Mechanical Face Seal Digital Twin for Early Failure Detection
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Solution Overview
Problem
Existing mechanical seal arrangements face challenges in predicting and preventing failures, particularly in critical applications where a secure seal is necessary over the lifespan, and existing monitoring systems are not cost-effective or simple to implement.
Innovation Solution
A method utilizing a digital twin that simulates and monitors the mechanical seal's operation by recording and processing data, allowing for rule-based operation, remote control, and continuous real-time monitoring, with data reduction techniques to enhance efficiency and security, using mathematical models and sensors to detect deviations and send countermeasures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature sensors are installed close to seal rings to monitor mechanical seal temperature, then early detection of potential failures is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent creates a digital twin (virtual copy) of the mechanical seal assembly that replicates its operational parameters and behavior. This digital model allows monitoring and failure prediction without adding physical sensors to the actual seal, thus improving reliability detection while avoiding the complexity of additional hardware installation.
Solution Approach 2:
The patent replaces physical temperature sensors and direct mechanical monitoring systems with a computational model (digital twin) that simulates seal behavior. This substitution eliminates the need for additional physical sensing components while maintaining the ability to detect potential failures through virtual monitoring and analysis.
2Reliability
If multiple sensors collect data from the mechanical seal for predictive diagnostics, then loss of lubrication detection is improved, but device complexity and cost increase
Solution Approach 1:
The digital twin creates a virtual representation of the mechanical seal system that models lubrication conditions and thermal behavior. This virtual model can detect lubrication loss and other anomalies without requiring multiple physical sensors, reducing hardware complexity while maintaining diagnostic capability.
Solution Approach 2:
The patent introduces a computational intermediary (the digital twin model) that processes and analyzes operational data to detect lubrication loss and other issues. This intermediary layer allows comprehensive monitoring without directly installing multiple sensors in the mechanical seal assembly, thereby reducing device complexity.
3Measurement precision
If operating data is transmitted to a central computer for digital twin simulation, then monitoring accuracy is improved, but data transmission energy consumption increases
Solution Approach 1:
The patent performs preliminary data processing and filtering at the source (mechanical seal assembly) before transmission. By pre-processing data locally to extract only relevant information, the system reduces the volume of data requiring transmission, thereby lowering energy consumption while maintaining monitoring accuracy through the digital twin.
4Reliability
If continuous real-time monitoring is implemented using digital twin, then failure prediction capability is improved, but energy consumption and computational load increase
Solution Approach 1:
The system performs preliminary data filtering and processing at the mechanical seal assembly before transmission to the central computer. This pre-processing reduces the computational load on the digital twin and minimizes data transmission requirements, enabling continuous monitoring while controlling energy consumption.
Solution Approach 2:
The patent implements monitoring at an appropriate level of detail - not every parameter is continuously monitored at maximum resolution. The digital twin focuses on critical parameters for failure prediction, using partial monitoring of essential variables rather than exhaustive continuous monitoring of all possible parameters, thus balancing prediction capability with energy efficiency.
Data Source
Figure 1
AI summary
The invention relates to a method for operating a mechanical face seal assembly (1) comprising a mechanical face seal (2) with a rotating seal ring (3) and a stationary seal ring (4) which define a seal gap (5) between their seal faces, said method comprising the steps of: detecting operating data and/or ambient data of the mechanical face seal assembly (2); transmitting the operating data and/or ambient data detected to a digital twin (31) of the mechanical face seal assembly (2); simulating and monitoring the operation of the mechanical face seal assembly (2) by means of the digital twin (31) on the basis of the operating data and/or ambient data of the mechanical face seal (2) transmitted ; and transmitting back a simulation result and/or data of the digital twin.