Failure prediction system for electric drive

Abstract

The utility model relates to a fault prediction system for an electric driving device, and the system comprises a vibration sensor disposed on the electric driving device, and the vibration sensor is bonded to a housing of the electric driving device in a lossless manner through a first bonding device; the temperature sensor is mounted on the electric driving device, and the temperature sensor is adhered to the shell of the electric driving device in a lossless manner through a second adhesive device; the processing module establishes first communication connection with the vibration sensor and the temperature sensor respectively and receives vibration parameters and temperature parameters through the first communication connection; and a control device which establishes a second communication connection with the processing module and receives the vibration parameter and the temperature parameter for fault prediction via the second communication connection.

Description

Technical Field

[0001] This utility model relates to the field of fault prediction technology for electric drive devices, and more specifically, to a fault prediction system for electric drive devices. Background Technology

[0002] In today's highly industrialized and automated era, electric drive systems, as core components for power output and motion control, are widely used in various production equipment, transportation vehicles, and intelligent automation systems. However, due to complex operating conditions, long-term continuous operation, and natural wear and tear of mechanical parts, electric drive systems are highly susceptible to various malfunctions during operation.

[0003] From a mechanical perspective, critical components of the motor, such as bearings and gears in the transmission system, are prone to wear, cracks, and even breakage due to friction and fatigue under long-term high-load and high-speed operation. Electrically, short circuits and open circuits in the motor windings, as well as aging and failure of electronic components in the electrical control system, also occur frequently. Once the electric drive unit malfunctions, it not only directly leads to equipment downtime and production interruptions, causing huge economic losses, but also, in certain scenarios such as high-speed production equipment and automated production lines, can trigger serious safety accidents, posing a significant threat to personnel safety.

[0004] Traditional fault detection methods mostly rely on manual inspections or troubleshooting based on obvious anomalies that occur after a fault has occurred. This reactive approach cannot detect faults in their early stages and take effective measures in a timely manner, making it difficult to meet the stringent requirements of modern industrial production for equipment reliability, stability, and continuous operation. Furthermore, traditional fault detection methods have limited access to a limited number and types of detection parameters and cannot achieve reliable fault prediction. Utility Model Content

[0005] The objective of this invention is to provide a fault prediction system for electric drive devices that overcomes at least one technical problem in the prior art. This system, based on the deployment of vibration and temperature sensors using a non-destructive installation method, allows for comprehensive and real-time monitoring of key state parameters of the electric drive device during operation. Furthermore, the system, based on known fault prediction algorithms, allows for the early and accurate prediction of potential faults in the electric drive device, thus providing maintenance personnel with ample time to implement targeted maintenance measures. This effectively prevents the occurrence and worsening of faults, significantly improves the operational reliability and stability of the electric drive device, and minimizes production losses and safety risks caused by equipment failures.

[0006] According to this utility model, a fault prediction system for an electric drive device is proposed. The fault prediction system includes: a vibration sensor mounted on the electric drive device, the vibration sensor being non-destructively bonded to the housing of the electric drive device via a first adhesive device; a temperature sensor mounted on the electric drive device, the temperature sensor being non-destructively bonded to the housing of the electric drive device via a second adhesive device; a processing module, such as a processing module mounted on the electric drive device, the processing module establishing a first communication connection with the vibration sensor and the temperature sensor respectively and receiving vibration parameters and temperature parameters via the first communication connection; and a control device, the control device establishing a second communication connection with the processing module and receiving vibration parameters and temperature parameters for fault prediction via the second communication connection.

[0007] According to this invention, a vibration sensor can be securely attached to the surface of the electric drive device's housing using a first adhesive device in a non-destructive bonding manner. A temperature sensor can be securely attached to the surface of the electric drive device's housing using a second adhesive device in a non-destructive bonding manner. This non-destructive bonding technology not only ensures a tight fit between the sensor and the electric drive device's housing, enabling accurate capture of minute vibration and temperature parameters generated during the electric drive device's operation, but also avoids any damage to the electric drive device's structure, ensuring its normal mechanical and electrical performance. Compared to traditional drilling and welding installation methods, non-destructive installation does not compromise the integrity of the equipment housing, prevents stress concentration caused by installation, reduces the risk of potential equipment failure, and also reduces the impact of installation on equipment downtime, improving maintenance efficiency.

