AE Sensor Inspection for Molded Product Machine Wear Detection
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Solution Overview
Problem
Existing machines used for producing molded products from powdery materials face issues with member deformation or damage due to high stress, leading to production disruptions and increased maintenance costs, as corrective and preventive maintenance strategies are inadequate in predicting and addressing these issues.
Innovation Solution
An inspection device using acoustic emission sensors to detect abnormalities in machine components, such as rolls and cam rails, by analyzing strain energy release as elastic waves, allowing for predictive maintenance to prevent component failure and maintain production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If corrective maintenance is performed only after damage is recognized, then maintenance costs are reduced, but machine operation rate decreases due to unexpected failures
Solution Approach 1:
The AE sensor performs preliminary detection of abnormality indications before actual damage occurs. By monitoring strain energy release in real-time during machine operation, the system enables predictive maintenance scheduling that prevents unexpected failures while avoiding unnecessary maintenance of still-serviceable components.
2Reliability
If preventive maintenance is performed frequently to ensure reliability, then machine operation rate is maintained, but maintenance costs increase due to replacement of still-available members
Solution Approach 1:
The system provides real-time feedback through the AE sensor that detects strain energy release patterns. This feedback enables condition-based maintenance decisions, replacing members only when abnormality indications are detected, thereby avoiding unnecessary replacement of still-serviceable components while maintaining high machine operation rates.
3Reliability
If AE sensor is attached to detect abnormality indications, then predictive maintenance capability is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical inspection systems with an acoustic emission sensing approach. The AE sensor detects strain energy release as elastic waves, providing predictive maintenance capability through a non-contact, non-intrusive measurement method that requires minimal modification to the existing machine structure.
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 timely replacement of components before they fail, improving machine operation rates without additional costs, ensuring consistent production of molded products.
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
AI summary
An inspection device configure 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 including an acoustic emission (AE) sensor detachably attached to the predetermined member of the machine or a portion adjacent to the predetermined member, and a controller configured to receive a signal outputted from the AE sensor disposed at the predetermined member of the machine or the portion adjacent to the predetermined member during operation of the machine, determine whether or not the predetermined member has an indication of abnormality in accordance with the signal, and output information on a result of determination.