Life Consumption Prediction for Mechanical Parts Using Steady State Segmentation
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Solution Overview
Problem
Conventional methods for predicting the life consumption of mechanical components in machines, such as aircraft engines, are inaccurate due to their failure to consider all significant load cycles and rely on predefined load sessions, leading to unnecessary replacements and potential failures.
Innovation Solution
A targeted calculation model is selected for each mechanical part, adapted to match its specific behavior, processing all operational data to calculate stresses, strains, and temperatures, allowing for optimized calculation speed and increased reliability by using multiple models and steady state conditions stored in a database.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods use predefined load sessions and ELCF cycles to predict life consumption, then the prediction process is simplified and faster, but the accuracy of life consumption prediction deteriorates due to not considering all significant load cycles
Solution Approach 1:
The patent segments the operational data into multiple individual load sessions, each analyzed separately with its own steady state conditions. This allows comprehensive consideration of all significant load cycles while maintaining systematic processing efficiency through structured segmentation of the overall prediction task.
Solution Approach 2:
The patent performs preliminary determination of steady state conditions for each load session before calculating life consumption. This preliminary action prepares the necessary parameters in advance, enabling accurate subsequent calculations without repeating complex analyses, thus maintaining productivity while improving precision.
2Ease of operation
If conventional methods use simplified cycle count focusing on specific engine components, then the calculation process is easier and faster, but the reliability of life consumption prediction deteriorates due to not considering all load cycles
Solution Approach 1:
The patent creates a universal framework that processes multiple types of operational data from various sensors simultaneously. The system handles different load session types and parameters through a unified approach using steady state conditions, making the comprehensive analysis as systematic and manageable as simplified methods while achieving superior reliability.
Solution Approach 2:
The patent transforms complex operational data into standardized steady state condition parameters for each load session. This parameter transformation maintains calculation tractability while capturing comprehensive operational information, thus preserving ease of operation while significantly improving prediction reliability through complete data utilization.
3Measurement precision
If more detailed knowledge of conditions in separate parts of the engine is used to determine life consumption of specific components, then the accuracy of component-specific life prediction is improved, but the device complexity and data processing requirements increase
Solution Approach 1:
The patent segments both the engine into separate components and the operational data into individual load sessions with specific steady state conditions for each component. This segmentation enables precise component-specific life prediction while maintaining systematic processing that prevents overwhelming complexity through structured organization.
Solution Approach 2:
The patent applies local quality by determining specific steady state conditions for each component based on its particular operational characteristics and location in the engine. This localized approach ensures each component's life consumption is predicted with appropriate detail and accuracy without uniformly complicating the entire system, as each component receives tailored analysis appropriate to its specific requirements.
Data Source
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AI summary
The present invention relates to a method for determining a level of life consumption of a critical area of a first mechanical part, comprising the steps of receiving a first set of data relating to the operation of the first mechanical part, determining a plurality of steady state conditions for the first set of operational data, determining a load history for the first mechanical part based on the plurality of determined steady states and the first set of operational data, selecting one of a plurality of predefined life consumption calculation models based on the type of the first mechanical part and the position of the critical area at the first mechanical part, and determining the level of life consumption for the critical area of the first mechanical part based on the selected life consumption calculation model and the determined load history. The present invention also relates to a corresponding system and computer program product.