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LIFETIME PREDICTION AND WEAR CONTROL OF MACHINE ELEMENTS USING EXPERT SYSTEMS

Exploitable results

Knowledge has been gained about the tribological behaviour of bevel gears, needle and axial cylindrical roller bearings and flat guideways used in lathes. Basic laboratory tests, simulated tests and tests on isolated elements have been carried out. Software has been produced to calculate lambda parameter, dynamic load ratings, rating life, contact and scuffing temperature, tooth root strength, surface durability, and loads and deformations. A final working expert system has been developed including tribological calculus, experimental knowledge on lubrication, maintenance and mechanics, and monitoring parameters data (vibration analysis, lubricant state, wear debris study). The knowledge based working system is able to select the suitable lubricant, analyse the state of the oil, diagnose the failure, predict the risk of failure and lifetime of machine components, and propose appropriate maintenance actions.
The expert system is a complete tool for maintenance, lifetime prediction and wear diagnosis of mechanical elements in any rotating lubricated machine with higher exposure to tribological wear. The tool will not only detect whether there is a problem or not, it will also search for the problem sources and will propose the best solutions. Finally, a selection of the best oils that fit a given machine and the suitable maintenance schedule are given to the user if requested. The main sources of information the system uses include tribological calculus, lubricant and wear particle analysis, vibration monitoring and expertise on lubricants, tribology, maintenance and mechanics. The system works in any portable personal computer (PC) under Windows 3.1. This allows the user to have an on the ground machine diagnosis. The tool is modular (parts of the system can be acquired separately) and it could be implemented in English and Spanish.

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