International Journal of Mechanical

Engineering (IJME)
ISSN(P): 2319–2240; ISSN(E): 2319–2259
Vol. 9, Issue 2, Feb–Mar 2019; 11–20
© IASET

REAL TIME CAR CONDITION MONITORING BY ANALYSIS OF INSTANT ANGULAR

SPEED

Abdulrahman S. Sait & Yaser A. Hadi

Research Scholar, Department of Mechanical Engineering, Yanbu Industrial College, Middle East Saudi Arabia

ABSTRACT

This task clarifies an instantaneous angular speed (IAS) test technique that is robust for engine condition monitoring
(CM). The pivot of the crankshaft is dependent on the cylinder speed, determined using the situation in this study. The tests
and the research discussed in this project offer a thorough understanding of the harmful implications for the quick angular
speed. Moreover, using the angular move procedure it demonstrates the subtleties in crankshaft motion. The optical
encoder is used to obtain data about angular motion.In the stage region, the sign was acquired and broken using the sign
average to decide the weaknesses and their location. National instruments are used and programming code for NI
LabView is produced for ongoing use. Optical encoders are tentatively investigated by implementing IAS studies under
multiple operating circumstances to cylinders that issue recognition devices.

KEYWORDS: Condition Monitoring, Instantaneous Angular Speed, Crankshaft, Angular Speed, Optical Encoder

Article History
Received: 09 Feb 2020 | Revised: 20 Feb 2020 | Accepted: 29 Feb 2020

INTRODUCTION

The diagnostics of motors are a major field in the assembly [1], use and production of vehicles. Since the principal
automotive engine in the nineteenth century, weaknesses in engines have been identified, but diagnostics have been done
on both sides. Most methods have been developed with the check of engine conditions to evaluate crankshaft angular speed
[2]. The accurate speed of the crankshaft with ordinary and unpredictable engine operation will be estimated [3].An optical
encoder to a 2014 FORD F150 engine has linked the estimate. Moreover, a Data Acquisition Board (DAQ) is used for
signal receipt [4]. Additionally, the sign synchronization using LabView programming is displayed. The aim is to make a
pragmatic contribution to the evaluation of accurate engine speed. Torn hardware can be blamed every time that unsafe
results or delays can occur [5]. At the start of the era, it is critical to distinguish problems from sudden failure [6].

Condition monitoring processes were therefore studied and linked to the distinction between such problems in
rotating equipment[7], the early identification of damage and a strategic distance away from appalling deception. This can
very well be described as a method for monitoring the circumstances of machines and allowing maintenance to be carried
out before failure [8]. The area of rotating machinery condition monitoring is unbelievable [9].Conditional surveillance
methods restrict the machine's private time and help cash/time by perceiving the damaged parts without requiring stopping
or evaluation[10]. This process improves damage identification methods by using sensors to obtain data concerning the
display of turning frameworks and changes in the practices of those frames observed.Some of these methodologies use an

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12 Abdulrahman S. Sait & Yaser A. Hadi

important discovery procedure, such as the oil examination of various petroleum products. The majority of the continuing
projects also focus on more advanced methods such as angular movement assessment, vibration-based analysis, model-
based analysis and mathematical modelling [11-12].

Vibration Anaylysis

Vibratory assessment is an anomaly search method that observes changes from the built-in frame vibratory mark [13]. It is
Vibration analysis, a well-established technique for condition monitoring of rotating machines, as the vibration patterns
differ depending on the fault or machine condition [14]. Amplitude, force and frequency vibration of any object movement
are shown. These can be combined in physical wonders, so that vibration information can be used to gather bits of
knowledge in the strength of the gear.A strategy for condition monitoring of rotating machinery is generally used to
examine vibration. Accelerometer is a gadget in this operation where vibration signals are collected from insufficient
components of the rotating device. Time-frequency analysis is one of the powerful tool used in vibration analyzes in the
significant area of structural surveillance. Commonly used, spectrally based signal analyzing method is strong to diagnose
a range of vibrational issues in rotating machines [15].

Figure 1: Deviations in Time and Frequency depending on a Vibration.

The usual working condition and in the defective working condition, the optical encoder sensor is connected to
the cellular shaft surface that is used for adaptable coupling techniques in the crankshaft pulley. In any event, a structured,
determined and estimated element is used to hang this sensor. In LabView programming, the sensor estimates accurate
speed by pulsing, which will be transferred to the DAQ board by sign. The reason behind the assessments is to explain the
source of inconsistency in the rotational speed. The original stage of the test is to differentiate between the rotational speed
variation and the vital operating stages of the test engine in case of complete insurgencies [16]. This test aim needs a quick
rotational speed estimate, as shown in the Figure 2.