[0008] The processing module establishes a first communication connection with both the vibration sensor and the temperature sensor. Its function is to collect and transmit vibration parameters acquired by the vibration sensor and temperature parameters measured by the temperature sensor in real time. The control device establishes a second communication connection with the processing module, receiving vibration and temperature parameters forwarded by the processing module for fault prediction, providing a data foundation for subsequent data analysis and fault diagnosis using known algorithms.

[0009] In some embodiments, the electric drive device includes a motor and a transmission device that is driveably connected to the motor.

[0010] In some embodiments, the vibration sensor of the fault prediction system includes: a first vibration sensor mounted on the housing of the motor and a second vibration sensor mounted on the housing of the transmission device.

[0011] In some embodiments, the temperature sensor of the fault prediction system includes: a first temperature sensor mounted on the housing of the motor and a second temperature sensor mounted on the housing of the transmission device.

[0012] According to this invention, the fault prediction system allows for comprehensive monitoring of different components of an electric drive device. The motor, as the power source of the electric drive device, directly affects the performance of the entire system due to the stability of its operating state. During power transmission, the transmission device is also prone to abnormal vibrations due to mechanical movements such as gear meshing and chain drive. By installing vibration sensors on both the motor and the transmission device, the vibration characteristics of different parts can be independently monitored and analyzed. Similarly, during motor operation, a large amount of heat is generated due to winding heating and core loss, while the temperature of components such as gears and bearings in the transmission device also rises due to friction. Monitoring the temperature of the motor and the transmission device separately allows for a more accurate assessment of the thermal state of each part of the electric drive device, and timely detection of potential faults caused by overheating. The data collected by the vibration and temperature sensors complement each other. For example, when the vibration sensor detects abnormal vibration, combining the data from the temperature sensor can determine whether the temperature change is caused by frictional heating due to mechanical component wear (abnormal vibration) or a simple electrical fault, greatly improving the accuracy of fault prediction.

[0013] In some embodiments, the first adhesive device and the second adhesive device respectively include a thermally conductive silicone layer and / or a pressure-sensitive adhesive tape layer.

[0014] In some embodiments, the thermally conductive silicone layer is in direct contact with the housing of the electric drive device, and the pressure-sensitive tape layer covers the outside of the thermally conductive silicone layer.

[0015] In some embodiments, the thickness of the first adhesive device and the second adhesive device is between 0.5 mm and 2 mm.

[0016] According to this utility model, the first and second adhesive devices can respectively include a thermally conductive silicone layer and / or a pressure-sensitive adhesive tape layer in their structural design. Due to its excellent thermal conductivity, the thermally conductive silicone layer can quickly transfer heat from the surface of the electric drive device housing to the temperature sensor, ensuring the accuracy of temperature measurement. Simultaneously, its soft and malleable properties allow it to tightly conform to the complex curved surfaces of the electric drive device housing, enhancing the stability of the sensor installation. The pressure-sensitive adhesive tape layer covers the outside of the thermally conductive silicone layer, utilizing its pressure-sensitive adhesion properties to further strengthen the connection between the sensor and the electric drive device housing, preventing the sensor from shifting or detaching due to external forces such as vibration and impact during the operation of the electric drive device. Furthermore, to ensure a strong connection and good thermal conductivity while avoiding negative impacts on sensor measurement accuracy, after extensive experimental and engineering practice verification, the thickness of the first and second adhesive devices is precisely controlled between 0.5 mm and 2 mm. This thickness range ensures sufficient adhesive strength and a good thermal conductivity path while effectively reducing vibration signal attenuation and temperature measurement delay caused by excessively thick adhesive devices.

[0017] In some embodiments, the processing module includes: a first signal processing module, through which the vibration sensor is connected to a control device; and a second signal processing module, through which the temperature sensor is connected to the control device. Additionally or alternatively, the processing module includes a communication module for data communication based on a predetermined communication protocol.

[0018] According to this invention, in order to improve the quality and reliability of the raw signals acquired by the sensors and facilitate efficient and accurate subsequent analysis by the control device, this fault prediction system also includes a first signal processing module and a second signal processing module. The vibration signal acquired by the vibration sensor is first preprocessed by the first signal processing module. Similarly, the temperature signal acquired by the temperature sensor undergoes similar preprocessing by the second signal processing module. These signal processing modules typically integrate multiple signal processing functions such as filtering, linearization correction, noise suppression, amplification, and analog-to-digital conversion, providing high-quality data input for subsequent analysis using known fault prediction algorithms.

