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reagent_material_flaw
[]
[ "Electrical line-frequency vibration from motor", "Bent shaft", "Shaft misalignment", "Loose bearing housing (mechanical looseness)", "Velocity sensor gain drift", "Rotor mass imbalance from blade deposit buildup" ]
easy
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Electrical line-frequency vibration from motor", "Loose bearing housing (mechanical looseness)", "Bent shaft", "Velocity sensor gain drift", "Shaft misalignment" ]
mechanical
Operator note: Induced-draft fan at 956 rpm. 1x radial amplitude 8.8 mm/s, 2x 0.8 mm/s, axial 1.1 mm/s. Amplitude scales ~speed^2 during run-up (2.2 mm/s at half speed). Blade buildup noted at last inspection.
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
5
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-00
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 956, 8.8, 0.8, 1.1, 2.2, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Electrical line-frequency vibration from motor", "Bent shaft", "Loose bearing housing (mechanical looseness)", "Rotor mass imbalance from blade deposit buildup", "Velocity sensor gain drift", "Shaft misalignment" ]
medium
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Bent shaft", "Velocity sensor gain drift", "Shaft misalignment", "Loose bearing housing (mechanical looseness)", "Electrical line-frequency vibration from motor" ]
mechanical
Induced-draft fan at 1110 rpm. 1x radial amplitude 11.7 mm/s, 2x 0.8 mm/s, axial 1.4 mm/s. Amplitude scales ~speed^2 during run-up (2.9 mm/s at half speed). Blade buildup noted at last inspection. badge reader log entry unrelated HMI screensaver restarted
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
3
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-01
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 1110, 11.7, 0.8, 1.4, 2.9, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Velocity sensor gain drift", "Loose bearing housing (mechanical looseness)", "Electrical line-frequency vibration from motor", "Rotor mass imbalance from blade deposit buildup", "Bent shaft", "Shaft misalignment" ]
medium
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Bent shaft", "Loose bearing housing (mechanical looseness)", "Shaft misalignment", "Velocity sensor gain drift", "Electrical line-frequency vibration from motor" ]
mechanical
Shift log excerpt (cleansed): Induced-draft fan at 1500 rpm. 1x radial amplitude 7.3 mm/s, 2x 1.5 mm/s, axial 1.0 mm/s. Amplitude scales ~speed^2 during run-up (1.8 mm/s at half speed). Blade buildup noted at last inspection. A colleague suspects 'shaft misalignment' because a similar symptom was seen once before (no m...
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
3
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-02
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 1500, 7.3, 1.5, 1, 1.8, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Rotor mass imbalance from blade deposit buildup", "Velocity sensor gain drift", "Electrical line-frequency vibration from motor", "Bent shaft", "Loose bearing housing (mechanical looseness)", "Shaft misalignment" ]
easy
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Electrical line-frequency vibration from motor", "Shaft misalignment", "Bent shaft", "Velocity sensor gain drift", "Loose bearing housing (mechanical looseness)" ]
mechanical
Shift log excerpt (cleansed): Induced-draft fan at 1284 rpm. 1x radial amplitude 11.4 mm/s, 2x 1.1 mm/s, axial 0.6 mm/s. Amplitude scales ~speed^2 during run-up (2.9 mm/s at half speed). Blade buildup noted at last inspection.
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
0
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-03
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 1284, 11.4, 1.1, 0.6, 2.9, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Shaft misalignment", "Loose bearing housing (mechanical looseness)", "Bent shaft", "Rotor mass imbalance from blade deposit buildup", "Electrical line-frequency vibration from motor", "Velocity sensor gain drift" ]
medium
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Electrical line-frequency vibration from motor", "Bent shaft", "Shaft misalignment", "Velocity sensor gain drift", "Loose bearing housing (mechanical looseness)" ]
mechanical
Induced-draft fan at 1094 rpm. 1x radial amplitude 8.3 mm/s, 2x 1.0 mm/s, axial 1.1 mm/s. Amplitude scales ~speed^2 during run-up (2.1 mm/s at half speed). Blade buildup noted at last inspection. duplicate log line suppressed x12 [INFO] heartbeat ok
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
3
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-04
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 1094, 8.3, 1, 1.1, 2.1, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Bent shaft", "Rotor mass imbalance from blade deposit buildup", "Shaft misalignment", "Loose bearing housing (mechanical looseness)", "Velocity sensor gain drift", "Electrical line-frequency vibration from motor" ]
medium
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Electrical line-frequency vibration from motor", "Shaft misalignment", "Velocity sensor gain drift", "Loose bearing housing (mechanical looseness)", "Bent shaft" ]
mechanical
Shift log excerpt (cleansed): Induced-draft fan at 1539 rpm. 1x radial amplitude 8.8 mm/s, 2x 1.4 mm/s, axial 1.0 mm/s. Amplitude scales ~speed^2 during run-up (2.2 mm/s at half speed). Blade buildup noted at last inspection. A colleague suspects 'shaft misalignment' because a similar symptom was seen once before (no m...
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
1
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-05
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 1539, 8.8, 1.4, 1, 2.2, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Electrical line-frequency vibration from motor", "Bent shaft", "Loose bearing housing (mechanical looseness)", "Rotor mass imbalance from blade deposit buildup", "Velocity sensor gain drift", "Shaft misalignment" ]
easy
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Bent shaft", "Electrical line-frequency vibration from motor", "Velocity sensor gain drift", "Loose bearing housing (mechanical looseness)", "Shaft misalignment" ]
mechanical
Operator note: Induced-draft fan at 1759 rpm. 1x radial amplitude 10.0 mm/s, 2x 0.5 mm/s, axial 0.9 mm/s. Amplitude scales ~speed^2 during run-up (2.5 mm/s at half speed). Blade buildup noted at last inspection.
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
3
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-06
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 1759, 10, 0.5, 0.9, 2.5, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Velocity sensor gain drift", "Bent shaft", "Electrical line-frequency vibration from motor", "Loose bearing housing (mechanical looseness)", "Shaft misalignment", "Rotor mass imbalance from blade deposit buildup" ]
medium
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Velocity sensor gain drift", "Shaft misalignment", "Loose bearing housing (mechanical looseness)", "Electrical line-frequency vibration from motor", "Bent shaft" ]
mechanical
Field report: Induced-draft fan at 1670 rpm. 1x radial amplitude 8.3 mm/s, 2x 0.8 mm/s, axial 0.6 mm/s. Amplitude scales ~speed^2 during run-up (2.1 mm/s at half speed). Blade buildup noted at last inspection. [INFO] heartbeat ok Note: shift change at 14:00
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
5
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-07
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 1670, 8.3, 0.8, 0.6, 2.1, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Electrical line-frequency vibration from motor", "Bent shaft", "Velocity sensor gain drift", "Loose bearing housing (mechanical looseness)", "Rotor mass imbalance from blade deposit buildup", "Shaft misalignment" ]
medium
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Loose bearing housing (mechanical looseness)", "Velocity sensor gain drift", "Electrical line-frequency vibration from motor", "Bent shaft", "Shaft misalignment" ]
mechanical
Shift log excerpt (cleansed): Induced-draft fan at 1032 rpm. 1x radial amplitude 6.7 mm/s, 2x 1.0 mm/s, axial 1.5 mm/s. Amplitude scales ~speed^2 during run-up (1.7 mm/s at half speed). Blade buildup noted at last inspection. A colleague suspects 'shaft misalignment' because a similar symptom was seen once before (no m...
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
4
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-08
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 1032, 6.7, 1, 1.5, 1.7, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Loose bearing housing (mechanical looseness)", "Rotor mass imbalance from blade deposit buildup", "Velocity sensor gain drift", "Shaft misalignment", "Electrical line-frequency vibration from motor", "Bent shaft" ]
easy
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Loose bearing housing (mechanical looseness)", "Electrical line-frequency vibration from motor", "Velocity sensor gain drift", "Bent shaft", "Shaft misalignment" ]
mechanical
Induced-draft fan at 1598 rpm. 1x radial amplitude 11.9 mm/s, 2x 1.1 mm/s, axial 0.9 mm/s. Amplitude scales ~speed^2 during run-up (3.0 mm/s at half speed). Blade buildup noted at last inspection.
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
1
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-09
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 1598, 11.9, 1.1, 0.9, 3, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Rotor mass imbalance from blade deposit buildup", "Loose bearing housing (mechanical looseness)", "Electrical line-frequency vibration from motor", "Bent shaft", "Velocity sensor gain drift", "Shaft misalignment" ]
medium
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Velocity sensor gain drift", "Bent shaft", "Electrical line-frequency vibration from motor", "Shaft misalignment", "Loose bearing housing (mechanical looseness)" ]
mechanical
Operator note: Induced-draft fan at 1639 rpm. 1x radial amplitude 7.4 mm/s, 2x 0.9 mm/s, axial 0.7 mm/s. Amplitude scales ~speed^2 during run-up (1.9 mm/s at half speed). Blade buildup noted at last inspection. Note: shift change at 14:00 duplicate log line suppressed x12
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
0
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-10
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 1639, 7.4, 0.9, 0.7, 1.9, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Shaft misalignment", "Electrical line-frequency vibration from motor", "Velocity sensor gain drift", "Bent shaft", "Loose bearing housing (mechanical looseness)", "Rotor mass imbalance from blade deposit buildup" ]
medium
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Velocity sensor gain drift", "Loose bearing housing (mechanical looseness)", "Shaft misalignment", "Bent shaft", "Electrical line-frequency vibration from motor" ]
mechanical
Ticket summary: Induced-draft fan at 1068 rpm. 1x radial amplitude 8.4 mm/s, 2x 1.4 mm/s, axial 1.4 mm/s. Amplitude scales ~speed^2 during run-up (2.1 mm/s at half speed). Blade buildup noted at last inspection. A colleague suspects 'bent shaft' because a similar symptom was seen once before (no measurement attached).
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
5
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-11
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 1068, 8.4, 1.4, 1.4, 2.1, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Rotor mass imbalance from blade deposit buildup", "Loose bearing housing (mechanical looseness)", "Electrical line-frequency vibration from motor", "Shaft misalignment", "Velocity sensor gain drift", "Bent shaft" ]
easy
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Shaft misalignment", "Loose bearing housing (mechanical looseness)", "Electrical line-frequency vibration from motor", "Velocity sensor gain drift", "Bent shaft" ]
mechanical
Induced-draft fan at 1797 rpm. 1x radial amplitude 9.8 mm/s, 2x 1.2 mm/s, axial 0.9 mm/s. Amplitude scales ~speed^2 during run-up (2.5 mm/s at half speed). Blade buildup noted at last inspection.
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
0
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-12
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 1797, 9.8, 1.2, 0.9, 2.5, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Rotor mass imbalance from blade deposit buildup", "Shaft misalignment", "Velocity sensor gain drift", "Bent shaft", "Electrical line-frequency vibration from motor", "Loose bearing housing (mechanical looseness)" ]
medium
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Loose bearing housing (mechanical looseness)", "Shaft misalignment", "Velocity sensor gain drift", "Electrical line-frequency vibration from motor", "Bent shaft" ]
mechanical
Shift log excerpt (cleansed): Induced-draft fan at 1294 rpm. 1x radial amplitude 10.5 mm/s, 2x 0.5 mm/s, axial 1.5 mm/s. Amplitude scales ~speed^2 during run-up (2.6 mm/s at half speed). Blade buildup noted at last inspection. badge reader log entry unrelated Note: shift change at 14:00
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
0
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-13
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 1294, 10.5, 0.5, 1.5, 2.6, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Rotor mass imbalance from blade deposit buildup", "Shaft misalignment", "Electrical line-frequency vibration from motor", "Bent shaft", "Loose bearing housing (mechanical looseness)", "Velocity sensor gain drift" ]
medium
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Shaft misalignment", "Velocity sensor gain drift", "Loose bearing housing (mechanical looseness)", "Bent shaft", "Electrical line-frequency vibration from motor" ]
mechanical
Operator note: Induced-draft fan at 1151 rpm. 1x radial amplitude 7.0 mm/s, 2x 1.0 mm/s, axial 1.0 mm/s. Amplitude scales ~speed^2 during run-up (1.8 mm/s at half speed). Blade buildup noted at last inspection. A colleague suspects 'bent shaft' because a similar symptom was seen once before (no measurement attached).
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
0
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-14
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 1151, 7, 1, 1, 1.8, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Shaft misalignment", "Rotor mass imbalance from blade deposit buildup", "Velocity sensor gain drift", "Loose bearing housing (mechanical looseness)", "Electrical line-frequency vibration from motor", "Bent shaft" ]
easy
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Bent shaft", "Velocity sensor gain drift", "Shaft misalignment", "Loose bearing housing (mechanical looseness)", "Electrical line-frequency vibration from motor" ]
mechanical
Ticket summary: Induced-draft fan at 1694 rpm. 1x radial amplitude 11.1 mm/s, 2x 1.1 mm/s, axial 0.6 mm/s. Amplitude scales ~speed^2 during run-up (2.8 mm/s at half speed). Blade buildup noted at last inspection.
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
1