Figure 2: The Waveform of Engine Speed Sensor.

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Real Time Car Condition Monitoring by Analysis of Instant Angular Speed 13

The assessment will first be numerically structured in this work. The LabView block diagram has been intended
to measure the precise speed and unpredictable engine operations of the crankshaft. In addition, the exact speed of the
engine shaft has been monitored continuously, thus forming part of the crankshaft angle. (4.) The reciprocal piston
movement in relation to the angle of the crank is represented by those velocity circumstances.

′
=

−2
= − +
√ −

=− −
√ −

L = rodlength (distance between piston pin and crank pin).

R = crankradius(distance betweencrank pin and crank center, half stroke).

A = crank angle (from cylinder bore centerline at top dead center).

x'= Velocity with respect to crank angle.

The test design is a systematic optical encoder that is legitely mounted and linked to the power supply on the free
part of the structure. The encoder has a 0 to + 5V pulse rectangular output with an angle resolution of 2000 driving forces
and a reference marker in a 360° crankshaft insurrection.In order to monitor and control the A/D transformation of the
analog measurement value, the encoder signal is passed on to an E6B2-CWZ6C. The rotating button of the encoder was
linked to the voltage vibration damper of the free portion of the bargain, Figure 3. With an uncommonly built support
connected to the engine body, the encoder body was fixed and focused in association with the crescent hatch. This
constituted the primary engine adjustment.

Figure 3: Single-Cylinder Dynamics Model.

The mathematical equation of angular speed is:

=− + Where R=0.02 and L=0.2
!

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14 Abdulrahman S. Sait & Yaser A. Hadi

Control of the Engine Performance Changes

The work shows the inconvenience of the oil engine ignition quality (Figure 4), is to be checked by using the crankshaft
angular velocity variety and its subsidiary. Contemporary programmable rational controllers empower estimates of quick
angular velocity, long distance recordings and quality documents.An optical
optical encoder is used to estimate Instant Angle
Speed (ISE),
SE), where the basic configuration and steady flag are the preferred position of this strategy.MS equations can be
used to prepare the collected information. The perception of changes in instantaneous speed cannot replace, but can be
used for early warning, fundamental estimates of weight or control. An increasingly precise assessment can be performed
at the point in which signs of crumbling of engine execution are obtained. The anticipated result is the removal of the
engine cycle abnormality. At the beginning of the examination period, the suggested technique shall be used and further
measures to demonstrate its usefulness and to establish the laws of closing shall be taken. The paper shows a fundamental
investigation into an amount of information gathered from two mass carriers operating under
under comparative conditions.
conditions

Figure 4: Petroleum Engine Waveforms.

Innovative Illustrations

From the cautious perception that the motor was vibrating when turned on, it was a test to plan for a hanging scheme with
the same development as the motor when it was drived
drived and walked along the lines. The enhanced design of the system
should be connected to the optical encoder,
encoder but adjusted to the pole focal point of the crankshaft. Depending on the space
available, two basic designs selected for the mechanism, the configuration of the crankshaft pulley to move the movement
to the encoder, and the configuration of the customizable connections to keep the encoder in the right position, precisely
aligned with the cap, clear in the following SolidWork figures, Figure
Fig 5 to Figure 12, applied
pplied before the start of the vehicle
workshop examinations.

Figure 5: Design of Crankshaft Pulley Cap. Figure 6: Design of Fixture Mechanism.

Impact Factor (JCC): 6.0742 NAAS Rating 3.30

Real Time Car Condition Monitoring by Analysis of Instant Angular Speed 15

Figure 7: Crankshaft Pulley Design. Figure 8: Flexible Coupling 6 mm to 10 mm.

Figure 9: Adjustable Links Design. Figure 10: Cubic to Connect each Two Links.

Figure 11: O.E. Connect to Crankshaft Pulley Cap. Figure 12: Mechanism Assembly.

Crankshaft Pulley Cap Design

The main structure was a plastic shaft linked to the crankshaft sweater's bolt cap, Figure 13. After the plastic shaft was
linked to the bolt cap, a misalignment was discovered. This intended the top of the crankshaft pole. When the poultry
rotates the encoder at a similar speed, this cap design is connected to the shaft of the optical encoder along those lines. The
first is 139 mm diameter and 18 mm thick to fit inside the pulley. It is designed with four rings. This is to be attached to the
pulley's surface with a diameter of 159 mm and a thickness of 10 mm. The third ring is 50 mm wide and 20 mm thick for
additional machines. The last is 10 mm in length and 40 mm in thickness with a 10 mm junction opening. The crankshaft
pulley cap with a small 10 mm shaft has been intended for the adaptable coupling to be connected to the shaft of the 6 mm
optical encoder.

