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The Methodic of Machines with Piston-Crank Mechanism Diagnosis

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The Methodic of Machines with Piston-Crank Mechanism Diagnosis 10th IMEKO TC10 Conference on Technical Diagnostics Budapest, HUNGARY, 2005, June 09-10 Symptoms and a Sensor for Permanent Diagnosis of Machines with a Piston-Crank Mechanism Piotr Bielawski Maritime University of Szczecin, Poland Abstract − The piston-crank mechanism and influence – vibrations of machine body, of its technical condition on safety is presented. Diagnostic – torsional vibrations of crankshaft, signals, which may be useful in diagnosing of mechanism – axial vibrations of crankshaft, elements are enumerated. The choice of taking the – torque, crankshaft free end as a point of diagnostic signals – angular velocity/acceleration of crankshaft. permanent measurement is justified. The classification of Information concerning the condition of the piston-crank machine units and their loads are done. There is pointed out mechanism is also given in time changing temperature the possibility to increase the diagnosis accuracy made by fluctuations of kinematics pairs elements and in changes of measurements on the free end of crankshaft. Attention is solid particles content in lubricating oil as well as in the drown to the necessity of considering dynamical content of oil mist in the crankcase. Such information is characteristics of machine unit in process of inference about more connected with the intensity of wearing process than the technical condition of the piston-crank mechanism with effects of wear. From this reason there are more useful elements. in monitoring of machine than in diagnosis and forecasting of machine condition. Keywords: piston-crank mechanism, torsional vibrations, Courses of pressures contain information about the axial vibrations. condition – the tight of working chamber. The limited inference about the condition of valves and piston rings and 1. INTRODUCTION cylinder liner is also possible. The closed indication courses are preferred [1]. Transducers for direct measurements of The majority of displacement machines, mainly piston pressures and transducers for head vibrations and machines, is equipped with a piston-crank mechanism. deformations of washers under head bolts are developed These machines are characterized by a very high maximum [10]. pressures of medium in the working chamber. The Absolute vibrations of machine body, which are mechanism consist of cylinder liner, piston with piston rod, measured near the crosshead guides, contain information crosshead slide, crosshead with bearing, connecting rod with about the condition (clearances) of slide bearings [9]. Such head and bottom end bearing, crankshaft and main bearing vibration may contain information about condition of screw in the most extended version. Mentioned elements form connection of piston rod and crosshead [2]. The tribological pairs – slide bearings. In all tribological pairs, measurement is made by accelerometers e.g. piezoelectric with the exception of main bearings, reciprocating or which are offered in commerce. oscillatory movement takes place. The large load of pairs The axial vibration of free end of crankshaft contains elements, which is result of very large maximum working information about crank bearings. Good results are reached pressures, and relative velocities with temporary zero with using absolute vibration acceleration measurement. values, make that tribological conditions in such pairs are There is no measurements systems for commercial using [9]. extreme difficult. Frequent starts and many inferences The attempt to build contactless electrodynamics accelerate the wear process. It leads to defect of pairs, as transducers for axial vibrations of rotating shaft was made. excessive clearance and/or machine seizure and failure. Components of body vibrations and axial vibrations are Failures are a menace to life, health and environment. The temporary periodical signals and they are generated by diagnosis of such mechanism is desirable for the sake of forces with changing sign [5]. safety and economic. In case of long crankshafts with many cranks, axial vibrations may also contain information about crankshaft 2. SIGNALS CONTAINING INFORMATION ABOUT alignment. The uneven wear of main bearings, deformation THE MECHANISM TECHNICAL CONDITION of machine body, changing of machine position in relation to cooperating machine has an influence on crankshaft From own researches made by author and publications alignment. Displacement of relative vibration is measured. result that an information about technical conditions of the Eddy current displacement transducers are useful for this piston crank mechanism is included in courses as follow, as purpose. Further research work on improving the model is functions of crankshaft angle rotation: continued to make it more useful for diagnosing of – pressure of medium in working chamber, crankshaft alignment[6]. 