[0019] In some embodiments, the vibration sensor and / or the temperature sensor are mounted adjacent to and above the bearing on the load side of the electric drive device.

[0020] According to this invention, in an electric drive device, the bearing on the load side is a key component that bears mechanical loads and transmits power; its operating condition directly affects the reliability of the entire electric drive device. Therefore, this invention optimizes the installation of vibration sensors and / or temperature sensors in a position adjacent to and above the bearing on the load side of the electric drive device. This installation position has significant advantages. From a vibration monitoring perspective, the vibration signals generated by the load-side bearing during operation propagate along the shaft system and housing. The vibration sensor installed adjacent to and above it can capture these vibration signals most directly and sensitively, thus more accurately reflecting the bearing's operating condition and promptly detecting vibration anomalies caused by bearing wear, fatigue spalling, or other faults. For temperature monitoring, the bearing's temperature rises significantly during operation due to frictional heat generation. The temperature sensor installed adjacent to and above the bearing can quickly and accurately measure temperature changes near the bearing, providing a reliable basis for determining whether the bearing is within its normal operating temperature range and effectively preventing serious faults such as burning and seizure caused by bearing overheating.

[0021] In some embodiments, the fault prediction system includes: a plurality of vibration sensors arranged along the axial direction of the electric drive device, the plurality of vibration sensors being arranged at a distance from each other; and / or a plurality of vibration sensors arranged circumferentially along the electric drive device, the plurality of vibration sensors being arranged at a distance from each other; and / or a plurality of temperature sensors arranged along the axial direction of the electric drive device, the plurality of temperature sensors being arranged at a distance from each other; and / or a plurality of temperature sensors arranged circumferentially along the electric drive device, the plurality of temperature sensors being arranged at a distance from each other.

[0022] According to this invention, in order to achieve comprehensive and three-dimensional monitoring of the operating status of the electric drive device and further improve the accuracy and reliability of fault prediction, this fault prediction system innovatively adopts a multi-dimensional sensor array arrangement scheme. Specifically, it includes arranging multiple vibration sensors along the axial direction of the electric drive device, with these sensors spaced at certain intervals. Through the axial sensor array, the vibration characteristics of the electric drive device at different axial positions can be acquired, and the propagation law and distribution characteristics of the vibration signal in the axial direction can be analyzed, thereby more comprehensively assessing the operating status of the shaft system and promptly detecting vibration anomalies caused by shaft misalignment, bending deformation, etc. Similarly, arranging multiple vibration sensors along the circumference of the electric drive device allows the circumferential sensor array to capture vibration differences in the circumferential direction, which is of great significance for detecting circumferential vibration changes caused by faults such as gear eccentricity and imbalance. Regarding the temperature sensor arrangement, a scheme of arranging multiple temperature sensors along both the axial and circumferential directions is also adopted. The axial temperature sensor array can monitor the temperature distribution of the electric drive device in the axial direction and promptly detect abnormal temperature gradients caused by local overheating. A circumferential temperature sensor array can reflect the temperature uniformity of the electric drive device in the circumferential direction, playing a crucial role in diagnosing temperature anomalies caused by uneven heat dissipation, local friction, and other reasons. Multi-dimensional sensor arrays collect more comprehensive data, providing richer data dimensions for known fault prediction algorithms, helping them to more accurately determine the type and location of faults.

[0023] In some embodiments, the fault prediction system includes a monitoring device with a human-machine interface, and the monitoring device establishes a third communication connection with the control device.

[0024] In some embodiments, the control device and / or monitoring device are configured to determine a fault based on a vibration parameter greater than a first threshold and / or a temperature parameter greater than a second threshold.

[0025] According to this utility model, the fault prediction system is equipped with a monitoring device featuring a human-machine interface (HMI), which establishes a third communication connection with the control device. The HMI provides equipment maintenance personnel with an intuitive and convenient platform for operation and information display. Through the HMI, maintenance personnel can view various operating parameters of the electric drive unit in real time, including vibration parameters, temperature parameters, and equipment operating status assessment results and fault prediction information derived by the control device based on these parameters and known algorithms. For example, the control device and / or monitoring device can use known algorithms to set reasonable thresholds. When the vibration parameter exceeds a pre-set first threshold, or the temperature parameter exceeds a second threshold, the control device and / or monitoring device determines that the electric drive unit may have a potential fault and promptly issues a warning signal on the HMI, reminding maintenance personnel to take appropriate maintenance measures.

