New Approaches for Supervision of Systems with Sliding Wear: Fundamental Problems and Experimental Results Using Different Approaches

Reliability and availability of technically complex and safety-critical systems are of increasing importance. Besides the degree of wear, the quality of mechanical systems is significant for the system reliability. The focus of this contribution is the development and application of readily applicable and easily interpretable algorithms for industrial data obtained from technical systems during operation. The methods are within the focus of the production-oriented automation programs (Industrial Internet, Automation 4.0, China 2025). In this contribution as example a hydraulically driven machine in which parts slide over each other is chosen as sliding wear example. Monitoring is applied to distinguish normal and abnormal operation as well as to define end of useful lifetime. In this contribution four different methods will be introduced and experimentally compared without the availability of objective information about the wear state. The approaches differ with respect to the used measurements and data preparation. As measurements Acoustic Emission and the hydraulic pressure of the driving machine are used. For processing the accumulation of damage related values, a machine learning algorithm, and a sensitivity matrix are used. For comparison the experimental validation is based on identical data sets. Different operational states of the system denoted as actual system state are defined and classified. The comparison shows that the four introduced methods provide similar classification results although the underlying measurements are based on different physical principles. The newly introduced approaches allow online evaluation of the actual system state and can serve within improved maintenance strategies.