Preliminary analysis of capture and processing of vibration signals

from a vertical mill rolls.

Mendes, C. J.1 , Oliveira, A. L. M. B1 , Pereira, G. C.1 , and Souto, C. R.1,*

1
Postgraduate Program in Mechanical Engineering, Federal University of Paraíba.
cintiajmendes@gmail.com, anne.louise@academico.ufpb.br, gcp2@academico.ufpb.br
*
Advisor: cicerosouto@cear.ufpb.br
PPGEM Scientific Writing Seminars: Season 2020
December 10 and 11th, 2020
www.ct.ufpb.br/ppgem

Keywords: Signal acquisition, Analysis, Fast necessary. An unscheduled shutdown caused by the
Fourier Transform, Hilbert-Huang Transform, Wavelet breakdown or mechanical failure of a hydraulic cylinder
Transform, PLC. terminal causes an immediate loss of performance in
the mill’s productivity.
Abstract

This work describes the capture procedures

and preliminary processing of vibration signals
from a mill vertical rollers. The behavior of
vibrational analysis was made through a sys-
tem acquisition using the logic controller pro-
grammable - PLC and signal processing meth-
ods such as fast transform Fourier, Hilbert- Figure 1: Vertical roller mill. Source: [10]
Huang Transform and Transformed Wavelet.
The results showed similarities in the processed Thus, the counter pressure cylinder is no longer trans-
signals between the Kurtosis curve that is re- mitted to the roller, until the replacement of the broken
lated to the amplitude of the captured signal. terminal occurs. The hydraulic cylinder terminals of
Thus, the data collected and processed will con-
vertical roller mills in cement industries are large and
tribute to a more accurate diagnosis to observe
high-mass equipment. Therefore, replacement work re-
the cause pattern of hydraulic terminals break-
age of a vertical mill, which causes stops and quires many hours of maintenance during equipment
productivity losses for the cement industry. interruptions. This can also cause the need to shut
down the clinker furnace, due to the lack of material.
1 Introduction The upper end of the complete cylinder has undergone
several regrettable mechanical failures including physi-
The cement industry is responsible for the manufacture cal damage. Breaks always occur in the curved profile
of a product that is widely requested in the most varied of the terminal (figure 2). The causes of the damage
types of masonry constructions, being mainly used to vary and appear as atypical occurrences. Among them
compose the concrete to be used in the works. Concrete we have: the types of material of the terminal, clear-
is considered the second most consumed material in the ances and mechanical wear on the components of the
world, second only to water [6]. hydraulic cylinder and connection arm with the roller.
Currently, the technology implemented in the produc- These parameters and procedures process excessive vi-
tion of cement in Brazilian industries is called ‘dry pro- brations. The history of malfunction due to damage
cess’ and has the following steps: Grinding and homog- has a non-periodic profile, but with more incidence in
enization of raw materials; Clinkerization of raw flour a specific roller position than in another.
in rotary kilns and subsequent cooling of the clinker;
Clinker grinding for and addition of plaster to obtain
cement; Bagging and shipping of the final product [16].
The grinding steps, which are fundamental steps in the
manufacture of cement, the grinding process is carried
out in vertical roller mills (figure 1), one of the essential
parts of this equipment is the hydraulic cylinder of the
roller, which plays a fundamental role in the pressure
grinding required to obtain the ground material with
suitable fine-grained properties and density, in which Figure 2: Grinding scheme of a vertical roller mill.
case constant monitoring of its perfect functioning is Source: [10]
This demonstration of the acquisition and analysis of
the vibration signal of the upper terminal of the hy-
draulic cylinder of the vertical mill of the Portland
cement industry produced by Elizabeth Cimentos, and
the application of signal processing techniques by mod-
eling using the Fast Fourier transform - FFT, Hilbert-
Huang and Wavelets, in order to find possible failure
frequencies and amplitude variations. And so to de-
tect possible causes of damage to the terminals of the
hydraulic cylinder, leading to a reduction that implies
corrective maintenance and loss of production.
2 Signal analysis
According to [7], a signal can be formally defined as a
function of one or more variables that carry informa-
tion about the nature of the physical phenomenon being
studied. For the generation, extraction of information
or reception of each signal there is a system involved,
that is, an entity capable of manipulating one or more
signals to perform a function.
Thus, a system is able to change the characteristics of
a signal, if desired. There are several classes of signals.
From these classes, each sign is characterized based on
the characteristic behavior of each one. So, for this
work it is relevant to know the difference between the
following classes of signals:
• Continuous and discrete signals over time. Where
the continuous signal is characterized by varying
continuously with time and the discrete signal has
the information only in a few moments of time,
the Nyquist rate (2B).
fs ≥ 2B (1)
Ts ≤
1
(2)
2B
The Nyquist rate is the foundation for digital processing
and signal reconstruction, since it mitigates the aliasing
effect, called signal falsification. Thus, as long as fs is
equal to or twice the bandwidth B of the signal (in Hz),
the discretized signal will consist of non-overlapping
repetitions of the original signal [9].
2.2 Technics and processing signals: Trans-
formed Fast Fourier - FFT
The history of FFT can be started with the advent of
computing and the need to use DFT (Discrete Fourier
Transform) to determine the spectral content of a signal
in the time domain, due to its inefficiency the evolution
brought about by. J. W. Cooley and J. W. Tukey in
1965, an article describing an efficient algorithm for im-
plementing DFT, this algorithm became known as Fast
Fourier Transform (FFT). The figure 3 demonstrates
the difference between the two methods with the same
number of samples the FFT does much less operations
to determine the spectrum. .

