Component Life Indicator for Dynamic Stress Monitoring
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Solution Overview
Problem
Existing maintenance schedules for machine components are often inefficient due to variations in operating conditions from typical sites, leading to premature component failure or unnecessary maintenance, as they do not accurately account for actual work life affected by use stresses such as road layout, weather, and loading practices.
Innovation Solution
A component life indicator system that includes sensors to monitor machine properties, a memory element to calculate a damage factor based on sensed data, and a processor to determine the actual work life of machine components, allowing for real-time stress monitoring and maintenance planning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If scheduled maintenance is performed based on fixed time intervals, then maintenance is ensured to be performed, but maintenance may be performed unnecessarily or too early
Solution Approach 1:
The patent applies dynamics by transitioning from static, fixed-time maintenance intervals to dynamic, condition-based maintenance scheduling. The system continuously monitors component conditions (vibration, temperature, pressure) and adjusts maintenance timing accordingly, allowing maintenance to be performed only when actually needed based on real-time component health status.
Solution Approach 2:
The patent implements feedback mechanisms through sensors that continuously monitor component operating conditions and feed this information back to the control system. This feedback loop enables the system to detect degradation trends and trigger maintenance actions only when component performance falls below acceptable thresholds, eliminating unnecessary early maintenance.
2Duration of action of stationary object
If component life is extended beyond designed work life, then component life is improved, but component failure may occur before scheduled maintenance
Solution Approach 1:
The patent applies preliminary action by detecting and addressing component degradation trends before they lead to failure. The monitoring system identifies early signs of component wear or malfunction and triggers maintenance actions in advance, preventing sudden failures while extending component operational life beyond traditional scheduled maintenance intervals.
Solution Approach 2:
The system uses real-time feedback from sensors monitoring component conditions to dynamically adjust maintenance scheduling. When component health deteriorates beyond predetermined thresholds, the feedback mechanism triggers timely maintenance actions, ensuring component reliability is maintained while maximizing useful life extension.
3Device complexity
If maintenance is performed based on typical work site conditions, then maintenance schedule is simplified, but actual component life cannot be accurately determined
Solution Approach 1:
The patent applies parameter changes by monitoring multiple dynamic operating parameters (vibration amplitude, temperature, pressure) that vary with actual work conditions. The system adjusts maintenance decisions based on real-time changes in these parameters, enabling accurate determination of actual component life under specific operating conditions rather than relying on generic scheduled intervals.
Solution Approach 2:
The patent replaces traditional mechanical/calendar-based maintenance scheduling with an electronic monitoring and data-processing system. Sensors and computer algorithms analyze real-time component data to determine actual life status, substituting simple time-based intervals with sophisticated condition-based assessment that accurately reflects actual component wear and stress.
Data Source
AI summary
A life indicator for a component of a machine is disclosed. The life indicator includes at least one sensor operably associated with the machine and configured to sense a property associated with the machine. The sensor is configured to output the sensed property as a data signal. The life indicator also includes a memory element having a first data structure that determines a damage factor for the component of the machine based at least in part on the data signal received from the at least one sensor. A processor executes the first data structure to determine the damage factor.