Energy Harvester Output for Machine Operational State Detection
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Solution Overview
Problem
Existing monitoring systems for machines and processes lack a reliable method to determine the operational state during data collection, leading to potential false alarms and inefficient data storage, as they often cannot distinguish between operating and non-operating states.
Innovation Solution
Utilizing an energy harvesting device associated with the machine or process to provide an output indicating its operational state, which is then correlated with data from monitoring systems to determine whether the machine is running, stopped, or in a specific operational mode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If wireless transducers periodically wake up to take readings on a time or periodic basis, then the monitoring system can collect data without continuous power consumption, but the machine or process may not be running when the sensor becomes active leading to false alarms and wasted storage space
Solution Approach 1:
An intermediary device (wireless transceiver with processor) is introduced between the sensor and the monitoring system. This intermediary captures the wake-up signal, determines machine operational state through multiple indicators (machine-on light, control system signals, historical data), and only transmits data when the machine is confirmed to be running, thus preventing false alarms while maintaining periodic sampling
Solution Approach 2:
The patent replaces direct mechanical/electrical connection methods (wired transducers with continuous power) with a wireless system that uses electromagnetic signals and intelligent processing to achieve both energy efficiency and reliable operation detection
2Measurement precision
If direct measurement of rotor speed using keyphasor is used to define when a machine is in operation, then the operational state can be accurately determined, but the installation effort and cost of extra transducer and wiring increases significantly
Solution Approach 1:
The wireless transceiver is designed to perform multiple functions: it serves as both the monitoring sensor and the operational state detector. By utilizing existing machine signals (control system outputs, machine-on lights) and environmental observations, it eliminates the need for separate keyphasor transducers and complex rotor speed measurement systems
Solution Approach 2:
Instead of directly measuring rotor speed through physical contact with the rotating component, the system copies operational state information from alternative sources such as control system signals and visual indicators, achieving the same diagnostic purpose with simpler instrumentation
3Adaptability or versatility
If vibration signature analysis is used to identify the operation mode of machinery, then the method can work in some instances, but false positives occur and vibration signatures may not be present on smoothly operating machines
Solution Approach 1:
The patent merges multiple detection methods into a single comprehensive system. It combines analysis of control system signals, machine visual indicators, historical operational data, and environmental factors to determine operational state, thereby compensating for the limitations of any single method including vibration analysis
Solution Approach 2:
The system incorporates feedback from multiple sources including historical data about machine operation patterns and real-time observations. This feedback loop allows the system to learn and adapt to specific machine behaviors, improving reliability by confirming operational state through multiple independent indicators rather than relying solely on vibration signatures
Data Source
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AI summary
Embodiments of the invention described herein use an output of an energy harvester (104) as an indication of the operating state of the machine (102), device, or process the energy harvester (104) is associated with. In one aspect, a system is described. The system is comprised of at least one of a machine (102) or process, a processor (108), and an energy harvesting device (104) associated with the machine (102) or process. The processor (108) is configured to use an output of the energy harvesting device (104) created by the machine (104) or process to determine whether the machine (102) or process is in a first operating state or a second operating state.