Motor Defect Diagnosis via Vibration Spectrum Analysis
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Solution Overview
Problem
Current motor defect diagnosis methods require professional expertise and expensive tools, relying on operation frequency data, making them inconvenient and costly for widespread use in industries.
Innovation Solution
A diagnosis method and device that utilize vibration and sound signals to automatically detect motor defects in real-time, using a vibration sensing module, signal processing, and a defect spectrum feature database, allowing for immediate diagnosis by plant working personnel without needing additional motor parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If professional personnel use expensive diagnosis tools with vibration analysis capabilities, then diagnosis precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts only the essential vibration signal processing capabilities from complex diagnosis tools, focusing specifically on spectral analysis and harmonic detection rather than comprehensive vibration analysis. This selective extraction maintains diagnostic accuracy for motor defects while simplifying the overall system architecture and reducing costs.
Solution Approach 2:
The patent creates a simplified copy of the diagnosis system that replicates the core functionality of expensive professional tools. By using a microcontroller-based system with basic vibration sensors and spectral analysis algorithms, the patent produces a cost-effective replica that can perform motor defect diagnosis without requiring complex hardware or expensive equipment.
2Measurement precision
If professional personnel manually analyze vibration signals, then diagnosis precision is improved, but productivity decreases due to limited personnel availability
Solution Approach 1:
The patent implements self-service automation where the vibration monitoring system automatically collects data, performs spectral analysis, identifies harmonics, and diagnoses motor defects without requiring professional personnel intervention. The system serves itself by executing diagnostic algorithms and generating reports autonomously, thereby maintaining high diagnosis precision while dramatically improving productivity and eliminating personnel availability constraints.
Solution Approach 2:
The patent replaces the mechanical process of manual vibration signal analysis with an automated electronic system. Instead of professionals manually examining vibration signals, the system uses microcontrollers, spectral analysis algorithms, and computer processing to automatically identify defects, substituting human expertise with automated computational methods that operate continuously without fatigue or availability limits.
3Measurement precision
If diagnosis tools require additional sensors like tachometers to obtain rotation speed data, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent makes the vibration sensor multi-functional by using it to simultaneously obtain both vibration amplitude data and rotation speed information. Through spectral analysis of the vibration signal, the system extracts rotational frequency content that serves as a proxy for rotation speed, eliminating the need for separate tachometer sensors while maintaining measurement precision for motor diagnosis.
Solution Approach 2:
The patent introduces spectral analysis as an intermediary method that translates vibration signal characteristics into useful diagnostic information. By analyzing the frequency spectrum of vibration signals, the system derives rotation speed data and defect characteristics without requiring direct measurement from separate sensors, using the vibration signal itself as an intermediary carrier of multiple diagnostic parameters.
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
Enables fast, cost-effective, and easy operation of motor defect diagnosis, primarily performed by plant workers, with consultant firms providing detailed analysis only when necessary, thus improving diagnosis speed and reducing operational costs.
Implementation Method 1
generating a vibration signal corresponding to a vibration of a motor by a vibration sensing module during operation of the motor
Data Source
AI summary
A diagnosis method of defects in a motor and a diagnosis device thereof are described. A vibration sensing module can generate a vibration signal corresponding to a vibration of a motor during operation of the motor. Then, a data pre-processing procedure is performed to eliminate noises of the vibration signal. After the data pre-processing procedure, an analyzing procedure is performed to determine a first harmonic of spectrum features in the spectrum of the pre-processed vibration signal. And, other spectrum feature(s) is(/are) retrieved from the spectrum of the pre-processed vibration signal according to the first harmonic. Finally, a comparison procedure is performed with a defect spectrum feature database according to the retrieved spectrum features, so as to determine a defect type of the motor.