THE ANNALS OF UNIVERSITY “DUNĂREA DE JOS “ OF GALAŢI 7

FASCICLE VIII, 2007 (XIII), ISSN 1221-4590

TRIBOLOGY

Paper present at

International Conference on
Diagnosis and Prediction in Mechanical
Engineering Systems (DIPRE’07)
26 - 27 October 2007, Galati, Romania

DIAGNIOSIS OF THE TECHNICAL STATE OF COMPLEX

MECHANICAL SYSTEMS
Ion CRUDU, Constantin SPÂNU, Monodora RÎPĂ, Claudiu TELETIN

University “Dunărea de Jos” Galati, Romania

constantin.spanu@ugal.ro

ABSTRACT
The paper presents a model for prediction and diagnosis of technical state of
complex mechanical systems based on the systems theory. In diagnosis studies is
used a model that has only input and output parameters as a representation of the
system function and behavior. In the paper the authors suggest a more complex
model which contains command and control parameters as well. According to the
prediction/diagnosis studies a model allows: mathematical expression of the
process, determination of the parameter values for the independent inputs and the
variable parameters, identification of both measurable and unmeasurable
parameters. Diagnosis prediction can be done for short, medium and long term. A
very important problem remain: passing from the tribomodel to the tribosystem in
order to diagnose the life time.

KEYWORDS: Diagnosis, prediction, tribosystem, tribomodel.

1. IMPLEMENTATION OF finally, passing to a new field of the scientific

SYSTEMS’ THEORY
Concerns for the future studies with respect to
the behavior of the present technical systems have
been carefully dealt with and special interest is still
attached to this matter. This is mainly due to the
emergence of determined-life complex systems such
as satellites, spatial ships etc.
Prediction or diagnosis implies an anticipation
of the future evolution of various processes occurring
inside the component parts of the complex technical
systems with a view of optimizing their relevant
parameters.
Diagnosis implies to pass from a mosaic of
knowledge related to a certain technical system to the
very structure of that knowledge. This is in fact
implementation of the systems’ theory [6], an
extension of the mathematical generalizations and,
creation.
A complex mechanical system can be divided
into technical systems of well determined functions
within a technological process.
Figure 1 illustrates the model of a technical
system based on a ‘black box’ principle [7].
A model, in the most general terms, is a
representation of the system function and behavior. It
refers to an existing operating system, a system being
designed or a system under study.
According to the prediction/diagnosis studies on
operating systems, the model allows for:
-mathematical expression of the of a process by
means of block diagrams, graphs, transfer matrices;
-determining the parameter values for the
independent inputs and the variable parameters;
-nominalization of both measurable and
unmeasurable parameters at the systems input and
output.
 THE ANNALS OF UNIVERSITY “DUNĂREA DE JOS “ OF GALAŢI 8
FASCICLE VIII, 2007 (XIII), ISSN 1221-4590
TRIBOLOGY

