EKG Sensors for Motor Vibration Analysis and Failure Estimation
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Solution Overview
Problem
Existing methods lack effective means to determine the health and estimated life of motors, particularly in critical applications where motor failure can pose risks or disrupt operations, leading to potential safety hazards and inefficiencies.
Innovation Solution
The use of electrocardiogram sensors to measure motor vibration, compare the signals with baseline data, and identify artifacts to estimate the time to failure, incorporating additional sensors for environmental factors like temperature and humidity to provide a comprehensive assessment of motor health.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional motor monitoring methods are used, then the system is simple and easy to implement, but the ability to accurately determine motor health and estimate time to failure is insufficient
Solution Approach 1:
The patent applies universality by using EKG sensors originally designed for biomedical applications to monitor motor health. The same sensor type and signal processing techniques used in cardiac monitoring are adapted to detect motor vibration patterns, allowing one technology to serve multiple purposes across different domains (medical and industrial), thereby improving measurement precision without proportionally increasing system complexity
Solution Approach 2:
The patent replaces traditional mechanical vibration sensors with EKG sensors that detect electrical signals generated by motor vibrations. This substitution transitions from direct mechanical measurement to electrical signal detection, enabling more precise health assessment through electrical field measurements while simplifying the sensing mechanism
2Reliability
If no motor health monitoring is implemented, then the system is simple and costs are low, but motor failure can cause safety hazards and operational disruptions
Solution Approach 1:
The patent implements preliminary action by continuously monitoring motor vibrations and comparing them against baseline patterns to detect early signs of degradation. By identifying artifacts and deviations before actual failure occurs, the system enables proactive maintenance scheduling, ensuring reliable operation while preventing safety hazards and disruptions before they happen
Solution Approach 2:
The patent establishes a feedback loop where motor vibration signals are continuously captured, analyzed for artifacts, compared to baselines, and used to update health assessments and predict time to failure. This closed-loop feedback system maintains high reliability by constantly adjusting maintenance predictions based on actual motor condition, while keeping the monitoring system manageable through automated analysis
3Productivity
If reactive maintenance is used instead of predictive maintenance, then the system is simpler to operate, but motor failures cause downtime and inefficiency
Solution Approach 1:
The patent enables proactive maintenance scheduling by predicting time to failure based on vibration artifact analysis. Maintenance activities are planned and executed before actual failure occurs, preventing unplanned downtime and maintaining high productivity. The system automatically generates maintenance recommendations, simplifying the operational complexity of predictive maintenance while maximizing operational efficiency
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for accurate estimation of motor life, enabling proactive maintenance and warranty strategies, reducing the risk of motor failure and associated hazards, while improving operational efficiency and safety.
Implementation Method 1
measuring, by an electrocardiogram sensor, vibration of the motor to obtain at least two electrical signals with each of the at least two electrical signals representing a harmonic of the vibration of the motor
Data Source
AI summary
A method for measuring health of a motor includes: (a) measuring, by an electrocardiogram sensor, vibration of the motor to obtain at least two electrical signals with each of the at least two electrical signals representing a harmonic of the vibration of the motor; (b) comparing each of the at least two electrical signals with a corresponding baseline; (c) based on the comparison, determining whether any one of the at least two electrical signals includes one or more artifacts wherein an artifact in a respective one of the at least two electrical signals is a deviation from a respective one of the corresponding baseline; and (d) based on any one of the at least two electrical signals including the one or more artifacts, providing an estimated time to failure for the motor.