Damage Estimation Device Using Component Status Classification
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Solution Overview
Problem
Current methods for estimating the degree of damage to devices operating in actual environments lack precision, particularly in distinguishing the optimal inspection period for high-load and low-load types, leading to potential overuse and failure prevention inefficiencies.
Innovation Solution
A damage estimation device that classifies operating statuses using component status classification processing, calculates damage degrees based on pre-measured simulation data, and accumulates results to create frequency distributions and integrated damage outputs, enabling the identification of effective component statuses for damage reduction and optimal maintenance cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inspection period is advanced for high-load type machines, then failure prevention capability is improved, but inspection cost and time loss increase
Solution Approach 1:
The patent changes the parameter of inspection timing from fixed periodic intervals to dynamic intervals based on accumulated damage degrees. By calculating real-time damage accumulation from operational data and comparing it against thresholds, the system adjusts inspection timing to match actual device condition, avoiding both premature and delayed inspections.
Solution Approach 2:
The patent implements a feedback mechanism where operational data is continuously collected, damage degree is calculated and accumulated, and inspection decisions are made based on this feedback loop. The system monitors device status, computes damage accumulation, and triggers inspections only when accumulated damage reaches predetermined thresholds, creating a closed-loop control system that optimizes inspection timing.
2Measurement precision
If extensive sensor deployment is used for damage measurement, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts and utilizes only the essential operational parameters already available from normal device operation (such as load, speed, temperature from control systems and basic sensors). By focusing on key parameters that most significantly contribute to damage accumulation rather than deploying comprehensive sensor arrays, the system achieves effective damage measurement with minimal additional complexity.
Solution Approach 2:
The patent creates a virtual model of damage accumulation by calculating equivalent damage degrees from operational data and storing them in a database. This virtual damage model copies the essential information needed for inspection decision-making without requiring physical sensors to directly measure damage, thereby reducing hardware complexity while maintaining measurement capability.
Data Source
AI summary
According to the present invention, the work status at an actual site is represented using a combination of component statuses. A degree of damage that takes into account the manner of use at the actual site is predicted by associating test data collected in a component status test. The objective of the present invention is to estimate, with high accuracy, the degree of damage to a device operating in an actual environment. In order to achieve this objective, this damage estimation device is provided with: a component status classification processing unit that classifies the operating status of a device; a component status characteristic amount storage unit that stores a characteristic amount for classification processing by the component status classification processing unit; and a damage degree storage unit for each component status, said damage degree storage unit storing the degree of damage to various regions of a device for each component status, wherein the degree of damage is measured in advance for each component status or is calculated using a simulation. The damage estimation device is characterized by collecting sensor/control data required for device status classification, classifying component status using the component status classification processing unit, calculating the classified result and the degree of damage corresponding to said result using the damage degree storage unit for each component status, and outputting the degree of damage.