1. Copyright © TWI Ltd 2013 Remote Condition Monitoring Using Vibrational Analysis for Train Door Control System VA-RCM Quarter 6 Meeting Vichaar Dimlaye TWI, 10 th March 2014

2. Copyright © TWI Ltd 2013 Content Review of Actions Project Management –Gantt Chart –Deliverable Status –Exploitation and Dissemination Quarter 6 Progress –Tasks Progress Finance Summary

3. Copyright © TWI Ltd 2013 Arising Actions from Q5 Meeting Action 1: VD to contact purchasing about capital request order for Hitex. Action 2: RG to arrange a meeting with Knorr-Brense in January. Action 3: VD to amend Gantt chart with respect to WP2. Action 4: RG to send analogue platform to MS. Action 5: VD to send TSB the exploitation plan as a separate attachment.

4. Copyright © TWI Ltd 2013 Gantt Chart

5. Copyright © TWI Ltd 2013 Deliverable Status D1.1 System Specification – Completed D1.2 Review of Final System Specification – 16/05/14 D2.1 Defect Detection Algorithm – Completed D2.2 Update on Defect Detection Algorithm - 06/06/14 D3.1 Firmware First Release – 21/04/14 D3.2 Firmware Final Release and report 29/08/14 D3.3 User Interface First Release – 23/06/14 D3.4 User Interface Final Release and Report – 29/08/14

6. Copyright © TWI Ltd 2013 Deliverable Status D4.1 Report on system identification – Completed D5.1 VARCM Beta Prototype – 28/02/14 D5.2 VARCM V1 System – 30/06/14 D5.3 Report on system development – 30/06/14 D6.1 Report on demonstration results – 29/08/14 D7.1 Interim Exploitation and Dissemination - Completed

7. Copyright © TWI Ltd 2013 Exploitation and Dissemination Produced project technical brief and flyers Attend conferences and events – Long Marston Rail Demo Day 19th Dec 2013 - Test and Trials Opportunities – Contact Gatwick Carriages –The Eleventh International Conference on Condition Monitoring and Machinery Failure Prevention Technologies, June 2014 – Abstract submitted Organise meeting with Knorr-Bremse (on hold) Disseminate internally through TWI membership pool Looking into further funding from TSB, H2020 or JIP to continue the development of “VARCM” system

8. Copyright © TWI Ltd 2013 Technical Progress

9. Copyright © TWI Ltd 2013 Vibration Measurements Change in bolt looseness was detected in the frequency domain of the acquired signal, Changes in pneumatic air pressure is the critical cause on door failures/slowness Experiments were carried out at East Coast to introduce different air pressure and vibration measurements were captured.

10. Copyright © TWI Ltd 2013 Bolt Looseness LOCATION #1 LOCATION #3 Accelerometer on adhesive mounting base 105 mm Accelerometer on adhesive mounting base The defect: Loosening of support beam bolts (all 4) by 2 turns each (subtle defect)

11. Copyright © TWI Ltd 2013 Statistical Analysis of data (door closing)

12. Copyright © TWI Ltd 2013 Statistical Analysis of data (door opening)

13. Copyright © TWI Ltd 2013 Train Door / Location of the sensor for change in air pressure Located in the side more sensitive to the closing shock

14. Copyright © TWI Ltd 2013 Equipment Compact chasis NI cDAQ-9184 Accelerometer Sensonics PZS1 Laptop with LabVIEW Software

15. Copyright © TWI Ltd 2013 Data Acquisition Data acquisition process were carried out while the door was closing A series of measurements were acquired under normal operating conditions. Some additional series were acquired with changes in pressures to simulate door failure. ScenariosPressureTime to closeNumber of Files Pressure Change 1High5s20 Base LineNormal6s20 Pressure Change 2Low8s10 Pressure Change 3Very Low13s20

16. Copyright © TWI Ltd 2013 Time Domain Data

17. Copyright © TWI Ltd 2013 Post Processing of the data Each scenario has a folder which stores the data acquired in EXCEL format. Matlab code to extract damage sensitive features : –Max Peak Raw Acceleration –Max Peak Filtered Acceleration –RMS Value Raw Acceleration –RMS Value Filtered Acceleration

18. Copyright © TWI Ltd 2013 Post Processing of the data The code puts away these parameters in four arrays. Length of the arrays = Number of files in the folder The mean value of each array is calculated All these features are saved as a structure. The code have to be run in the four folders.

19. Copyright © TWI Ltd 2013 Post Processing of the data Another Matlab code carries out the plotting of the data. Two types of graphs: –Control Chart –Trend Chart Max peak of the acceleration RMS value of the acceleration Max peak of the raw acceleration RMS value of the raw acceleration Filtered Unfiltered Filtered Unfiltered

20. Copyright © TWI Ltd 2013 Post Processing of the data – Control chart This chart shows all the data acquired for the four different scenarios together with some limits. These limits are calculated using baseline data: –Intermediate limit:Mean of the baseline –Upper limit: Mean+ 3standard_deviation –Lower limit: Mean- 3standard_deviation

21. Copyright © TWI Ltd 2013 Results (RMS Raw Acceleration Value)

22. Copyright © TWI Ltd 2013 Results (RMS Acceleration VS Time to close)

23. Copyright © TWI Ltd 2013 Progress on Firmware Hardware: –Analog Devices ADXL001-70BEZ single axis +-70g accelerometer on an EVAL-ADXL001-70Z evaluation board, –Analog Devices AD7980 16-bit 1MSPS ADC on an EVAL- AD7980SDZ evaluation board NXP LPC4357FET256 on a Keil MCB4357 evaluation board Software: –Keil MDK-ARM Professional v4 version 4.73 Status: –Accelerometer data sampled at 1MSPS via an SPI(SSP1) interface of the LPC4357FET256.

24. Copyright © TWI Ltd 2013 Conclusion Vibration measurements can be used to detect both bolt looseness and air pressure, Good correlations between change in air pressure (and hence speed of door) and damage sensitive feature (RMS), Large datasets is always required to increase sensitivity. Successful algorithm(based on Euclidean Distance and features extraction) implementation to assess simulated defects.

25. Copyright © TWI Ltd 2013