Overview
The main goal of the project was to develop management and monitoring system using multi-sensor-based measurement and analysis techniques, particularly for selected faults in large marine diesel engines and stationary power plants.
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In order to create the systems, the following objectives had to be met:
- the mapping of the propagation of Acoustic Emissions (AE) in the machines to determine attenuation and frequency distortions, optimise sensor positioning, and to enable source decomposition
- development of intelligent signal processing applications which can reliably process performance indicators elicited from the sensor array
- development of new sensors
- identification of engine conditions and faults, such as cylinder condition related faults, to improve automatic and intelligent engine management and monitoring
- identification of components of the signals focusing on piston ring/cylinder liner interaction/lubrication.
- Measurements were made from laboratory studies, test bed trials, and preliminary field measurements of the AE signal attenuation-frequency characteristics through machine structures using an array of sensors.
- After initial testing using existing sensors a new robust high-temperature AE sensor specification was developed and the new sensors have been field tested.
- Information from tests carried out on machines has been used to map AE signals onto mechanical events. This involved characterisation of segments of time-series which contain signatures relating to mechanical events which are used to indicate running conditions (speed, power output) as well as monitoring conditions such as injector timing and component wear and degradation. The sensor array chosen provides a spatial as well as temporal map of events and enables reconstitution of signals.
- Intelligent signal processing applications, capable of automatically diagnosing specific engine faults and conditions, have been developed.
Funding
Results
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Based on models derived from test bed machines and field tests made on full-scale engines, systems have been developed that use a two-sensor array (per cylinder) of Acoustic Emission (AE) transducers. The sensor array has been chosen to optimise the ability to monitor wear and degradation of critical machine parts. The idea of an array of AE transducers is an advance on previous AE sensor approaches with one (or a few) sensor(s). It represents an innovation in AE monitoring, bringing the technology closer to conventional acoustics, and allowing the development of temporal and spatial 'source maps' for a machine. The results have been widely disseminated through 22 publications in conferences and journals and postgraduate theses. Sensor development was required for this industrial application and a new, less expensive, more robust sensor has been used in long-term online monitoring of engines. In this application, sensitivity of the sensors has not been a problem so that a trade-off between sensitivity, broadband frequency response and temperature has been possible.