Operation-State Sensor Diagnosis for Complete Abnormality Detection
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Solution Overview
Problem
Existing diagnostic systems for industrial devices struggle to accurately diagnose abnormalities when sound samples corresponding to the current operation state are not pre-stored, leading to incomplete diagnosis capabilities.
Innovation Solution
A diagnostic apparatus that includes an operation state determination unit, a reference data creation unit, and a diagnosis unit, which stores and compares sensor values across various operation states to determine whether a device is normal or abnormal, ensuring comprehensive sample preparation and accurate diagnosis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sound samples are pre-stored for all operation states, then diagnosis accuracy is improved, but device complexity and data storage requirements increase
Solution Approach 1:
The system performs preliminary action by automatically creating and storing reference sensor data for all operation states in advance. The reference data creation unit systematically collects sensor values across different operation states and stores them as reference data, so that when diagnosis is needed, pre-prepared reference data is already available for comparison, eliminating the need for manual sample collection and ensuring complete coverage of all operation states.
Solution Approach 2:
The system changes the parameter of data representation from raw sound samples to processed sensor value data. By converting sound data into sensor values and creating feature amount vectors, the system reduces data dimensionality and storage requirements while maintaining diagnostic capability. The reference data is stored as structured sensor values associated with operation states rather than raw audio files.
2Device complexity
If sound samples are not pre-stored for all operation states, then device complexity is reduced, but diagnosis completeness deteriorates
Solution Approach 1:
The reference data creation unit performs preliminary action by systematically collecting and storing sensor data for all operation states before diagnosis is needed. This ensures that reference data exists for every possible operation state, guaranteeing that diagnosis can be performed completely and accurately regardless of which operation state the device is currently in.
Solution Approach 2:
The diagnostic apparatus achieves universality by creating a comprehensive reference data set that covers all operation states. The system is designed to handle any operation state that the device may encounter, making the diagnosis system universally applicable across the entire operating range of the device without requiring state-specific configurations.
3Measurement precision
If manual sound sample collection is performed, then data accuracy is improved, but time consumption increases
Solution Approach 1:
The system implements self-service by automatically collecting, processing, and storing reference sensor data without manual intervention. The reference data creation unit autonomously performs the entire workflow of acquiring sensor values, determining operation states, creating feature amount vectors, and storing reference data, eliminating the time-consuming manual sample collection process while maintaining high data accuracy through systematic automated measurement.
Solution Approach 2:
The system replaces the mechanical process of manual sound sample collection with an automated electronic data acquisition and processing system. Sensors automatically capture device data, and the control unit processes this information to create reference data, substituting manual operations with automated electronic systems that are both faster and more accurate.
Data Source
AI summary
A diagnostic apparatus determines, at a reference time, whether a device is normal or abnormal, and in which operation state the device is at the time. A reference data creation unit repeats a process of storing sensor values acquired from the device while changing the operation state at the reference time in association with each of the determined operation states until there is no non-corresponding operation state with which the acquired sensor value is not yet associated. At a diagnosis time at which it is not known whether the device is normal or abnormal, an operation state and a sensor value of the device at the time is acquired. The stored sensor value associated with the acquired operation state is read to compare the sensor value acquired at the diagnosis time with the read sensor value to display a result of determination on whether the device is normal or abnormal.