Rolling Bearing Peak Re-Detection for Replacement Timing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for predicting the replacement timing of rolling bearings, such as those described in Japanese Unexamined Utility Model Registration Application Publication No. H02-140451, are inaccurate due to the potential deviation of peak frequencies from theoretical values and lack of clear relationships between spectral intensity changes and remaining lifespan, making it difficult to reliably predict when a bearing needs replacement.
Innovation Solution
A method and device that involves detecting a specific peak within a first frequency range including a theoretical frequency, followed by re-detecting this peak within a narrower second frequency range, using vibration data to predict the replacement timing based on the amplitude and timing of both the initial and re-detected peaks, with a fitting curve determining the actual replacement time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If spectral intensity is calculated based on theoretical frequency, then the prediction method is simple to implement, but the prediction accuracy deteriorates when peak frequency deviates from theoretical frequency
Solution Approach 1:
The patent applies preliminary action by performing peak detection in a broader first frequency range before narrowing down to a second frequency range. This preliminary broad detection ensures that even if the peak frequency deviates from theoretical values, the initial peak is captured, and subsequent refinement improves accuracy without missing the actual peak.
Solution Approach 2:
The patent implements dynamics by adaptively adjusting the frequency range for peak detection. Instead of using a fixed theoretical frequency, the system dynamically expands the search to a first frequency range when deviation is detected, then refines to a second frequency range, allowing the detection method to adapt to actual peak frequency variations.
2Reliability
If a broad frequency range is used for peak detection, then the likelihood of detecting the actual peak increases, but the complexity of the detection process increases
Solution Approach 1:
The patent applies segmentation by dividing the peak detection process into two distinct stages: first frequency range detection and second frequency range detection. This segmentation allows the system to first ensure reliable peak capture with a broader range, then reduce complexity by narrowing the range in the second stage, managing the trade-off between reliability and complexity.
Solution Approach 2:
The first frequency range detection serves as a preliminary action that ensures the actual peak is captured even with frequency deviation. This preliminary broad detection increases reliability, and the subsequent second frequency range detection refines the result while managing complexity through the staged approach.
Data Source
AI summary
The present disclosure provides a rolling-bearing replacement-timing prediction device and method enabling a more accurate replacement-timing prediction. A frequency spectrum of vibration data indicating vibration of a rolling bearing is determined for every sampling period and is stored in association with the sampling period into a storage unit. A specific peak not appearing during a normal state is detected from the frequency spectrum within a first frequency range including a theoretical frequency at which a peak occurs during an abnormality. When the specific peak is detected, a specific peak is detected as a re-detection specific peak within a second frequency range, which includes the specific peak and is smaller than the first frequency range, from at least one frequency spectrum stored in the storage unit prior to this sampling period, and the replacement timing of the rolling bearing is predicted based on the specific peak and the re-detection specific peak.