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Structural Health Monitoring of Walking Dragline Excavator Using Acoustic Emission

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Structural Health Monitoring of Walking Dragline Excavator Using Acoustic Emission applied sciences Article Structural Health Monitoring of Walking Dragline Excavator Using Acoustic Emission Vera Barat 1,2, Artem Marchenkov 1,* , Dmitry Kritskiy 3, Vladimir Bardakov 1,2, Marina Karpova 1, Mikhail Kuznetsov 1, Anastasia Zaprudnova 1, Sergey Ushanov 1,2 and Sergey Elizarov 2 1 Moscow Power Engineering Institute, 14, Krasnokazarmennaya Str., 111250 Moscow, Russia; [email protected] (V.B.); [email protected] (V.B.); [email protected] (M.K.); [email protected] (M.K.); [email protected] (A.Z.); [email protected] (S.U.) 2 LLC “Interunis-IT”, 20b, Entuziastov Sh., 111024 Moscow, Russia; [email protected] 3 JSC “SUEK”: 20b, Lenin Str., 660049 Krasnoyarsk, Russia; [email protected] * Correspondence: [email protected] Abstract: The article is devoted to the organization of the structural health monitoring of a walking dragline excavator using the acoustic emission (AE) method. Since the dragline excavator under study is a large and noisy industrial facility, preliminary prospecting researches were carried out to conduct effective control by the AE method, including the study of AE sources, AE waveguide, and noise parameters analysis. In addition, AE filtering methods were improved. It is shown that application of the developed filtering algorithms allows to detect AE impulses from cracks and defects against a background noise exceeding the useful signal in amplitude and intensity. Using the proposed solutions in the monitoring of a real dragline excavator during its operation made it possible to identify a crack in one of its elements (weld joint in a dragline back leg). Citation: Barat, V.; Marchenkov, A.; Kritskiy, D.; Bardakov, V.; Karpova, M.; Kuznetsov, M.; Zaprudnova, A.; Keywords: acoustic emission; structure health monitoring; walking excavator; AE impulse detection Ushanov, S.; Elizarov, S. Structural Health Monitoring of Walking Dragline Excavator Using Acoustic Emission. Appl. Sci. 2021, 11, 3420. 1. Introduction https://doi.org/10.3390/app11083420 The dragline excavator is a widely known type of heavy equipment used in civil engineering and surface mining industry. Commonly, a system of a dragline consists of Academic Editor: a large bucket that is suspended from a boom with wire ropes (Figure1). The hoist rope Giuseppe Lacidogna is usually driven by diesel or electric motors. Its main function is to support the dragline bucket and hoist-coupler assembly from the boom. The dragrope is generally applied to Received: 10 March 2021 move the bucket horizontally. Unlike conventional types of excavators, dragline digs by Accepted: 7 April 2021 dragging the bucket only in one direction—towards the excavator [1]. Published: 11 April 2021 Currently, most dragline systems are operated in the open pit mining industry to process blasted rocks located both above and below the horizon level of the dragline Publisher’s Note: MDPI stays neutral excavator. Moreover, draglines have large dimensions—the boom length may reach with regard to jurisdictional claims in 90 m, the total height can constitute up to 100 m, and the bucket capacity may achieve published maps and institutional affil- 20 tons. Nowadays, the design of draglines is favorable due to a short working cycle and iations. high performance. Currently, more than 500 walking dragline excavators are in operation in the world, of which more than 200 are in Russia. Leading dragline manufacturers are Caterpillar, Liebherr, Uralmash, Bucyrus, and others. Draglines operate all year-round in detrimental weather conditions: significant tem- Copyright: © 2021 by the authors. perature fluctuations, great levels of humidity, and even regions with increased seismic Licensee MDPI, Basel, Switzerland. activity. Both the influence of external weather conditions and constant cyclic loadings This article is an open access article can lead to the formation of fatigue fracture-initiating defects in the metal elements of distributed under the terms and the dragline structure. Such defects can reduce the operation life of the equipment due conditions of the Creative Commons Attribution (CC BY) license (https:// to premature destruction. The breakdown basically causes considerable financial costs creativecommons.org/licenses/by/ associated with equipment downtime, repair costs, and terrible accidents [2]. The most 4.0/). common type of dragline excavator damage is cracks in the back legs; for the period from Appl. Sci. 2021, 11, 3420. https://doi.org/10.3390/app11083420 https://www.mdpi.com/journal/applsci Appl. Sci. 2021, 11, x FOR PEER REVIEW 2 of 15 premature destruction. The breakdown basically causes considerable financial costs asso- ciated with equipment