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-15
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 1694, 11.1, 1.1, 0.6, 2.8, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Velocity sensor gain drift", "Loose bearing housing (mechanical looseness)", "Bent shaft", "Shaft misalignment", "Electrical line-frequency vibration from motor", "Rotor mass imbalance from blade deposit buildup" ]
medium
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Loose bearing housing (mechanical looseness)", "Electrical line-frequency vibration from motor", "Shaft misalignment", "Bent shaft", "Velocity sensor gain drift" ]
mechanical
Operator note: Induced-draft fan at 908 rpm. 1x radial amplitude 9.4 mm/s, 2x 0.9 mm/s, axial 1.4 mm/s. Amplitude scales ~speed^2 during run-up (2.4 mm/s at half speed). Blade buildup noted at last inspection. Note: shift change at 14:00 [INFO] heartbeat ok
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
5
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-16
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 908, 9.4, 0.9, 1.4, 2.4, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Bent shaft", "Electrical line-frequency vibration from motor", "Shaft misalignment", "Rotor mass imbalance from blade deposit buildup", "Velocity sensor gain drift", "Loose bearing housing (mechanical looseness)" ]
medium
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Loose bearing housing (mechanical looseness)", "Electrical line-frequency vibration from motor", "Shaft misalignment", "Velocity sensor gain drift", "Bent shaft" ]
mechanical
Operator note: Induced-draft fan at 1362 rpm. 1x radial amplitude 7.9 mm/s, 2x 1.1 mm/s, axial 1.0 mm/s. Amplitude scales ~speed^2 during run-up (2.0 mm/s at half speed). Blade buildup noted at last inspection. A colleague suspects 'loose bearing housing (mechanical looseness)' because a similar symptom was seen once b...
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
3
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-17
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 1362, 7.9, 1.1, 1, 2, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Loose bearing housing (mechanical looseness)", "Shaft misalignment", "Velocity sensor gain drift", "Electrical line-frequency vibration from motor", "Bent shaft", "Rotor mass imbalance from blade deposit buildup" ]
easy
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Loose bearing housing (mechanical looseness)", "Electrical line-frequency vibration from motor", "Velocity sensor gain drift", "Bent shaft", "Shaft misalignment" ]
mechanical
Engineer's handoff: Induced-draft fan at 1052 rpm. 1x radial amplitude 9.2 mm/s, 2x 1.3 mm/s, axial 0.9 mm/s. Amplitude scales ~speed^2 during run-up (2.3 mm/s at half speed). Blade buildup noted at last inspection.
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
5
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-18
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 1052, 9.2, 1.3, 0.9, 2.3, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Shaft misalignment", "Loose bearing housing (mechanical looseness)", "Velocity sensor gain drift", "Rotor mass imbalance from blade deposit buildup", "Electrical line-frequency vibration from motor", "Bent shaft" ]
medium
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Bent shaft", "Shaft misalignment", "Loose bearing housing (mechanical looseness)", "Velocity sensor gain drift", "Electrical line-frequency vibration from motor" ]
mechanical
Induced-draft fan at 1786 rpm. 1x radial amplitude 9.8 mm/s, 2x 0.9 mm/s, axial 1.2 mm/s. Amplitude scales ~speed^2 during run-up (2.5 mm/s at half speed). Blade buildup noted at last inspection. Note: shift change at 14:00 badge reader log entry unrelated
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
3
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-19
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 1786, 9.8, 0.9, 1.2, 2.5, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Loose bearing housing (mechanical looseness)", "Rotor mass imbalance from blade deposit buildup", "Bent shaft", "Shaft misalignment", "Electrical line-frequency vibration from motor", "Velocity sensor gain drift" ]
medium
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Electrical line-frequency vibration from motor", "Loose bearing housing (mechanical looseness)", "Velocity sensor gain drift", "Bent shaft", "Shaft misalignment" ]
mechanical
Ticket summary: Induced-draft fan at 1101 rpm. 1x radial amplitude 6.2 mm/s, 2x 0.9 mm/s, axial 1.3 mm/s. Amplitude scales ~speed^2 during run-up (1.6 mm/s at half speed). Blade buildup noted at last inspection. A colleague suspects 'bent shaft' because a similar symptom was seen once before (no measurement attached).
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
1
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-20
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 1101, 6.2, 0.9, 1.3, 1.6, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
reagent_material_flaw
[]
[ "Bent shaft", "Rotor mass imbalance from blade deposit buildup", "Loose bearing housing (mechanical looseness)", "Velocity sensor gain drift", "Electrical line-frequency vibration from motor", "Shaft misalignment" ]
easy
[ "Does 1x phase stay stable and rotate with a trial weight?", "Do harmonics 3x-10x appear (looseness)?", "Does vibration vanish instantly at power cut (electrical)?" ]
[ "Bent shaft", "Loose bearing housing (mechanical looseness)", "Velocity sensor gain drift", "Electrical line-frequency vibration from motor", "Shaft misalignment" ]
mechanical
Ticket summary: Induced-draft fan at 1396 rpm. 1x radial amplitude 8.8 mm/s, 2x 0.7 mm/s, axial 0.6 mm/s. Amplitude scales ~speed^2 during run-up (2.2 mm/s at half speed). Blade buildup noted at last inspection.
reagent_material_flaw
Rotor mass imbalance from blade deposit buildup
1
fam:MECH-IMBALANCE
SYN-MECH-IMBALANCE-21
null
CC-BY-4.0
null
[ "Imbalance force = m*e*omega^2, so 1x amplitude grows with speed squared.", "Misalignment raises 2x and axial; looseness generates many harmonics." ]
null
synthetic_template
train
rotating_machinery
[ 1396, 8.8, 0.7, 0.6, 2.2, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Fan vibration dominated by 1x
null
flawed_hypothesis
[]
[ "Static overload beyond yield", "Weld porosity reducing static strength", "Strain gauge saturation inflating stress", "Thermal expansion mismatch stress", "Hydrogen embrittlement of the bracket steel", "High-cycle fatigue driven by near-resonant excitation, not static overload" ]
medium
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Static overload beyond yield", "Strain gauge saturation inflating stress", "Weld porosity reducing static strength", "Hydrogen embrittlement of the bracket steel", "Thermal expansion mismatch stress" ]
mechanical
Engineer's handoff: Engineer claims brackets crack from static overload. Measured peak static stress 70 MPa vs yield 295 MPa. Bracket natural frequency 60.7 Hz; motor runs at 58.9 Hz. Strain gauge shows 2.6e+06 cycles/day at +/-39 MPa. Fracture surface shows beach marks.
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
5
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-00
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 70, 295, 60.7, 39, 58.9, 2622240, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "Static overload beyond yield", "Weld porosity reducing static strength", "Strain gauge saturation inflating stress", "Thermal expansion mismatch stress", "Hydrogen embrittlement of the bracket steel", "High-cycle fatigue driven by near-resonant excitation, not static overload" ]
hard
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Thermal expansion mismatch stress", "Static overload beyond yield", "Weld porosity reducing static strength", "Hydrogen embrittlement of the bracket steel", "Strain gauge saturation inflating stress" ]
mechanical
Field report: Engineer claims brackets crack from static overload. Measured peak static stress 76 MPa vs yield 265 MPa. Bracket natural frequency 60.2 Hz; motor runs at 58.4 Hz. Strain gauge shows 2.6e+06 cycles/day at +/-67 MPa. Fracture surface shows beach marks. [INFO] heartbeat ok HMI screensaver restarted
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
5
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-01
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 76, 265, 60.2, 67, 58.4, 2600640, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "Strain gauge saturation inflating stress", "Static overload beyond yield", "Weld porosity reducing static strength", "High-cycle fatigue driven by near-resonant excitation, not static overload", "Hydrogen embrittlement of the bracket steel", "Thermal expansion mismatch stress" ]
hard
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Strain gauge saturation inflating stress", "Static overload beyond yield", "Thermal expansion mismatch stress", "Hydrogen embrittlement of the bracket steel", "Weld porosity reducing static strength" ]
mechanical
Operator note: Engineer claims brackets crack from static overload. Measured peak static stress 68 MPa vs yield 279 MPa. Bracket natural frequency 56.3 Hz; motor runs at 54.6 Hz. Strain gauge shows 2.4e+06 cycles/day at +/-43 MPa. Fracture surface shows beach marks. A colleague suspects 'hydrogen embrittlement of the b...
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
3
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-02
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 68, 279, 56.3, 43, 54.6, 2432160, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "Strain gauge saturation inflating stress", "Static overload beyond yield", "High-cycle fatigue driven by near-resonant excitation, not static overload", "Thermal expansion mismatch stress", "Weld porosity reducing static strength", "Hydrogen embrittlement of the bracket steel" ]
medium
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Static overload beyond yield", "Hydrogen embrittlement of the bracket steel", "Weld porosity reducing static strength", "Strain gauge saturation inflating stress", "Thermal expansion mismatch stress" ]
mechanical
Engineer's handoff: Engineer claims brackets crack from static overload. Measured peak static stress 52 MPa vs yield 332 MPa. Bracket natural frequency 58.7 Hz; motor runs at 56.9 Hz. Strain gauge shows 2.5e+06 cycles/day at +/-37 MPa. Fracture surface shows beach marks.
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
2
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-03
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 52, 332, 58.7, 37, 56.9, 2535840, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "Hydrogen embrittlement of the bracket steel", "Thermal expansion mismatch stress", "Strain gauge saturation inflating stress", "High-cycle fatigue driven by near-resonant excitation, not static overload", "Weld porosity reducing static strength", "Static overload beyond yield" ]
hard
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Thermal expansion mismatch stress", "Weld porosity reducing static strength", "Hydrogen embrittlement of the bracket steel", "Strain gauge saturation inflating stress", "Static overload beyond yield" ]
mechanical
Engineer claims brackets crack from static overload. Measured peak static stress 67 MPa vs yield 269 MPa. Bracket natural frequency 51.6 Hz; motor runs at 50.1 Hz. Strain gauge shows 2.2e+06 cycles/day at +/-49 MPa. Fracture surface shows beach marks. [INFO] heartbeat ok badge reader log entry unrelated
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
3
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-04
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 67, 269, 51.6, 49, 50.1, 2229120, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "Static overload beyond yield", "Hydrogen embrittlement of the bracket steel", "Strain gauge saturation inflating stress", "High-cycle fatigue driven by near-resonant excitation, not static overload", "Thermal expansion mismatch stress", "Weld porosity reducing static strength" ]
hard
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Static overload beyond yield", "Thermal expansion mismatch stress", "Hydrogen embrittlement of the bracket steel", "Strain gauge saturation inflating stress", "Weld porosity reducing static strength" ]
mechanical
Shift log excerpt (cleansed): Engineer claims brackets crack from static overload. Measured peak static stress 68 MPa vs yield 269 MPa. Bracket natural frequency 56.5 Hz; motor runs at 54.8 Hz. Strain gauge shows 2.4e+06 cycles/day at +/-50 MPa. Fracture surface shows beach marks. A colleague suspects 'weld porosity re...
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
3
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-05
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 68, 269, 56.5, 50, 54.8, 2440800, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "Thermal expansion mismatch stress", "Hydrogen embrittlement of the bracket steel", "Static overload beyond yield", "High-cycle fatigue driven by near-resonant excitation, not static overload", "Weld porosity reducing static strength", "Strain gauge saturation inflating stress" ]
medium
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Thermal expansion mismatch stress", "Hydrogen embrittlement of the bracket steel", "Strain gauge saturation inflating stress", "Static overload beyond yield", "Weld porosity reducing static strength" ]
mechanical
Ticket summary: Engineer claims brackets crack from static overload. Measured peak static stress 52 MPa vs yield 291 MPa. Bracket natural frequency 57.9 Hz; motor runs at 56.2 Hz. Strain gauge shows 2.5e+06 cycles/day at +/-41 MPa. Fracture surface shows beach marks.
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
3
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-06
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 52, 291, 57.9, 41, 56.2, 2501280, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "Weld porosity reducing static strength", "Hydrogen embrittlement of the bracket steel", "High-cycle fatigue driven by near-resonant excitation, not static overload", "Static overload beyond yield", "Thermal expansion mismatch stress", "Strain gauge saturation inflating stress" ]
hard
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Thermal expansion mismatch stress", "Hydrogen embrittlement of the bracket steel", "Weld porosity reducing static strength", "Static overload beyond yield", "Strain gauge saturation inflating stress" ]
mechanical
Engineer claims brackets crack from static overload. Measured peak static stress 46 MPa vs yield 271 MPa. Bracket natural frequency 61.3 Hz; motor runs at 59.5 Hz. Strain gauge shows 2.6e+06 cycles/day at +/-59 MPa. Fracture surface shows beach marks. Note: shift change at 14:00 [INFO] heartbeat ok
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
2
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-07
