AE Sensor State Detection for Linear Motion Guides
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional diagnostic methods for linear motion rolling guide units face challenges in accurately detecting operating states in real time due to vibration interference, time-consuming lubricating oil extraction, and susceptibility to electrical noise, making it difficult to predict failures and maintain these units effectively.
Innovation Solution
A state detecting apparatus using an AE sensor to detect wave motions generated by collisions, slips, and cracks within the rolling guide unit, with signal processing units to extract relevant parameters and compare them against thresholds, allowing for real-time determination of the operating state without disassembly or interference from external vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If vibration detection method is used to diagnose operating state, then diagnostic information can be obtained, but vibration generation sources from ball spinning and revolving interfere with accurate detection of abnormality-related vibrations
Solution Approach 1:
The invention extracts only the frequency component corresponding to the ball revolution frequency from the vibration signal spectrum. By isolating this specific frequency component, the method eliminates interference from other vibration sources such as ball spinning, enabling accurate detection of abnormality-related vibrations at the ball-rail contact portion.
2Measurement precision
If oil evaluation method is used to diagnose operating state, then lubrication quality can be assessed, but extraction of lubricating oil requires stopping the linear motion rolling guide unit and takes extra time
Solution Approach 1:
The invention replaces the mechanical oil extraction and laboratory analysis system with a non-contact vibration detection system. By measuring vibration characteristics directly during operation, the method eliminates the need to stop the linear motion rolling guide unit for lubricating oil extraction and analysis, thereby maintaining high operating efficiency while achieving accurate diagnostic results.
3Measurement precision
If electrical resistance method or temperature measuring method is used, then operating state can be measured, but both methods are susceptible to electrical noise and difficult to measure when movable block moves slow
Solution Approach 1:
The invention replaces electrical measurement methods (electrical resistance and temperature measurement) with mechanical vibration detection. By using vibration sensors to detect mechanical vibrations from ball-rail interactions, the method eliminates susceptibility to electrical noise and enables accurate measurement regardless of the movable block's speed, including slow motion conditions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate, real-time detection of the operating state and prediction of failures, improving maintenance and extending the lifespan of linear motion rolling guide units while ensuring the quality of equipment that incorporates them.
Implementation Method 1
a detection unit for detecting a wave motion which is elastically generated due to at least one of collision which occurs between a rolling surface contained in the linear motion rolling guide unit and a rolling body
Data Source
AI summary
A state detecting apparatus S for detecting a current operating state of an LM (linear motion) system includes an AE sensor 1 generating a detection signal Sae by detecting an AE wave elastically generated when a plurality of balls contained in the LM system revolve in a circulation portion while spinning themselves; and a signal processing unit 4 generating a parameter indicating an intensity of the AE wave based on only the detection signal Sae corresponding to an operating frequency of the ball, and uses the parameter to determine a lubrication state of the LM system. Thereby, it is possible to provide the state detecting apparatus capable of predicting failure occurrence in the LM system; providing an improved maintenance to a user of the LM system and further longer lifetime thereof; and providing a performance guarantee and an improved quality of a device or equipment manufactured using the LM system.