Condition Monitoring in Liquid Food Packaging Machines
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Solution Overview
Problem
Existing condition monitoring techniques for food packaging machines lack specificity in identifying the origin of fault conditions within the machinery, making it difficult to determine which components need servicing, thus relying heavily on operator experience and increasing the risk of production standstills.
Innovation Solution
A method that utilizes an event timing signal to identify signal values specific to individual machine components by matching vibration measurement signals with predefined mechanical actions, enabling condition assessment of each component through time-domain matching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If frequency or time-frequency analysis of vibration data from sensors is used to detect fault conditions, then fault detection capability is improved, but specificity in identifying the origin of faults deteriorates
Solution Approach 1:
The patent segments the overall vibration signal into component-specific signals by associating vibration data with individual machine components through operational data. Each component's vibration pattern is separated and analyzed independently, enabling specific identification of which component is malfunctioning while maintaining the ability to detect faults overall.
2Area of stationary object
If vibration sensors monitor multiple mechanical components simultaneously, then comprehensive monitoring coverage is improved, but difficulty in identifying specific component origins deteriorates
Solution Approach 1:
The patent introduces operational data as an intermediary that links vibration sensor data to specific machine components. This intermediary information enables the system to attribute vibration patterns to individual components even when multiple components are monitored simultaneously, resolving the difficulty of identifying fault origins.
3Reliability
If condition monitoring is performed on hundreds of components in the packaging machine, then comprehensive fault detection is improved, but complexity of the monitoring system deteriorates
Solution Approach 1:
The patent creates a universal monitoring framework that can handle hundreds of components through a standardized process: collecting operational data, associating vibration patterns with components, and evaluating conditions. This multi-functional approach allows comprehensive monitoring of all components using the same methodology, avoiding the need for component-specific complex analysis for each of the hundreds of parts.
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
This approach improves the specificity and efficiency of condition monitoring, allowing for accurate identification of faulty components and estimating their remaining useful life, thereby reducing production downtime and enhancing maintenance effectiveness.
Implementation Method 1
Each sensor tends to pick up vibrations from a plurality of different mechanical components in the packaging machine
Data Source
AI summary
A monitoring device for condition assessment of a packaging machine for producing packages of liquid food comprises a signal interface for connection to a plurality of vibration sensors in the packaging machine. The monitoring device includes logic to: receive measurement signals from the vibration sensors and obtain an event timing signal, MES, indicative of predefined work events of the packaging machine, wherein the respective work event corresponds to a mechanical action by a respective component in the packaging machine when operating to produce the packages. The monitoring device further includes logic to: identify, by use of the MES and in the measurement signals, signal values associated with the respective component, and evaluate the signal values for condition assessment of the respective component. The provision and use of the MES thus facilitates condition assessment of individual components in a packaging machine.