Movable Unit Fault Diagnosis with Acoustic and Vibration Monitoring
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Solution Overview
Problem
Existing diagnostic systems struggle to identify components with abnormalities in a target member formed of multiple components, requiring large-scale data processing systems for vibration measurement, and are inefficient in diagnosing fault symptoms.
Innovation Solution
A fault symptom diagnostic system that utilizes acoustic emission and vibration detection to identify abnormal components by alternating between monitoring processing stages, including acoustic emission and vibration measurement based on predetermined conditions, reducing the need for extensive data collection and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If vibration measurement is used to identify abnormal components in a target member formed of multiple components, then component identification capability is improved, but data processing system complexity and data storage requirements increase significantly
Solution Approach 1:
The patent segments the monitoring approach into two distinct phases: acoustic emission monitoring for early fault detection and vibration monitoring for component identification. This segmentation allows each method to be applied only when needed, reducing overall data processing complexity while maintaining component identification capability.
Solution Approach 2:
The patent applies preliminary acoustic emission monitoring to detect early signs of component abnormalities before they manifest as significant vibration patterns. By detecting faults in advance through acoustic emission, the system avoids the need for continuous vibration monitoring and large-scale data processing from the initial stage.
2Reliability
If continuous vibration monitoring is performed from the initial stage after start of use, then component abnormality detection capability is improved, but data collection and storage requirements increase significantly
Solution Approach 1:
The patent implements periodic switching between acoustic emission monitoring and vibration monitoring based on predetermined conditions. Acoustic emission monitoring is performed first, and only when specific conditions are met does the system transition to vibration monitoring, creating a periodic rather than continuous data collection pattern that reduces overall data volume.
Solution Approach 2:
The patent performs preliminary acoustic emission monitoring to detect early fault conditions before transitioning to vibration monitoring. This preliminary action allows the system to capture critical fault information early in the component lifecycle without requiring continuous vibration data collection from the initial stage.
3Measurement precision
If acoustic emission monitoring is performed repeatedly with high detection frequency, then fault detection accuracy is improved, but measurement data processing load increases
Solution Approach 1:
The patent dynamically adjusts the monitoring strategy based on acoustic emission detection results. When acoustic emission waves are detected, the system transitions to vibration monitoring with appropriate frequency. When no acoustic emission is detected, the system maintains lower monitoring intensity, dynamically optimizing the balance between detection accuracy and processing load.
Solution Approach 2:
The patent uses acoustic emission monitoring as a preliminary screening step before initiating more resource-intensive vibration monitoring. This preliminary action filters out cases where vibration monitoring is unnecessary, reducing overall data processing load while maintaining high fault detection accuracy when needed.
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
Effectively identifies and diagnoses fault symptoms in components of a target member with reduced data collection and processing, enabling efficient maintenance recommendations.
Implementation Method 1
acoustic emission detection information acquisition unit configured to acquire acoustic emission detection information indicating a status of acoustic emission waves generated from the movable unit as detected by an acoustic emission sensor
Implementation Method 2
vibration detection information acquisition unit configured to acquire vibration detection information indicating a status of vibrations generated in the component as detected by a vibration sensor
Data Source
AI summary
A fault symptom diagnostic system includes a fault symptom recognition unit configured to recognize a fault symptom of a component of a movable unit. The fault symptom recognition unit executes first monitoring processing of repeatedly executing acoustic emission measuring processing and determining whether or not a first determination condition under which a number of times of detecting acoustic emission waves is equal to or larger than a predetermined number of times of determination is established, and when the first determination condition is established, ends the first monitoring processing and executes second monitoring processing of repeatedly executing vibration measuring processing of acquiring vibration detection information by a vibration detection information acquisition unit and recognizing a vibration level of the component based on vibration detection information, and recognizing a fault symptom of the component based on an magnitude of increase in the vibration level of the component.