Balancing Machine Error Detection via Signal-Model Comparison
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Solution Overview
Problem
Existing balancing machines lack an efficient method for automatic detection and identification of errors during operation, leading to potential residual unbalance and equipment damage, which can cause significant failures and losses in production processes.
Innovation Solution
A method that uses signal-model-based and process-model-based approaches to analyze measurement signals from a rotor's rotational frequency and vibrations, comparing calculated features with predetermined normal features to identify discrepancies and allocate error symptoms, allowing for real-time error detection and diagnosis without interrupting the balancing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If automatic monitoring of balancing machines is carried out by randomly checking balancing results and individually checking directly measurable values, then some errors can be detected, but detailed error identification cannot be achieved and requires specialist staff analysis
Solution Approach 1:
The patent implements a feedback mechanism where measurement signals from the balancing machine are continuously fed to an evaluation computer that automatically analyzes vibration characteristics, compares them with reference values, and provides real-time error identification. This closed-loop feedback system eliminates the need for specialist staff manual analysis while achieving comprehensive error detection.
Solution Approach 2:
The patent replaces the manual mechanical process of specialist staff analyzing measurement results with an automated computer-based evaluation system. The evaluation computer automatically processes vibration signals, performs spectral analysis, and identifies error types, substituting human expert analysis with automated computational methods.
2Measurement precision
If signal spectra and time frequency representations are analyzed to detect errors, then more detailed error information can be obtained, but the analysis requires long measurement times and specialist staff
Solution Approach 1:
The patent performs preliminary action by pre-storing reference vibration characteristics and evaluation criteria in the evaluation computer before actual balancing operations. This allows the system to immediately compare real-time measurement signals against predefined standards, enabling rapid error identification without requiring lengthy post-measurement analysis or specialist staff involvement.
Solution Approach 2:
The patent transforms complex vibration signals into simplified error indicators by changing the parameter representation from raw time-frequency spectra to discrete error types and severity levels. This parameter transformation enables the system to provide actionable error identification results quickly, reducing analysis time while maintaining precision.
3Productivity
If comprehensive error detection and identification is implemented during normal balancing operation, then production interruptions are prevented, but the system complexity and computational requirements increase
Solution Approach 1:
The patent implements a universal evaluation computer system that performs multiple functions: it monitors vibration signals, performs spectral analysis, compares measurements with reference values, identifies error types, and provides diagnostic information. This multi-functional system achieves comprehensive error detection during normal balancing operations without requiring separate dedicated systems for each function, thereby limiting the increase in overall system complexity.
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 reliable and user-friendly error reporting, allowing for immediate identification and diagnosis of errors during normal operation, reducing the risk of residual unbalance and equipment damage, and improving production efficiency by preventing interruptions.
Implementation Method 1
the rotor is set in rotation, and as a result the forces due to unbalance generate vibrations which can be measured by a vibration sensor
Data Source
AI summary
A method is disclosed for the automatic detection and identification of errors in a balancing machine during operation, in which a rotor provided with an unbalance is rotatably mounted in a vibratory bearing in the balancing machine and is set in rotation by a drive, the rotational frequency of the rotating rotor and the vibrations stimulated by the rotor are measured and measurement signals which comprise the measured values of the rotational frequency and the vibrations are generated and delivered to an evaluation computer. The evaluation calculation is based on mathematical models of the dynamic properties of the balancing machine which describe stimulations of the machine structure due to the unbalance, in particular in the balancing planes, and/or due to the rotor geometry and/or due to the bearing and/or possible damage to the bearing. Features such as vibration characteristics and/or process parameters are calculated by a signal-model-based method from the measurement signals, and discrepancies are established by comparing the calculated features with predetermined normal features of an error-free process.