Machine Excitation Diagnosis for Early Defect Detection
Solution Overview
Problem
Existing machine diagnostic methods are time-consuming and challenging to perform on assembled components, necessitating frequent maintenance.
Innovation Solution
A system comprising a frame with machines, actuators, controllers, sensors, and an overriding controller that coordinates excitations to measure response indicators, allowing for early detection of defects through synchronized performance and analysis of state vectors, including mechanical and electrical parameters, with optional AI for advanced correlation detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional diagnostic methods are used on assembled machines, then maintenance can be performed, but the process is time-consuming and requires disassembly
Solution Approach 1:
The system performs preliminary diagnostic actions by continuously monitoring machines during normal operation using embedded sensors. This allows defects to be detected early without requiring time-consuming disassembly later, as the diagnostic data is already collected during regular machine operation.
Solution Approach 2:
The machines perform self-diagnosis through embedded sensors and control systems that automatically monitor their own operation. The control systems analyze operational data and can identify defects without external intervention, eliminating the need for manual disassembly and inspection.
2Productivity
If machines are operated continuously without frequent maintenance, then productivity increases, but defects may go undetected
Solution Approach 1:
The system implements continuous feedback loops where sensors monitor machine operation in real-time and feed data back to control systems. This allows the system to detect defects during continuous operation without interrupting productivity, maintaining both operational continuity and reliability.
Solution Approach 2:
The patent replaces traditional mechanical inspection methods with electronic sensing and data analysis systems. Sensors and control algorithms detect defects through electrical and electronic means during operation, eliminating the need to stop machines for manual inspection.
3Measurement precision
If multiple sensors and controllers are added for comprehensive monitoring, then diagnostic capability improves, but system complexity increases
Solution Approach 1:
The control systems serve multiple functions: they control machine operation, collect diagnostic data, analyze sensor signals, and identify defects. This multi-functionality reduces the need for separate dedicated diagnostic hardware, improving measurement precision without proportionally increasing system complexity.
Solution Approach 2:
The patent combines sensing, control, and diagnostic functions into integrated systems. Sensors are embedded within existing machine components, and control systems handle both operation and diagnosis, merging multiple functions into unified subsystems to manage complexity.
4Reliability
If diagnostic data is collected during flight operations, then safety improves and maintenance time reduces, but data acquisition complexity increases
Solution Approach 1:
The aircraft systems perform self-monitoring during flight operations using embedded sensors and onboard computers. The systems automatically collect, process, and analyze diagnostic data without requiring external equipment or complex ground-based acquisition systems, improving safety while managing complexity through self-sufficiency.
Data Source
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AI summary
A system (1A; 1D, 1E), comprises: a frame (F); a plurality of machines (10A-10E) mounted on the frame (F), each machine (10A-10E) having an actuator (101, 102, 14) and being operable in an defined condition; one or more controllers (11) to control the actuators (101, 102, 14) so as to exert an excitation of each of the machines (10A-10E); at least one sensor (12, 108) to measure at least one response indicator of a response of the system (1A; 1D, 1E) to the excitations of the machines (10A-10E); and a diagnosis system (13) adapted to receive the at least one measured response indicator.