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 46, 271, 61.3, 59, 59.5, 2648160, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "Hydrogen embrittlement of the bracket steel", "High-cycle fatigue driven by near-resonant excitation, not static overload", "Thermal expansion mismatch stress", "Strain gauge saturation inflating stress", "Weld porosity reducing static strength", "Static overload beyond yield" ]
hard
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Thermal expansion mismatch stress", "Strain gauge saturation inflating stress", "Hydrogen embrittlement of the bracket steel", "Weld porosity reducing static strength", "Static overload beyond yield" ]
mechanical
Operator note: Engineer claims brackets crack from static overload. Measured peak static stress 41 MPa vs yield 251 MPa. Bracket natural frequency 51.0 Hz; motor runs at 49.5 Hz. Strain gauge shows 2.2e+06 cycles/day at +/-34 MPa. Fracture surface shows beach marks. A colleague suspects 'weld porosity reducing static s...
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
1
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-08
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 41, 251, 51, 34, 49.5, 2203200, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "Thermal expansion mismatch stress", "Strain gauge saturation inflating stress", "Static overload beyond yield", "Hydrogen embrittlement of the bracket steel", "Weld porosity reducing static strength", "High-cycle fatigue driven by near-resonant excitation, not static overload" ]
medium
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Hydrogen embrittlement of the bracket steel", "Weld porosity reducing static strength", "Thermal expansion mismatch stress", "Static overload beyond yield", "Strain gauge saturation inflating stress" ]
mechanical
Engineer's handoff: Engineer claims brackets crack from static overload. Measured peak static stress 51 MPa vs yield 263 MPa. Bracket natural frequency 54.3 Hz; motor runs at 52.7 Hz. Strain gauge shows 2.3e+06 cycles/day at +/-56 MPa. Fracture surface shows beach marks.
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
5
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-09
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 51, 263, 54.3, 56, 52.7, 2345760, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "Weld porosity reducing static strength", "Thermal expansion mismatch stress", "Static overload beyond yield", "Hydrogen embrittlement of the bracket steel", "Strain gauge saturation inflating stress", "High-cycle fatigue driven by near-resonant excitation, not static overload" ]
hard
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Thermal expansion mismatch stress", "Strain gauge saturation inflating stress", "Weld porosity reducing static strength", "Hydrogen embrittlement of the bracket steel", "Static overload beyond yield" ]
mechanical
Ticket summary: Engineer claims brackets crack from static overload. Measured peak static stress 49 MPa vs yield 294 MPa. Bracket natural frequency 59.7 Hz; motor runs at 57.9 Hz. Strain gauge shows 2.6e+06 cycles/day at +/-60 MPa. Fracture surface shows beach marks. HMI screensaver restarted Unrelated: cafeteria chill...
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
5
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-10
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 49, 294, 59.7, 60, 57.9, 2579040, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "Strain gauge saturation inflating stress", "High-cycle fatigue driven by near-resonant excitation, not static overload", "Static overload beyond yield", "Weld porosity reducing static strength", "Thermal expansion mismatch stress", "Hydrogen embrittlement of the bracket steel" ]
hard
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Static overload beyond yield", "Weld porosity reducing static strength", "Thermal expansion mismatch stress", "Hydrogen embrittlement of the bracket steel", "Strain gauge saturation inflating stress" ]
mechanical
Engineer claims brackets crack from static overload. Measured peak static stress 76 MPa vs yield 326 MPa. Bracket natural frequency 50.6 Hz; motor runs at 49.1 Hz. Strain gauge shows 2.2e+06 cycles/day at +/-55 MPa. Fracture surface shows beach marks. A colleague suspects 'hydrogen embrittlement of the bracket steel' b...
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
1
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-11
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 76, 326, 50.6, 55, 49.1, 2185920, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "Static overload beyond yield", "High-cycle fatigue driven by near-resonant excitation, not static overload", "Weld porosity reducing static strength", "Hydrogen embrittlement of the bracket steel", "Strain gauge saturation inflating stress", "Thermal expansion mismatch stress" ]
medium
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Thermal expansion mismatch stress", "Static overload beyond yield", "Hydrogen embrittlement of the bracket steel", "Strain gauge saturation inflating stress", "Weld porosity reducing static strength" ]
mechanical
Field report: Engineer claims brackets crack from static overload. Measured peak static stress 44 MPa vs yield 282 MPa. Bracket natural frequency 49.1 Hz; motor runs at 47.6 Hz. Strain gauge shows 2.1e+06 cycles/day at +/-67 MPa. Fracture surface shows beach marks.
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
1
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-12
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 44, 282, 49.1, 67, 47.6, 2121120, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "Hydrogen embrittlement of the bracket steel", "High-cycle fatigue driven by near-resonant excitation, not static overload", "Thermal expansion mismatch stress", "Static overload beyond yield", "Weld porosity reducing static strength", "Strain gauge saturation inflating stress" ]
hard
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Hydrogen embrittlement of the bracket steel", "Static overload beyond yield", "Weld porosity reducing static strength", "Strain gauge saturation inflating stress", "Thermal expansion mismatch stress" ]
mechanical
Operator note: Engineer claims brackets crack from static overload. Measured peak static stress 59 MPa vs yield 321 MPa. Bracket natural frequency 53.9 Hz; motor runs at 52.3 Hz. Strain gauge shows 2.3e+06 cycles/day at +/-47 MPa. Fracture surface shows beach marks. Firmware banner printed at boot [INFO] heartbeat ok
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
1
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-13
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 59, 321, 53.9, 47, 52.3, 2328480, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "High-cycle fatigue driven by near-resonant excitation, not static overload", "Hydrogen embrittlement of the bracket steel", "Thermal expansion mismatch stress", "Weld porosity reducing static strength", "Strain gauge saturation inflating stress", "Static overload beyond yield" ]
hard
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Thermal expansion mismatch stress", "Strain gauge saturation inflating stress", "Static overload beyond yield", "Hydrogen embrittlement of the bracket steel", "Weld porosity reducing static strength" ]
mechanical
Shift log excerpt (cleansed): Engineer claims brackets crack from static overload. Measured peak static stress 69 MPa vs yield 281 MPa. Bracket natural frequency 51.0 Hz; motor runs at 49.5 Hz. Strain gauge shows 2.2e+06 cycles/day at +/-35 MPa. Fracture surface shows beach marks. A colleague suspects 'hydrogen embritt...
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
0
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-14
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 69, 281, 51, 35, 49.5, 2203200, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "Static overload beyond yield", "Strain gauge saturation inflating stress", "High-cycle fatigue driven by near-resonant excitation, not static overload", "Weld porosity reducing static strength", "Thermal expansion mismatch stress", "Hydrogen embrittlement of the bracket steel" ]
medium
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Hydrogen embrittlement of the bracket steel", "Thermal expansion mismatch stress", "Strain gauge saturation inflating stress", "Weld porosity reducing static strength", "Static overload beyond yield" ]
mechanical
Engineer's handoff: Engineer claims brackets crack from static overload. Measured peak static stress 64 MPa vs yield 336 MPa. Bracket natural frequency 54.7 Hz; motor runs at 53.1 Hz. Strain gauge shows 2.4e+06 cycles/day at +/-54 MPa. Fracture surface shows beach marks.
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
2
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-15
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 64, 336, 54.7, 54, 53.1, 2363040, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "Thermal expansion mismatch stress", "Hydrogen embrittlement of the bracket steel", "Static overload beyond yield", "Strain gauge saturation inflating stress", "High-cycle fatigue driven by near-resonant excitation, not static overload", "Weld porosity reducing static strength" ]
hard
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Strain gauge saturation inflating stress", "Static overload beyond yield", "Weld porosity reducing static strength", "Hydrogen embrittlement of the bracket steel", "Thermal expansion mismatch stress" ]
mechanical
Engineer's handoff: Engineer claims brackets crack from static overload. Measured peak static stress 66 MPa vs yield 304 MPa. Bracket natural frequency 51.9 Hz; motor runs at 50.3 Hz. Strain gauge shows 2.2e+06 cycles/day at +/-31 MPa. Fracture surface shows beach marks. badge reader log entry unrelated [INFO] heartbea...
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
4
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-16
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 66, 304, 51.9, 31, 50.3, 2242080, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "High-cycle fatigue driven by near-resonant excitation, not static overload", "Static overload beyond yield", "Strain gauge saturation inflating stress", "Thermal expansion mismatch stress", "Hydrogen embrittlement of the bracket steel", "Weld porosity reducing static strength" ]
hard
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Strain gauge saturation inflating stress", "Static overload beyond yield", "Thermal expansion mismatch stress", "Weld porosity reducing static strength", "Hydrogen embrittlement of the bracket steel" ]
mechanical
Operator note: Engineer claims brackets crack from static overload. Measured peak static stress 49 MPa vs yield 321 MPa. Bracket natural frequency 55.1 Hz; motor runs at 53.4 Hz. Strain gauge shows 2.4e+06 cycles/day at +/-56 MPa. Fracture surface shows beach marks. A colleague suspects 'hydrogen embrittlement of the b...
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
0
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-17
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 49, 321, 55.1, 56, 53.4, 2380320, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "Thermal expansion mismatch stress", "Hydrogen embrittlement of the bracket steel", "High-cycle fatigue driven by near-resonant excitation, not static overload", "Weld porosity reducing static strength", "Strain gauge saturation inflating stress", "Static overload beyond yield" ]
medium
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Static overload beyond yield", "Thermal expansion mismatch stress", "Strain gauge saturation inflating stress", "Weld porosity reducing static strength", "Hydrogen embrittlement of the bracket steel" ]
mechanical
Operator note: Engineer claims brackets crack from static overload. Measured peak static stress 69 MPa vs yield 306 MPa. Bracket natural frequency 50.5 Hz; motor runs at 49.0 Hz. Strain gauge shows 2.2e+06 cycles/day at +/-62 MPa. Fracture surface shows beach marks.
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
2
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-18
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 69, 306, 50.5, 62, 49, 2181600, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "Thermal expansion mismatch stress", "High-cycle fatigue driven by near-resonant excitation, not static overload", "Strain gauge saturation inflating stress", "Weld porosity reducing static strength", "Static overload beyond yield", "Hydrogen embrittlement of the bracket steel" ]
hard
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Weld porosity reducing static strength", "Hydrogen embrittlement of the bracket steel", "Thermal expansion mismatch stress", "Strain gauge saturation inflating stress", "Static overload beyond yield" ]
mechanical
Operator note: Engineer claims brackets crack from static overload. Measured peak static stress 56 MPa vs yield 313 MPa. Bracket natural frequency 48.9 Hz; motor runs at 47.4 Hz. Strain gauge shows 2.1e+06 cycles/day at +/-44 MPa. Fracture surface shows beach marks. Firmware banner printed at boot duplicate log line su...
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
1
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-19
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 56, 313, 48.9, 44, 47.4, 2112480, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "Hydrogen embrittlement of the bracket steel", "Strain gauge saturation inflating stress", "Static overload beyond yield", "Weld porosity reducing static strength", "High-cycle fatigue driven by near-resonant excitation, not static overload", "Thermal expansion mismatch stress" ]
hard
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Hydrogen embrittlement of the bracket steel", "Weld porosity reducing static strength", "Static overload beyond yield", "Strain gauge saturation inflating stress", "Thermal expansion mismatch stress" ]
mechanical
Shift log excerpt (cleansed): Engineer claims brackets crack from static overload. Measured peak static stress 56 MPa vs yield 334 MPa. Bracket natural frequency 55.6 Hz; motor runs at 53.9 Hz. Strain gauge shows 2.4e+06 cycles/day at +/-45 MPa. Fracture surface shows beach marks. A colleague suspects 'static overload ...
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
4
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-20
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 56, 334, 55.6, 45, 53.9, 2401920, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
flawed_hypothesis
[]
[ "High-cycle fatigue driven by near-resonant excitation, not static overload", "Strain gauge saturation inflating stress", "Static overload beyond yield", "Hydrogen embrittlement of the bracket steel", "Weld porosity reducing static strength", "Thermal expansion mismatch stress" ]
medium
[ "What is the S-N life at the measured stress amplitude?", "Does detuning the bracket stiffness drop the amplitude?", "Is fracture surface ductile dimple or striated?" ]
[ "Hydrogen embrittlement of the bracket steel", "Strain gauge saturation inflating stress", "Thermal expansion mismatch stress", "Weld porosity reducing static strength", "Static overload beyond yield" ]
mechanical
