Fan Life Prediction Using CPU Temperature and Utilization
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Solution Overview
Problem
Existing methods for predicting the life of a fan in a control unit for factory automation systems require a temperature sensor, which can fail, making it difficult to accurately determine the remaining life expectancy.
Innovation Solution
A life prediction device that calculates the internal temperature of a control unit using a central processing unit's utilization, temperature, and rotation speed, and uses this data to estimate the fan's life expectancy without a dedicated temperature sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a temperature sensor is installed to measure fan temperature for life prediction, then the accuracy of life prediction is improved, but the system complexity and potential for sensor failure increase
Solution Approach 1:
The patent extracts the temperature measurement function from a dedicated temperature sensor and relocates it to the CPU's existing operational parameters. By using CPU utilization, CPU temperature, and fan rotation speed data that the CPU already collects for control purposes, the system eliminates the need for a separate temperature sensor while maintaining the capability to predict fan life based on temperature conditions
Solution Approach 2:
The CPU is made multi-functional by having it perform both its primary control function and the secondary function of temperature measurement for life prediction. The existing CPU parameters (utilization, temperature, rotation speed control) are repurposed to provide the temperature data needed for fan life prediction, making the CPU serve multiple functions without adding separate components
2Reliability
If maintenance is performed frequently to prevent system shutdown, then system availability is improved, but productivity is reduced due to increased maintenance time
Solution Approach 1:
The patent implements feedback by continuously monitoring fan temperature through CPU parameters and using this information to predict remaining fan life. This feedback loop enables the system to transition from preventive maintenance (fixed schedules) to predictive maintenance (condition-based), allowing maintenance to be performed only when actually needed based on real-time temperature data and life prediction
Solution Approach 2:
The system performs preliminary life prediction calculations using current temperature data and historical patterns to forecast when the fan will fail. This preliminary action allows maintenance to be scheduled just before actual failure occurs, maximizing system availability while minimizing unnecessary maintenance interruptions
Data Source
AI summary
A CPU unit is a life prediction device for a fan. The CPU unit includes a temperature calculation unit to calculate internal temperature of the CPU unit on the basis of at least one of the utilization of the CPU unit, the temperature a CPU, and the rotation speed of the fan; and a storage unit to store fan life data that indicates the life of the fan relative to temperature. A control unit includes a life prediction unit to calculate remaining life expectancy of the fan on the basis of the fan life data and the internal temperature calculated by the temperature calculation unit.