The higher frequency functions which can be

applied take various forms, such as:
- linear function
y  t   a  bt (2)
- n-th order parabolic function.
y  t   a0  a1t  a2 t 2  ...  an t n (3)
Fig. 1. The structure of a one-function technical - power function
system { x }  { y } [7]. y t   a  t b (4)
- exponential function
For the diagnosis studies the authors suggest [8, y  t   a  et (5)
9] a model (fig. 2) which contains command and
control parameters as well. The parameters of the or y  t   a  b t
and y  t   k  a  e t
(6)
working process with respect to the material, power - modified exponential function
requirements and the characteristic parameter y  t   a  bk t (7)
(mechanical output, heat loss, etc) are considered
input-output parameters. - semi-logarithmic function
The system command parameters are both y  t   a  b ln t (8)
construction parameters (contact shape, material of - logistic function
the contact components, etc.) and operating k
parameters (loading, working speed, lubrication, etc). y t   (9)
1  be  ct
The control parameter is the thermal regime
(working temperature etc). - hyperbolic function
1 b
This model can be used in the diagnosis studies y t   or y  t   a  (10)
of technological systems in various fields (metallurgy, a  bt ct
chemistry, food, etc.) - Johnson function
a
ln y  t   k  (11)
bt
- Gompertz function
ln y  t   k  ae  t (12)
-Tornquyist function
kt k a  t 
y t   or y t  
at bt
t c
or y  t   bt (13)
ta
Fig. 2. The structure of a model for technical - exponential power function
systems prediction. y  t   e at t b (14)
In all functions, y stands for dependant
Dependence of output values on the input and variables; t-for time, a0, a1, a2 … an, b, k function
command values has the form: parameters.
y  f  x,u  (1) These methods can be used for short, medium
The model is fitted with a feedback link which and long-term predictions.
highlights the influence of the output values on the The term is chosen depending on the out of use
input ones. process. This can be based on a wear or fatigue
process when the life time can be established from the
2. DIAGNOSIS OF THE OPERATING initial calculations at the design stage. If there is no
such calculation support, some life times are propo-
SYSTEMS sed informatively. Upon the action of circumstance
factor, such as overloads, modification of the working
Practically, the diagnosis technique allow for environment etc, diagnosis is made on short term (0.5
the use of models based on extrapolations of dynamic to 2 years). When ordinary factors are involved (the
series, explanatory and intuitive (qualitative) load varies within known limits, working regime is
predictions models. known, etc), the diagnosis is made on medium term
Based on the extrapolations of dynamic series, (1 to 5 years). If the process is considered to occur
various statistics–mathematical functions can be used. during a longer time (low-frequency variable loads,
The evolution of the out-of-use process is based on ordinary loading and speed), we shall have a long-
the time factor. term diagnosis (up to 10 years).
 THE ANNALS OF UNIVERSITY “DUNĂREA DE JOS “ OF GALAŢI 9
FASCICLE VIII, 2007 (XIII), ISSN 1221-4590
TRIBOLOGY

An important problem is to select analytical components get out of use. From figure 3 [8] it can be
functions out of those given above. seen that the damage of the surface layer due to wear is
The extrapolation analytical function is chosen present in 50% cases and due to corrosion in 20% cases.
by the variation coefficient method. A comparison is
made between the graphic of the real values of the
absolute derivative, relative derivative and elasticity
function having the form of the extrapolation
functions described above.
The absolute derivative is calculated by the
relation:
dy
 t   (15)
dt
The relative derivative
Fig. 3. Types of decay/damage of the technical
dy 1 dy 1 d  ln y 
 t       (16) components [8].
dt y y dt dt
In the elasticity function The wear damage depends on the type of
d  ln y  d  ln t  d  ln y  tribosystem [9, 10] and therefore on the tribomodel
 t   ;  (fig. 4).
dt dt d  ln t 
Each type of tribomodel involves a special
it results testing technique so as to ensure a max life time.
dy 1 The wear damage occurs in the surface layer;
 t  
 (17)
dt y the general form of such a tribomodel is given in
After the function to be extrapolated has been figure 5 [8, 9, 10].
chosen, its parameters are determined by the least In the initial and final stage the surface layer
square method. contains the following parameters :
- X1-roughness;
 u  t     y  t   y  t 
2
2
0 (18) - X2-hardness of micro-hardness (HB0, HB1);
which should lead to the min value. In the - X3-tension (0, 1);
relation (18), the following notations were used: - X4-chemical composition as a result of the
y0  t  real values of the predicted process; testing conditions and environment (x40, x41);
- X5-metallurgical structure (x50, x51);
y  t  the selected diagnosis/prediction function. - X6-purity (x60, x61).
It is obtained  u  t  , the sum of the squares
2 The characteristics which define the life time on
the design stage (CT) depend on the type of
of the value deviations calculated by the function tribosystem:
y  t  with respect to the observed values y0  t  . - initial and final clearance (sliding tribosystem);
- thickness of the layer which can be removed
3. DIAGNOSIS ON THE DESIGN (abrasive tribosystem);
STAGE - operating time (rolling and cavitation
tribosystem).
The design stage diagnosis mainly takes into
account the cause for which some of the technical

Fig. 4. Types of tribosystems with the corresponding tribomodels [10].