• Analog and digital signals. An analog signal is de-

fined as a signal that has analogous (proportional)
time variation, and the digital signal refers to
the transmission of a sequence of values, which
are represented by digits of some encoded form,
usually binary, Figure 3: Comparison between standard DFT and
FFT. Source: [3]

• Periodic and non-periodic signals. A periodic

2.3 Techniques and processing signals: Trans-
signal is continuous over time, whereas a non-
formed Hilbert-Huang
periodic signal does not follow the same rule.
The envelope technique is based on the detection of
2.1 Sampling Theorem and Nyquist the signal envelope, that is, the recovery of the signal
contour. It is possible to obtain the signal envelope
The sampling frequency principle for reconstructing a in time through the analog envelope detector, using a
continuous signal over time is based on the Nyquist rate, passive circuit, or through digital technique using the
or also called, Sampling Theorem. Thus, since a real Hilbert transform shown in the equation 3:
(analog) signal has a limited spectrum in a frequency
range in (B) Hz, it can be reconstructed without errors, 1
Z +∞
x(τ )
from its samples and its reconstruction [9]. y(t) = P dτ (3)
π −∞ t −τ
Equation 1 shows the relationship of the sampling fre-
quency fs and equation 2 shows the relationship of the Where y(t) is the Hilbert transform that describes the
sampling period Ts as a function of the signal frequency relationship between the real y(t)) and imaginary x(t)
(B).If, and only if, it is sampled at a rate fs (sampling values captured in the signal obtained from a system
frequency) greater than or equal to 2B. In other words, and P represents the main Cauchy value [5].
The envelope technique is composed of a set of proce- level, and finally the signal is decomposed to the ex-
dures applied to the signal: pected level [17]. The figure 4 demonstrates the process
described above.
• Captures the signal in the time domain;

• Pass the signal to the frequency domain;

• A filter is applied in the range of interest;

• Return the signal for the time domain;

• Detects the signal envelope;
• Returns to the frequency domain.
Presented by [8], the Hilbert-Huang Transform consists
of a decomposition (empirical mode decomposition -
IMF) in empirical oscillatory modes of the temporal
record, that is, functions intrinsic to the system (in-
trinsic mode function), followed by the application of
the Hilbert transform on these functions. Through this
technique, information about the instantaneous frequen-
cies and amplitudes of each IMF is obtained over time.
The set of these instantaneous frequencies and ampli-
tudes for all MFIs generates the Hilbert spectrum. The
decomposition of the series in MFIs facilitates the ap-
plication and especially the interpretation of the result
Figure 4: Decomposition of the discrete transform of
Wavelets . Source: Adapted from: [2].
The family of Wavelets most used is the family of
Daubechies. Created by Ingrid Daubechies is the
only family of Wavelets that has compact support and
smooth decay. The compact support prevents Wavelets
spread across the spectrum and decay soft prevents the
Wavelets introduce high frequency artifacts [12].
2.5 Comparative
The table 1 it makes a comparison between the tech-
niques used in this article.
FFT Wavelet Hilbert-Huang

obtained from the Hilbert transform that is described Base

Frequency
A priori
Global Convolution Uncertainty
A priori
Global Convolution Uncertainty
Adaptive
Local-Certain Differentiation

by the equation 3. The set of instantaneous frequen- Presentation

Signal Non-Linear
Energy-Frequency
No
Energy Time-Frequency
No
Energy Time-Frequency
Yes
Stationary Yes No No
cies and amplitudes generates the Hilbert spectrum,
through this spectrum it is possible to identify not Table 1: Comparison between processing techniques sig-
only the frequency over time of the MFI, but also the nals source Source: [13].
variation of signal amplitude [14].

