State evaluation system, state evaluation apparatus, and state evaluation method
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Solution Overview
Problem
It is challenging to accurately evaluate abnormalities in industrial equipment, such as compressors, due to the difficulty in distinguishing between elastic waves generated by abrasion and those caused by normal vibration or stress/strain, which hinders timely maintenance and replacement.
Innovation Solution
A state evaluation system comprising a sensor, filter, signal processor, and evaluator that detects and processes elastic waves to extract feature values, allowing for the accurate identification of abnormalities by filtering out waves based on abrasion frequencies and evaluating the equipment based on a combination of these values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If elastic waves are detected from the outside of the compressor using an AE sensor, then the compressor can be monitored without internal sensors, but it becomes difficult to distinguish between elastic waves generated by abnormalities and those generated by normal vibration or stress/strain
Solution Approach 1:
The patent segments the elastic wave signal into different frequency components using Fourier transformation. By dividing the continuous signal into frequency domains, the system can separately analyze and identify abnormal waves from normal operational waves based on their distinct frequency characteristics, thereby resolving the difficulty of distinguishing between abnormal and normal elastic waves while maintaining external sensor placement.
Solution Approach 2:
The patent applies local quality by focusing analysis on specific frequency bands where abnormal elastic waves are most prominent. The signal processing system identifies and emphasizes frequency ranges characteristic of abnormalities (such as high-frequency components from friction or impact) while filtering out or de-emphasizing frequencies associated with normal compression operations, enabling accurate abnormality detection despite external sensor placement.
2Reliability
If the compressor is monitored continuously to detect abnormalities early, then timely maintenance can be performed, but the system complexity and cost of monitoring equipment increases
Solution Approach 1:
The patent extracts only the essential features from the complex elastic wave signal for abnormality detection. By applying Fourier transformation and identifying specific frequency characteristics, the system extracts meaningful information (abnormal frequency components) from the overwhelming amount of raw signal data, achieving reliable monitoring with simplified processing requirements rather than complex comprehensive analysis systems.
Solution Approach 2:
The monitoring system uses the compressor's own operational characteristics (its natural vibration frequencies and operational patterns) as reference data for normal operation. By comparing detected elastic waves against the compressor's self-established baseline, the system can identify abnormalities without requiring external reference systems or complex predefined thresholds, reducing overall system complexity while maintaining high reliability.
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
Enables precise abnormality evaluation in industrial equipment by distinguishing between elastic waves from abrasion and those from normal operation, facilitating timely maintenance without the need for internal sensors.
Implementation Method 1
a sensor 10, an amplifier 11, a filter 12
Data Source
AI summary
A state evaluation system includes a sensor, a filter, a signal processor, and an evaluator. The sensor detects elastic waves which are generated from industrial equipment in operation. The filter can pass elastic waves having frequency characteristics based on abrasion which is generated in the industrial equipment. The signal processor extracts a plurality of feature values using the elastic waves passing through the filter. The evaluator evaluates an abnormality of the industrial equipment on the basis of a combination of the extracted plurality of feature values.