Linear Actuator Wear Detection Using External Force Monitoring
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Solution Overview
Problem
Linear actuators, such as pneumatic, hydraulic, and electric cylinders, face issues with wear due to excessive lateral loads, leading to problems like air leaks, oil leaks, and reduced precision in stopping positions, which can cause equipment trouble and affect product quality.
Innovation Solution
A wear detection method and system that uses a physical amount detection sensor to compare detected external forces with pre-stored standard data, determining if the actuator is in a normal or abnormal state by applying a lateral load different from the linear movement direction, and using a computation/storage/determination processing device to assess the actuator's condition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a linear actuator is used with lateral load application, then the actuator can perform pushing and pulling operations on pressure-receiving objects, but wear occurs on components (rod, packing, piston, cylinder tube) leading to air leaks, oil leaks, and precision loss
Solution Approach 1:
The patent applies preliminary action by detecting wear conditions before they lead to actual failures. The external force detection sensor continuously monitors the linear actuator during operation, and the computation/storage/determination device compares detected forces with predetermined thresholds to identify wear early, enabling preventive maintenance before air leaks, oil leaks, or precision loss occur
Solution Approach 2:
The patent implements feedback through a closed-loop monitoring system where the external force detection sensor provides real-time data to the computation/storage/determination device, which processes the information and provides feedback about the actuator's condition. This continuous feedback mechanism allows for ongoing assessment of wear and lateral load conditions
2Productivity
If continuous operation of worn linear actuators is maintained, then productivity is preserved, but equipment trouble and quality issues occur
Solution Approach 1:
The system performs preliminary detection of wear conditions through continuous external force monitoring. By comparing detected forces with predetermined thresholds before actual failures occur, the system enables early intervention that maintains productivity while preventing equipment trouble and quality issues
3Reliability
If external force detection sensors are installed to detect wear, then wear can be detected early, but device complexity increases
Solution Approach 1:
The external force detection sensor serves multiple functions: it detects lateral loads during normal operation, monitors wear conditions through continuous measurement, and provides data for both preventive maintenance and operational optimization. This multi-functionality reduces the need for separate dedicated wear detection systems
Solution Approach 2:
The linear actuator system performs self-diagnosis through the external force detection sensor and computation/storage/determination device, which automatically monitor wear conditions and compare detected forces with predetermined thresholds. This self-service capability reduces the need for external inspection systems and manual maintenance scheduling
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 method allows for the automatic detection of wear before it leads to significant trouble, preventing issues like air leaks, oil leaks, and precision loss, thereby ensuring equipment reliability and product quality.
Implementation Method 1
a physical amount detection sensor, and a computation/storage/determination processing device. In a wear detection method for a linear actuator... pre-detecting with a physical amount detection sensor an external force generated between a mounting member and a tube
Data Source
AI summary
A wear detection method and system for a linear actuator such as a pneumatic cylinder, a hydraulic cylinder, an electric cylinder or the like. A physical amount detection sensor 9 is mounted on a linear actuator in which a push-pull member connected to a rod 2 pushes and pulls a pressure-receiving object while applying a lateral load in a direction different from the linear movement direction. An external force that is generated between a tube and the mounting member when the pressure-receiving object is pushed and pulled is detected by the physical amount detection sensor 9 and compared with standard external force data, which was detected in a state without abnormalities and stored in a computation/storage/determination processing device 10, to computationally determine whether the linear actuator is in a normal state or an abnormal state.