Cyclic Signal Condition Monitoring for Unknown Fault Detection

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Solution Overview

Problem

Current condition-based monitoring systems require prior knowledge of a faulty state to effectively monitor equipment, and they struggle to determine the operational status of apparatuses emitting or receiving cyclic signals without pre-observed fault conditions.

Innovation Solution

A method that processes cyclic signals by sampling and comparing measured values to predetermined distributions, using statistical analysis and function approximation to identify deviations and determine the operational state of equipment, allowing for monitoring without prior knowledge of faulty states.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If prior knowledge of faulty state is required for condition monitoring, then measurement precision is improved, but adaptability deteriorates

Engineering Contradiction:
Improvefault detection accuracyVSAvoidability to monitor unknown faults
Core Design Contradiction:
Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The system performs preliminary action by learning the normal operational characteristics of equipment during a training phase before actual monitoring begins. Statistical parameters (mean, standard deviation) are pre-calculated from healthy operation data, enabling the system to detect deviations without needing prior knowledge of specific fault signatures. This resolves the contradiction by preparing the system in advance with normal state references while maintaining adaptability to unknown faults.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The monitoring system performs self-service by automatically adapting to different equipment and operational conditions without requiring retraining with faulty data. The system uses unsupervised statistical methods that automatically establish baselines and detect anomalies, enabling it to monitor any equipment type without pre-programmed fault knowledge. This maintains both precision through statistical comparison and adaptability to new equipment types.

Inventive Principle:
Principle #25Self-service

2Reliability

If preventive maintenance is performed at fixed intervals, then reliability is improved, but loss of time increases

Engineering Contradiction:
Improveequipment reliabilityVSAvoiddowntime for maintenance
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The system applies dynamics by transitioning from static fixed-interval maintenance schedules to dynamic condition-based maintenance. The monitoring system continuously evaluates equipment state in real-time, allowing maintenance timing to adapt dynamically to actual equipment conditions. This resolves the contradiction by maintaining reliability through continuous monitoring while minimizing downtime by performing maintenance only when actually needed rather than at predetermined intervals.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The system implements feedback by continuously monitoring equipment parameters and using this information to determine when maintenance is actually needed. The statistical comparison between current operation and learned normal state provides feedback that triggers maintenance only when deviations indicate potential failures. This maintains reliability through continuous assessment while reducing unnecessary maintenance downtime by acting only when conditions warrant intervention.

Inventive Principle:
Principle #23Feedback

3Productivity

If condition monitoring is performed during operation, then productivity is improved, but measurement precision deteriorates

Engineering Contradiction:
Improveequipment uptimeVSAvoidfault detection accuracy
Core Design Contradiction:
ProductivityVSMeasurement precision

Solution Approach 1:

The system replaces complex mechanical intervention with statistical analysis of operational data. Instead of requiring equipment shutdown for physical inspection or testing, the system substitutes mechanical assessment with computational comparison of operational parameters against learned statistical models. This resolves the contradiction by maintaining productivity through continuous operation while achieving measurement precision through advanced statistical detection methods that can identify faults during normal operation.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12140508B2Systems and methods for condition monitoring
Publication Date: 2024.11.12 GREEN RUNNING LTD
  • US12140508B2 patent drawing
  • US12140508B2 patent drawing
  • US12140508B2 patent drawing

AI summary

A method for monitoring the status of an apparatus comprises processing in a processor a cyclic signal emitted and/or received by said apparatus, by sampling at least part of a plurality of cycles of the cyclic signal at n points to provide n measured values; comparing the n measured values to a predetermined distribution of values at said n points representing a first state of the apparatus; and if the n measured values fall outside predetermined criteria relating to the predetermined distribution, providing an indication that the apparatus is not in the first state.