Malfunction Diagnosing Apparatus Using Repeated Vibration Analysis
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Solution Overview
Problem
Existing malfunction diagnosing systems often incorrectly determine apparatus issues due to accidental sound generation during diagnosis, leading to errors in identifying actual malfunctions.
Innovation Solution
A malfunction diagnosing apparatus that collects and analyzes vibration data using sensors, performs spectrum analysis via Fast Fourier Transform, and determines abnormality by comparing feature quantities against predetermined thresholds, with repeated operating sequences to confirm malfunction detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If one-time detection is used to determine malfunction, then diagnostic speed is improved, but diagnostic accuracy deteriorates due to false positives from accidental sound generation
Solution Approach 1:
The system performs periodic detection by executing the same operation multiple times and analyzing whether abnormal sounds occur consistently across repetitions. This periodic approach filters out accidental one-time sounds while identifying genuine malfunctions that persist across multiple operation cycles, thereby resolving the contradiction between speed and accuracy.
Solution Approach 2:
The system uses feedback by comparing sound data from multiple detection results and using predetermined thresholds to determine whether an abnormal sound is genuine. The feedback mechanism allows the system to adjust its diagnosis based on accumulated evidence from repeated measurements, improving diagnostic accuracy without significantly increasing overall diagnosis time.
2Measurement precision
If repeated detection is performed to improve accuracy, then diagnostic accuracy is improved, but diagnostic time increases
Solution Approach 1:
The system performs a predetermined number of repeated operations at the same timing, which is optimized to balance accuracy improvement with time consumption. This structured periodic detection ensures sufficient repetitions for accurate diagnosis while preventing excessive time loss through predetermined iteration limits.
Solution Approach 2:
The system replaces complex mechanical analysis with signal processing techniques, specifically spectrum analysis using Fast Fourier Transform. This substitution allows for efficient processing of repeated sound data, enabling multiple detections to be performed and analyzed quickly, thus improving accuracy without proportionally increasing diagnostic time.
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
Prevents wrongful diagnosis by accurately identifying malfunctions through repeated analysis and threshold comparisons, reducing false positives and enhancing diagnostic precision.
Implementation Method 1
acquiring an X-axis vibration signal and a Y-axis vibration signal generated by the diagnosis target motor during operation of the diagnosis target motor through a vibration sensor
Implementation Method 2
performing spectrum analysis via Fast Fourier Transform
Data Source
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AI summary
A malfunction diagnosing apparatus (1) includes a data collector (101) that collects vibration data generated when a diagnosed apparatus (2) operates in a predetermined operating sequence, a data analyzer (102) that analyzes the collected vibration data and calculate a feature quantity, a malfunction detector (103) that determines, based on the calculated feature quantity, whether or not something is wrong with the diagnosed apparatus (2), and a controller (105) that controls the data analyzer (102) and the malfunction detector (103) and controls, if it is determined that something wrong with the diagnosed apparatus (2), the diagnosed apparatus (2) to repeat the operating sequence that it is determined that something is wrong with the diagnosed apparatus (2) for a predetermined number of times. The malfunction detector (103) determines that malfunction occurs in the diagnosed apparatus (2) if it is determined that something is wrong with the diagnosed apparatus (2) in the operating sequences repeated for the predetermined number of times.