Equipment State Diagnosis Using Combined Sensor State Quantities
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Solution Overview
Problem
In production and power generation equipment, it is challenging to detect abnormal state changes that do not affect process values, such as device malfunctions or changes in raw material or outside temperatures, as these may not be reflected in standard process control measurements.
Innovation Solution
A diagnosis device that processes measurement data from sensors to derive individual and general state quantities, combining various equipment parameters like sound and temperature, allowing for the detection of state changes beyond process value changes by integrating these quantities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If process control is performed to maintain process values at target values, then production stability is improved, but abnormal equipment state changes that do not affect process values cannot be detected
Solution Approach 1:
The patent segments equipment state monitoring into two independent parts: process value monitoring (for production stability) and equipment state quantity monitoring (for detecting abnormal changes). By separating these monitoring functions and analyzing equipment state quantities independently from process values, the system can detect equipment abnormalities even when process values remain within target ranges.
2Measurement precision
If multiple sensors and state quantities are monitored to detect all equipment changes, then detection capability is improved, but system complexity increases
Solution Approach 1:
The patent extracts and focuses on specific equipment state quantities (sound, temperature, vibration) that are directly indicative of equipment health, separating them from the broader process control system. By selecting and monitoring only the most relevant state quantities rather than all possible parameters, the system achieves high detection capability while maintaining manageable complexity.
3Loss of information
If equipment state changes are monitored independently from process values, then abnormal state detection is improved, but integration with existing process control becomes difficult
Solution Approach 1:
The patent creates a multi-functional monitoring system that can operate independently to detect equipment state changes while also being compatible with existing process control systems. The equipment state quantity analysis serves multiple purposes: detecting abnormalities, providing maintenance information, and potentially feeding back to process control, making the system universally applicable without requiring complete system redesign.
Data Source
AI summary
The processing unit performs: first processing that derives individual previous state quantities and individual new state quantities, the individual previous state quantities being various state quantities for the equipment calculated by processing previous measurement data from the sensors, and the individual new state quantities being various state quantities for the equipment calculated by processing new measurement data; and second processing that derives a general previous state quantity and a general new state quantity, the general previous state quantity being a general state quantity for the equipment that combines the various individual previous state quantities, and the general new state quantity being a general state quantity for the equipment that combines the various individual new state quantities.