Electric Drive Fault Diagnosis Using Mapped Part Replacement Data
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Solution Overview
Problem
Existing fault diagnosis systems for electric drives in industrial locations are inefficient due to reliance on manual databases and limited accuracy in identifying affected components, especially in diverse operating environments, leading to potential misidentification and increased downtime.
Innovation Solution
A diagnostic system that receives fault data from electric drives, parses fault codes, and uses mapped data generated from historical fault information to determine the necessary drive parts for replacement, incorporating confidence values based on frequency of replacement and co-replacement, thereby facilitating accurate maintenance and inventory management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual databases and expert-based fault diagnosis are used, then implementation simplicity is maintained, but diagnosis accuracy and reliability deteriorate due to subjectivity and limited expertise
Solution Approach 1:
The patent replaces manual expert-based diagnosis with an automated computer-based system that uses algorithms and data processing to identify faulty components. The system substitutes human expert analysis with computational methods including fault code parsing, historical data comparison, and confidence value calculations, thereby eliminating subjectivity while maintaining implementation feasibility through software-based solutions.
Solution Approach 2:
The system enables self-service fault diagnosis by automatically analyzing fault codes and determining affected components without requiring external expert intervention. The computer-based system independently processes fault information, compares it with historical data, and generates diagnosis results, allowing the electric drive system to diagnose its own faults autonomously.
2Reliability
If periodic maintenance with component replacement is performed, then reliability is maintained, but downtime and productivity are reduced due to unnecessary replacements
Solution Approach 1:
The system performs preliminary fault detection and component identification before actual failures occur or before scheduled maintenance. By continuously monitoring fault codes and analyzing them in real-time, the system identifies components that need replacement in advance, allowing maintenance to be performed only when necessary, thus avoiding unnecessary downtime while maintaining reliability.
Solution Approach 2:
The system implements feedback mechanisms by continuously monitoring fault codes, comparing them with historical data, and adjusting maintenance recommendations based on actual fault patterns. This feedback loop enables the system to learn from past failures and improve its accuracy in predicting which components need replacement, reducing unnecessary maintenance activities and associated downtime.
3Measurement precision
If comprehensive fault data collection from multiple drive types is implemented, then diagnosis accuracy improves, but data processing complexity and time increase
Solution Approach 1:
The patent implements a universal fault diagnosis system that can handle multiple types of electric drives through a single computer-based platform. The system uses standardized fault code parsing and configurable data structures that adapt to different drive types without requiring separate diagnosis systems for each drive model, thereby maintaining data processing efficiency while achieving comprehensive multi-type drive diagnosis accuracy.
Data Source
AI summary
The present disclosure relates to diagnosing a fault in an electric drive of a process plant. The fault diagnosis method includes receiving fault data from an electric drive upon occurrence of the fault. The method further includes obtaining a fault code and a drive type associated with the electric drive from the fault data. In addition, the method comprises determining one or more drive parts to replace by comparing the fault code and the drive type with a mapped data for a plurality of drive types. The mapped data for each drive type includes a relation between a plurality of fault codes and a plurality of drive parts. The method further includes initiating a maintenance operation involving replacement of the one or more drive parts to address the fault.