Motor Conformance Testing With Time-Correlated Sensor Data
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Solution Overview
Problem
Current motor rebuild test stands lack a systematic, time-correlated data acquisition system, leading to unreliable conformance testing and increased risk of catastrophic failures due to ad-hoc testing processes that fail to account for cross-domain symptoms like temperature and vibration during motor rebuilds.
Innovation Solution
A conformance test apparatus that uses a plurality of sensors to gather time-correlated data from multiple domains, configured with wireless communication for remote data storage and analysis, minimizing operator interaction and ensuring consistent testing through automated test runs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If ad-hoc testing processes are used in motor rebuild test stands, then operator flexibility and ease of operation are improved, but measurement precision and reliability of conformance testing deteriorate due to failure to account for cross-domain symptoms
Solution Approach 1:
The testing system is segmented into multiple independent sensor channels, each dedicated to measuring specific parameters (vibration, temperature, current, voltage) in distinct domains. This segmentation allows each sensor to specialize in its domain while the integrator coordinates them systematically, resolving the contradiction by maintaining operator flexibility through modular design while improving measurement precision through dedicated measurement pathways for each parameter type.
Solution Approach 2:
The integrator serves as a universal platform that handles multiple sensor types and domains simultaneously, coordinating vibration sensors, temperature sensors, current sensors, and voltage sensors through a single time-correlated data acquisition system. This multi-functionality enables systematic cross-domain analysis while maintaining ease of operation through centralized control.
2Measurement precision
If multiple sensors are used to gather data from multiple domains, then measurement precision and reliability are improved, but device complexity increases due to need for time-correlated data acquisition systems
Solution Approach 1:
Multiple sensor channels measuring different domains (vibration, temperature, current, voltage) are merged into a single integrator that performs time-correlated data acquisition. This combining approach improves measurement precision by systematically correlating cross-domain symptoms in time, while managing device complexity through unified data handling and centralized coordination within the integrator.
Solution Approach 2:
The integrator acts as an intermediary between multiple independent sensor channels and the data analysis system. It receives data from various sensors, applies time-correlation processing, and outputs coordinated results, thereby simplifying the overall system architecture while enabling precise multi-domain measurement through its mediating function.
3Productivity
If automated test runs with wireless communication are implemented, then productivity and reliability are improved through consistent testing, but device complexity increases due to wireless communication infrastructure
Solution Approach 1:
The test stand system performs automated test runs that execute independently without requiring continuous operator intervention. The system self-manages data acquisition, processing, and transmission through wireless communication, improving productivity by enabling unattended operation while managing complexity through automated workflows that reduce the need for manual system coordination.
Solution Approach 2:
Physical wired connections for data transmission are replaced with wireless communication systems. This substitution improves productivity by enabling remote data access and eliminating physical connection constraints, while managing device complexity through modern wireless technologies that integrate seamlessly with the existing sensor and processor architecture.
Data Source
AI summary
Conformance testing of a rebuilt motor includes disposing a motor under test in a motor test stand, coupling a plurality of sensors to the motor under test including a first vibrational sensor to the motor under test; a first temperature sensor to the motor under test; a first rotational speed sensor to the motor under test. A set of test parameters are received comprising parameters for a conformance test, the test parameters including a vibrational sensor parameter, a temperature sensor parameter, and a rotational speed parameter. A motor under test is placed in an on-state and a processing device receives sensor data simultaneously from the sensors, determines that the rotational speed satisfies the rotational speed parameter, and stores time sampled sensor data received from the plurality of sensors relative to a time zero corresponding to a time when the rotational speed satisfies the rotational speed.