Portable Vibration Sensor for Early Rotating Machine Fault Detection
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Solution Overview
Problem
Conventional devices for detecting malfunctions in rotating machines, such as turbines and compressors, fail to provide early detection and often require permanent installation, making them unsuitable for portable use and unable to display time-dependent trends in operational states, which complicates timely identification of malfunctions.
Innovation Solution
A portable device that samples and analyzes vibration data from rotating machines using a detecting unit, frequency analyzer, and display unit to provide real-time, chronological analysis of frequency data, allowing for early detection of malfunctions and reduced size through primary determination capabilities, enabling use without permanent installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional malfunction detection device is used, then malfunction detection capability is provided, but the device size is large and requires fixed installation
Solution Approach 1:
The patent extracts only the essential malfunction detection function from the conventional device, implementing a simplified version that uses a single sensor to detect vibration signals and determines malfunctions based on signal characteristics, eliminating unnecessary components that increased device size
Solution Approach 2:
The patent replaces complex mechanical detection systems with electronic signal processing, using vibration sensors and frequency analysis to detect malfunctions, which significantly reduces the physical size of the detection device while maintaining detection capability
2Volume of moving object
If a stethoscope is used for portable malfunction detection, then device portability is achieved, but considerable skill is required to operate it
Solution Approach 1:
The device performs automatic malfunction determination by analyzing vibration signals and comparing them against stored reference data, eliminating the need for operator expertise in interpreting complex vibration patterns. The system self-diagnoses malfunctions based on frequency analysis and signal characteristics
Solution Approach 2:
The patent replaces the mechanical stethoscope with an electronic vibration detection system that uses sensors and digital signal processing to automatically identify malfunctions, converting manual skill-based detection into automated electronic analysis
3Reliability
If conventional malfunction detection devices are installed, then malfunction detection is provided, but permanent installation is required
Solution Approach 1:
The detection device is designed with universal applicability, using standard vibration sensors and power interfaces that can be adapted to various rotating machines without permanent installation. The device can be temporarily mounted and removed as needed, serving multiple machines and locations
4Measurement precision
If conventional devices display determination results only, then malfunction identification is provided, but time-dependent trends are not displayed
Solution Approach 1:
The device stores reference vibration signals representing normal operation before malfunction occurs, and compares current signals against these pre-stored references to detect deviations. This preliminary storage of baseline data enables accurate malfunction identification while providing contextual information about operational changes over time
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
Enables early detection of rotating machine malfunctions and reduces device size, making it portable while providing real-time operational state monitoring, thus improving the timeliness and ease of identifying changes in machine operation.
Implementation Method 1
a detecting unit for sampling and detecting vibration of the rotating machine with a predetermined sampling frequency
Data Source
AI summary
Provided is a device for detecting a malfunction of a rotating machine, the device being able to early detect the malfunction and to have a reduced size. The device includes a detecting unit for detecting vibration of the machine, sampling a signal indicative of the vibration with a predetermined sampling frequency, and outputting, at a time at intervals of a predetermined period, a plurality of the sampled data detected within the predetermined period, a storage for storing the plurality of the sampled data, a frequency analyzer for analyzing the frequency of the plurality of the sampled data, a determination unit for performing a primary determination based on the result of the analysis, a display unit for displaying the result of the analysis in chronological order and in real time, and a communication unit for transmitting the plurality of the sampled data to an information-processing device for performing a secondary determination.