Machine Fault Detection Using Time-Synced Internal and External Signals
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods are unable to monitor machines in real-time during productive operation due to the large volume of data requiring excessive computing power, and lack of necessary computing power for processing, making it difficult to detect faults promptly.
Innovation Solution
A method involving the capture of internal and external machine signals, their broadband transmission to a scalable data processing system, and fault detection using a common time base, allowing for direct intervention or output of fault messages when issues are detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If real-time monitoring of machines is implemented during productive operation, then fault detection capability is improved, but the large volume of data requires excessive computing power
Solution Approach 1:
The patent extracts and separates the data processing function from the machine itself by transmitting signals to an external data processing system. This extraction allows the machine to maintain full computing power for production while the external system handles the computationally intensive fault detection analysis of the captured signals.
Solution Approach 2:
The patent introduces broadband transmission as an intermediary between the machine and the data processing system. This intermediary enables real-time transfer of large volumes of signal data without requiring the machine to possess excessive computing power locally, thus resolving the contradiction between real-time monitoring capability and available computing resources.
2Measurement precision
If comprehensive signal capture is performed both inside and outside the machine, then diagnostic precision is improved, but device complexity increases
Solution Approach 1:
The data processing system serves multiple functions: it receives signals from multiple sources (inside and outside the machine), processes all this data for fault detection, and can directly intervene in the machine. This multi-functionality consolidates what would otherwise require multiple separate systems into a single unified platform, maintaining diagnostic precision while managing system complexity.
Solution Approach 2:
The patent merges internal machine signals and external observer signals into a single diagnostic framework processed by one data processing system. This combining of multiple signal sources and functions into a unified system achieves comprehensive diagnostic precision without the complexity of multiple independent systems.
3Speed
If broadband transmission is used to transmit captured signals, then data transmission speed is improved, but loss of time for signal processing decreases
Solution Approach 1:
The system performs preliminary action by continuously capturing and transmitting signals via broadband transmission before faults occur. This continuous real-time transmission ensures that when a fault does occur, the data is already available for immediate processing and intervention, minimizing the loss of time in fault response.
Solution Approach 2:
The patent maintains continuity of useful action through uninterrupted broadband transmission of signals from the machine to the data processing system. This continuous data flow ensures that the system is always ready to detect and respond to faults immediately, eliminating delays associated with batch processing or periodic sampling.
Data Source
AI summary
A system for the early detection of and response to faults in a machine includes a machine having at least one furst capture device for capturing first signals inside the machine and a first data transmission interface for the broadband transmission of the captured signals inside the machine, at least one second capture device disposed outside the machine for capturing at least one second signal outside the machine, wherein the second capture device has a second data transmission interface for the broadband transmission of the at least one second signal, a data processing system having a broadband data transmission interface, a broadband data transmission channel for transmitting signals between the data transmission interfaces, wherein the data processing system is configured to detect faults using the signals inside the machine and outside the machine based on a common time base and to directly act on the machine.