Machine Condition Determination Using Pre-Calculated Load Data Matching
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for predicting the life consumption of machine components are inaccurate due to their failure to consider all significant load cycles and require complex, time-consuming calculations, especially when actual load sessions differ from predetermined ones.
Innovation Solution
A method that uses a database of predefined machine conditions to match and select the most representative steady state condition from received load data, allowing for efficient determination of machine condition parameters without complex calculations, and optionally uses a second database for pre-calculated values to anonymize sensitive parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional methods (ELCF cycles) are used to predict life consumption, then the prediction process is simplified, but accuracy deteriorates when actual load sessions differ from predetermined ones
Solution Approach 1:
The patent pre-calculates and stores machine condition parameters for multiple predefined steady state conditions in a database before actual operation. When determining life consumption, the system matches actual load data against these pre-calculated conditions, avoiding complex real-time calculations while maintaining accuracy across diverse operating scenarios
Solution Approach 2:
The system transforms the approach from using single-parameter ELCF cycle counting to multi-parameter machine condition assessment. By storing and comparing multiple load parameters (power level angle, rotor speeds, temperatures, pressures) against pre-calculated steady state conditions, the system achieves higher prediction accuracy without proportional increases in computational complexity
2Measurement precision
If detailed calculations are performed to determine machine condition parameters accurately, then prediction accuracy improves, but calculation time increases
Solution Approach 1:
The system pre-calculates machine condition parameters (temperatures, flows, torques) for numerous steady state conditions and stores them in a database. During operation, the system matches actual load data against these pre-computed values, retrieving results instantly rather than performing complex real-time calculations, thus achieving both accuracy and speed
Solution Approach 2:
The patent creates a database of copied pre-calculated machine condition parameters from predefined steady state conditions. Instead of recalculating parameters during operation, the system copies and matches against stored values, dramatically reducing calculation time while maintaining the accuracy of detailed thermodynamic models
3Ease of operation
If conventional ELCF cycle methods are used, then the method is easy to implement, but it only considers one engine parameter and misses other significant load cycles
Solution Approach 1:
The system extends the functionality from single-parameter ELCF cycle counting to multi-parameter machine condition assessment. The database stores machine condition parameters for multiple steady state conditions covering various operating scenarios, enabling the system to account for diverse load cycles (power level angle, rotor speeds, temperatures, pressures) while maintaining a unified matching approach that is as easy to implement as conventional methods
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
There is provided a method for determining a machine condition indicative of life consumption of a machine component subjected to loads during machine operation, comprising the steps of: receiving a set of load data, for a selected point in time, resulting from the machine operation; from a first database comprising predefined machine conditions associated to different sets of load data for the machine, selecting one of the predefined machine conditions, which is most representative of the received set of load data. There is also provided a computer program product comprising code for performing the method and a system configured to perform the method.