Engine Bearing Damage Detection Using Natural-Frequency Vibration Filtering

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Solution Overview

Problem

Existing methods for detecting bearing damage in engines lack effectiveness, as they require additional hardware and cannot accurately distinguish between vibration signals caused by combustion knocking and bearing damage, leading to inadequate detection and potential engine failure.

Innovation Solution

A method that processes vibration signals from engines using a signal processing filter to separate and integrate signals of specific natural frequency bands, allowing for the detection of bearing damage without additional hardware by distinguishing between combustion knocking and bearing-related vibrations, particularly during engine deceleration or idle states.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a vibration sensing means is used to detect bearing damage, then the detection capability is improved, but it becomes difficult to distinguish between combustion knocking and bearing damage vibrations

Engineering Contradiction:

Improvebearing damage detection accuracyVSAvoidsignal discrimination capability

Core Design Contradiction:

Measurement precisionVSLoss of information

Solution Approach 1:

The vibration signal is segmented into different frequency bands using a signal processing filter. The bearing damage detection unit specifically analyzes vibrations in the natural frequency band of the bearing (typically 1-3 kHz), separating them from combustion knocking signals which occur at different frequencies. This segmentation allows accurate detection of bearing damage without confusion from knocking signals.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A signal processing filter acts as an intermediary between the vibration sensing means and the bearing damage detection unit. This filter processes the raw vibration signal by attenuating frequencies outside the bearing's natural frequency band while preserving the bearing-related vibrations, thereby enabling accurate detection without additional hardware sensors.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If additional hardware is added to detect bearing damage, then the detection accuracy is improved, but the device complexity increases

Engineering Contradiction:

Improvebearing damage detection accuracyVSAvoidhardware configuration

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The vibration sensing means, originally designed for detecting combustion knocking, is made multi-functional by using it also for bearing damage detection. The existing sensor is reused for dual purposes: monitoring combustion events and detecting bearing vibrations, eliminating the need for additional dedicated hardware while maintaining detection accuracy.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent replaces the need for additional mechanical hardware sensors with a signal processing-based solution. By using digital signal processing techniques (filtering, frequency analysis) in the control unit, the system achieves bearing damage detection capability without adding physical sensing components, thereby reducing device complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If the engine operates continuously without monitoring, then the productivity is maintained, but the risk of engine stall due to bearing failure increases

Engineering Contradiction:

Improveengine operation continuityVSAvoidengine operation safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The bearing damage detection unit continuously monitors vibration signals and detects early signs of bearing deterioration before actual failure occurs. By identifying abnormal vibrations in the bearing's natural frequency band ahead of time, the system enables preventive maintenance actions, avoiding sudden bearing failure and engine stall, thus maintaining both productivity and reliability.

Inventive Principle:

Principle #10Preliminary action

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 enables accurate detection of bearing damage, preventing further engine deterioration, allowing for limp home mode operation and timely maintenance, thereby reducing the risk of engine stall and extending the life of the bearing.

Implementation Method 1

extracts and integrates a signal of a predetermined natural frequency band through a signal processing filter from the vibration signal of the bearing

Methodology Applied

Scientific EffectNatural frequency: Resonance

Data Source

PatentUS11506570B2Method for sensing damage of bearing of engine using vibration signal

Publication Date: 2022.11.22 HYUNDAI MOTOR CO LTD

AI summary

A method for sensing damage of bearing of engine using a vibration signal may include separating a vibration signal of an engine sensed by a vibration sensor installed at one side of the engine of a vehicle into a vibration signal by combustion knocking and a vibration signal of a bearing installed between a crank pin and a connecting rod; extracting, by a signal processing filter, a signal of a predetermined natural frequency band from the vibration signal of the bearing; determining whether the vibration signal of the bearing is higher than a predetermined bearing damage threshold, in a predetermined engine state condition in order to sense breakage of the bearing during operation of the engine; and confirming that the bearing has been damaged.