Fan Impeller Mass Change Detection Using Torque and Speed
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Solution Overview
Problem
Existing fan systems face inefficiencies and potential failures due to contamination build-ups on the impeller, leading to mass imbalances and increased vibration, which are difficult to detect without additional instrumentation or manual inspection, posing risks and increasing operational costs.
Innovation Solution
A method and apparatus that induce a torque to the fan impeller to determine changes in angular speed, calculating the present mass based on the torque and angular speed derivatives, using a frequency converter and estimator to detect mass changes without additional instrumentation, by representing the mass as a parameter and comparing it to a reference mass to issue notifications for contamination build-ups.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual detection or vibration measurements are used to detect contamination build-ups, then contamination can be detected, but additional instrumentation or manual inspection is required, increasing operating cost
Solution Approach 1:
The fan motor itself is used to generate the torque pulses for excitation, and the existing speed sensor provides the speed signal for analysis. The system uses its own operational parameters (current, speed) to detect contamination, eliminating the need for separate detection instrumentation.
Solution Approach 2:
The existing motor and speed sensor serve multiple functions: motor operation and contamination detection. The same components used for driving the fan are also utilized for monitoring contamination build-up, making the system multi-functional without adding dedicated detection equipment.
2Reliability
If visual inspection or vibration measurements are implemented, then contamination can be detected, but manual inspection or additional instrumentation increases operational costs
Solution Approach 1:
The system continuously monitors the relationship between torque pulses and speed changes, providing real-time feedback on contamination levels. This enables early detection and monitoring of contamination build-up trends, allowing preventive maintenance before failures occur.
Solution Approach 2:
The monitoring system uses the fan's own operational parameters without requiring external inspection resources. The system self-monitors its performance degradation, eliminating the need for manual inspection labor while maintaining high reliability.
3Productivity
If the fan operates continuously, then productivity is maintained, but contamination accumulates on the impeller, leading to mass imbalance and potential failure
Solution Approach 1:
The system detects contamination build-up early in the accumulation process, before it causes significant mass imbalance or failure. By monitoring continuously during operation, contamination is identified at stages when maintenance can be scheduled without interrupting overall productivity.
Solution Approach 2:
The monitoring of contamination occurs continuously during fan operation without interrupting the useful action. The system maintains continuous detection capability while the fan operates, enabling real-time awareness of contamination levels without stopping production.
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 solution allows for the detection of mass changes in fan impellers without extra instrumentation, reducing operational costs and preventing failures by accurately estimating contaminant accumulation, thereby ensuring efficient fan operation and safety.
Implementation Method 1
a frequency converter for inducing a torque to a fan impeller, and for determining a change in an angular speed of the fan impeller, induced by the torque
Implementation Method 2
determining, on a basis of the change in the angular speed and the torque, a value for a first parameter representing a present mass of the fan impeller
Data Source
AI summary
A method for determining a change in a mass of a fan impeller. The method includes inducing a torque to the fan impeller and determining a change in the angular speed of the fan impeller, induced by the torque. A value for a first parameter representing a present mass of the fan impeller is determined on the basis of the change in the angular speed and the torque. The change in the mass is then determined on the basis of the first parameter and a second parameter representing the reference mass of the fan impeller.