AE Sensor Inspection for Molded Product Machine Abnormality Detection
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Solution Overview
Problem
Existing machines used for producing molded products from powdery materials face challenges in detecting malfunctions proactively, leading to inefficient maintenance practices that either incur unnecessary costs or fail to prevent production disruptions.
Innovation Solution
An inspection device utilizing acoustic emission (AE) sensors to detect abnormalities in machine components by capturing and analyzing elastic waves generated during operation, allowing for predictive maintenance and timely replacement of worn or damaged parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If corrective maintenance is performed only after damage recognition, then maintenance costs are reduced, but machine operation rate decreases due to unexpected stoppages
Solution Approach 1:
The AE sensor performs preliminary detection of abnormal sounds and vibrations in machine components before actual damage occurs. By continuously monitoring during operation, the system identifies early signs of degradation in rolls, shafts, bearings, and cam rails, enabling maintenance to be scheduled before failure happens, thus maintaining high machine operation rates while avoiding unnecessary preventive maintenance costs
2Reliability
If preventive maintenance is performed frequently, then machine reliability is improved, but maintenance costs increase due to replacement of still available members
Solution Approach 1:
The system provides real-time feedback through the AE sensor about the actual condition of machine components. This feedback mechanism allows maintenance decisions to be based on actual wear and degradation levels rather than fixed schedules, enabling maintenance to be performed only when necessary, thus avoiding replacement of still-available members while maintaining high machine operation rates
3Measurement precision
If AE sensor is attached to detect abnormality, then predictive maintenance capability is improved, but device complexity increases
Solution Approach 1:
The AE sensor is designed to be detachably attached to various machine components, allowing the machine itself to perform the inspection function without requiring complex integrated sensing systems. The simple, standalone sensor design minimizes added complexity while providing sophisticated abnormality detection capabilities through acoustic emission monitoring
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 proactive detection of component abnormalities, improving machine operation efficiency and reducing maintenance costs by anticipating and addressing issues before they cause production defects.
Implementation Method 1
AE is a phenomenon that strain energy having been accumulated is released when a solid is deformed or destructed, and part of the strain energy is radiated as an elastic wave. The AE sensor senses such an AE wave.
Data Source
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AI summary
An inspection device (S) is configured to detect an indication of abnormality occurred to a predetermined member of a machine used for production of a molded product from a powdery material, the inspection device (S) including an AE sensor (S1) detachably attached to the predetermined member of the machine or a portion adjacent to the predetermined member, and a controller (S3) configured to receive a signal outputted from the AE sensor (S1) disposed at the predetermined member of the machine or the portion adjacent to the predetermined member during operation of the machine, determine whether the predetermined member has an indication of abnormality in accordance with the signal, and output information on a result of determination.