[0026] In some embodiments, the vibration sensor, the temperature sensor, and some or all of the processing module are integrated into a single component.

[0027] According to this utility model, in order to simplify the system structure, improve the system's reliability and stability, and reduce installation space and wiring complexity, this utility model integrates some or all of the vibration sensor, temperature sensor, and processing module into a single component. This integrated design has multiple advantages. On the one hand, by highly integrating related functional modules, the number of connecting cables and interfaces between modules can be effectively reduced, lowering the risk of signal transmission failures due to cable aging, loose interfaces, etc., and improving the overall reliability of the system. On the other hand, the integrated component can undergo overall optimization design and debugging during the manufacturing process to ensure that the collaborative performance between functional modules reaches its optimal state, thereby improving the system's stability and the accuracy of data acquisition and transmission. In addition, the integrated design also significantly reduces the overall size and weight of the system, facilitating installation and deployment in various space-constrained application scenarios.

[0028] In some embodiments, the electric drive device includes: a first electric drive device for suspending a conveyor chain; and / or a second electric drive device for an elevator; and / or a third electric drive device for a rotary table; and / or a fourth electric drive device for a lifting device. The fault prediction system for electric drive devices proposed in this invention has extremely wide applicability. Electric drive devices encompass various types, including but not limited to a first electric drive device for suspending a conveyor chain, a second electric drive device for an elevator, a third electric drive device for a rotary table, and a fourth electric drive device for a lifting device. It should be understood that, in addition to production workshops, the fault prediction system can be widely applied to fault prediction of electric drive devices in many fields such as industrial automation, transportation, and intelligent equipment. Attached Figure Description

[0029] Figure 1 A schematic block diagram of a fault prediction system for an electric drive device according to some embodiments of the present invention is shown;

[0030] Figure 2 A simplified schematic diagram of the electric drive unit and the sensor mounted thereon is shown;

[0031] Figure 3 A schematic diagram of an exemplary adhesive device is shown. Detailed Implementation

[0032] In the various embodiments described, the same reference numerals or element names are used for the same elements, and the disclosure contained throughout the specification can be applied semantically to elements with the same reference numerals or element names. Furthermore, in the various embodiments, the number, implementation, and / or arrangement of elements are not limited to the examples shown, but other numbers, implementations, and / or arrangements can be selected according to actual needs.

[0033] This invention is not limited to the embodiments shown, but includes or extends to all technical equivalents that fall within the scope of the appended claims. The positional descriptions chosen in the specification, such as, for example, top, bottom, left, right, etc., refer to the direct description and the accompanying drawings, and can be adapted to new positions according to their meaning when the positions change.

[0034] The features disclosed in this utility model document are important for the implementation of embodiments in different design aspects, not only individually but also in any combination.

[0035] In this document, the term “A or B” includes both “A and B” and “A or B”, rather than exclusively including only “A” or only “B”, unless otherwise specified.

[0036] In this document, the term "exemplary" means "used as an example, instance, or illustration," and not as a "model" to be precisely copied. Any implementation described herein is not necessarily to be construed as preferred or advantageous over other implementations. Furthermore, this invention is not limited to any stated or implied theory given in the foregoing technical field, background art, invention description, or specific embodiments.

[0037] Additionally, terms such as “first,” “second,” etc., may be used in this document for reference purposes only and are not intended to be limiting. For example, unless the context clearly indicates otherwise, the words “first,” “second,” and other such numerical terms relating to structures or elements do not imply order or sequence.

[0038] Figure 1 A schematic block diagram of a fault prediction system 100 for an electric drive device 10 according to some embodiments of the present invention is shown. Figure 1 As shown, the fault prediction system 100 may include a vibration sensor 20 and a temperature sensor 30 mounted on the electric drive unit 10. Advantageously, the vibration sensor 20 can be non-destructively bonded to the housing of the electric drive unit 10 using a first adhesive device 21, and the temperature sensor 30 can be non-destructively bonded to the housing of the electric drive unit 10 using a second adhesive device 22. Furthermore, the fault prediction system 100 may include a processing module 40, for example, a processing module 40 mounted on the electric drive unit 10, which can establish first communication connections with the vibration sensor 20 and the temperature sensor 30 respectively and receive vibration parameters and temperature parameters via the first communication connections. The fault prediction system 100 may include a control device 60, which can establish a second communication connection with the processing module 40 and receive vibration parameters and temperature parameters for fault prediction via the second communication connection.