downtime, repair costs, and terrible accidents [2]. The most com- mon type of dragline excavator damage is cracks in the back legs; for the period from 2015 to 2020, 15 accidents caused by breakage of back legs and five accidents caused by break- age of the dragline boom were registered in Russia. The most widely spread non-destructive testing (NDT) of dragline structural compo- nents is ultrasonic testing, which is carried out in the welded joints of an excavator twice a year. However, this method does not allow detect abrupt changes in the stress–strain Appl. Sci. 2021, 11, 3420 2 of 15 state. Furthermore, it is extremely time-consuming and leads to long-lasting downtime. Draglines are commonly equipped with a structural health monitoring system with video supervision systems and an electrical equipment diagnostics system, but operational 2015 to 2020, 15 accidents caused by breakage of back legs and five accidents caused by monitoring of thebreakage metal structures of the dragline conditions boom were is usually registered not in Russia.performed. FigureFigure 1. Basic components1. Basic components of a dragline of ESH-20.90: a dragline 1—back ESH-20.90: legs, 2—boom, 1—back 3—hoist legs, rope,2—boom, 4—mast, 3—hoist 5—bucket, rope, 6—dragrope. 4— mast, 5—bucket, 6—dragrope. The most widely spread non-destructive testing (NDT) of dragline structural compo- nents is ultrasonic testing, which is carried out in the welded joints of an excavator twice In this paper,a year. the However,possibility this of method using doesthe acoustic not allow emission detect abrupt (AE) changes method in theto stress–straindetect defects in the draglinestate. Furthermore, metal structures it is extremely is discussed. time-consuming and leads to long-lasting downtime. AE is a non-destructiveDraglines are commonlytesting (NDT) equipped method with based a structural on the health physical monitoring phenomenon system with of video elastic waves emissionsupervision when systems a material and an electrical undergoes equipment irreversible diagnostics changes system, in but its operational internal moni- structure, for example,toring of because the metal of structures crack formation. conditions The is usually AE method not performed. has a high sensitivity In this paper, the possibility of using the acoustic emission (AE) method to detect to crack detectiondefects and is in used the dragline to detect metal cracks structures at early is discussed.stages of their growth. An important advantage of the AE AEmethod is a non-destructive is the ability to testing detect (NDT) defects method located based at ona great the physical distance phenomenon from the control point;of cracks elastic and waves other emission defects when emit a material AE waves, undergoes which irreversible propagate changes over the in itstest- internal ing structure andstructure, can be detected for example, by the because AE sensors of crack formation.at about 10 The m AEfrom method the defect. has a high The sensitivity AE method is passive,to crackit does detection not require and is probing used to detect action, cracks which at early allows stages it ofto theirbe effectively growth. An used important advantage of the AE method is the ability to detect defects located at a great distance from in structural health monitoring systems for monitoring loaded structures in the operating the control point; cracks and other defects emit AE waves, which propagate over the testing mode without decommissioning.structure and can be detected by the AE sensors at about 10 m from the defect. The AE AE testing providesmethod is passive,low noise it does immunity, not require th probingerefore, action, such whichexperiments allows it toare be tradition- effectively used ally carried out forin structural equipment health when monitoring the operat systemsion forof equipment monitoring loaded is suspended. structures Recently, in the operating the technology ofmode AE monitoring without decommissioning. which requires the use of specific methods for detecting AE signals against a AEnoise testing background provides low has noise beco immunity,me more therefore, popular such [3–5]. experiments AE monitoring are traditionally is carried out for equipment when the operation of equipment is suspended. Recently, the performed for both statically and dynamically loaded equipment. Most widespread ap- technology of AE monitoring which requires the use of specific methods for detecting plication of AE AEtesting signals in againstthe operating a noise background mode is testing has become of bearings, more popular compressors, [3–5]. AE monitoring and pumps [6–8]. Theis various performed defects for both have statically a specif andic dynamically AE signature loaded with equipment. a certain periodicity Most widespread connected with aapplication rotation frequency. of AE testing
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