Current Monitoring Sensor Data Extraction for Motor Diagnosis
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Solution Overview
Problem
Existing facility diagnosis methods, such as those described in JP 2013-104795 A, face challenges in determining threshold values for motor abnormality diagnosis and extracting relevant sensor data under specific conditions, leading to reduced usability and inefficiency in monitoring motor operations.
Innovation Solution
A sensor device and current monitoring system that include a sensor data acquisition unit, analysis unit, extraction condition setting unit, and user interface, allowing for the easy determination of extraction conditions and improved usability by extracting specific data based on analysis results and user-defined conditions, and displaying only data that satisfies these conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing material presence determination unit and speed status determination unit are used for detection under specific conditions, then motor diagnosis can be performed, but the usability is lowered and only a part that satisfies specific conditions needs to be extracted from sensor data
Solution Approach 1:
The patent combines the material presence determination unit, speed status determination unit, and current sensor into a single integrated sensor device. This merging eliminates the need to use separate units for detection, allowing continuous motor diagnosis without requiring data extraction based on specific conditions, thereby improving usability while maintaining diagnosis reliability
Solution Approach 2:
The sensor device is designed to perform multiple functions: it can detect current values, determine material presence, determine speed status, and provide diagnosis information all through a single device. This multi-functionality allows the device to operate effectively across different conditions without requiring separate specialized units, enhancing both usability and diagnostic capability
2Measurement precision
If threshold values are set according to individual differences between carrier units, then accurate abnormality diagnosis can be performed, but the complexity of determining threshold values increases
Solution Approach 1:
The sensor device automatically determines threshold values based on the actual operating characteristics of each individual carrier unit. The device performs self-calibration by analyzing its own sensor data to establish appropriate thresholds, eliminating the need for manual threshold setting and reducing complexity while maintaining accurate diagnosis for each unit's individual differences
3Duration of action of stationary object
If sensor data is continuously acquired for motor monitoring, then continuous diagnosis is possible, but the amount of data to be processed increases
Solution Approach 1:
The sensor device extracts and provides only the essential diagnosis information needed for motor monitoring rather than processing all raw sensor data. By extracting key diagnostic parameters and threshold comparisons, the system maintains continuous monitoring capability while significantly reducing the volume of data that needs to be processed and stored
Data Source
AI summary
A sensor device includes: a sensor data acquisition unit that acquires sensor data of a measurement target from a sensor; a sensor data analysis unit that analyzes the data acquired by the sensor data acquisition unit; an extraction data setting unit that sets extraction conditions indicating a part desired to be extracted from among all the sensor data; a specific condition extraction unit that extracts a part from among all the sensor data based on an analysis result and the extraction conditions; and a user interface unit that allows a user to input/output information. Further, the user interface unit includes simple condition setting means by which a simple condition being at least one or more of the extraction conditions among the extraction conditions can be set in the sensor data analysis unit, and detection result display means that displays data satisfying the simple condition in the sensor data analysis unit.