[0039] In some further extended embodiments, such as Figure 1 As shown, the fault prediction system 100 may include a first signal processing module 41, through which the vibration sensor 20 is connected to the control device 60; and a second signal processing module 42, through which the temperature sensor 30 is connected to the control device 60. According to this invention, to improve the quality and reliability of the raw signals acquired by the sensors and facilitate efficient and accurate subsequent analysis by the control device 60, the fault prediction system 100 also specifically includes a first signal processing module 41 and a second signal processing module 42. The vibration signal acquired by the vibration sensor 20 is first preprocessed by the first signal processing module 41. Similarly, the temperature signal acquired by the temperature sensor 30 undergoes similar preprocessing by the second signal processing module 42. The corresponding signal processing modules typically integrate multiple signal processing functions such as filtering, linearization correction, noise suppression, amplification, and analog-to-digital conversion, providing high-quality data input for subsequent analysis using known fault prediction algorithms.

[0040] In some further extended embodiments, such as Figure 1 As shown, the fault prediction system 100 may include a monitoring device 70 with a human-machine interface, and the monitoring device 70 establishes a third communication connection with the control device 60.

[0041] According to this invention, the vibration sensor 20 can be configured as a suitable vibration sensor, such as a piezoelectric vibration sensor or a MEMS vibration sensor. The temperature sensor 30 can be configured as a suitable temperature sensor, such as a resistance temperature sensor, a digital temperature sensor, an infrared temperature sensor, or a thermocouple temperature sensor. The control device 60 can be configured as a suitable control device, such as a programmable logic controller, a distributed control system controller, an embedded controller, an industrial computer, or a field-programmable gate array.

[0042] According to this invention, the vibration sensor 20 can be securely attached to the housing surface of the electric drive device 10 using a first adhesive device 21 in a non-destructive bonding manner. The temperature sensor 30 can be securely attached to the housing surface of the electric drive device 10 using a second adhesive device 22 in a non-destructive bonding manner. This non-destructive bonding technology not only ensures a tight fit between the sensor and the housing of the electric drive device 10, enabling accurate capture of subtle vibration and temperature parameters generated during the operation of the electric drive device 10, but also avoids any damage to the main structure of the electric drive device 10, ensuring its normal mechanical and electrical performance. Compared with traditional installation methods such as drilling and welding, non-destructive installation does not damage the integrity of the equipment housing, prevents stress concentration caused by installation, reduces the risk of potential equipment failure, and also reduces the impact of installation process on equipment downtime, improving maintenance efficiency.

[0043] According to this invention, the processing module 40 can establish a first communication connection with the vibration sensor 20 and the temperature sensor 30 respectively. Its function is to collect and transmit in real time the vibration parameters acquired by the vibration sensor 20 and the temperature parameters measured by the temperature sensor 30. The control device 60 establishes a second communication connection with the processing module 40, and receives the vibration parameters and temperature parameters forwarded by the processing module 40 for fault prediction, providing a data basis for subsequent data analysis and fault judgment using known algorithms.

[0044] According to this utility model, the fault prediction system 100 is equipped with a monitoring device 70 with a human-machine interface (HMI), which establishes a third communication connection with the control device 60. The HMI provides equipment maintenance personnel with an intuitive and convenient platform for operation and information display. Through the HMI, maintenance personnel can view various operating parameters of the electric drive device 10 in real time, including vibration parameters, temperature parameters, and equipment operating status assessment results and fault prediction information obtained by the control device 60 based on these parameters and known algorithms. For example, the control device 60 and / or the monitoring device 70 can use known algorithms to set reasonable thresholds. When the vibration parameter exceeds a preset first threshold, or the temperature parameter exceeds a second threshold, the control device 60 and / or the monitoring device 70 determines that the electric drive device 10 may have a potential fault and promptly issues a warning signal on the HMI to remind maintenance personnel to take appropriate maintenance measures.

[0045] It should be understood that this application focuses on the creation of the system architecture of the fault prediction system 100. The information interaction methods performed within the different communication connections of the fault prediction system 100's system architecture can be any information interaction method known in the prior art. These information interaction methods may include, but are not limited to, the sending, transmission, and processing of different types of messages. It should be understood that these communication connections of the fault prediction system 100 can be any form of communication channel. In some embodiments, the communication connection may involve a wired channel, such as a cable, optical fiber, or network cable. In some embodiments, the communication connection may involve a wireless channel, such as a wireless communication connection based on WLAN or Bluetooth technology.

