Electromechanical Joining Wear Detection from Force-Torque Curves
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Solution Overview
Problem
Existing electromechanical joining systems face challenges in early detection of wear on components, leading to potential system failure and increased maintenance costs.
Innovation Solution
A method that utilizes a monitoring device to link actual values from an electrical drive with additional measurement values of force or torque curves over time, detected by sensors, to identify imminent wear in wear-prone components, allowing for timely replacement and reducing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If wear-prone components are monitored using only actual values from the electrical drive, then the monitoring system is simple, but wear detection precision is insufficient
Solution Approach 1:
The patent combines actual values from the electrical drive with additional measurement values from sensors (force sensors, torque sensors, acceleration sensors, temperature sensors) into a unified monitoring system. This merging of multiple data sources enables precise wear detection by analyzing the combined information through algorithms that correlate different measurement types, thereby achieving high measurement precision without requiring an overly complex system architecture.
Solution Approach 2:
The monitoring device is designed to handle multiple types of input data (actual values from the electrical drive and additional measurement values from various sensors) and perform multiple functions including wear detection, anomaly identification, and predictive maintenance. This multi-functional approach allows the system to achieve high wear detection precision while maintaining relatively simple device complexity through a universal monitoring platform.
2Reliability
If components are replaced at usual maintenance intervals, then system reliability is maintained, but productivity is reduced due to unnecessary downtime
Solution Approach 1:
The monitoring system performs preliminary detection of wear by continuously analyzing actual values and additional measurement values to identify early signs of component degradation. By detecting wear at an early stage before it leads to failure, the system enables planned replacement during convenient downtime rather than forcing unscheduled stops, thereby maintaining system reliability while minimizing impact on productivity.
Solution Approach 2:
The system provides continuous feedback through the monitoring device that analyzes the combined data from the electrical drive and sensors. This feedback mechanism allows for real-time assessment of component condition, enabling dynamic adjustment of maintenance schedules based on actual wear rates rather than fixed intervals, thus optimizing both reliability and productivity by replacing components only when necessary.
Data Source
AI summary
An electromechanical joining system that uses an output force or output torque for performing a joining method and includes an electrical drive connected for driving a screw drive and is configured for generating actual values of force or torque that are provided as input variables to a monitoring device. The system includes a sensor configured for measuring the course of the forces or torques over time during the joining method and for detecting additional measurement values that are supplied to the monitoring device as input variables. Wherein the monitoring device links the supplied actual values with the supplied additional measurement values to detect upcoming wear of a wear-prone component of the electromechanical joining system. A method for analyzing the status of the electromechanical joining system is also disclosed.