Diagnosis System Using Current Waveform Data for Driver Device Condition Monitoring
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Solution Overview
Problem
Existing diagnosis systems for rotating devices face accuracy issues due to environmental influences, such as ambient temperature, affecting the condition determination of apparatuses like machining tools and pumps, as they rely on sensors installed near the devices.
Innovation Solution
A diagnosis system that acquires waveform data related to the current supplied to the driver device, allowing for condition determination based on changes caused by forces applied in specific directions, independent of the environmental influences, using a measurement unit that can be installed away from the driver device, reducing maintenance burdens and enabling continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are installed near the driver device to detect vibration, then the ability to detect device condition is improved, but the measurement precision deteriorates due to environmental influences such as ambient temperature
Solution Approach 1:
The patent introduces current waveform data as an intermediary measurement parameter. Instead of directly measuring vibration near the driver device (which is affected by temperature), the system measures electrical current waveforms that are transmitted through wiring to the driver device. The current waveforms contain information about the device condition but are measured in a location less affected by environmental factors, thus acting as a mediator between the device and the measurement system.
Solution Approach 2:
The patent replaces the mechanical vibration sensing system with an electrical measurement system. Instead of using acceleration sensors that physically detect vibration (and are therefore exposed to environmental conditions), the system uses electrical current measurements to infer device condition. This substitution of measurement domain (from mechanical to electrical) resolves the contradiction by eliminating the direct exposure to environmental influences.
2Reliability
If sensors are installed near the driver device, then the condition monitoring capability is improved, but the ease of operation deteriorates due to maintenance burdens and interruption of continuous operation
Solution Approach 1:
The measurement system is relocated to measure current waveforms at a position away from the driver device, using the electrical current itself as a mediator to carry information about the device condition. This allows the measurement apparatus to be installed in a more accessible location that does not require interruption of device operation and is easier to maintain.
Solution Approach 2:
The system uses the existing electrical current that already flows to the driver device as the measurement signal. No separate power supply or additional wiring is needed - the operational current itself serves the dual purpose of driving the device and providing diagnostic information. This self-service approach eliminates the need for separate sensor installations and reduces maintenance complexity.
Data Source
AI summary
A diagnosis system is configured to diagnose an apparatus including a driver device. The system includes an acquisition unit configured to acquire waveform data indicating a waveform related to a current to be supplied to the driver device, and a determination unit configured to determine a condition of the apparatus. The determination unit is configured to obtain, based on the waveform data, a change caused by a component of a force in a particular direction applied to the driver device, and to determine the condition of the apparatus based on the obtained change. The diagnosis device determines the condition of the apparatus accurately.