[0046] In some further extended embodiments, such as Figure 2 As shown, the electric drive unit 10 may include a motor 12 and a transmission device 14 that is driveably connected to the motor 12. The vibration sensor 20 of the fault prediction system 100 may include a first vibration sensor 20 mounted on the housing of the motor 12 and a second vibration sensor 20 mounted on the housing of the transmission device 14. The temperature sensor 30 of the fault prediction system 100 may include a first temperature sensor 30 mounted on the housing of the motor 12 and a second temperature sensor 30 mounted on the housing of the transmission device 14.

[0047] Advantageously, the fault prediction system 100 allows for comprehensive monitoring of different components of the electric drive unit 10. The stability of the motor 12's operating state, as the power source of the electric drive unit 10, directly affects the performance of the entire system. Meanwhile, the transmission device 14 is prone to abnormal vibration during power transmission due to mechanical movements such as gear meshing and chain drive. By installing vibration sensors 20 on both the motor 12 and the transmission device 14, the vibration characteristics of different parts can be independently monitored and analyzed. Similarly, during operation, the motor 12 generates a large amount of heat due to winding heating and core loss, while the gears, bearings, and other components in the transmission device 14 also experience temperature increases due to friction. Monitoring the temperatures of the motor 12 and the transmission device 14 separately allows for a more accurate assessment of the thermal state of each part of the electric drive unit 10, and timely detection of potential faults caused by overheating. The data collected by the vibration sensor 20 and the temperature sensor 30 complement each other. For example, when the vibration sensor 20 detects abnormal vibration, it can be combined with the data from the temperature sensor 30 to determine whether the temperature change is caused by frictional heat generation due to wear of mechanical parts (abnormal vibration) or simply by electrical fault, which greatly improves the accuracy of fault prediction.

[0048] In some further extended embodiments, the vibration sensor 20 and / or temperature sensor 30 can be mounted adjacent to and above the load-side bearing of the electric drive unit 10. According to this invention, in the electric drive unit 10, the load-side bearing, as a key component bearing mechanical loads and transmitting power, directly affects the reliability of the entire electric drive unit 10. Therefore, this invention optimizes the mounting of the vibration sensor 20 and / or temperature sensor 30 to be adjacent to and above the load-side bearing of the electric drive unit 10. This mounting position has significant advantages. From a vibration monitoring perspective, the vibration signals generated by the load-side bearing during operation propagate along the shaft system and housing. The vibration sensor 20, mounted adjacent to and above it, can most directly and sensitively capture these vibration signals, thereby more accurately reflecting the bearing's operating status and promptly detecting vibration anomalies caused by bearing wear, fatigue spalling, or other faults. For temperature monitoring, the bearing temperature will rise significantly due to frictional heat during operation. The temperature sensor 30 installed above and adjacent to the bearing can quickly and accurately measure the temperature change near the bearing, providing a reliable basis for judging whether the bearing is within the normal operating temperature range, and effectively preventing serious failures such as burning and seizure caused by bearing overheating.