Shift log excerpt (cleansed): Engineer claims brackets crack from static overload. Measured peak static stress 46 MPa vs yield 345 MPa. Bracket natural frequency 61.6 Hz; motor runs at 59.8 Hz. Strain gauge shows 2.7e+06 cycles/day at +/-70 MPa. Fracture surface shows beach marks.
flawed_hypothesis
High-cycle fatigue driven by near-resonant excitation, not static overload
0
fam:MECH-FATIGUE-RESONANCE
SYN-MECH-FATIGUE-RESONANCE-21
null
CC-BY-4.0
null
[ "Beach marks indicate progressive fatigue growth.", "Driving near natural frequency amplifies dynamic stress by the quality factor." ]
null
synthetic_template
train
structural_dynamics
[ 46, 345, 61.6, 70, 59.8, 2661120, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Bracket cracks attributed to overload
null
reagent_material_flaw
[]
[ "Gear backlash out of tolerance from assembly", "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting", "Accelerometer cable triboelectric noise", "Shaft misalignment", "Pinion tooth crack (single broken tooth)", "Bearing defect at BPFO" ]
medium
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Shaft misalignment", "Pinion tooth crack (single broken tooth)", "Gear backlash out of tolerance from assembly", "Accelerometer cable triboelectric noise", "Bearing defect at BPFO" ]
mechanical
Ticket summary: Gear mesh frequency 1379 Hz with sidebands at +/-43.1 Hz (pinion speed) growing 57% in 3 weeks. Oil analysis: viscosity 53 cSt at 40C vs spec 106 cSt; Fe particles 86 ppm. Oil changed 4 weeks ago from a different supplier.
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
1
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-00
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 1379, 57, 53, 86, 43.09375, 106, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting", "Gear backlash out of tolerance from assembly", "Shaft misalignment", "Accelerometer cable triboelectric noise", "Pinion tooth crack (single broken tooth)", "Bearing defect at BPFO" ]
hard
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Pinion tooth crack (single broken tooth)", "Accelerometer cable triboelectric noise", "Gear backlash out of tolerance from assembly", "Shaft misalignment", "Bearing defect at BPFO" ]
mechanical
Field report: Gear mesh frequency 1247 Hz with sidebands at +/-39.0 Hz (pinion speed) growing 113% in 3 weeks. Oil analysis: viscosity 63 cSt at 40C vs spec 126 cSt; Fe particles 79 ppm. Oil changed 4 weeks ago from a different supplier. badge reader log entry unrelated Note: shift change at 14:00
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
0
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-01
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 1247, 113, 63, 79, 38.96875, 126, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Accelerometer cable triboelectric noise", "Pinion tooth crack (single broken tooth)", "Gear backlash out of tolerance from assembly", "Shaft misalignment", "Bearing defect at BPFO", "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting" ]
hard
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Shaft misalignment", "Accelerometer cable triboelectric noise", "Bearing defect at BPFO", "Gear backlash out of tolerance from assembly", "Pinion tooth crack (single broken tooth)" ]
mechanical
Ticket summary: Gear mesh frequency 1032 Hz with sidebands at +/-32.2 Hz (pinion speed) growing 74% in 3 weeks. Oil analysis: viscosity 51 cSt at 40C vs spec 102 cSt; Fe particles 110 ppm. Oil changed 4 weeks ago from a different supplier. A colleague suspects 'shaft misalignment' because a similar symptom was seen onc...
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
5
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-02
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 1032, 74, 51, 110, 32.25, 102, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Shaft misalignment", "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting", "Accelerometer cable triboelectric noise", "Bearing defect at BPFO", "Gear backlash out of tolerance from assembly", "Pinion tooth crack (single broken tooth)" ]
medium
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Pinion tooth crack (single broken tooth)", "Gear backlash out of tolerance from assembly", "Accelerometer cable triboelectric noise", "Shaft misalignment", "Bearing defect at BPFO" ]
mechanical
Gear mesh frequency 651 Hz with sidebands at +/-20.3 Hz (pinion speed) growing 66% in 3 weeks. Oil analysis: viscosity 60 cSt at 40C vs spec 120 cSt; Fe particles 62 ppm. Oil changed 4 weeks ago from a different supplier.
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
1
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-03
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 651, 66, 60, 62, 20.34375, 120, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Pinion tooth crack (single broken tooth)", "Shaft misalignment", "Bearing defect at BPFO", "Gear backlash out of tolerance from assembly", "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting", "Accelerometer cable triboelectric noise" ]
hard
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Pinion tooth crack (single broken tooth)", "Gear backlash out of tolerance from assembly", "Accelerometer cable triboelectric noise", "Shaft misalignment", "Bearing defect at BPFO" ]
mechanical
Shift log excerpt (cleansed): Gear mesh frequency 749 Hz with sidebands at +/-23.4 Hz (pinion speed) growing 56% in 3 weeks. Oil analysis: viscosity 60 cSt at 40C vs spec 120 cSt; Fe particles 110 ppm. Oil changed 4 weeks ago from a different supplier. Firmware banner printed at boot Note: shift change at 14:00
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
4
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-04
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 749, 56, 60, 110, 23.40625, 120, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Gear backlash out of tolerance from assembly", "Shaft misalignment", "Accelerometer cable triboelectric noise", "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting", "Bearing defect at BPFO", "Pinion tooth crack (single broken tooth)" ]
hard
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Shaft misalignment", "Pinion tooth crack (single broken tooth)", "Gear backlash out of tolerance from assembly", "Bearing defect at BPFO", "Accelerometer cable triboelectric noise" ]
mechanical
Field report: Gear mesh frequency 1244 Hz with sidebands at +/-38.9 Hz (pinion speed) growing 66% in 3 weeks. Oil analysis: viscosity 49 cSt at 40C vs spec 98 cSt; Fe particles 127 ppm. Oil changed 4 weeks ago from a different supplier. A colleague suspects 'shaft misalignment' because a similar symptom was seen once b...
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
3
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-05
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 1244, 66, 49, 127, 38.875, 98, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting", "Bearing defect at BPFO", "Pinion tooth crack (single broken tooth)", "Gear backlash out of tolerance from assembly", "Accelerometer cable triboelectric noise", "Shaft misalignment" ]
medium
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Pinion tooth crack (single broken tooth)", "Bearing defect at BPFO", "Gear backlash out of tolerance from assembly", "Accelerometer cable triboelectric noise", "Shaft misalignment" ]
mechanical
Ticket summary: Gear mesh frequency 1230 Hz with sidebands at +/-38.4 Hz (pinion speed) growing 92% in 3 weeks. Oil analysis: viscosity 67 cSt at 40C vs spec 134 cSt; Fe particles 146 ppm. Oil changed 4 weeks ago from a different supplier.
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
0
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-06
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 1230, 92, 67, 146, 38.4375, 134, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Pinion tooth crack (single broken tooth)", "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting", "Shaft misalignment", "Accelerometer cable triboelectric noise", "Bearing defect at BPFO", "Gear backlash out of tolerance from assembly" ]
hard
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Shaft misalignment", "Gear backlash out of tolerance from assembly", "Pinion tooth crack (single broken tooth)", "Bearing defect at BPFO", "Accelerometer cable triboelectric noise" ]
mechanical
Field report: Gear mesh frequency 1274 Hz with sidebands at +/-39.8 Hz (pinion speed) growing 77% in 3 weeks. Oil analysis: viscosity 54 cSt at 40C vs spec 108 cSt; Fe particles 78 ppm. Oil changed 4 weeks ago from a different supplier. duplicate log line suppressed x12 Unrelated: cafeteria chiller alarm acknowledged
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
1
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-07
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 1274, 77, 54, 78, 39.8125, 108, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Pinion tooth crack (single broken tooth)", "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting", "Shaft misalignment", "Accelerometer cable triboelectric noise", "Gear backlash out of tolerance from assembly", "Bearing defect at BPFO" ]
hard
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Gear backlash out of tolerance from assembly", "Shaft misalignment", "Accelerometer cable triboelectric noise", "Pinion tooth crack (single broken tooth)", "Bearing defect at BPFO" ]
mechanical
Engineer's handoff: Gear mesh frequency 1221 Hz with sidebands at +/-38.2 Hz (pinion speed) growing 63% in 3 weeks. Oil analysis: viscosity 57 cSt at 40C vs spec 114 cSt; Fe particles 122 ppm. Oil changed 4 weeks ago from a different supplier. A colleague suspects 'bearing defect at bpfo' because a similar symptom was ...
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
1
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-08
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 1221, 63, 57, 122, 38.15625, 114, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Pinion tooth crack (single broken tooth)", "Shaft misalignment", "Gear backlash out of tolerance from assembly", "Bearing defect at BPFO", "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting", "Accelerometer cable triboelectric noise" ]
medium
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Gear backlash out of tolerance from assembly", "Bearing defect at BPFO", "Shaft misalignment", "Pinion tooth crack (single broken tooth)", "Accelerometer cable triboelectric noise" ]
mechanical
Ticket summary: Gear mesh frequency 1098 Hz with sidebands at +/-34.3 Hz (pinion speed) growing 92% in 3 weeks. Oil analysis: viscosity 67 cSt at 40C vs spec 134 cSt; Fe particles 109 ppm. Oil changed 4 weeks ago from a different supplier.
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
4
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-09
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 1098, 92, 67, 109, 34.3125, 134, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Accelerometer cable triboelectric noise", "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting", "Shaft misalignment", "Gear backlash out of tolerance from assembly", "Pinion tooth crack (single broken tooth)", "Bearing defect at BPFO" ]
hard
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Gear backlash out of tolerance from assembly", "Accelerometer cable triboelectric noise", "Shaft misalignment", "Bearing defect at BPFO", "Pinion tooth crack (single broken tooth)" ]
mechanical
Gear mesh frequency 1115 Hz with sidebands at +/-34.8 Hz (pinion speed) growing 100% in 3 weeks. Oil analysis: viscosity 52 cSt at 40C vs spec 104 cSt; Fe particles 125 ppm. Oil changed 4 weeks ago from a different supplier. Unrelated: cafeteria chiller alarm acknowledged Firmware banner printed at boot
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
1
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-10
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 1115, 100, 52, 125, 34.84375, 104, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting", "Shaft misalignment", "Accelerometer cable triboelectric noise", "Pinion tooth crack (single broken tooth)", "Bearing defect at BPFO", "Gear backlash out of tolerance from assembly" ]
hard
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Bearing defect at BPFO", "Shaft misalignment", "Accelerometer cable triboelectric noise", "Gear backlash out of tolerance from assembly", "Pinion tooth crack (single broken tooth)" ]
mechanical
Ticket summary: Gear mesh frequency 1352 Hz with sidebands at +/-42.2 Hz (pinion speed) growing 58% in 3 weeks. Oil analysis: viscosity 46 cSt at 40C vs spec 92 cSt; Fe particles 111 ppm. Oil changed 4 weeks ago from a different supplier. A colleague suspects 'shaft misalignment' because a similar symptom was seen once...
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
0
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-11
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 1352, 58, 46, 111, 42.25, 92, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting", "Bearing defect at BPFO", "Pinion tooth crack (single broken tooth)", "Accelerometer cable triboelectric noise", "Gear backlash out of tolerance from assembly", "Shaft misalignment" ]
medium
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Gear backlash out of tolerance from assembly", "Pinion tooth crack (single broken tooth)", "Bearing defect at BPFO", "Accelerometer cable triboelectric noise", "Shaft misalignment" ]
mechanical
Gear mesh frequency 1301 Hz with sidebands at +/-40.7 Hz (pinion speed) growing 68% in 3 weeks. Oil analysis: viscosity 68 cSt at 40C vs spec 136 cSt; Fe particles 126 ppm. Oil changed 4 weeks ago from a different supplier.
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
0
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-12
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 1301, 68, 68, 126, 40.65625, 136, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Shaft misalignment", "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting", "Gear backlash out of tolerance from assembly", "Pinion tooth crack (single broken tooth)", "Accelerometer cable triboelectric noise", "Bearing defect at BPFO" ]
hard
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Pinion tooth crack (single broken tooth)", "Gear backlash out of tolerance from assembly", "Bearing defect at BPFO", "Shaft misalignment", "Accelerometer cable triboelectric noise" ]
mechanical
Operator note: Gear mesh frequency 1272 Hz with sidebands at +/-39.8 Hz (pinion speed) growing 43% in 3 weeks. Oil analysis: viscosity 46 cSt at 40C vs spec 92 cSt; Fe particles 84 ppm. Oil changed 4 weeks ago from a different supplier. Unrelated: cafeteria chiller alarm acknowledged HMI screensaver restarted
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
1
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-13
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 1272, 43, 46, 84, 39.75, 92, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting", "Gear backlash out of tolerance from assembly", "Bearing defect at BPFO", "Pinion tooth crack (single broken tooth)", "Shaft misalignment", "Accelerometer cable triboelectric noise" ]
hard