 THE ANNALS OF UNIVERSITY “DUNĂREA DE JOS “ OF GALAŢI
FASCICLE VIII, 2007 (XIII), ISSN 1221-4590
TRIBOLOGY
Fig. 5. General form of tribomodel based on the surface layer and a special
characteristic [8, 9, 10].
During the operation of the tribosystem and
tribomodel testing, the following is monitored:
- level of vibrations;
- presence of shock;
- amount of material removed by wear, etc.
The group of control parameters ‘U’ refers to
construction and testing conditions:
a) the construction of the tribosystem and tribo-
model
u1 - material subject to wear;
u2 - construction dimensions;
u3 - shape of contact (point, linear, flat or cylin-
der surface);
b) surface testing conditions;
u4 - loading,
u5 - presence and type of lubricant,
u6 - temperature of the working environment,
u7 - other characteristics.
Finally it should be noted the problem of
passing from the tribomodel to the tribosystem in
order to diagnose the life time.
4. CONCLUSION
Prediction or diagnosis is connected by the
future evolution of various processes occurring inside
the component parts of the complex technical systems
with a view of optimizing their relevant parameters.
Diagnosis implies a work for structure of the
accumulated knowledge. This structure must be based
on the systems theory.
For diagnosis studies is used a model that has
only input and output parameters as a representation
of the system function and behavior.
In the paper the authors suggest a more complex
model which contains command and control para-
meters as well. The system command parameters are
both construction parameters (contact shape, material
of the contact components, etc.) and operating
parameters (loading, working speed, lubrication, etc).
The control parameter is the thermal regime (working
temperature etc).
10
According to the prediction/diagnosis studies a
model allows: mathematical expression of the
process, determination of the parameter values for the
independent inputs and the variable parameters,
identification of both measurable and unmeasurable
parameters.
For diagnosis studies can be used vary func-
tions, time dependent: linear, n-th order parabolic,
power, exponential, modified exponential, semi-
logarithmic, logistic, hyperbolic, Johnson function,
Gompertz function, Tornquyist function, exponential
power. These functions can be used for short,
medium and long-term predictions. An important
problem is to select analytical functions out of those
given above.
In the design stage diagnosis mainly takes into
account the cause for which some of the technical
components get out of use.
It should be noted the problem of passing from
the tribomodel to the tribosystem in order to diagnose
the life time.
REFERENCES
1. Angheloiu, I. et al.,. 1980, Introducere în sisteme tehnice mari,
Ed. Militară, Bucureşti.
2. Ionescu, Gh., Mleşniţă, R., Poiană, N., 1980, Metode şi tehnici
de cercetare a produselor, Ed. Ştiinţifică şi Enciclopedică,
Bucureşti.
3. Antipenco, V.S., Kaţ G.B., Petrusov. V.A., 1990, Modern i
metodî optimizaţii parametriceskii riadov maşin, Iz.
Masinostroenie, Moskva.
4. Collins, J.A., 1981, Failure of materials in mechanical design -
analysis, prediction, prevention, A.Willey – Intersciece Publi-
cation, Ed. John Willey & Sons, New York, Singapore.
5. Mînzu, V., Lang, B., 2001, Commande automatique des
systèmes linéaires continues, Ellipses Edition Marketing, Paris.
6. Zadeh, L.A., Polak, E., 1980, Teoria sistemelor, Ed. Tehnică,
Bucureşti.
7. Czichos, H., Habig, K.H., 2003, Tribologie – Handbuch, Ed.
Friedr.Vieweg & Sohn Verlag, G.W.V. Fachverlag Gmb. H
Wiesbaden.
8. Crudu, I., 2000, Bazele proiectării în organe de maşini, Ed.
Alma, Galaţi.
9. Crudu, I., 2003, Fiabilitatea şi calitatea sistemelor mecanice,
Ed. S.C. F&F Internaţional, Gheorghieni.
10. Crudu, I., 2007, Tribosistem – Tribomodel în studiul
sistemelor mecanice (in print).
THE ANNALS OF UNIVERSITY “DUNĂREA DE JOS “ OF GALAŢI 11
FASCICLE VIII, 2007 (XIII), ISSN 1221-4590
TRIBOLOGY