal performances.

Originality/value

A single-structured HGMB is proposed to address the urgent demand for high-speed, cryogenic turboexpanders with frequent starts/stops. This design applies a single-bearing structure to realize the characteristics of both GB and AMB, greatly simplifying the implementation, reducing air friction loss and raising critical speeds. This paper provides a fresh perspective on the development of cryogenic turboexpanders for hydrogen liquefaction. It theoretically validates the feasibility and provides a design guide for a single-structured HGMB system.

Details

Industrial Lubrication and Tribology, vol. 75 no. 10
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 27 November 2023

Davood Javanmardi and Mohammad Ali Rezvani

Bearings are critical components used to support loads and facilitate motion for rotating and sliding parts of the machinery. Bearing malfunctions can cause catastrophic failures…

Abstract

Purpose

Bearings are critical components used to support loads and facilitate motion for rotating and sliding parts of the machinery. Bearing malfunctions can cause catastrophic failures. Hence, failure analysis and endeavors to improve bearing performance are essential discussions for worldwide designers, manufacturers and end users of vital machinery. This study aims to investigate a type of roller bearing from the railway industry with premature failures. The task arises because locomotives’ maintenance and service life quality are vital to railway operations while providing transportation services for the nation. To assist in maintaining the designated locomotives, the present study scrutinizes the causes of failure of heavy-duty roller bearings from locomotive bogie axleboxes.

Design/methodology/approach

It is intended to inspect this bearing service life and statistically scrutinize its design parameters to reveal the failures’ shortcomings and origins. The significant measures include examinations of their failures’ primary and vital factors by comparing them with a real-life service history of 16 roller bearings of the same type. The bearings come from the axleboxes of a locomotive bogie with an axle load of 20 tons. The bearing loads are estimated using the EN13104 standard document and confirmed by the finite element method using ABAQUS engineering software. To validate the finite element modeling results, the bearings’ stress analysis is performed using the Hertzian contact theory that demonstrated perfect conformity. The said methods are also used to search for the areas susceptible to failures in these bearings. With the inclusion and exploitation of the bearing maintenance conditions and the logbook recordings of the locomotives for the past seven years, the critical cause for this type of bearing’s failures is surveyed and discussed.

Findings

With the inclusion and exploitation of the bearing maintenance conditions and the logbook recordings of the locomotives for the past seven years, the critical cause for this type of bearing’s failures is surveyed and discussed. As a crucial result, it is found that deprived maintenance and inadequate lubrication are the root causes of the loss of the selected bearings.

Originality/value

For the designated locomotives, the origins of the heavy-duty roller bearing failures and its design shortcomings are revealed by examining and comparing them with a real-life service history of many of the same types of bearings. The novelty of the research is in using the combination of the methods mentioned above and its decent outcome.

Details

World Journal of Engineering, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1708-5284

Keywords

Article
Publication date: 11 March 2022

Ying Lv, Jinlong Feng, Guangbin Wang and Hua Li

This study aims to improve the maneuverability and stability of four-wheel chassis in a small paddy field; a front axle swing steering four-wheel chassis with optimal steering is…

Abstract

Purpose

This study aims to improve the maneuverability and stability of four-wheel chassis in a small paddy field; a front axle swing steering four-wheel chassis with optimal steering is designed.

Design/methodology/approach

When turning, the front inner wheel stops and the rear inner wheel is in the following state. The hydraulic drive system of the walking wheel adopts a driving mode in which two front-wheel motors are connected in series and two rear wheel motors in parallel. The chassis uses a combination of a gasoline engine with a water cooling system, a CVT continuously variable transmission and a hydraulic drive system to increase the control capability. The front axle rotary chassis adopts a step-less variable speed engine and a hydraulic control system to solve the hydraulic stability of the chassis in uphill and downhill conditions so as to effectively control the over-speed of the wheel-side drive motors. Through the quadratic orthogonal rotation combination design test, the mathematical models of uphill and downhill front-wheel pressures and test factors are established.

Findings

The results show that the chassis stability is optimal when the back pressure is 0.5 MPa, and the rotating slope is 4°. The uphill and downhill pressures of the front wheels are 2.38 MPa and 1.5 MPa, respectively.