2.4 Techniques and processing signals: Trans- 2.6 Time-domain techniques - Kurtosis and
formed from Wavelet VRMS.

The word “Wavelet” comes from the French word “On- Vibration signals must also be analyzed by statisti-
dalette”, which means small wave. The role of trans- cal techniques so you can obtain characteristics global
formed from Wavelet continues is: signal. Therefore, this article will use two important
techniques in the vibrations analysis of machines.
The RMS value of the normalized signal (equation 5) is
−τ the second statistical moment of the signal that provides
Z
1 ∗t
CW TΨ
x (τ, s) = ΨΨ
x (τ, s) =p x(t)Ψ dt
|s| s an estimate of the vibration energy. It is a parameter
(4) widely used to estimate the severity of vibration of ma-
chine casings and describes the state stationary of a
In this equation s acts as a scale factor and τ acts
variable time signal [11].
as a window displacement factor; Ψ is known with a
function Wavelet mother this function is applied over
the function under analysis (x(t)), in windows and with
s
1 T
Z
different dimensions defined by the scale value s. The RM S = (x(t) − x̄)2 (5)
T 0
equation 4 can be seen as a general form of the trans-
form that can vary depending on the function assumed
by Ψ. Thus, the Fourier transform is understood as a Where T It is Period and x̄ It is The average of signal.
particular case of the Wavelet with the Wavelet mother Kurtosis (equation 6) is the normalized fourth-order
being the exponential function [12]. statistical moment of the signal. It provides the impul-
Analysis of the discrete transform of Wavelet performs sive nature of the signal by driving isolated peaks and
a multi resolution analysis. It uses two sets of functions can serve as an indication of failure in rotating elements
called Scale functions and Wavelet that are associated such as bearings [17].
with low-pass (L) and high-pass (H) filters. The dis-
1 T
crete signal is approach A1 causes it to be decomposed 4
R
T 0 (x(t) − x̄)
into approximation A2 and detail (D2) on the second K= 4
(6)
(RM S)
3 Methodology [15] stated that most programmable logic controllers
are completed with an HMI, human machine interface.
This section will be used to describe the methods for Especially in an operation process that remains pro-
acquiring the vibration signal from the upper terminal ductive, of which operators and maintainers need to
of the hydraulic cylinder on the vertical mill machine interact almost daily with the machine to set up its op-
of rolls. erating parameters, commands and perform diagnostics.
At the beginning of the introduction of PLCs on the
3.1 Vertical roller mill market, the user interface was very similar to that ex-
isting on relay panels. Today, with the reduction in the
Currently, vertical mills are installed together with a cost of liquid crystal displays, man-machine interfaces
variety of continuous monitoring systems that include have emerged HMI.
oil levels, temperatures, pressure, drive motor current
and material layer on the grinding table. gaps and 3.3 Signal acquisition - Procedure
mechanical failures when fixing the rollers and safety
backrests, this risk increases considerably. First, the best point for installing the VTV122 sensor
from the manufacturer IFM was verified, the dimen-
In the field of data acquisition process theory studies,
sions of which are shown in the figure 6 The sensor’s
acquiring data can be simply defined as measuring real-
operating range varies from 0 to 25mm / s, supply volt-
world information. Most real-world events and their
age from 9.6 to 32VDC, the sensor response and analog
measurement are of an analog nature. That is, the
range from 4 to 20 mA [4].
measurement can lead to a range of continuous values.
Being able to have several physical quantities of interest:
light, temperature, pressure, displacement, in this work
the physical magnitude of interest is displacement. All
these quantities have energy.
Thus, it is necessary for its measurement to use de-
vices capable of receiving this energy and converting it
into a form of energy manipulable by electronic circuits.
These devices are sensors and transducers. The sensors
and transducers take the physical quantities of analog
quantities and convert them into electrical quantities,
such as voltage, current or impedance. In the study in Figure 6: Dimensions of the VTV122 sensor. Source:
question, the VTV122 sensor was used. For the process [4].
of acquisition and processing of vibration signals, the
diagram shown in Figure 5:
Taking based on the operating characteristics of the
sensor and the indication of the manufacturer of the
vertical mill, the best point for installing the sensors
indicated in the Figure was determined 7. At the termi-
nal that articulates the hydraulic system and the mill
roll.

Figure 5: Representation of the system in a diagram

Blocks. Source: Author’s collection

3.2 Programmable logic controllers - PLC

One of the most used controllers in the industry today,

is the PLC (programmable logic controllers) equipment Figure 7: Installation point for the VTV122 sensor at
developed to command and monitor the most diverse
machines and or processes, largely inserted in the au-
tomation of large factories.
It can be defined as the control system based on current
events which make use of a single sequence to carry out
the scheduled operations. Thus, with the pre-defined
data, the equipment monitors all inputs, run the logic,
and then I managed to update the outputs. Centralizing
the combinations between sensors and actuators. These
are connected on a single bus, however, the processing
logic remains centralized.
the vertical mill terminal. Source: Author’s
personal file.
The signal used was the controller used, compactlogix
1769, shown in the figure 8 manufactured by Rockwell,
it is part of the Logix controller family, uses RSLogix
programming software 5000, has Ethernet communi-
cation ports and allows remote configuration via the
device net network, it is compact and features analog
and digital inputs and outputs. For the application in
question,analog input is used [1].
 In addition, it is also noted that the normal frequency
distribution by the histogram is shifted to dear (figure
11).

