Semi-real-time monitoring of cracking on couplings by neural network analysis of acoustic emission signals

Abstract

This paper presents the results obtained during the development of a semi-real-time monitoring methodology based on Neural Network Pattern Recognition of Acoustic Emission (AE) signals for early detection of cracks in couplings used in aircraft and engine drive systems. AE signals were collected in order to establish a baseline of a gear-testing fixture background noise and its variations due to rotational speed and torque. Also, simulated cracking signals immersed in background noise were collected. EDM notches were machined in the driving gear and the load on the gearbox was increased until damaged was induced. Using these data, a Neural Network Signal Classifier (NNSC) was implemented and tested. The testing showed that the NNSC was capable of correctly identifying six different classes of AE signals corresponding to different gearbox operation conditions. Also, a semi-real-time classification software was implemented. This software includes functions that allow the user to view and classify AE data from a dynamic process as they are recorded at programmable time intervals. The software is capable of monitoring periodic statistics of AE data, which can be used as an indicator of damage presence and severity in a dynamic system. The semi-real-time classification software was successfully tested in situations where a delay of 10 seconds between data acquisition and classification was achieved with a hit rate of 50 hits/second per channel on eight active AE channels.