Mechanical Device Life Estimation via Load and Lubricant Analysis
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Solution Overview
Problem
Traditional methods for predicting the remaining useful life of mechanical devices, such as wind turbines, are ineffective due to changing operational loads, rotational speeds, ambient temperatures, corrosion, and lubricant states, which alter the rated life over time.
Innovation Solution
A method that acquires load spectra and lubricant states over a predetermined time range to determine operating states, using these to calculate an estimated life by weighting reference lives based on the proportion of operating time for each state, employing means such as weighted arithmetic, harmonic, or geometric means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional rated life prediction methods are used, then the prediction process is simple, but the prediction accuracy deteriorates due to changing operational conditions
Solution Approach 1:
The patent segments the operational history into multiple time intervals and divides the life prediction into rated life (from manufacturer) and remaining useful life (calculated). It further segments the operational conditions into different states (normal, abnormal, idle) and calculates equivalent operating hours for each segment, then combines them using weighted averages to get the total equivalent operating hours.
Solution Approach 2:
The patent changes the parameter of life prediction from a static rated life value to a dynamic calculation that incorporates multiple varying parameters including operational loads, rotational speeds, ambient temperatures, corrosion factors, and lubricant states. These parameters are continuously monitored and used to calculate equivalent operating hours that reflect actual wear conditions.
2Measurement precision
If multiple operational parameters are monitored to improve prediction accuracy, then the determination precision improves, but the data acquisition and processing complexity increases
Solution Approach 1:
The patent creates a multi-functional determination system that simultaneously monitors and processes multiple parameters (operational loads, rotational speeds, temperatures, corrosion, lubricant state) through a unified methodology. The same data acquisition framework handles all parameters, and the same calculation methodology integrates all factors to determine both equivalent operating hours and remaining useful life, reducing the need for separate specialized systems.
Solution Approach 2:
The patent introduces equivalent operating hours as an intermediary parameter that mediates between the multiple monitored parameters and the final remaining useful life calculation. Instead of directly combining complex multi-parameter data, the system first converts all operational conditions into equivalent operating hours that represent actual wear, which then serves as the basis for calculating remaining useful life.
3Reliability
If real-time monitoring of operational conditions is implemented, then the remaining useful life determination becomes accurate, but the system complexity and data processing requirements increase
Solution Approach 1:
The patent performs preliminary calculations by determining equivalent operating hours for different operational states (normal, abnormal, idle) before calculating the final remaining useful life. It pre-establishes the relationship between operational conditions and equivalent hours, and pre-processes historical data to create a foundation for real-time predictions without requiring complex real-time computation of all parameters simultaneously.
Solution Approach 2:
The patent implements a dynamic determination methodology where the remaining useful life is continuously updated as new operational data becomes available. The system adapts to changing operational conditions by rec calculating equivalent operating hours based on current and historical data, allowing the prediction to evolve dynamically rather than requiring a complete re-analysis of all parameters at each step.
Data Source
AI summary
A method for determining an estimated life of a mechanical device includes (1) acquiring a load spectrum of the mechanical device within a predetermined time range; (2) acquiring a lubricant state of the mechanical device within the predetermined time range; (3) determining a plurality of operating states experienced by the mechanical device within the predetermined time range based on the acquired load spectrum and the acquired lubricant state, and (4) determining an estimated life of the mechanical device based on the plurality of operating states of the mechanical device within the predetermined time range. Each operating state corresponds to a particular range of load values in the load spectrum and a particular degree of contamination in the lubricant state. The method may also determine the remaining useful life of a mechanical device. The method may be implemented in a device for determining the estimated life of a mechanical device.