Abstract
Recently, in order to reduce high maintenance costs and to increase operating ratio in manufacturing systems, condition-based maintenance (CBM) has been developed. CBM is carried out with indicators, which show equipment’s faults and performance deterioration. In this study, indicator signal acquisition and condition monitoring are applied to a ball-screw-driven stage. Although ball-screw is a typical linearly reciprocating part and is widely used in industry, it has not gained attention to be diagnosed compared to rotating parts such as motor, pump, and bearing. First, the vibration-based monitoring method, which uses vibration signal to monitor the condition of a machine, is proposed. Second, Wavelet transform is used to analyze the defect signals in time-frequency domain. Finally, the failure diagnosis system is developed using the analysis, and then its performance is evaluated. Using the system, we estimated the severity of failure and detect the defect position. The low defect frequency (≈58.7 Hz) is spread all over the time in the Wavelet-filtered signal with low frequency range. Its amplitude reflects the progress of defect. The defect position was found in the signal with high frequency range (768~1,536 Hz). It was detected from the interval between abrupt changes of signal.
Highlights
Today’s manufacturing systems have become gradually automated for the purposes of productivity improvement and cost savings
A PC-based ball-screw failure diagnosis system was designed by applying the analysis of defect frequencies based on Wavelet transform, to detect and diagnose the defects of a ball-screw through the developed vibration monitoring method
A condition monitoring method was developed by using a diagnosis system to detect and warn of failures in ball-screw-driven stage (Table 2)
Summary
Today’s manufacturing systems have become gradually automated for the purposes of productivity improvement and cost savings. Unlike traditional maintenance that needs to be carried out on a regular time basis, the CBM detects any system defect early and identifies the cause of failure efficiently through use of indicator signals that reflect the actual operation condition of systems and reduces unnecessary costs and maintenance efforts [4, 5]. A defect detection and diagnosis method was proposed for the ball-screw-driven stage, a representative linearly reciprocating mechanical module, and a failure diagnosis system was designed and applied through the use of CBM. For this process, firstly, normal and defect frequencies were derived from the common failure of the ball-screw. The system is stand-alone and PC-based one so that it can be applied to various manufacturing equipment pieces or facilities
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