Figure 8: Compactlogix 1769. Source: Personal archive

of the author.

4 Results and discussions

The hydraulic cylinder has the function of supporting

the rollers by positioning them so that the material is
compressed, the movement of the hydraulic cylinder is
axial. To understand the vibrational behavior of the
machine, as the natural frequency of the terminal was
not known, we chose to start the study of the vibrations Figure 11: Frequency distribution signal and histogram
behavior of the set. When subjected to a rotation of consequences.
33,201 rpm of the reducer that start the mill.
Then the tool was used Wavelet GUI that provides an
The acquisitions were made using a PLC with an ac-
accurate noise reduction process, allowing us to adjust
quisition rate of 20 samples per second. The signals
the necessary parameters to reduce the noise of a signal
were captured for 25 days with an hour of acquisition /
shown in the figure 12. Where the original signal goes
day. Of these 25 acquisitions, 3 showed inconsistencies
through a process to discover the coefficient threshold
due to energy fluctuations. Initially, the classic tech-
and thus removes the noise from the signal at the end
niques of signal analysis were used, the FFT was the
of this process, there is a change in the signal and its
first, but due to the signal being noisy, we opted to use
noise is removed for further analysis.
more appropriate techniques, it is perceived by the first
signal that the FFT is concentrated in lower frequency
levels. , with the envelope is in evidence and as you
observe the other days shows this same behavior in all
22 signs analyzed the figure 9 represents the signs with
the envelope.

Figure 12: Removing the signal noise.

Figure 9: Hilbert transform - Technique of aging lope.
The idea of using Wavelet it came due to trying to find
a pattern in this signal and through decomposition it
could be visualized. However when loading the signal
initially it is noted that it is not possible to find a
certain pattern in the figure 10.
Before updating the signal, you can have a preview
of the new signal, its new frequency distribution, now
with the normal distribution adjusted, its spectrum
(frequency). frequency x energy) and the wave family
used for this analysis which was Daubechies can be seen
in the figure 13.

Figure 13: Normal distribution, spectrum and signal.

As soon as the signal is updated, one realizes that a

Figure 10: Decomposition of the signal with noise. signal without noise is still non-linear, so the Hilbert-
Huang analysis would be the most appropriate for this With the analysis of the signal processing methods to-
signal, so the analysis continued through this process. gether, the kurtosis data of each signal and its VRMS
with noise and without noise were saved.
The figure 14 it demonstrates the decomposition of the
Hilbert-Huang transform in 3d, initially visualizing the
functions in an intrinsic way (MFIs) and at the end the
residual. MFIs have 10 modes and are on a graphAm-
plitude Versus Time versus mode, among the 22 signals
analyzed, the decomposition format followed as shown
only by changing the place where the greatest ampli-
tude was sometimes at the beginning or end of time.
Generally, MFIs can indicate where the high frequency
impacts on rotating elements are, taking into account
the high amplitudes and comparing with the spectrum,
it is corroborated that this analysis will actually be at
low frequencies.
Figure 17: Kurtosis of the signal with and without
noise.

One signal practically superimposes the other except

for some samples that are at odds with others, but the
difference between them is in the order of 0.01 (figures
17 and 18).

Figure 14: IMFs.

The figure 15 represents the Hilbert spectrum. The

frequency versus time graph is a graph indicating the
instantaneous energy at each point in the IMF. The
graph represents the instantaneous frequency spectrum
of each decomposed component of the original mixed
signal. The MFIs appear on the graph with a distinct
change in color, more energy on the yellow side and
compared to the FFT the energy peaks are in the same-
place.
Figure 18: VRMS of the signal with and without noise.

It was then decided to use the signal amplitude values

because generally very high amplitudes can indicate
failures so the comparison between them was made.

Figure 15: Hilbert spectrum.

The figure 16 demonstrates the spectrum graph in the

form 3D. Here the MFIs can be better perceived by the
yellowish color and the higher their energy levels are in
relation to the other points.

Figure 19: Comparison with noise.

And here it can be noticed that there is a pattern be-

tween kurtosis and amplitude much closer than VRMS
and with the removal of the noise the signals follow
exactly the same direction of linearity as if there was a
Figure 16: Hilbert spectrum in 3d. correlation between them (figures 19 and 20).
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Figure 20: Comparison without noise.
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5 Conclusion has insipientes em máquinas rotativas baseado
em análise de vibração e lógica fuzzy. Tese de
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this method can contribute to the detection of failure Sul, Porto Alegre - RS, 2000.
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