Piston Machine Leak Detection via Vibration Fourier Analysis
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Solution Overview
Problem
Current methods fail to accurately detect and localize fluid leaks in piston machines, as pressure drops can be caused by various factors beyond leaks, making it difficult to distinguish and pinpoint leaks effectively.
Innovation Solution
A method involving attaching vibration sensors to piston machine pipes, calculating complex harmonic Fourier amplitudes, low-pass filtering, and monitoring deviation amplitudes to detect leaks, which allows for early detection and localization by distinguishing between dynamic variations and noise components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressure drop monitoring is used to detect leaks, then leak detection capability is provided, but false positives occur due to other factors causing pressure drops
Solution Approach 1:
The patent segments the leak detection problem by using multiple independent sensors (vibration sensors on pipes, pressure sensors, temperature sensors) to monitor different physical parameters simultaneously. This segmentation allows the system to distinguish between pressure drops caused by leaks versus other factors by analyzing the pattern across multiple parameters rather than relying on pressure alone.
Solution Approach 2:
The patent introduces vibration signals as an intermediary indicator that specifically correlates with leak conditions. By using vibration sensors on pipes and analyzing vibration patterns, the system creates an intermediate measurement that is more specifically indicative of leaks than pressure alone, thereby improving measurement precision for leak localization.
2Measurement precision
If multiple leak indicators are monitored, then detection accuracy improves, but system complexity increases
Solution Approach 1:
The patent merges multiple monitoring functions into a single integrated system that simultaneously processes vibration signals, pressure data, and temperature information. By combining these indicators and analyzing them together using signal processing techniques (Fourier analysis, wavelet transforms), the system achieves improved detection accuracy without proportionally increasing complexity, as the processing is unified rather than separate for each parameter.
Solution Approach 2:
The patent replaces complex mechanical diagnostic procedures with automated signal processing and computational analysis. Instead of manual inspection or simple mechanical gauges, the system uses digital sensors and computer-based analysis algorithms to process multiple indicators, thereby managing system complexity through automation and software rather than additional mechanical components.
3Measurement precision
If vibration sensors are attached to pipes, then leak localization capability is improved, but installation complexity increases
Solution Approach 1:
The patent designs the vibration sensors and mounting system to be universal and multi-functional. The same vibration sensors attached to pipes serve multiple purposes: detecting leaks, characterizing leak severity, and providing diagnostic information about pump condition. This multi-functionality justifies the installation effort and reduces overall system complexity by consolidating multiple detection capabilities into a single sensor placement.
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 method enables early and accurate detection of leaks by monitoring deviation amplitudes, reducing false positives and improving cost efficiency in identifying malfunctioning pumps, thereby minimizing downtime and costs.
Implementation Method 1
measuring the vibration at the at least one vibration sensor
Implementation Method 2
calculating at least one complex harmonic Fourier amplitude of the measured vibration signal
Data Source
AI summary
A machine includes at least one piston and a pump shaft. A method for detecting a leak in the machine includes receiving a vibration signal from a vibration sensor disposed on at least one of an upstream pipe and a downstream pipe of the machine, receiving a rotational speed signal and an angular shaft position signal from a speed and position sensor disposed on the machine, calculating a rotational speed and an angular shaft position of the pump shaft, calculating at least one complex harmonic Fourier amplitude of the received vibration signal, low pass filtering the at least one complex harmonic Fourier amplitude, calculating a deviation amplitude as a magnitude of a complex difference between the filtered amplitude and a base amplitude, and monitoring the deviation amplitude to detect a leakage.