Machine-Tool Diagnostics Using Paired Vibration and Position Data
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Solution Overview
Problem
Current diagnostic systems for machine-tools are inadequate in accurately evaluating fault states across various machine-tool parts and workpieces due to limited sensor data processing, failing to detect unknown faults and requiring precise sensor placement, which restricts their effectiveness in monitoring machining processes.
Innovation Solution
A diagnostic system utilizing at least two sensors, including a vibration sensor and a position sensor, with data pairing and filtering processes, along with temperature compensation, to accurately evaluate fault states and identify unknown conditions by processing data from multiple sensors simultaneously, allowing for precise identification of machine-tool and workpiece faults.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If data from multiple sensors are processed independently, then the system can handle multiple data sources, but the diagnostic accuracy is limited and cannot identify unknown fault states
Solution Approach 1:
The patent combines data from multiple sensors (vibration sensor and position sensor) through a data pairing process that synchronizes and integrates their outputs. This merging of previously independently processed data streams enables the system to achieve higher diagnostic accuracy and identify unknown fault states that single sensors cannot detect.
2Reliability
If vibration sensors are used to monitor machine parts, then rolling bearing damage can be detected, but damages of guide and other machine parts cannot be detected
Solution Approach 1:
The patent creates a universal diagnostic system that can detect various types of faults across different machine parts by combining vibration sensor data with position sensor data. The position sensor information enables the system to identify faults in guides and other parts beyond just rolling bearings, making the monitoring system versatile for comprehensive machine health assessment.
3Reliability
If sensors measure only exceeding limit values, then protective function is provided, but diagnostic capability is not available
Solution Approach 1:
The patent performs preliminary data pairing and filtering processing on sensor data before fault occurrence, creating a baseline of normal operation characteristics. This preliminary action enables the system to not only provide protective alerts when limits are exceeded but also to diagnose fault conditions by comparing current data against the established baseline, thereby preserving diagnostic information.
Data Source
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AI summary
The object of the invention is a method for technical diagnostics of machine-tools by means of a diagnostic system of machine-tools employing at least two sensors to be placed on machine-tools, wherein at least one sensor is a vibration sensor and at least one other sensor is a position sensor, with the measured data being evaluated by an evaluation process comprising measured data pairing step, step of filtering the processed data, and step of comparing the processed data with model states.