Sensor-Based Failure Mode Detection Using Structural Parameters
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Solution Overview
Problem
Existing failure mode specifying systems for apparatuses, such as mining machines and construction equipment, face challenges in accurately determining failure modes due to varying coefficients in physical models influenced by installation environments and usage conditions, leading to potential misidentification of failure signs.
Innovation Solution
A failure mode specifying system that includes data obtaining, apparatus structural parameter estimation, and failure mode specification based on sensor data, using a database structure to estimate and set threshold values for structural parameters, thereby accurately identifying failure modes without requiring advance simulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coefficient of the physical model is set by a designer or the like in advance, then the simulation can be performed, but the failure mode may not be accurately specified due to variations in installation environments and usage conditions
Solution Approach 1:
The system performs preliminary simulation calculations to determine threshold values for apparatus structural parameters before actual failure mode specification. By pre-calculating what parameter values would indicate specific failure modes, the system prepares reference data that accounts for normal variations in installation environments and usage conditions, enabling more accurate failure detection when actual measurements are compared against these pre-established thresholds
Solution Approach 2:
The system transitions from using fixed coefficients in physical models to using variable apparatus structural parameters that are estimated from actual sensor data. By monitoring changes in these parameters over time and comparing them against threshold values, the system can adapt to different installation environments and usage conditions while maintaining accurate failure mode specification
2Measurement precision
If the coefficient is set too large or too small, then the physical model may not accurately represent the apparatus, but the failure mode may still be incorrectly identified
Solution Approach 1:
The system establishes threshold values for apparatus structural parameters based on simulation results and feeds this information back into the failure mode specification process. By continuously comparing estimated parameters against these thresholds, the system can accurately identify failure modes even when parameter values vary, as the feedback mechanism adjusts the interpretation of parameter values relative to known failure conditions
Solution Approach 2:
The system performs preliminary simulation calculations to establish threshold values that define the boundaries between normal operation and various failure modes. This pre-established reference framework allows the system to accurately interpret measured parameters and identify failures, even when the absolute parameter values vary due to environmental or usage conditions
Data Source
AI summary
There is provided a failure mode specifying system or the like that suitably specifies a failure mode of an apparatus. A failure mode specifying system 10 includes a communication portion 11 that obtains data including a detection value of a sensor 22 which is installed in an apparatus 20, an apparatus structural parameter estimating portion 14 that estimates a predetermined apparatus structural parameter based on a structure and properties of the apparatus 20, based on the data which is obtained by the communication portion 11, a failure mode specifying portion 16 that specifies a failure mode indicating a kind of failure or failure sign of the apparatus 20, based on the apparatus structural parameter, and an input-output portion 18 that presents the failure mode which is specified by the failure mode specifying portion 16.