Early diagnosis of failures can prevent financial losses and industry downtime. In this article, the author proposes an early fault diagnosis technique for rotor-bearing faults. The proposed technique is based on the recognition of sound signals. The author measured and analyzed the three states of the rotor-bearing system: the rotor-bearing system under normal operating conditions, the rotor-bearing system with faulty bearings, and the rotor-bearing system with rotor friction. In this article, an original feature extraction method is described, namely, the 1/3 doubling method (a method of selecting the amplitude of the frequency ratio that is a multiple of 30% of the maximum amplitude). This method is used to form feature vectors. A classification of the obtained vectors was performed by the KNN (K-nearest neighbor classifier), the SVM (support vector machine), and the decision tree. The method is also compared with the Fourier synchrosqueezed transform. The experimental results show that the method can diagnose early faults of rotor-bearing systems simply and quickly and can be used to protect the safe operation of mechanical equipment.
The feedback control system was designed to control the pipeline blockage and leakage fault. Based on the open-loop engine system, different degrees of faults were simulated, and the changes in system parameters when faults occur were analyzed. Then, the faults were injected into the engine system with feedback control, and the effects of the controller to different degrees of faults and the changes of the parameters of the electric pump with the controller were studied. The simulation results showed that under the action of the feedback control system, the deviation of the engine system parameters caused by these faults can recover to the set value within a few seconds. When the fault disappears, the system parameters can be still within the normal operating range.
The propulsion system is one of the important and vulnerable sub-systems in a strap-on launch vehicle. Among different failure modes, the thrust drop fault is the most common and remediable one. It degrades vehicle attitude tracking ability directly. To this end, this paper focuses on the design and application of attitude reconstruction problems with a thrust loss fault during the ascending flight phase. We firstly analyze the special failure modes and impacts on the propulsion system through a Failure Modes and Effects Analysis (FMEA). Then, six degrees of freedom dynamic and kinematic models are formulated, which are integrated into the Matlab/Simulink environment afterward. The above models’ validation is realized through numerical simulations with different fault severity. Simulation results show that the max attitude deviation is only 0.67° approximately in the pitch angle channel under normal conditions, and the flight attitude angle deviation is directly proportional to the thrust loss percentage when the thrust drop fault occurs. Based on the validated models, a practical reconfigurable ideal through adjusting the control allocation matrix is analyzed. Then, an automation redistribution mechanism based on the moment equivalent principle before and after the thrust drop is proposed to realize proportional allocation of virtual control command among the actuators. The effectiveness of the designed attitude reconstruction method is demonstrated through numerical simulations and comparison analysis under various fault scenarios. The results show that the rocket attitude can be quickly adjusted to the predetermined program angle within about 2.5 s after the shutdown failure of a single engine, and the flight speed and altitude can also reach the required value with another 17 s engine operation. Therefore, the designed control reconfiguration strategy can deal with the thrust loss fault with high practicability and can be applied to real-time FTC systems. Last but not least, conclusions and prospects are presented to inspire researchers with further exploration in this field.
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