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Gear backlash out of tolerance from assembly", "Pinion tooth crack (single broken tooth)", "Bearing defect at BPFO", "Shaft misalignment", "Accelerometer cable triboelectric noise" ]
mechanical
Operator note: Gear mesh frequency 1339 Hz with sidebands at +/-41.8 Hz (pinion speed) growing 48% in 3 weeks. Oil analysis: viscosity 59 cSt at 40C vs spec 118 cSt; Fe particles 128 ppm. Oil changed 4 weeks ago from a different supplier. A colleague suspects 'pinion tooth crack (single broken tooth)' because a similar...
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
0
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-14
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 1339, 48, 59, 128, 41.84375, 118, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Shaft misalignment", "Accelerometer cable triboelectric noise", "Gear backlash out of tolerance from assembly", "Pinion tooth crack (single broken tooth)", "Bearing defect at BPFO", "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting" ]
medium
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Bearing defect at BPFO", "Pinion tooth crack (single broken tooth)", "Accelerometer cable triboelectric noise", "Shaft misalignment", "Gear backlash out of tolerance from assembly" ]
mechanical
Operator note: Gear mesh frequency 1010 Hz with sidebands at +/-31.6 Hz (pinion speed) growing 67% in 3 weeks. Oil analysis: viscosity 63 cSt at 40C vs spec 126 cSt; Fe particles 131 ppm. Oil changed 4 weeks ago from a different supplier.
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
5
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-15
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 1010, 67, 63, 131, 31.5625, 126, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Shaft misalignment", "Gear backlash out of tolerance from assembly", "Accelerometer cable triboelectric noise", "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting", "Pinion tooth crack (single broken tooth)", "Bearing defect at BPFO" ]
hard
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Accelerometer cable triboelectric noise", "Bearing defect at BPFO", "Gear backlash out of tolerance from assembly", "Pinion tooth crack (single broken tooth)", "Shaft misalignment" ]
mechanical
Shift log excerpt (cleansed): Gear mesh frequency 1306 Hz with sidebands at +/-40.8 Hz (pinion speed) growing 77% in 3 weeks. Oil analysis: viscosity 61 cSt at 40C vs spec 122 cSt; Fe particles 62 ppm. Oil changed 4 weeks ago from a different supplier. [INFO] heartbeat ok HMI screensaver restarted
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
3
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-16
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 1306, 77, 61, 62, 40.8125, 122, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Gear backlash out of tolerance from assembly", "Bearing defect at BPFO", "Shaft misalignment", "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting", "Accelerometer cable triboelectric noise", "Pinion tooth crack (single broken tooth)" ]
hard
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Bearing defect at BPFO", "Accelerometer cable triboelectric noise", "Shaft misalignment", "Gear backlash out of tolerance from assembly", "Pinion tooth crack (single broken tooth)" ]
mechanical
Gear mesh frequency 1290 Hz with sidebands at +/-40.3 Hz (pinion speed) growing 96% in 3 weeks. Oil analysis: viscosity 60 cSt at 40C vs spec 120 cSt; Fe particles 71 ppm. Oil changed 4 weeks ago from a different supplier. A colleague suspects 'pinion tooth crack (single broken tooth)' because a similar symptom was see...
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
3
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-17
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 1290, 96, 60, 71, 40.3125, 120, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Gear backlash out of tolerance from assembly", "Shaft misalignment", "Accelerometer cable triboelectric noise", "Pinion tooth crack (single broken tooth)", "Bearing defect at BPFO", "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting" ]
medium
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Accelerometer cable triboelectric noise", "Pinion tooth crack (single broken tooth)", "Bearing defect at BPFO", "Gear backlash out of tolerance from assembly", "Shaft misalignment" ]
mechanical
Field report: Gear mesh frequency 923 Hz with sidebands at +/-28.8 Hz (pinion speed) growing 65% in 3 weeks. Oil analysis: viscosity 48 cSt at 40C vs spec 96 cSt; Fe particles 145 ppm. Oil changed 4 weeks ago from a different supplier.
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
5
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-18
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 923, 65, 48, 145, 28.84375, 96, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Shaft misalignment", "Pinion tooth crack (single broken tooth)", "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting", "Bearing defect at BPFO", "Accelerometer cable triboelectric noise", "Gear backlash out of tolerance from assembly" ]
hard
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Accelerometer cable triboelectric noise", "Pinion tooth crack (single broken tooth)", "Shaft misalignment", "Gear backlash out of tolerance from assembly", "Bearing defect at BPFO" ]
mechanical
Ticket summary: Gear mesh frequency 1245 Hz with sidebands at +/-38.9 Hz (pinion speed) growing 94% in 3 weeks. Oil analysis: viscosity 60 cSt at 40C vs spec 120 cSt; Fe particles 133 ppm. Oil changed 4 weeks ago from a different supplier. Unrelated: cafeteria chiller alarm acknowledged badge reader log entry unrelated
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
2
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-19
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 1245, 94, 60, 133, 38.90625, 120, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Bearing defect at BPFO", "Pinion tooth crack (single broken tooth)", "Shaft misalignment", "Accelerometer cable triboelectric noise", "Gear backlash out of tolerance from assembly", "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting" ]
hard
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Pinion tooth crack (single broken tooth)", "Accelerometer cable triboelectric noise", "Shaft misalignment", "Bearing defect at BPFO", "Gear backlash out of tolerance from assembly" ]
mechanical
Operator note: Gear mesh frequency 928 Hz with sidebands at +/-29.0 Hz (pinion speed) growing 93% in 3 weeks. Oil analysis: viscosity 62 cSt at 40C vs spec 124 cSt; Fe particles 62 ppm. Oil changed 4 weeks ago from a different supplier. A colleague suspects 'bearing defect at bpfo' because a similar symptom was seen on...
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
5
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-20
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 928, 93, 62, 62, 29, 124, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
reagent_material_flaw
[]
[ "Bearing defect at BPFO", "Accelerometer cable triboelectric noise", "Under-viscosity lubricant causing loss of EHL film and pinion surface pitting", "Pinion tooth crack (single broken tooth)", "Gear backlash out of tolerance from assembly", "Shaft misalignment" ]
medium
[ "Is oil viscosity grade the specified ISO VG?", "Does ferrography show fatigue spall particles?", "Is time-synchronous average showing distributed or localized damage?" ]
[ "Accelerometer cable triboelectric noise", "Gear backlash out of tolerance from assembly", "Bearing defect at BPFO", "Pinion tooth crack (single broken tooth)", "Shaft misalignment" ]
mechanical
Shift log excerpt (cleansed): Gear mesh frequency 948 Hz with sidebands at +/-29.6 Hz (pinion speed) growing 73% in 3 weeks. Oil analysis: viscosity 50 cSt at 40C vs spec 100 cSt; Fe particles 70 ppm. Oil changed 4 weeks ago from a different supplier.
reagent_material_flaw
Under-viscosity lubricant causing loss of EHL film and pinion surface pitting
2
fam:MECH-GEAR-PITTING
SYN-MECH-GEAR-PITTING-21
null
CC-BY-4.0
null
[ "Thin oil film -> metal contact -> pitting -> modulation sidebands at the damaged gear's shaft speed.", "A single cracked tooth produces an impulsive once-per-rev, not a smooth sideband growth." ]
null
synthetic_template
train
gearbox
[ 948, 73, 50, 70, 29.625, 100, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Gearbox sidebands rise after oil change
null
instrumentation_artifact
[]
[ "Thermal growth of ballscrew", "Encoder line-count misconfiguration", "Servo gains too low", "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error", "Load mass increased", "Interferometer air-turbulence error" ]
easy
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Encoder line-count misconfiguration", "Thermal growth of ballscrew", "Interferometer air-turbulence error", "Servo gains too low", "Load mass increased" ]
mechanical
Shift log excerpt (cleansed): Linear stage repeatability 2 um unidirectional but 41 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 41 um on reversal. Servo gains unchanged for 2 years.
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
3
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-00
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 2, 41, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error", "Interferometer air-turbulence error", "Encoder line-count misconfiguration", "Servo gains too low", "Thermal growth of ballscrew", "Load mass increased" ]
medium
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Thermal growth of ballscrew", "Encoder line-count misconfiguration", "Interferometer air-turbulence error", "Servo gains too low", "Load mass increased" ]
mechanical
Shift log excerpt (cleansed): Linear stage repeatability 4 um unidirectional but 45 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 45 um on reversal. Servo gains unchanged for 2 years. HMI screensaver restarted [INFO] heartbeat ok
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
0
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-01
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 4, 45, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error", "Servo gains too low", "Thermal growth of ballscrew", "Interferometer air-turbulence error", "Load mass increased", "Encoder line-count misconfiguration" ]
medium
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Thermal growth of ballscrew", "Encoder line-count misconfiguration", "Load mass increased", "Servo gains too low", "Interferometer air-turbulence error" ]
mechanical
Ticket summary: Linear stage repeatability 1 um unidirectional but 41 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 41 um on reversal. Servo gains unchanged for 2 years. A colleague suspects 'servo gains too low' because a similar symptom was seen once before (no m...
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
0
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-02
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 1, 41, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Servo gains too low", "Thermal growth of ballscrew", "Load mass increased", "Encoder line-count misconfiguration", "Interferometer air-turbulence error", "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error" ]
easy
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Load mass increased", "Thermal growth of ballscrew", "Interferometer air-turbulence error", "Servo gains too low", "Encoder line-count misconfiguration" ]
mechanical
Engineer's handoff: Linear stage repeatability 4 um unidirectional but 18 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 18 um on reversal. Servo gains unchanged for 2 years.
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
5
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-03
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 4, 18, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Encoder line-count misconfiguration", "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error", "Servo gains too low", "Interferometer air-turbulence error", "Thermal growth of ballscrew", "Load mass increased" ]
medium
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Interferometer air-turbulence error", "Servo gains too low", "Thermal growth of ballscrew", "Load mass increased", "Encoder line-count misconfiguration" ]
mechanical
Linear stage repeatability 2 um unidirectional but 28 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 28 um on reversal. Servo gains unchanged for 2 years. [INFO] heartbeat ok duplicate log line suppressed x12
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
1
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-04
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 2, 28, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Thermal growth of ballscrew", "Load mass increased", "Servo gains too low", "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error", "Encoder line-count misconfiguration", "Interferometer air-turbulence error" ]
medium
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Thermal growth of ballscrew", "Interferometer air-turbulence error", "Servo gains too low", "Load mass increased", "Encoder line-count misconfiguration" ]
mechanical
Field report: Linear stage repeatability 2 um unidirectional but 58 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 58 um on reversal. Servo gains unchanged for 2 years. A colleague suspects 'thermal growth of ballscrew' because a similar symptom was seen once before...
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
3
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-05
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 2, 58, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error", "Interferometer air-turbulence error", "Encoder line-count misconfiguration", "Load mass increased", "Thermal growth of ballscrew", "Servo gains too low" ]
easy
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Load mass increased", "Thermal growth of ballscrew", "Encoder line-count misconfiguration", "Servo gains too low", "Interferometer air-turbulence error" ]
mechanical
Linear stage repeatability 3 um unidirectional but 22 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 22 um on reversal. Servo gains unchanged for 2 years.
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
0
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-06
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 3, 22, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Servo gains too low", "Encoder line-count misconfiguration", "Thermal growth of ballscrew", "Interferometer air-turbulence error", "Load mass increased", "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error" ]
medium
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Interferometer air-turbulence error", "Encoder line-count misconfiguration", "Thermal growth of ballscrew", "Load mass increased", "Servo gains too low" ]
mechanical
Linear stage repeatability 2 um unidirectional but 52 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 52 um on reversal. Servo gains unchanged for 2 years. badge reader log entry unrelated [INFO] heartbeat ok