10th IMEKO TC10 Conference on Technical Diagnostics Budapest, HUNGARY, 2005, June 09-10 Absolute torsional vibrations, measured at the free end – there is possibility to accurate measure of TDC of the of crankshaft, contain information about the condition of chosen piston main bearings, which are placed close to nodes of torsional it is purposeful to built sensor for above mentioned vibrations (torsional vibrations are main reason of magnitudes of enumerated values of crankshaft free end and accelerated wear of bearings) [11]. Knowledge about to adopt it for permanent diagnosis of piston-crank torsional vibrations modes, position of torsional vibrations mechanism elements. Such sensor should allow to nodes and resonance frequencies of vibrating system is measuring angular rotation/position, angular acceleration, necessary. Industrial transducers of torsional vibrations are displacement and velocity of axial rotation and TDC of very expensive and not easy to use. Measurements of piston. The sensor for permanent diagnosis of machines absolute vibrations of the crankshaft free end are substituted should be very precise and reliable, should be easy to with measurements of relative vibrations. assemble, should not make difficult to use of machine, It seems to be possible to forecast wear defects of should be inexpensive, and it should be integrated with crankshaft and bearings based on axial and torsional machine elements which operate with shaft. vibrations permanent measured. This method is described in The achievement of all features is made difficult because [7]. of: In multi cylinder machines absorbed or delivered torque – free end of crankshaft is also last, a little longer main has a value, which depends on the angle of rotation. bearing journal. Deformations of crankshaft due to Momentary values of torque depend not only on absorbed or forces and torques make that journal vibrates in axial delivered moment, but also on friction moments in and torsional directions and move in bearing radius, tribological pairs of the piston-crank mechanism. Friction unparallel of journal and baring bushing periodical moments depend from load and condition of pairs; so course changes; of machines torque contain information about condition of – other auxiliary machines may also be driven from the tribological pairs of piston crank mechanism [8]. Torsional free end e.g. oil pumps. There are sometimes stresses in connection shaft between machines are result of assembled torsional or axial vibration dumpers; torque. There exist industrial systems for measurements of – axis of the threaded hole is non coaxial with the torsional stresses in connection shaft. These transducers are journal axis. This is the result of many technological quite expensive and not easy to use. operations during the production process and little The variable torque takes result in nonstationary of requirements for threaded hole precision; angular velocity. Momentary values of angular velocity are – there are no industrial transducers for contactless different than mean value. The mean value of shaft angular measurements of velocity and/or acceleration of velocity is called rotational speed. There exist relations axial vibrations. between torque and crankshaft angular accelerations [8]. The researches about building an integrated transducer Courses of relative accelerations of torsional vibrations are for multi cylinder piston compressor with gear oil pump superimposed with courses of angular accelerations of shaft driven from shaft free end are made. In put into practice at crankshaft free end. Courses of angular acceleration may solution, additional shaft between shaft journal and pump, be determined by incremental transducers (optical, drive the pump and it is used for assembling movable parts inductive, magnetic, eddy current) of angle rotation of shaft of transducers. There are used Ferraris sensors to measure and its differential with respect to time. The main angular acceleration of shaft, eddy current sensors to disadvantage of this measurement is loss of information measure axial displacement, special electrodynamic sensors contained in constant values of differentiated signal. to measure velocity of axial vibrations and optical Transducers which operate according to Ferraris principle incremental sensors of angle rotation. (Galileo Ferraris 1847 – 1897) are now available in sale. They give electrical signals, proportional to relative 4. SOURCES OF ADDITIONAL INFORMATIONS accelerations in linear and rotational movement. But AND THEIR USABILITY usability of them for measurements of angular accelerations of crankshaft free end has not been pointed up to now. Periodical or immediate measurements of additional
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