Electromagnetic Brake Vibration Sensing for Equipment Fault Detection
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Solution Overview
Problem
Existing abnormality detection systems for brake devices do not effectively detect abnormalities in the equipment on which they are installed, rather than the brake devices themselves.
Innovation Solution
An abnormality detection apparatus that utilizes sensor data related to vibration of the equipment during brake device operation to detect abnormalities in the equipment, employing an electromagnetic brake to apply controlled vibrations and analyze the resulting sensor data for abnormality detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a brake device is used to detect abnormalities in the brake device itself through vibration signals, then the brake device abnormality detection capability is improved, but the ability to detect abnormalities in the equipment on which the brake device is installed deteriorates
Solution Approach 1:
The vibration sensor is designed to perform multiple detection functions: it detects both brake device abnormalities (through direct vibration signals from the brake) and equipment abnormalities (through vibration signals transmitted from the equipment structure). This multi-functional approach allows a single sensor system to address both detection needs without requiring separate detection systems.
Solution Approach 2:
The vibration sensor acts as an intermediary that captures vibration signals from both the brake device and the equipment. By analyzing the characteristics and sources of these vibration signals, the system can distinguish between brake abnormalities and equipment abnormalities, enabling comprehensive monitoring through a single sensing component.
2Measurement precision
If additional vibration application devices are installed to detect equipment abnormalities, then the equipment abnormality detection capability is improved, but the device complexity increases
Solution Approach 1:
The brake device itself serves as the vibration source for equipment abnormality detection. When the brake operates, it generates vibration signals that propagate through the equipment structure. By monitoring these naturally occurring vibrations during normal brake operation, the system detects equipment abnormalities without requiring separate vibration application devices or additional excitation mechanisms.
Solution Approach 2:
The existing brake device and vibration sensor are utilized for dual purposes: the brake continues its primary function of stopping the movable part while simultaneously serving as a vibration source for equipment condition monitoring. The sensor detects both brake performance and equipment health, eliminating the need for additional specialized devices.
3Productivity
If the brake device operates continuously to maintain production, then the productivity is improved, but the opportunity to perform dedicated abnormality detection reduces
Solution Approach 1:
The abnormality detection system operates continuously during brake device operation rather than requiring separate inspection periods. The vibration sensor continuously monitors vibration signals while the brake is in use, enabling real-time detection of both brake and equipment abnormalities without interrupting production or requiring the system to stop for dedicated testing.
Solution Approach 2:
The detection system dynamically adapts to the operating conditions by analyzing vibration signals during actual brake operation. The system processes vibration data in real-time as the brake operates under various loads and conditions, allowing abnormality detection to occur dynamically during continuous production rather than during static inspection periods.
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 detection of equipment abnormalities without the need for additional vibration application devices, allowing for continuous operation and reducing errors in abnormality detection.
Implementation Method 1
sensor data related to a vibration of the equipment and obtained during operation of a brake device that brakes a motion of a movable part in the equipment
Data Source
AI summary
An abnormality detection apparatus detects an abnormality of equipment according to sensor data that is related to a vibration of the equipment and is obtained while a brake device for braking a motion of a movable part of the equipment is in operation.