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Physics-based acoustic monitoring for innovative fault diagnosis in rotating machinery

Rotating machinery, such as centrifugal pumps, turbines, bearings, and other critical systems, is the backbone of various industrial processes. Their failures can lead to significant maintenance costs and downtime. To ensure their continuous operation, we propose a fault diagnosis and monitoring framework that leverages the innovative use of acoustic sensors for early fault detection, especially in components less accessible for traditional vibration-based monitoring strategies. The main objective of the proposed project is to develop a fault diagnosis and monitoring framework for rotating machinery, including the fusion of acoustic sensors and physics-based models. By combining real-time monitoring data from acoustic sensors with an understanding of first principles, the framework will enable maintenance practitioners to identify and categorize different failure modes such as wear, fatigue, cavitation, reduced flow, bearing damage, impeller damage, misalignment, etc. In the initial phase, the focus will be on centrifugal pumps using the existing test set-up at the University of Twente. Sorama specializes in acoustic sensors to locate noise sources and will provide acoustic cameras to capture sound patterns related to pump deterioration during various operating conditions. These acoustic signals will then be correlated with the different failure modes and mechanisms that will be described by physics-based models, such as wear, fatigue, cavitation, corrosion, etc. Furthermore, a recently published data set by the Dynamics Based Maintenance research group that includes vibration analysis data and motor current analysis data of various fault scenarios, such as mentioned above, will be used as validation. The anticipated outcome of this project is a versatile framework for a physics-informed acoustic monitoring system. This system is designed to enhance early fault detection significantly, reducing maintenance costs and downtime across a broad spectrum of industrial applications, from centrifugal pumps to turbines, bearings, and beyond​.