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
5
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-07
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 2, 52, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Interferometer air-turbulence error", "Encoder line-count misconfiguration", "Servo gains too low", "Thermal growth of ballscrew", "Load mass increased", "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error" ]
medium
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Servo gains too low", "Encoder line-count misconfiguration", "Thermal growth of ballscrew", "Load mass increased", "Interferometer air-turbulence error" ]
mechanical
Shift log excerpt (cleansed): Linear stage repeatability 2 um unidirectional but 47 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 47 um on reversal. Servo gains unchanged for 2 years. A colleague suspects 'servo gains too low' because a similar symptom was seen onc...
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
5
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-08
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 2, 47, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Thermal growth of ballscrew", "Load mass increased", "Interferometer air-turbulence error", "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error", "Encoder line-count misconfiguration", "Servo gains too low" ]
easy
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Load mass increased", "Servo gains too low", "Thermal growth of ballscrew", "Interferometer air-turbulence error", "Encoder line-count misconfiguration" ]
mechanical
Engineer's handoff: Linear stage repeatability 4 um unidirectional but 35 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 35 um on reversal. Servo gains unchanged for 2 years.
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
3
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-09
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 4, 35, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Servo gains too low", "Encoder line-count misconfiguration", "Load mass increased", "Thermal growth of ballscrew", "Interferometer air-turbulence error", "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error" ]
medium
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Load mass increased", "Encoder line-count misconfiguration", "Servo gains too low", "Interferometer air-turbulence error", "Thermal growth of ballscrew" ]
mechanical
Linear stage repeatability 4 um unidirectional but 48 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 48 um on reversal. Servo gains unchanged for 2 years. [INFO] heartbeat ok HMI screensaver restarted
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
5
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-10
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 4, 48, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Encoder line-count misconfiguration", "Thermal growth of ballscrew", "Load mass increased", "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error", "Servo gains too low", "Interferometer air-turbulence error" ]
medium
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Interferometer air-turbulence error", "Encoder line-count misconfiguration", "Load mass increased", "Thermal growth of ballscrew", "Servo gains too low" ]
mechanical
Ticket summary: Linear stage repeatability 2 um unidirectional but 30 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 30 um on reversal. Servo gains unchanged for 2 years. A colleague suspects 'thermal growth of ballscrew' because a similar symptom was seen once befo...
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
3
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-11
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 2, 30, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Servo gains too low", "Interferometer air-turbulence error", "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error", "Load mass increased", "Encoder line-count misconfiguration", "Thermal growth of ballscrew" ]
easy
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Load mass increased", "Encoder line-count misconfiguration", "Thermal growth of ballscrew", "Interferometer air-turbulence error", "Servo gains too low" ]
mechanical
Engineer's handoff: Linear stage repeatability 4 um unidirectional but 28 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 28 um on reversal. Servo gains unchanged for 2 years.
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
2
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-12
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 4, 28, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Thermal growth of ballscrew", "Encoder line-count misconfiguration", "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error", "Servo gains too low", "Load mass increased", "Interferometer air-turbulence error" ]
medium
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Servo gains too low", "Load mass increased", "Thermal growth of ballscrew", "Interferometer air-turbulence error", "Encoder line-count misconfiguration" ]
mechanical
Field report: Linear stage repeatability 3 um unidirectional but 35 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 35 um on reversal. Servo gains unchanged for 2 years. Firmware banner printed at boot Note: shift change at 14:00
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
2
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-13
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 3, 35, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Encoder line-count misconfiguration", "Load mass increased", "Thermal growth of ballscrew", "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error", "Servo gains too low", "Interferometer air-turbulence error" ]
medium
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Interferometer air-turbulence error", "Encoder line-count misconfiguration", "Thermal growth of ballscrew", "Servo gains too low", "Load mass increased" ]
mechanical
Linear stage repeatability 3 um unidirectional but 32 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 32 um on reversal. Servo gains unchanged for 2 years. A colleague suspects 'interferometer air-turbulence error' because a similar symptom was seen once before (no m...
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
3
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-14
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 3, 32, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Servo gains too low", "Interferometer air-turbulence error", "Load mass increased", "Thermal growth of ballscrew", "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error", "Encoder line-count misconfiguration" ]
easy
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Load mass increased", "Interferometer air-turbulence error", "Thermal growth of ballscrew", "Servo gains too low", "Encoder line-count misconfiguration" ]
mechanical
Ticket summary: Linear stage repeatability 4 um unidirectional but 56 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 56 um on reversal. Servo gains unchanged for 2 years.
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
4
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-15
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 4, 56, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Thermal growth of ballscrew", "Load mass increased", "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error", "Interferometer air-turbulence error", "Servo gains too low", "Encoder line-count misconfiguration" ]
medium
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Interferometer air-turbulence error", "Thermal growth of ballscrew", "Encoder line-count misconfiguration", "Load mass increased", "Servo gains too low" ]
mechanical
Ticket summary: Linear stage repeatability 2 um unidirectional but 36 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 36 um on reversal. Servo gains unchanged for 2 years. duplicate log line suppressed x12 Unrelated: cafeteria chiller alarm acknowledged
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
2
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-16
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 2, 36, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Load mass increased", "Encoder line-count misconfiguration", "Thermal growth of ballscrew", "Servo gains too low", "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error", "Interferometer air-turbulence error" ]
medium
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Interferometer air-turbulence error", "Servo gains too low", "Encoder line-count misconfiguration", "Load mass increased", "Thermal growth of ballscrew" ]
mechanical
Engineer's handoff: Linear stage repeatability 3 um unidirectional but 48 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 48 um on reversal. Servo gains unchanged for 2 years. A colleague suspects 'interferometer air-turbulence error' because a similar symptom was se...
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
4
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-17
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 3, 48, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Thermal growth of ballscrew", "Load mass increased", "Encoder line-count misconfiguration", "Servo gains too low", "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error", "Interferometer air-turbulence error" ]
easy
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Thermal growth of ballscrew", "Load mass increased", "Encoder line-count misconfiguration", "Servo gains too low", "Interferometer air-turbulence error" ]
mechanical
Linear stage repeatability 3 um unidirectional but 16 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 16 um on reversal. Servo gains unchanged for 2 years.
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
4
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-18
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 3, 16, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Servo gains too low", "Encoder line-count misconfiguration", "Load mass increased", "Interferometer air-turbulence error", "Thermal growth of ballscrew", "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error" ]
medium
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Thermal growth of ballscrew", "Encoder line-count misconfiguration", "Load mass increased", "Servo gains too low", "Interferometer air-turbulence error" ]
mechanical
Operator note: Linear stage repeatability 2 um unidirectional but 52 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 52 um on reversal. Servo gains unchanged for 2 years. HMI screensaver restarted Note: shift change at 14:00
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
5
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-19
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 2, 52, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Servo gains too low", "Encoder line-count misconfiguration", "Thermal growth of ballscrew", "Interferometer air-turbulence error", "Load mass increased", "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error" ]
medium
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Thermal growth of ballscrew", "Interferometer air-turbulence error", "Servo gains too low", "Encoder line-count misconfiguration", "Load mass increased" ]
mechanical
Engineer's handoff: Linear stage repeatability 4 um unidirectional but 18 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 18 um on reversal. Servo gains unchanged for 2 years. A colleague suspects 'thermal growth of ballscrew' because a similar symptom was seen once ...
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
5
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-20
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 4, 18, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Servo gains too low", "Thermal growth of ballscrew", "Interferometer air-turbulence error", "Load mass increased", "Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error", "Encoder line-count misconfiguration" ]
easy
[ "Does error flip sign with approach direction only?", "Does a linear-scale (full-closed) loop remove it?", "Is error constant across stroke positions?" ]
[ "Load mass increased", "Encoder line-count misconfiguration", "Interferometer air-turbulence error", "Servo gains too low", "Thermal growth of ballscrew" ]
mechanical
Shift log excerpt (cleansed): Linear stage repeatability 4 um unidirectional but 57 um bidirectional. Motor encoder reports in-position; external interferometer disagrees by a constant 57 um on reversal. Servo gains unchanged for 2 years.
instrumentation_artifact
Lost motion/backlash between motor encoder and load (semi-closed loop) shows as reversal error
4
fam:MECH-ENCODER-BACKLASH
SYN-MECH-ENCODER-BACKLASH-21
null
CC-BY-4.0
null
[ "Semi-closed loop control cannot see backlash between motor and table.", "Thermal growth drifts with time, not with direction of travel." ]
null
synthetic_template
train
motion_control
[ 4, 57, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Positioning error blamed on servo tuning
null
instrumentation_artifact
[]
[ "Bearing friction increase", "Clamp meter calibration error on one phase", "Mechanical overload of the motor", "Cooling fan blocked", "Winding insulation breakdown", "Supply voltage unbalance from a high-resistance connection causing negative-sequence heating" ]
medium
[ "Thermal image of the terminal connections?", "Does current unbalance follow the supply phase when leads are rotated?", "Motor current at no-load?" ]
[ "Mechanical overload of the motor", "Winding insulation breakdown", "Cooling fan blocked", "Bearing friction increase", "Clamp meter calibration error on one phase" ]
electrical
Engineer's handoff: 3-phase motor running hot (114 C). Phase currents 20.2/23.8/27.3 A; line voltages 398/398/378 V (unbalance 5.1%). Mechanical load unchanged. One supply connection shows discoloration.
instrumentation_artifact
Supply voltage unbalance from a high-resistance connection causing negative-sequence heating
5
fam:ELEC-MOTOR-UNBAL
SYN-ELEC-MOTOR-UNBAL-00
null
CC-BY-4.0
null
[ "Each 1% voltage unbalance can cause ~6-10% current unbalance and much higher rotor heating.", "Mechanical overload raises all three currents equally." ]
null
synthetic_template
train
motors
[ 114, 20.2, 23.8, 398, 398, 27.3, 378, 5.084745762711874, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Motor overheating with balanced load
null
instrumentation_artifact
[]
[ "Winding insulation breakdown", "Bearing friction increase", "Mechanical overload of the motor", "Clamp meter calibration error on one phase", "Cooling fan blocked", "Supply voltage unbalance from a high-resistance connection causing negative-sequence heating" ]
hard
[ "Thermal image of the terminal connections?", "Does current unbalance follow the supply phase when leads are rotated?", "Motor current at no-load?" ]
[ "Clamp meter calibration error on one phase", "Winding insulation breakdown", "Mechanical overload of the motor", "Cooling fan blocked", "Bearing friction increase" ]
