Failure Diagnosis System with Cable-Length Adaptive Filtering
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Solution Overview
Problem
Existing failure diagnosis systems face challenges in accurately identifying abnormality in multiple diagnosis target devices disposed within a facility due to noise and attenuation issues caused by varying cable lengths, which can reduce the accuracy of diagnosis processes.
Innovation Solution
The proposed failure diagnosis system employs a processing unit with a filtering and correction process for vibration information, adjusting filtering and amplification based on cable lengths to maintain high accuracy, and a notification unit that identifies abnormal devices through a user-friendly interface displaying sensor information on a facility layout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sensors are disposed in multiple diagnosis target devices within a facility, then the system can monitor multiple devices, but noise and attenuation issues caused by varying cable lengths reduce diagnosis accuracy
Solution Approach 1:
The system applies different filtering and amplification parameters to vibration information based on the specific cable length of each sensor. The abnormality determination unit adjusts the filtering degree and amplification factor locally for each sensor's data, ensuring that each device's vibration information is processed according to its individual cable characteristics, thereby maintaining high diagnosis accuracy across multiple devices
Solution Approach 2:
The system changes the processing parameters (filtering degree and amplification factor) based on cable length. Sensors with longer cables receive stronger amplification and different filtering compared to sensors with shorter cables. This dynamic parameter adjustment compensates for the attenuation and noise differences caused by varying cable lengths, resolving the contradiction between monitoring multiple devices and maintaining diagnosis accuracy
2Adaptability or versatility
If vibration information is transmitted through cables of varying lengths, then sensors can be flexibly disposed, but noise and attenuation increase with cable length
Solution Approach 1:
The system continuously processes vibration information through adaptive filtering and amplification based on cable length. The abnormality determination unit maintains continuous monitoring and adjustment of processing parameters, ensuring that the useful vibration signal remains strong and clear regardless of cable length, thereby compensating for the harmful effects of noise and attenuation
Solution Approach 2:
The abnormality determination unit acts as an intermediary between the sensors and the diagnosis system. It receives vibration information from sensors with varying cable lengths and applies intermediate processing (filtering and amplification) tailored to each cable's characteristics, mediating the harmful effects of noise and attenuation before the data reaches the final diagnosis stage
3Productivity
If the system processes vibration information from multiple sensors with different cable lengths, then comprehensive monitoring is achieved, but determining appropriate filtering and amplification becomes complex
Solution Approach 1:
The system implements self-service through automatic cable length detection and parameter selection. The abnormality determination unit automatically determines the appropriate filtering degree and amplification factor based on the detected cable length of each sensor, eliminating the need for manual configuration and reducing the complexity of processing parameter determination while maintaining comprehensive monitoring coverage
Data Source
AI summary
A failure diagnosis system includes: a sensor; an abnormality determination unit that determines whether an abnormality occurs in a diagnosis target device corresponding to the sensor on the basis of diagnosis target information detected by the sensor; a screen display controller that identifiably notifies a diagnosis target device for which it is determined by the abnormality determination unit that the abnormality occurs; a layout setting unit that sets a facility layout of a facility; and a disposition setting unit that sets a disposition of each diagnosis target device in the facility layout. The screen display controller identifiably notifies a diagnosis target device associated with a sensor that detects diagnosis target information that is a basis of the determination that the abnormality occurs, in a disposition screen display region 521 in which diagnosis information acquisition units are disposed on the facility layout.