Originality/value

The influence of external changes on the pressure of hydraulic motors is studied through experiments, which lays the foundation for further research.

Details

Journal of Engineering, Design and Technology, vol. 22 no. 2
Type: Research Article
ISSN: 1726-0531

Keywords

Article
Publication date: 9 January 2024

Fatih Selimefendigil and Hakan F. Oztop

This study aims to examine the effects of cross-flow and multiple jet impingement on conductive panel cooling performance when subjected to uniform magnetic field effects. The…

Abstract

Purpose

This study aims to examine the effects of cross-flow and multiple jet impingement on conductive panel cooling performance when subjected to uniform magnetic field effects. The cooling system has double rotating cylinders.

Design/methodology/approach

Cross-flow ratios (CFR) ranging from 0.1 to 1, magnetic field strength (Ha) ranging from 0 to 50 and cylinder rotation speed (Rew) ranging from −5,000 to 5,000 are the relevant parameters that are included in the numerical analysis. Finite element method is used as solution technique. Radial basis networks are used for the prediction of average Nusselt number (Nu), average surface temperature of the panel and temperature uniformity effects when varying the impacts of cross-flow, magnetic field and rotations of the double cylinder in the cooling channel.

Findings

The effect of CFR on cooling efficiency and temperature uniformity is favorable. By raising the CFR to the highest value under the magnetic field, the average Nu can rise by up to 18.6%, while the temperature drop and temperature difference are obtained as 1.87°C and 3.72°C. Without cylinders, magnetic field improves the cooling performance, while average Nu increases to 4.5% and 8.8% at CR = 0.1 and CR = 1, respectively. When the magnetic field is the strongest with cylinders in channel at CFR = 1, temperature difference (ΔT) is obtained as 2.5 °C. The rotational impacts on thermal performance are more significant when the cross-flow effects are weak (CFR = 0.1) compared to when they are substantial (CFR = 1). Cases without a cylinder have the worst performance for both weak and severe cross-flow effects, whereas using two rotating cylinders increases cooling performance and temperature uniformity for the conductive panel. The average surface temperature lowers by 1.2°C at CFR = 0.1 and 0.5°C at CFR = 1 when the worst and best situations are compared.

Originality/value

The outcomes are relevant in the design and optimization-based studies for electric cooling, photo-voltaic cooling and battery thermal management.

Details

International Journal of Numerical Methods for Heat & Fluid Flow, vol. 34 no. 3
Type: Research Article
ISSN: 0961-5539

Keywords

Article
Publication date: 18 March 2024

Taotao Jin, Xiuhui Cui, Chuanyue Qi and Xinyu Yang

This paper aims to develop a specific type of mobile nonrigid support friction stir welding (FSW) robot, which can adapt to aluminum alloy trucks for rapid online repair.

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Abstract

Purpose

This paper aims to develop a specific type of mobile nonrigid support friction stir welding (FSW) robot, which can adapt to aluminum alloy trucks for rapid online repair.

Design/methodology/approach

The friction stir welding robot is designed to complete online repair according to the surface damage of large aluminum alloy trucks. A rotatable telescopic arm unit and a structure for a cutting board in the shape of a petal that was optimized by finite element analysis are designed to give enough top forging force for welding to address the issues of inadequate support and significant deformation in the repair process.

Findings

The experimental results indicate that the welding robot is capable of performing online surface repairs for large aluminum alloy trucks without rigid support on the backside, and the welding joint exhibits satisfactory performance.

Practical implications

Compared with other heavy-duty robotic arms and gantry-type friction stir welding robots, this robot can achieve online welding without disassembling the vehicle body, and it requires less axial force. This lays the foundation for the future promotion of lightweight equipment.

Originality/value

The designed friction stir welding robot is capable of performing online repairs without dismantling the aluminum alloy truck body, even in situations where sufficient upset force is unavailable. It ensures welding quality and exhibits high efficiency. This approach is considered novel in the field of lightweight online welding repairs, both domestically and internationally.

Details

Industrial Robot: the international journal of robotics research and application, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 0143-991X

Keywords

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