electrical
Field report: 3-phase motor running hot (97 C). Phase currents 22.4/20.2/30.2 A; line voltages 395/399/375 V (unbalance 6.1%). Mechanical load unchanged. One supply connection shows discoloration. [INFO] heartbeat ok badge reader log entry unrelated
instrumentation_artifact
Supply voltage unbalance from a high-resistance connection causing negative-sequence heating
5
fam:ELEC-MOTOR-UNBAL
SYN-ELEC-MOTOR-UNBAL-01
null
CC-BY-4.0
null
[ "Each 1% voltage unbalance can cause ~6-10% current unbalance and much higher rotor heating.", "Mechanical overload raises all three currents equally." ]
null
synthetic_template
train
motors
[ 97, 22.4, 20.2, 395, 399, 30.2, 375, 6.093649775497114, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Motor overheating with balanced load
null
instrumentation_artifact
[]
[ "Mechanical overload of the motor", "Clamp meter calibration error on one phase", "Supply voltage unbalance from a high-resistance connection causing negative-sequence heating", "Winding insulation breakdown", "Bearing friction increase", "Cooling fan blocked" ]
hard
[ "Thermal image of the terminal connections?", "Does current unbalance follow the supply phase when leads are rotated?", "Motor current at no-load?" ]
[ "Bearing friction increase", "Winding insulation breakdown", "Cooling fan blocked", "Mechanical overload of the motor", "Clamp meter calibration error on one phase" ]
electrical
Ticket summary: 3-phase motor running hot (115 C). Phase currents 20.6/22.8/27.8 A; line voltages 398/401/378 V (unbalance 5.8%). Mechanical load unchanged. One supply connection shows discoloration. A colleague suspects 'winding insulation breakdown' because a similar symptom was seen once before (no measurement attac...
instrumentation_artifact
Supply voltage unbalance from a high-resistance connection causing negative-sequence heating
2
fam:ELEC-MOTOR-UNBAL
SYN-ELEC-MOTOR-UNBAL-02
null
CC-BY-4.0
null
[ "Each 1% voltage unbalance can cause ~6-10% current unbalance and much higher rotor heating.", "Mechanical overload raises all three currents equally." ]
null
synthetic_template
train
motors
[ 115, 20.6, 22.8, 398, 401, 27.8, 378, 5.836377538017171, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Motor overheating with balanced load
null
instrumentation_artifact
[]
[ "Cooling fan blocked", "Clamp meter calibration error on one phase", "Supply voltage unbalance from a high-resistance connection causing negative-sequence heating", "Mechanical overload of the motor", "Winding insulation breakdown", "Bearing friction increase" ]
medium
[ "Thermal image of the terminal connections?", "Does current unbalance follow the supply phase when leads are rotated?", "Motor current at no-load?" ]
[ "Winding insulation breakdown", "Cooling fan blocked", "Mechanical overload of the motor", "Bearing friction increase", "Clamp meter calibration error on one phase" ]
electrical
Operator note: 3-phase motor running hot (121 C). Phase currents 23.5/22.5/31.7 A; line voltages 400/400/380 V (unbalance 5.1%). Mechanical load unchanged. One supply connection shows discoloration.
instrumentation_artifact
Supply voltage unbalance from a high-resistance connection causing negative-sequence heating
2
fam:ELEC-MOTOR-UNBAL
SYN-ELEC-MOTOR-UNBAL-03
null
CC-BY-4.0
null
[ "Each 1% voltage unbalance can cause ~6-10% current unbalance and much higher rotor heating.", "Mechanical overload raises all three currents equally." ]
null
synthetic_template
train
motors
[ 121, 23.5, 22.5, 400, 400, 31.7, 380, 5.084745762711865, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Motor overheating with balanced load
null
instrumentation_artifact
[]
[ "Supply voltage unbalance from a high-resistance connection causing negative-sequence heating", "Mechanical overload of the motor", "Cooling fan blocked", "Winding insulation breakdown", "Clamp meter calibration error on one phase", "Bearing friction increase" ]
hard
[ "Thermal image of the terminal connections?", "Does current unbalance follow the supply phase when leads are rotated?", "Motor current at no-load?" ]
[ "Clamp meter calibration error on one phase", "Bearing friction increase", "Winding insulation breakdown", "Mechanical overload of the motor", "Cooling fan blocked" ]
electrical
Operator note: 3-phase motor running hot (97 C). Phase currents 22.4/23.8/30.2 A; line voltages 399/397/379 V (unbalance 5.1%). Mechanical load unchanged. One supply connection shows discoloration. badge reader log entry unrelated duplicate log line suppressed x12
instrumentation_artifact
Supply voltage unbalance from a high-resistance connection causing negative-sequence heating
0
fam:ELEC-MOTOR-UNBAL
SYN-ELEC-MOTOR-UNBAL-04
null
CC-BY-4.0
null
[ "Each 1% voltage unbalance can cause ~6-10% current unbalance and much higher rotor heating.", "Mechanical overload raises all three currents equally." ]
null
synthetic_template
train
motors
[ 97, 22.4, 23.8, 399, 397, 30.2, 379, 5.093400280839125, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Motor overheating with balanced load
null
instrumentation_artifact
[]
[ "Cooling fan blocked", "Bearing friction increase", "Winding insulation breakdown", "Clamp meter calibration error on one phase", "Supply voltage unbalance from a high-resistance connection causing negative-sequence heating", "Mechanical overload of the motor" ]
hard
[ "Thermal image of the terminal connections?", "Does current unbalance follow the supply phase when leads are rotated?", "Motor current at no-load?" ]
[ "Cooling fan blocked", "Bearing friction increase", "Mechanical overload of the motor", "Winding insulation breakdown", "Clamp meter calibration error on one phase" ]
electrical
3-phase motor running hot (100 C). Phase currents 23.0/22.8/31.1 A; line voltages 396/395/376 V (unbalance 5.1%). Mechanical load unchanged. One supply connection shows discoloration. A colleague suspects 'mechanical overload of the motor' because a similar symptom was seen once before (no measurement attached).
instrumentation_artifact
Supply voltage unbalance from a high-resistance connection causing negative-sequence heating
4
fam:ELEC-MOTOR-UNBAL
SYN-ELEC-MOTOR-UNBAL-05
null
CC-BY-4.0
null
[ "Each 1% voltage unbalance can cause ~6-10% current unbalance and much higher rotor heating.", "Mechanical overload raises all three currents equally." ]
null
synthetic_template
train
motors
[ 100, 23, 22.8, 396, 395, 31.1, 376, 5.089102124742977, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Motor overheating with balanced load
null
instrumentation_artifact
[]
[ "Supply voltage unbalance from a high-resistance connection causing negative-sequence heating", "Winding insulation breakdown", "Mechanical overload of the motor", "Bearing friction increase", "Cooling fan blocked", "Clamp meter calibration error on one phase" ]
medium
[ "Thermal image of the terminal connections?", "Does current unbalance follow the supply phase when leads are rotated?", "Motor current at no-load?" ]
[ "Clamp meter calibration error on one phase", "Cooling fan blocked", "Mechanical overload of the motor", "Winding insulation breakdown", "Bearing friction increase" ]
electrical
Field report: 3-phase motor running hot (117 C). Phase currents 20.3/22.3/27.4 A; line voltages 402/396/382 V (unbalance 5.1%). Mechanical load unchanged. One supply connection shows discoloration.
instrumentation_artifact
Supply voltage unbalance from a high-resistance connection causing negative-sequence heating
0
fam:ELEC-MOTOR-UNBAL
SYN-ELEC-MOTOR-UNBAL-06
null
CC-BY-4.0
null
[ "Each 1% voltage unbalance can cause ~6-10% current unbalance and much higher rotor heating.", "Mechanical overload raises all three currents equally." ]
null
synthetic_template
train
motors
[ 117, 20.3, 22.3, 402, 396, 27.4, 382, 5.110602593440127, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Motor overheating with balanced load
null
instrumentation_artifact
[]
[ "Cooling fan blocked", "Supply voltage unbalance from a high-resistance connection causing negative-sequence heating", "Bearing friction increase", "Clamp meter calibration error on one phase", "Mechanical overload of the motor", "Winding insulation breakdown" ]
hard
[ "Thermal image of the terminal connections?", "Does current unbalance follow the supply phase when leads are rotated?", "Motor current at no-load?" ]
[ "Clamp meter calibration error on one phase", "Winding insulation breakdown", "Cooling fan blocked", "Mechanical overload of the motor", "Bearing friction increase" ]
electrical
Shift log excerpt (cleansed): 3-phase motor running hot (115 C). Phase currents 23.4/22.3/31.6 A; line voltages 400/395/380 V (unbalance 5.1%). Mechanical load unchanged. One supply connection shows discoloration. [INFO] heartbeat ok Unrelated: cafeteria chiller alarm acknowledged
instrumentation_artifact
Supply voltage unbalance from a high-resistance connection causing negative-sequence heating
1
fam:ELEC-MOTOR-UNBAL
SYN-ELEC-MOTOR-UNBAL-07
null
CC-BY-4.0
null
[ "Each 1% voltage unbalance can cause ~6-10% current unbalance and much higher rotor heating.", "Mechanical overload raises all three currents equally." ]
null
synthetic_template
train
motors
[ 115, 23.4, 22.3, 400, 395, 31.6, 380, 5.106382978723404, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Motor overheating with balanced load
null
instrumentation_artifact
[]
[ "Mechanical overload of the motor", "Clamp meter calibration error on one phase", "Supply voltage unbalance from a high-resistance connection causing negative-sequence heating", "Bearing friction increase", "Winding insulation breakdown", "Cooling fan blocked" ]
hard
[ "Thermal image of the terminal connections?", "Does current unbalance follow the supply phase when leads are rotated?", "Motor current at no-load?" ]
[ "Winding insulation breakdown", "Bearing friction increase", "Cooling fan blocked", "Clamp meter calibration error on one phase", "Mechanical overload of the motor" ]
electrical
3-phase motor running hot (116 C). Phase currents 23.1/23.0/31.2 A; line voltages 399/400/379 V (unbalance 5.3%). Mechanical load unchanged. One supply connection shows discoloration. A colleague suspects 'winding insulation breakdown' because a similar symptom was seen once before (no measurement attached).
instrumentation_artifact
Supply voltage unbalance from a high-resistance connection causing negative-sequence heating
2
fam:ELEC-MOTOR-UNBAL
SYN-ELEC-MOTOR-UNBAL-08
null
CC-BY-4.0
null
[ "Each 1% voltage unbalance can cause ~6-10% current unbalance and much higher rotor heating.", "Mechanical overload raises all three currents equally." ]
null
synthetic_template
train
motors
[ 116, 23.1, 23, 399, 400, 31.2, 379, 5.335087644836818, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Motor overheating with balanced load
null
instrumentation_artifact
[]
[ "Bearing friction increase", "Cooling fan blocked", "Winding insulation breakdown", "Mechanical overload of the motor", "Supply voltage unbalance from a high-resistance connection causing negative-sequence heating", "Clamp meter calibration error on one phase" ]
medium
[ "Thermal image of the terminal connections?", "Does current unbalance follow the supply phase when leads are rotated?", "Motor current at no-load?" ]
[ "Mechanical overload of the motor", "Clamp meter calibration error on one phase", "Winding insulation breakdown", "Bearing friction increase", "Cooling fan blocked" ]
electrical
Operator note: 3-phase motor running hot (111 C). Phase currents 22.7/22.7/30.6 A; line voltages 400/399/380 V (unbalance 5.1%). Mechanical load unchanged. One supply connection shows discoloration.
instrumentation_artifact
Supply voltage unbalance from a high-resistance connection causing negative-sequence heating
4
fam:ELEC-MOTOR-UNBAL
SYN-ELEC-MOTOR-UNBAL-09
null
CC-BY-4.0
null
[ "Each 1% voltage unbalance can cause ~6-10% current unbalance and much higher rotor heating.", "Mechanical overload raises all three currents equally." ]
null
synthetic_template
train
motors
[ 111, 22.7, 22.7, 400, 399, 30.6, 380, 5.089058524173028, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Motor overheating with balanced load
null
instrumentation_artifact
[]
[ "Mechanical overload of the motor", "Winding insulation breakdown", "Supply voltage unbalance from a high-resistance connection causing negative-sequence heating", "Cooling fan blocked", "Bearing friction increase", "Clamp meter calibration error on one phase" ]
hard
[ "Thermal image of the terminal connections?", "Does current unbalance follow the supply phase when leads are rotated?", "Motor current at no-load?" ]
[ "Cooling fan blocked", "Mechanical overload of the motor", "Clamp meter calibration error on one phase", "Winding insulation breakdown", "Bearing friction increase" ]
electrical
Engineer's handoff: 3-phase motor running hot (121 C). Phase currents 20.1/21.9/27.1 A; line voltages 399/396/379 V (unbalance 5.1%). Mechanical load unchanged. One supply connection shows discoloration. badge reader log entry unrelated Note: shift change at 14:00
instrumentation_artifact
Supply voltage unbalance from a high-resistance connection causing negative-sequence heating
2
fam:ELEC-MOTOR-UNBAL
SYN-ELEC-MOTOR-UNBAL-10
null
CC-BY-4.0
null
[ "Each 1% voltage unbalance can cause ~6-10% current unbalance and much higher rotor heating.", "Mechanical overload raises all three currents equally." ]
null
synthetic_template
train
motors
[ 121, 20.1, 21.9, 399, 396, 27.1, 379, 5.097738597163676, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Motor overheating with balanced load
null
instrumentation_artifact
[]
[ "Winding insulation breakdown", "Mechanical overload of the motor", "Supply voltage unbalance from a high-resistance connection causing negative-sequence heating", "Bearing friction increase", "Clamp meter calibration error on one phase", "Cooling fan blocked" ]
hard
[ "Thermal image of the terminal connections?", "Does current unbalance follow the supply phase when leads are rotated?", "Motor current at no-load?" ]
[ "Clamp meter calibration error on one phase", "Cooling fan blocked", "Bearing friction increase", "Winding insulation breakdown", "Mechanical overload of the motor" ]
electrical
Field report: 3-phase motor running hot (99 C). Phase currents 22.1/23.6/29.8 A; line voltages 402/398/382 V (unbalance 5.1%). Mechanical load unchanged. One supply connection shows discoloration. A colleague suspects 'cooling fan blocked' because a similar symptom was seen once before (no measurement attached).
instrumentation_artifact
Supply voltage unbalance from a high-resistance connection causing negative-sequence heating
2
fam:ELEC-MOTOR-UNBAL
SYN-ELEC-MOTOR-UNBAL-11
null
CC-BY-4.0
null
[ "Each 1% voltage unbalance can cause ~6-10% current unbalance and much higher rotor heating.", "Mechanical overload raises all three currents equally." ]
null
synthetic_template
train
motors
[ 99, 22.1, 23.6, 402, 398, 29.8, 382, 5.101954480074462, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 ]
Motor overheating with balanced load
null
End of preview. Expand in Data Studio

