Data acquisition is a crucial stage in the execution of condition monitoring (CM) of rotating machinery, by means of vibration analysis. However, the major challenge in the execution of this technique lies in the features of the recording equipment (accuracy, resolution, sampling frequency and number of channels) and the cost they represent. The present work proposes a low-cost data acquisition system, based on Raspberry-Pi, with a high sampling frequency capacity in the recording of up to three channels. To demonstrate the effectiveness of the proposed data acquisition system, a case study is presented in which the vibrations registered in a bearing are analyzed for four degrees of failure.

Increasing industrial competitiveness has led to an increased global interest in condition monitoring. In this sector, rotating machinery plays an important role, where the bearing is one of the most critical components. Many vibration-based signal treatments are already being used to identify features associated with bearing faults. The information embedded in such features are employed in the construction of health indicators, which allow for evaluation of the current operating status of the machine. In this work, the use of contour maps to represent the diagnosis map of a bearing, used as a health map, is presented for the first time. The results show that the proposed method is promising, allowing for the satisfactory detection and evaluation of the severity of bearing damage. In this initial stage of the research, our results suggest that this method can improve the classification of bearing faults and, therefore, optimise maintenance processes.

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In autonomous railway systems, where there is no driver acting as the primary fault detector, annoying interior noise caused by track defects can go unnoticed for long periods. One of the main contributors to this phenomenon is rail corrugation, a recurring defect that generates vibrations and acoustic emissions, directly affecting passenger comfort and accelerating infrastructure deterioration. This work presents a methodology for the automatic detection of corrugated track sections, based on the mathematical modeling of the spectral content of onboard-recorded acoustic signals. The hypothesis is that these defects produce characteristic peaks in the frequency domain, whose position depends on speed but whose wavelength remains constant. The novelty of the proposed approach lies in the formulation of two functional spectral indices—IIAPD (permissive) and EWISI (restrictive)—that combine power spectral density (PSD) and fast Fourier transform (FFT) analysis over spatial windows, incorporating adaptive frequency bands and dynamic prominence thresholds according to train speed. This enables robust detection without manual intervention or subjective interpretation. The methodology was validated under real operating conditions on a commercially operated metro line and compared with two reference techniques. The results show that the proposed approach achieved up to 19% higher diagnostic accuracy compared to the best-performing reference method, maintaining consistent detection performance across all evaluated speeds. These results demonstrate the robustness and applicability of the method for integration into autonomous trains as an onboard diagnostic system, enabling reliable, continuous monitoring of rail corrugation severity using reproducible mathematical metrics.

The development of low-cost data acquisition equipment is relevant in the increasingly automated industry of today. This study presents the optimization of low-cost data acquisition equipment performance to achieve acquisition speeds of 200 kHz. This was possible by evaluating two essential aspects: considering the influence of the power supplied by the power source and changing the type of data used from “Double” to “uint”. This equipment was validated through the acquisition of known waves and vibration signals from a bearing test bench. The frequency component was satisfactorily identified in each case, for both the known waves and the damaged bearing components. This demonstrated the viability of developing low-cost data acquisition equipment that can be implemented to monitor bearing condition.

Welcome to the WIT Press eLibrary - the home of the Transactions of the Wessex Institute collection, providing on-line access to papers presented at the Institute's prestigious international conferences and from its State-of-the-Art in Science & Engineering publications.