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proactive maintenance cost a fraction of the total cost of replacement and required man-hours and most
importantly the indirect cost of the turbine shut down.
This paper reflects simple analysis conducted on the operational data received from the generator bearing
of a 1.5 MW wind turbine. The bearing malfunction was identified by ear from the bottom of the tower at
the time of operation.
2. VIBRATION ANALYSIS METHODS:
Vibration analysis is by far the most prevalent method for machine condition monitoring as it has a number
of advantages compared with other methods. One main advantage is that vibration responds without any
intervening time to changes in machine condition. Therefore it can be used for both permanent and
intermittent monitoring. Vibration analysis has superior characteristics for industrial use and is thus chosen
to be the type of analysis in this paper.
Due to rotating elements such as shafts and bearings, vibration signals tend to be periodic. Modulating
frequencies are produced by specific faults of rotating elements including gears, bearing, and shaft. As a
result, the key task to diagnose bearing/gearbox faults is to detect these modulating signals. Demodulation
is an important step in bearing fault detection and thus in the most of machine condition monitoring. The
theory behind this method is well described in the literature such as [2], and is not the purpose of this paper.
2.1 Modulation:
Sidebands occur when a signal is under the effect of modulation, a phenomena that occurs when a so-called
carrier signal, has its amplitude or frequency to vary with time. The first case, when the amplitude varies
with time, is known as amplitude modulation (AM) and the latter case, when the frequency varies with
time, is called frequency modulation (FM) or phase modulation (PM), where the FM simply is the time
derivative of the PM. As the name implies, the carrier frequency carries the intelligence which is called the
modulator. For example in gear vibration signals, the gear mesh frequency and its harmonics are the
carriers and the shaft rotating speeds of the meshing gears are the modulators. Vibration signals with
bearing faults can be modeled as an AM of a carrier signal at the resonance frequency by periodic pulses.
In so-called Envelope Analysis the signal envelope is extracted by amplitude modulation and frequency
analyzed to reveal the repetition frequencies even when these have a small random fluctuation. In the next
section, one of the common approaches that can be used for demodulation is presented.
2.2 Narrowband Demodulation:
Narrowband demodulation techniques select an interesting frequency band for further analysis as an
alternative to analyzing the entire frequency-domain signal. This is performed by plotting the spectrum, and
then select the frequency band in frequency-domain (which usually has the highest energy). Therefore,
bandwidth filter is applied on the FFT of the signal instead of the signal in time-domain.
The algorithm for narrowband amplitude demodulation is now briefly described:
a) Apply the FFT on the input signal.
b) A frequency band of interest is selected.
c) New zero spectrum is generated.
d) The new spectrum is filled with the selected frequency band by shifting it to the left hand end of the new
spectrum, i.e. the lower limit of the selected band starts at the zero frequency.
e) Apply inverse FFT on the spectrum.
f) The narrowband amplitude demodulated signal in time-domain is then calculated by taking the absolute
value of the complex analytic signal.
g) The spectrum of the narrowband amplitude demodulated signal is calculated via absolute value of FFT.
Note that the narrowband selection does not change the length of the signal in the time domain. To have a
better understanding of this procedure, the flowchart of this process is drawn in Figure 2.
(2)
(3)
(
(4)
4. CONCLUSION:
This paper briefly demonstrated the application of demodulation analysis on the operational vibration
signals. Only drive-end data from the generator bearing of a wind turbine were chosen to be reflected in the
paper. The results indicated the presence of fault(s) on the outer race before any inspection to be done by
the authors.
To validate the results, the bearing was cut by a water jet cutting machine. Water jet cut was chosen since
no heat is introduced to the rolling elements. It was shown that there was a local fault on the outer race.
Although there was not enough information to perform the root cause analysis, this type of fault most likely
comes from misalignment which can cause very high loads. The misalignment and load could be due to
either the shaft or housing, however it is not certain. Further investigations and inspections are required.
An online condition monitoring system with a reliable analysis could reduce the maintenance cost (cost of
new parts, man-hour at site, loss of production, etc.) and generally the revenue loss by an early indication
of the fault, primarily with a scheduled and proactive maintenance at a proper time. In addition, when a
localized outer race fault has been diagnosed by the monitoring system, for example, the faulty bearing
does not need to be replaced but only to be rotated 180 degrees; the bearing can operate as new to save
cost. The cost of the analysis is small.
It is suggested that collecting additional data such as torque/load will provide supplementary information
regarding the status of the bearing, and will lead to firm results. This information could be either collected
by torque sensors or calculated by having power and rotational speed.
Still, more sophisticated analysis is required to be able to develop a comprehensive analysis tool. For
instance, gearbox data/information will be essential in order to isolate the gear vibration signatures (as
shown in Figure 6), so that the monitoring system can handle all typical mechanical faults,.
5. ACKNOWLEDGMENT:
The authors would like to thank the TransAlta Corporation for providing the operational data and the
bearings, and the Natural Sciences and Engineering Research Council (NSERC) of Canada for financial
support under the Industrial Research Chair program.
6. REFERENCES:
[1] Alewine, K., Chen, W., Wind Turbine Generator Failure Modes Analysis and Occurrence,
Windpower 2010, Dallas, Texas, May 24-26, 2010
[2] Rabe, U., K. Janser, and Wt Arnold. "Vibrations of free and surface-coupled atomic force microscope
cantilevers: theory and experiment", Review of Scientific Instruments 67.9 (1996): 3281-3293.
[3] Andreas Meisingseth, Demodulation Techniques in Gearbox Diagnostics, July 2012
[4] Randall, R. Vibration Based Condition Monitoring, 2012, John Wiley & Sons]
[5] Chui, C. K., 1992, An Introduction to Wavelets, Academic Press, New York, pp. 1-200.
7. BIOGRAPHY:
Ehsan Mollasalehi received the B.Sc. degree in Mechanical Engineering (M.E.) from
K.N. Toosi University of Technology, Tehran, Iran in 2010, and the M.Sc. degree in M.E.
from the University of Calgary, Calgary, Canada in 2012. He is currently a Ph.D. student
in M.E. at the University of Calgary.
His primary research interests are in the areas of fault detection and diagnostics, vibration
and noise control, and Dynamics. Currently, he is working on condition monitoring of
mechanical components of large scale wind turbines.
He is a member of ASME, and Canadian Machinery Vibration Association (CMVA).