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Design and Implementation of Acoustic Sensing System for Online Early Fault Detection in Industrial Fans

Industrial fans play a critical role in manufacturing facilities, and a sudden shutdown of critical fans can cause significant disruptions. Ensuring early, effective, and accurate detection of fan malfunctions first requires confirming the characteristics of anomalies resulting from initial damage to rotating machinery. In addition, sensing and detection must rely on the use of sensors and sensing characteristics appropriate to various operational abnormalities. This research proposes an online industrial fan monitoring and fault detection technique based on acoustic signals as a physical sensing index. The proposed system detects and assesses anomalies resulting from preliminary damage to rotating machinery, along with improved sensing resolution bandwidth features for microphone sensors as compared to accelerometer sensors. The resulting Intelligent Prediction Integration System with Internet (IPII) is built to analyze rotation performance and predict malfunctions in industrial fans. The system uses an NI cRIO-9065 embedded controller and a real-time signal sensing module. The kernel algorithm is based on an acoustic signal enhancement filter (ASEF) as well as an adaptive Kalman filter (AKF). The proposed scheme uses acoustic signals with adaptive order-tracking technology to perform algorithm analysis and anomaly detection. Experimental results showed that the acoustic signal and adaptive order analysis method could effectively perform real-time early fault detection and prediction in industrial fans.