Figure 13: Installed Bolt Cap.

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16 Abdulrahman S. Sait & Yaser A. Hadi

Adjustable Links Mechanism Design

The entire structure was produced of AISI-1050 carbon steel, but the structure was sufficiently loud to produce elevated
vibration, Figure 14. Therefore, the best material was chosen that was wood, because it was cheaper, easier to process, and
lightweight. The adjustable connections, which have been intended to keep the optical encoder in place, are composed of
four connections of various sizes depending on the room available before the motor. The first connection is the Z-axis, 180
mm long and 6 mm in diameter. Secondly, the Y-axis is produced of 300 mm long and 6 mm in diameter. The third axis
has a diameter of 300 mm and the X-axis 6 mm. Fourth, connect the 180 mm long and 6 mm diameter length of the
encoder to be installed on the Y-axis. There are three cubic crossings of all 20 mm wood and two 6 mm end holes on the
two axes, (X-Y), each of which consists of a total of 20×20 mm wood.

Figure 14: Installing AISI-1050 Carbon Steel Mechanism.

Experimental Results and Analysis

Seek methods to install the system of the engine. We went up with the concept that the engine block does not have to be
changed. The concept is easy to change and simple. The concept is that a piece of metal is 180 mm long and 6 mm
diameter welded together on this welded washer, as illustrated in Figure 15. The adjustable joints are connected to the
metal portion, Figure 16. Moreover, as shown in the Figure 17, the crankshaft pulley has been focused. This link is then
connected to the optical encoder (OE). Next, the crankshaft pulley cap has been machined; it matches the pulley precisely.
By using a flexible coupling, the encoder is connected to the cap to absorb shock at engine beginning.

Figure 15: Installing Adjustable Links.

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Real Time Car Condition Monitoring by Analysis of Instant Angular Speed 17

Figure 16: Fit of Crankshaft Pulley Cap.

The following results show the detection of faults by comparing the eight cylinders in the Figure17healthy full
waves. Figure18, demonstrates that cylinder fault of 3 and 4 is due to cylinder injection disconnection at a rotary velocity
of 650 rpm. Figure19 indicated that the engine is operating at 610 rpm in an unhealthy manner (ancient oil, ancient filters
and ancient spark plugs). Figure 20, shows that the cylinders 1 fault at 600 minutes owing to a disconnected spark plug.
The wire of the spark plug is also disconnected in the same way as the one at 626 rpm, Figure21. Lastly, the piston
misfiring failure of cylinder 1 at 616 rpm, Figure 22.

Figure 17: Full 8 Waves.

Figure 18: Cylinder Injection Disconnected at 650 rpm.

Figure 19: All Faulty 610 rpm.

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18 Abdulrahman S. Sait & Yaser A. Hadi

Figure 20: Cylinder-1 Spark Plug Disconnected at 600 rpm

Figure 21: Disconnected Spark Plug Wire 626 rpm

Figure 22: Faulty Misfire 1 Piston 616 rpm

CONCLUSIONS

As we knew, fault diagnosis consists of three levels. First, to ensure whether or not the fault is present, second, to
determine where the fault occurs, and second, to determine the particular portion that occurs. The method used to diagnose
the internal combustion engine can be skilled for the first two degrees using instantaneous angular speed based on
crankshaft. I would also like to highlight the many issues and how to fix them via vehicle workshop trials. First of all is the
O.E. When the pulley is rotating, it must be rotating and has been solved by developing a cover, which fits inside the
pulley or bolt. Second, the shell box is misaligned and solved with a design change that will overcome the misalignment
from a plastic bolt to a crankshaft pulley cap. The third issue lies in the heavily weighted elevated vibration duo and the
material is converted to hard wood. Following that, O.E. was observed. It has altered the resolution to (50, 100, 200, 350
PPR) too elevated (2000 PPR). The key issue is that of the fourth mechanism, which must be adjustable for changes in
sizes if required, solved by creating cubic joints for each two rods that can alter sizes. The following issue was that rigid
connection created elevated vibrations, which were resolved by changing to flexible connection. The final problem, the
usb-6009 DAQ NI panel did not understand the signals due to elevated turns, and solved the matter by developing cubic
joints to make measurements changeable for each rod. In this paper as well as in the CM matrices, the data given was
based on several CM journals. This data was primarily supported by the following references.

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Real Time Car Condition Monitoring by Analysis of Instant Angular Speed 19

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Impact Factor (JCC): 6.0742 NAAS Rating 3.30