Challenge details:

Real-time condition monitoring of gearboxes, motors, roller shafts, and bearings in Roller Brake Test (RBT) machines is a complex task due to the variable-speed nature of their operation. Unlike systems that run at a constant speed, RBT machines experience frequent and rapid changes in motor speed during vehicle testing cycles—ramping up to 700 RPM, braking, and then accelerating to 1500 RPM in subsequent cycles. These fluctuations result in dynamic vibrations which if not monitored continuously will result in RBT breakdown and unplanned maintenance.

The core challenge lies in accurately assessing the health of critical components such as roller shafts, gearboxes, and bearings, which are subjected to high mechanical stress and wear. These components are vital to the performance and safety of the testing process, and their failure can lead to costly downtime and compromised test results.

Additionally, the vibration characteristics of these components vary not only with speed but also with load and braking force, making it difficult to establish fixed thresholds for fault detection. We invite solutions to monitor such dynamic, rapid conditions to issue timely alerts for potential failures, reduce reliance on manual inspections, and enhance the overall reliability and efficiency of the RBT process.