1UNIVERSITY OF CENTRAL LANCASHIRESCHOOL OF ENGINEERINGMODULE ASSESSMENTMODULE CODE: ER4109MODULE TITLE: Intelligent MaintenanceMODULE TUTOR: Dr. Ahmed Onsy / Wilbert SinzaraSEMESTER 2: 2020/21Submission Date and Time: 11:59 pm, 8th May 2021Venue/Campus: PRESTON CAMPUSName ………………………………2ER4109 ‘Intelligent Maintenance’–Module Assessment 2020/21Instructions to Candidates:Value: This assignment constitutes 100% of the grade for this module.Submission Date and Time:11:59 pm, 8th April 2021Submission RulesThe professional report generated in the assignment should be 1500 words not includingrelevant material (Appendices). The assignment should be your own work and written in yourown words and any information taken from other resources should be referenced. It will bechecked for plagiarism using Turnitin. Any plagiarism or copying from others will be dealt withthrough the university’s plagiarism procedures.Your assignment must be submitted electronically via Blackboard (Assignments tab) by thesubmission time. The report should be contained in a Word document, or PDF No other meansof submission will be accepted. The software code will be submittedindependently.Any assignment submitted late, but within 5 working days of the deadline, will be given amaximum mark of 100%. Assignments submitted more than 5 working days after the deadlinewill not be marked, and a mark of 0% will berecorded.Learning Outcome to be assessed: 1Demonstrate the ability to apply scientific principles and concepts relevant tointelligent maintenance engineering in a practical context.2Use fundamental knowledge to investigate new and emerging technologies inmachines diagnostic, health monitoring and condition monitoring.3Critically apply advanced level knowledge, to a wide range of intelligent systemsengineering topics and their practical implementation in maintenance industry. 3ER4109 ‘Intelligent Maintenance’–Module Assessment 2020/21‘Vibration Analytics PLC’ is a systems engineering company that develops conditionmonitoring systems for different industries to support a wide range of applications,including oil and gas, aerospace, wind turbines, and automotive and industrialmachinery.As a Research and Development (R&D) engineer in the ‘Vibration Analytics PLC’company, you have been asked to design and develop a condition monitoring system(CMS) for a wind turbine manufacturer that has requested a condition monitoringsystem to monitor a new design of gearbox that will replace one of their current windturbine gearboxes (see Appendix A). The CMS should utilize at least two differentmonitoring techniques, such as vibration, acoustic emission, or online oil analysis, inorder to provide reliable information about normal and abnormal gearboxes andpossible gearbox failures. The CMS should also include the measurement oftemperature and speed.Provide a detailed, professional report for your R&D director that contains thefollowing:1- An evaluation of three condition monitoring techniques that can be used in yourcondition monitoring system for the mechanical power transitions and theirapplication in predictive/condition based and proactive maintenance strategies.2- A design of a condition monitoring system that incorporates vibration analysisand at least one other monitoring technique and their sensors, signalconditioning and data acquisition (DAQ)/ microcontroller. Equations andcalculations for the provided gearbox design to be included in theappendices.3- A development condition monitoring software program using NI LabVIEW/C++or other tools to log the measurement data and provide the following parametersand warning alarms when limits are exceeded (logged data files should beincluded in the appendices):a) Vibration analysis of a mechanical power transition elementsb) Gearbox input shaft speedc) Temperature of gearbox oil or ambient air4- A proposal that could be offered to the wind turbine manufacturer to developyour CMS in the next phases of development that improve for the following:(a) Further development to your CMS such as the use of an intelligent conditionmonitoring approaches to eliminate any false alarms that the traditionalCMS.(b) Use of IoT in CMS.4Assessment CriteriaThe Department’s Principles of Assessment will be used to determine grading levels. 1An evaluation of three condition monitoring techniques that can be used inyour condition monitoring system for the mechanical powertransitions andtheir application in predictive/condition based and proactive maintenancestrategies.15%2A design of a condition monitoring system that incorporates vibrationanalysis and at least one other monitoring technique and their sensors,signal conditioning and data acquisition (DAQ)/ microcontroller. Equationsand calculations for the provided gearbox design to be included in theappendices.15%3a) A development condition monitoring software program using NILabVIEW/C++ or other tools (e.g. Fluke instrument data)to log the measurement data and provide the following parameters andwarning alarms when limits are exceeded (logged data files should beincluded in the appendices):b) Vibration analysis of a mechanical gearbox elements; introducedetection of different faults.c) Gearbox input shaft speedd) Temperature of gearbox oil or ambient air30%4 (a)A proposal that could be offered to the wind turbine manufacturer todevelop your CMS in the next phases of development that improve for thefollowing:(a) Further development to your CMS such as the use of an intelligentcondition monitoring approaches to eliminate any false alarms that thetraditional CMS.20%4 (b)Use of IoT in CMS.10%5Report presentation, structure, clarify of information, use of references.10% 5Appendix AWind turbine dataExample for wind turbine main elements is shown in Figure 1.Wind Turbine gearbox data:Gearbox type: Helical gearbox; example is show in Figure 2.No. of stages: 2Gears data: StageNumber of teethst1Gear A: 54Gear B: 15nd2Gear C: 51Gear D: 18 Bearings data:For simplification, assume that all the gearbox bearings shown in Figure 3 [input shaft bearings (1,2), intermediate shaft bearings (3, 4), and output shaft bearings (5, 6)] are ball bearings and ofthe same type and have the data provided in Table 1 and Figure 4.Table 1, Bearing dimensions ParametermmOuter diameter62Inner diameter25Pitch diameter of rollers(P)44Diameter of roller (B)8Number of rollers (N)10Contact angle (Ø)13° Note: you may assume any other required data.Figure 3, source www.skf.comFigure 1, sourceFigure 4, source www.skf.com6