[0049] In some embodiments, the fault prediction system 100 may include: a plurality of vibration sensors 20 arranged along the axial direction of the electric drive device 10, the plurality of vibration sensors 20 being arranged at intervals between each other; and / or a plurality of vibration sensors 20 arranged circumferentially along the electric drive device 10, the plurality of vibration sensors 20 being arranged at intervals between each other; and / or a plurality of temperature sensors 30 arranged along the axial direction of the electric drive device 10, the plurality of temperature sensors 30 being arranged at intervals between each other; and / or a plurality of temperature sensors 30 arranged circumferentially along the electric drive device 10, the plurality of temperature sensors 30 being arranged at intervals between each other. According to this invention, in order to achieve comprehensive and three-dimensional monitoring of the operating status of the electric drive device 10 and further improve the accuracy and reliability of fault prediction, the fault prediction system 100 innovatively adopts a multi-dimensional sensor array arrangement scheme. Specifically, it includes a plurality of vibration sensors 20 arranged along the axial direction of the electric drive device 10, these vibration sensors 20 being arranged at certain intervals between each other. By using an axial sensor array, the vibration characteristics of the electric drive unit 10 at different axial positions can be acquired, and the propagation law and distribution characteristics of the vibration signal in the axial direction can be analyzed. This allows for a more comprehensive assessment of the shaft system's operating status and timely detection of vibration anomalies caused by shaft misalignment, bending deformation, or other reasons. Similarly, by arranging multiple vibration sensors 20 along the circumference of the electric drive unit 10, the circumferential sensor array can capture the vibration differences of the electric drive unit 10 in the circumferential direction, which is of great significance for detecting circumferential vibration changes caused by faults such as gear eccentricity and imbalance. Regarding the arrangement of temperature sensors 30, a scheme of arranging multiple temperature sensors 30 along both the axial and circumferential directions is also adopted. The axial temperature sensor array 30 can monitor the temperature distribution of the electric drive unit 10 in the axial direction and promptly detect abnormal temperature gradients caused by local overheating. The circumferential temperature sensor array 30 can reflect the temperature uniformity of the electric drive unit 10 in the circumferential direction, playing a crucial role in diagnosing temperature anomalies caused by uneven heat dissipation, local friction, or other reasons. The data collected by the multi-dimensional sensor array is more comprehensive, providing rich data dimensions for known fault prediction algorithms, which helps the algorithms to more accurately determine the type and location of faults.

[0050] In some embodiments, the first adhesive device 21 and the second adhesive device 22 may respectively include a thermally conductive silicone layer 220 and / or a pressure-sensitive adhesive tape layer 221. In some embodiments, such as Figure 3As shown, the thermally conductive silicone layer 220 directly contacts the housing of the electric drive device 10, and the pressure-sensitive adhesive tape layer 221 covers the outside of the thermally conductive silicone layer 220. In some embodiments, the thickness of the first adhesive device 21 and the second adhesive device 22 is between 0.5 mm and 2 mm. Advantageously, the first adhesive device 21 and the second adhesive device 22 may respectively include the thermally conductive silicone layer 220 and / or the pressure-sensitive adhesive tape layer 221 in their structural design. Due to its good thermal conductivity, the thermally conductive silicone layer 220 can quickly transfer heat from the surface of the housing of the electric drive device 10 to the temperature sensor 30, ensuring the accuracy of temperature measurement. At the same time, its soft and malleable properties allow it to closely conform to the complex curved surface of the housing of the electric drive device 10, enhancing the stability of the sensor installation. The pressure-sensitive adhesive tape layer 221 covers the outside of the thermally conductive silicone layer 220. Utilizing its pressure-sensitive adhesion properties, it further strengthens the connection between the sensor and the housing of the electric drive device 10, preventing displacement or detachment of the sensor due to external forces such as vibration and impact during operation of the electric drive device 10. Furthermore, to ensure a strong connection and good thermal conductivity while avoiding negative impacts on sensor measurement accuracy, extensive experiments and engineering practice have verified that the thickness of the first adhesive component 21 and the second adhesive component 22 is precisely controlled between 0.5 mm and 2 mm. This thickness range ensures sufficient adhesive strength and a good thermal conductivity path while effectively reducing vibration signal attenuation and temperature measurement delay caused by excessively thick adhesive components.

[0051] In some embodiments, some or all of the vibration sensor 20, temperature sensor 30, first signal processing module 41, and second signal processing module 42 are integrated into a single component. According to this invention, to simplify the system structure, improve system reliability and stability, and reduce installation space and wiring complexity, some or all of the vibration sensor 20, temperature sensor 30, first signal processing module 41, and second signal processing module 42 are integrated into a single component. This integrated design has multiple advantages. On the one hand, by highly integrating related functional modules, the number of connecting cables and interfaces between modules can be effectively reduced, lowering the risk of signal transmission failures due to cable aging, loose interfaces, etc., and improving the overall reliability of the system. On the other hand, the integrated component can undergo overall optimization design and debugging during the manufacturing process to ensure that the collaborative performance between functional modules reaches its optimal state, thereby improving system stability and the accuracy of data acquisition and transmission. Furthermore, the integrated design significantly reduces the overall size and weight of the system, facilitating installation and deployment in various space-constrained application scenarios.

