Component Damage Evaluation Using Precalculated Load Scaling
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Solution Overview
Problem
Current methods for determining the remaining service life of drive and control-specific components in devices are inefficient, requiring high computing effort and not capable of fast, real-time damage calculation, which hinders optimal maintenance and operation strategies.
Innovation Solution
A method that uses pre-calculated load-specific reference data to directly determine theoretical damage to components by scaling it with actual load data, allowing for quasi-real-time calculation of remaining service life, with low computing effort during operation and reduced costs by pre-defining load horizons and failure mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional damage calculation methods are used, then measurement precision of damage is improved, but computing effort and calculation time increase significantly
Solution Approach 1:
The patent pre-calculates damage values for all possible load levels before operation and stores them in the evaluation unit. During operation, only the actual load level needs to be identified and the corresponding pre-calculated damage value retrieved, eliminating the need for complex real-time damage calculations while maintaining high precision
Solution Approach 2:
The patent segments the continuous load spectrum into discrete load levels, each with pre-calculated damage values. This segmentation allows the system to handle complex damage calculations by breaking them down into manageable discrete states that can be stored and retrieved efficiently
2Reliability
If complex damage calculation methods are applied, then reliability of damage determination is improved, but device complexity increases
Solution Approach 1:
The patent creates a simplified copy of the damage calculation model by pre-calculating and storing damage values for discrete load levels. This copy allows the evaluation unit to determine damage reliably without implementing the full complexity of the original calculation methods during operation
Solution Approach 2:
Complex calculations are performed in advance during the planning and development phase, storing results in the evaluation unit. This transfers computational complexity from the operational phase to the development phase, simplifying the device while maintaining reliability
3Productivity
If real-time damage calculation is implemented, then productivity of maintenance planning is improved, but computing effort during operation increases
Solution Approach 1:
All computationally intensive damage calculations are performed in advance and stored. During operation, the system only needs to identify the current load level and retrieve the corresponding pre-calculated damage value, enabling real-time monitoring with minimal energy consumption
Solution Approach 2:
The patent extracts the computationally intensive calculation step from the operational phase and moves it to the development phase. During operation, only simple data retrieval and summation are needed, dramatically reducing energy consumption while maintaining real-time capability
Data Source
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AI summary
The invention relates to a method for direct determination of theoretical damage to at least one component (1) of a device (2), comprising the following method steps: providing load-specific reference data in an evaluation unit (3); detecting load-specific actual data by a load detection system (4) and transmitting the data to the evaluation unit (3); and scaling the load-specific reference data to the load-specific actual data for calculating the theoretical damage to the at least one component (1) and determining the remaining service life. The invention further relates to a system for carrying out the method and to a computer program product.