Industrial Systems Diagnostics (FSI-VMD)

The aim of the subject is to acquire comprehensive theoretical and above all practical knowledge and experience in the field of diagnostics and maintenance of industrial systems.

Basic knowledge of physics, mathematics, statistics, electrical engineering and mechanics is assumed, at the level of completed subjects within the university studies.

The subject is focused on the issue of technical diagnostics of industrial systems. As part of the course, the student will acquire extensive theoretical and, above all, practical knowledge and experience, which he will apply in his future industrial practice. Assessing the condition of industrial facilities is part of the management of every small and large company, it helps profit, competitiveness and the overall development of the company. Of course, comprehensive diagnostics must also be followed by consistent maintenance, which is also discussed in the course. The teaching of the subject is consistently based on the latest contemporary knowledge. The content of the discussed topics follows from the outline of the lectures and laboratory exercises.

The laboratory exercise ends with a credit (it is awarded in the 13th teaching week). In order to obtain it, 100% participation in the exercises, activity in the exercises and preparation, submission and recognition by the teacher of protocols (reports) from all prescribed laboratory exercises are required. In the event of a student's absence from the exercise, his/her replacement is required, the method of replacement will be determined by the relevant teacher or subject guarantor. Further details are communicated and explained to students at the beginning of the semester. Obtaining a credit is a necessary condition for participation in the exam. The exam consists of a written part followed by an oral interview. In the written part, the student processes the five assigned questions. Orientation in the studied issue is checked in the oral part. The evaluation of the written part, the oral part and the overall evaluation of the exam is given by the classification scale according to ECTS.

1. Meaning of technical diagnostics, basic terms and terminology. Division of technical diagnostics according to various criteria.


2. Signal analysis used in diagnostics. Signal - distribution and description. Measuring string, channel. Multifunctional measuring cards. Signal analyzers. Measurement interference. Digitization of analog signals. Quantization and sampling. Frequency analysis. Fourier transform. DFT and FFT transformations. Aliasing. Leakage error. Examples of analyzers used in diagnostics of industrial systems.


3. Causes of failures of technical equipment. Failure - mechanism and causes of failure. Wear and tear. Other causes of malfunctions. Fault, defect, damage.


4. Non-destructive testing (NDT). Purpose, selected methods and techniques of NDT. Damage, failures (defects) of bearings.


5. Technical diagnostics. Diagnosability. Diagnosis. Fault, defect. Diagnostic quantity, means, system. Diagnostician. Division of technical diagnostics according to diagnostic quantity and device. Multiparametric diagnostics. Models of diagnosed objects.


6. Current trends in technical diagnostics. Remote monitoring, online system management, data evaluation, visualization. Diagnostic expert system. Artificial intelligence, use of fuzzy sets and neural networks.


7. Vibrodiagnosis. Vibration. Measured quantities - deflection, speed, acceleration. Vibration measurement-vibrometers, vibrometers, analyzers. Vibration sensors and their properties. MEMS accelerometers. Calibration curve, sensor sensitivity. Attaching sensors. Vibrations measured on non-rotating machine parts.


8. Vibrodiagnosis. Vibration assessment. Frequency analysis. Analyzer settings. Spectrum analysis methods. Cascade diagrams. Phase shift. Acceleration envelope. Spectrograph. Cepstral analysis. Alternative methods for measuring the technical condition of rolling bearings. Orbital analysis. Modal analysis. A method of making visible the operating shapes of oscillations. Phase measurement. On-line vibration diagnostics. Trends in vibrodiagnostics. Online vibration systems from various companies. On-line vibration system - SIPLUS CMS system.


9. Basics of fault diagnosis. Static, dynamic and torque unbalance, fly-mounted rotor, misalignment. Bent shaft, eccentric rotor. Gear and belt transmissions. Pumps and compressors. Resonance. Electric motors. Operational vibrodiagnostics – balancing, setting up, vibrodiagnostics of rolling bearings, diagnostics of electric motors, transmissions, machine systems.


10. Electrodiagnosis. Electrical devices and their diagnostics. Diagnostics of asynchronous motors - faults and failures, FFT analysis of the stator current, diagnostic methods focused on the machine winding, measurement of short circuit between windings and phases. Diagnostics of transformers, partial discharges and insulating liquids. Cable diagnostics.


11. Thermodiagnostics. Passive and active thermography. Noise diagnostics. Acoustic emission. Ultrasound.


12. Tribodiagnostics. Diagnostics of the state of wear of machine components. Lubricant degradation diagnostics. Assembly and optical measurement.


13. Reliability of elements and systems. Restorable and non-restorable object. Repairable and non-repairable object. Reliability indicators. Methods of increasing reliability. Maintenance. Maintenance generation. Breakdown of maintenance. Modern approaches in maintenance. Total Productive Maintenance (TPM). Virtual and augmented reality. Digital twin. Edge computing. 

1. Off-line diagnostics, vibration analyzers.


2. Vibration measurement with the A4500-VA5 Pro analyzer.


3. Vibration measurement and evaluation with the A4500-VA5 Pro analyzer.


4. On-line vibration systems-Multilog On-line systems IMx-8.


5. On-line vibration systems (Simotics Connect 400), description, use, data.


6. SIPLUS CMS vibration system, description, analysis, use.


7. SIPLUS CMS system - measurement and data processing.


8. Evaluation of vibrations using neural networks, fuzzy systems and expert systems.


9. Electrodiagnostics of machines and equipment, practical measurements.


10. Thermodiagnostics, use, practical activity.


11. Multiparametric diagnostics and diagnostic protocol.


12. Maintenance, TPM (total productive maintenance) method, solving real cases from industrial practice.


13. Reliability of elements and systems. Examples from practice.