[0052] In some embodiments, the electric drive device 10 may include: a first electric drive device for suspending a conveyor chain; and / or a second electric drive device for an elevator; and / or a third electric drive device for a rotary table; and / or a fourth electric drive device for a lifting device. The fault prediction system 100 for the electric drive device 10 proposed in this invention has extremely wide applicability. The electric drive device 10 encompasses various types, including but not limited to a first electric drive device for suspending a conveyor chain, a second electric drive device for an elevator, a third electric drive device for a rotary table, and a fourth electric drive device for a lifting device. It should be understood that, in addition to production workshops, the fault prediction system 100 can be widely applied to fault prediction of the electric drive device 10 in many fields such as industrial automation, transportation, and intelligent equipment.

[0053] Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make possible changes and modifications to the technical solution of the present invention by utilizing the above-disclosed technical content without departing from the spirit and scope of the present invention. Therefore, any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention shall fall within the protection scope of the technical solution of the present invention.

Claims

1. A failure prediction system for an electric drive arrangement, characterized by The fault prediction system (100) comprises: a vibration sensor (20) mounted on the electric drive (10), which is non-destructively bonded to the housing of the electric drive by a first bonding means (21); a temperature sensor (30) mounted on the electric drive, which is non-destructively bonded to the housing of the electric drive (10) by a second bonding means (22); a processing module (40) which establishes a first communication connection with the vibration sensor and the temperature sensor and receives the vibration parameters and the temperature parameters via the first communication connection; and a control device (60) which establishes a second communication connection with the processing module and receives the vibration parameters and the temperature parameters for fault prediction via the second communication connection.

2. The failure prediction system for an electric drive apparatus according to claim 1, characterized by, The electric drive (10) comprises an electric machine (12) and a transmission device (14) in transmission connection with the electric machine (12), wherein the vibration sensor of the fault prediction system comprises a first vibration sensor mounted on the housing of the electric machine and a second vibration sensor mounted on the housing of the transmission device; and wherein the temperature sensor of the fault prediction system comprises a first temperature sensor mounted on the housing of the electric machine and a second temperature sensor mounted on the housing of the transmission device.

3. The failure prediction system for an electric drive apparatus according to claim 1, characterized by, The first bonding means (21) and the second bonding means (22) each comprise a heat-conducting silicone layer (220) and / or a layer of pressure-sensitive adhesive tape (221).

4. The fault prediction system for an electric drive according to claim 3, characterized in that the heat-conducting silicone layer directly contacts the housing of the electric drive, and the layer of pressure-sensitive adhesive tape is applied on the outside of the heat-conducting silicone layer; and / or the thickness of the first bonding means and the second bonding means is between 0.5 mm and 2 mm.

5. The failure prediction system for an electric drive apparatus according to one of claims 1 to 4, characterized in that, The processing module comprises: a first signal processing module (41) via which the vibration sensor is connected to the control device; a second signal processing module (42) via which the temperature sensor is connected to the control device.

6. The failure prediction system for an electric drive apparatus according to one of claims 1 to 4, characterized in that, The vibration sensor and / or the temperature sensor are mounted adjacent to and above the bearing on the load side of the electric drive.

7. The failure prediction system for an electric drive apparatus according to one of claims 1 to 4, characterized in that, The fault prediction system comprises: a plurality of vibration sensors arranged along the axial direction of the electric drive, which are arranged at a distance from one another; and / or a plurality of vibration sensors arranged along the circumferential direction of the electric drive, which are arranged at a distance from one another; and / or a plurality of temperature sensors arranged along the axial direction of the electric drive, which are arranged at a distance from one another; and / or a plurality of temperature sensors arranged along the circumferential direction of the electric drive, which are arranged at a distance from one another.

8. The fault prediction system for an electric drive according to one of claims 1 to 4, characterized in that the fault prediction system comprises a monitoring device (70) with a human-machine interface, which establishes a third communication connection with the control device; and / or the third communication connection is a wireless communication connection. The control device and / or monitoring device is configured to determine a fault based on a vibration parameter greater than a first threshold value and / or a temperature parameter greater than a second threshold value.

9. The failure prediction system for an electric drive apparatus according to one of claims 1 to 4, characterized in that, Part or all of the vibration sensor, the temperature sensor, and the processing module are integrated as an all-in-one component.

10. The failure prediction system for an electric drive apparatus according to one of claims 1 to 4, characterized by, The electric drive device comprises a first electric drive device for suspending a conveyor chain; and / or a second electric drive device for a lift; and / or a third electric drive device for a rotary table; and / or a fourth electric drive device for a spreader.

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