Epistemic Debugging Benchmark (v2)

A benchmark for diagnosing failed experiments and engineering faults. Each item gives a messy evidence summary plus competing hypotheses, and the model has to work out which cause the evidence actually supports, which near-miss explanations it rules out, and which follow-up check would tell them apart. It tests reasoning about evidence; it is not a fault-code lookup.

Project: Epistemic-Debugging-Benchmark on GitHub. Baseline model: punyajain/epidebug-mm-v3.

Splits

split rows
train 1177
validation 301
test 337

The test split holds out whole failure families (BIO-SAMPLE-HOLD, CHEM-HPLC-DEGAS, ELEC-PCB-ELECTROMIGRATION, MAT-CONCRETE-CHLORIDE, MECH-BOLT-PRELOAD, MFG-TOOLWEAR, ROB-PREMATURE-OPEN, SEN-LOCKIN-PHASE, SW-TEMPORAL-LEAK, THM-FOULING), so no paraphrase or variant of a test family appears in train. Scores on test measure generalization to new failure mechanisms.

Domains

domain rows
mechanical 174
electrical 164
robotics 166
chemistry 74
materials 108
software_ml 144
fluids_thermal 110
manufacturing_industrial 553
biology_lab 155
sensors 143
physics_priors 24

Sources

source_type rows
synthetic_template 1275
expert_authored_synthetic 62
synthetic_schema_harvest 89
harvested_public_ai4i 296
synthetic_physics_prior 24
expert_authored_synthetic_paraphrase 65
real_pipeline_sim_injected_fault 4

Most rows are synthetic, generated from expert-written failure families with physics priors and hard near-miss distractors. harvested_public_ai4i rows come from the public AI4I 2020 predictive-maintenance dataset (UCI, CC BY 4.0). real_pipeline_sim_injected_fault rows are robot pick-and-place runs from a simulated UR5 pipeline with injected gripper faults. Every row has a source_type field so you can filter.

Fields

id, group_id (failure family), source_type, domain, subdomain, failure_category (one of 4), difficulty (easy/medium/hard/expert), title, evidence, physics_priors, competing_hypotheses, plus gold labels for the cause, the ruled-out hypotheses, and the discriminating follow-up.

Scoring

Report accuracy and macro-F1 on failure_category, top-1 accuracy at ranking the gold hypothesis (shuffle the options so the gold one isn't always first), and follow-up selection accuracy, all on the test split.

Baseline (epidebug-mm-v3, CPU, frozen MiniLM + small heads)

metric validation test
category accuracy 0.548 0.496
category macro-F1 0.513 0.501
hypothesis ranking (shuffled) 0.578 0.632
follow-up selection 0.492 0.362

Much lower than v1 of this benchmark, on purpose: the near-miss distractors are harder and test families are held out. Lots of headroom.

Limitations

The data is mostly synthetic and template-based, so there will be repeated patterns. Labels are author-assigned, not peer-reviewed. The evidence is text summaries; raw sensor, image and CAD data are not included. Don't use the benchmark for safety certification.

Citation

@misc{jain2026epidebug,
  title={Epistemic Debugging Benchmark},
  author={Punya Malaiya Jain},
  year={2026},
  url={https://github.com/Punyajain-cmd/Epistemic-Debugging-Benchmark}
}
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