Gear Pump Wear Monitoring With Normalization Characteristic Maps
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Solution Overview
Problem
Existing methods for monitoring the condition of gear pumps in extracorporeal blood treatment devices, such as dialysis machines, are not reliable and do not provide accurate predictions for remaining service life, leading to potential failures and inefficiencies.
Innovation Solution
A method involving the creation of a normalization characteristic map for a reference gear pump, which relates volume flow, pressure, and torque to determine the condition of a new gear pump, and an operating characteristic map during operation, allowing for the assessment of wear and prediction of remaining service life using a regression model.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing monitoring methods are used, then device operation continues, but reliability of condition monitoring is insufficient
Solution Approach 1:
The patent creates a normalization characteristic map for a new reference gear pump before actual wear occurs. This preliminary characterization establishes baseline relationships between volume flow, pressure, torque, and speed that serve as a reference for future condition monitoring and wear prediction
Solution Approach 2:
The system continuously monitors actual operating parameters (volume flow, pressure, torque, speed) and compares them against the normalization characteristic map. This feedback mechanism enables ongoing assessment of gear pump condition and prediction of remaining service life based on deviations from expected performance
2Measurement precision
If simple monitoring is used, then ease of operation is maintained, but measurement precision of wear condition deteriorates
Solution Approach 1:
The normalization characteristic map serves multiple functions: it characterizes new pump performance, enables condition monitoring, predicts wear, and determines remaining service life. This multi-functionality achieves high measurement precision without requiring separate systems for each purpose
Solution Approach 2:
The system monitors changes in operating parameters (volume flow, pressure, torque, speed) and their relationships over time. By tracking how these parameters deviate from the normalization map, the system achieves accurate wear assessment through parameter analysis rather than direct physical measurement
3Loss of time
If no predictive modeling is used, then device complexity is reduced, but loss of time for maintenance planning increases
Solution Approach 1:
The regression model is prepared in advance using the normalization characteristic map and historical operating data. This preliminary modeling enables rapid prediction of remaining service life when needed, reducing maintenance planning time without requiring complex real-time computations
Solution Approach 2:
The system creates a mathematical model (regression model) that copies and represents the complex relationships in the gear pump's behavior. This simplified mathematical representation enables fast predictions without requiring direct analysis of the physical system's complexity
Data Source
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AI summary
Method for monitoring the condition of a gear pump (1) of a device (100) for extracorporeal blood treatment, comprising the steps of: - determining a normalization characteristic map, wherein the normalization characteristic map for a new reference gear pump (1) relates a volume flow (Q) of a fluid (2) generated by the reference gear pump (1), a pressure (Δp) of the fluid (2) at the reference gear pump, a torque (M) generated by the reference gear pump (1), and a speed (n) of the reference gear pump (1) to one another, - during operation of the gear pump (1), determining an operating characteristic map, wherein the operating characteristic map for a gear pump (1) used during a specific operating period relates a volume flow (Q) of the fluid (2) generated by the gear pump (1), a pressure (Δp) of the fluid (2) at the gear pump (1),a torque (M) generated by the gear pump (1) and a speed (n) of the gear pump (1) are related to each other, and - determining the state of the gear pump (1) as a function of the normalization characteristic map and the operating characteristic map.,