Handheld Pump Fault Detection via Acoustic Signal Analysis

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Solution Overview

Problem

Existing fault detection methods for pump assemblies, such as those using vibration sensors, are cumbersome and require bulky equipment, making it difficult for service workers to identify faults without invasive measurements.

Innovation Solution

A method utilizing a handheld communication device with a microphone to contactlessly measure sound signals from a pump assembly, processing these signals to detect faults, and recognizing conditions through spectral analysis, eliminating the need for sensors on the pump assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If vibration sensors are used for fault detection, then measurement precision is improved, but device complexity and ease of operation deteriorate due to bulky equipment and invasive installation

Engineering Contradiction:

Improvefault detection accuracyVSAvoidservice worker convenience

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The patent replaces mechanical vibration sensors with acoustic measurement using a microphone. The microphone captures sound waves emitted by the pump assembly, which are then processed to detect faults. This substitution eliminates the need for physical contact with the pump, making the detection process non-invasive and significantly easier to operate while maintaining fault detection capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces sound waves as an intermediary medium between the fault source and the detection device. Instead of directly measuring mechanical vibrations, the system captures acoustic emissions that propagate through the air from the pump assembly. This intermediary approach allows remote, contactless detection while preserving the ability to identify mechanical faults

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If vibration sensors are fitted to the pump housing, then fault detection capability is improved, but ease of manufacture and ease of operation worsen due to cumbersome installation

Engineering Contradiction:

Improvefault detection capabilityVSAvoidsystem implementation simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the mechanical sensor attachment system with an acoustic measurement system. The microphone is positioned to receive sound waves from the pump assembly without requiring any physical attachment, mounting brackets, or coupling agents. This eliminates the complex installation process while maintaining reliable fault detection through acoustic signal analysis

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If contactless sound measurement is used, then ease of operation is improved, but measurement precision may deteriorate due to environmental noise interference

Engineering Contradiction:

Improvenon-invasive measurementVSAvoidsound signal accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The patent transforms the sound signal from the time domain to the frequency domain using Fast Fourier Transform (FFT). This parameter transformation allows the system to analyze the spectral content of the acoustic signal, identifying characteristic frequencies associated with specific faults. By working in the frequency domain, the system can distinguish fault-related sounds from background noise based on their spectral signatures

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent implements a feedback mechanism where the processed acoustic signal is continuously analyzed and compared against known fault patterns. The system provides real-time feedback about the pump assembly's condition, allowing operators to monitor fault development and take corrective action. This closed-loop approach enhances measurement precision by continuously validating the detected signals

Inventive Principle:

Principle #23Feedback

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 non-invasive, contactless fault detection using a smartphone or similar device, allowing service workers to identify faults easily and efficiently without the need for bulky equipment, improving the simplicity and effectiveness of fault detection.

Implementation Method 1

contactless measuring a sound signal emanating from the pump assembly by use of a microphone connected to or implemented in the handheld communication device

Methodology Applied

Scientific EffectAcoustic wave detection: Sound

Data Source

PatentEP3207256B1Method and system for detection of faults in pump assembly via handheld communication device

Publication Date: 2023.11.29 GRUNDFOS HLDG

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AI summary

A method for detecting faults or operational parameters in a pump assembly by use of a handheld communication device is described. The pump assembly includes an electric motor and a pump, wherein the pump assembly or electric motor has at least one rotating shaft The method comprises the steps of: a) contactless measuring a sound signal emanating from the pump assembly by use of a microphone connected to or implemented in the handheld communication device, b) processing the measured sound signal, and c) recognising one or more sound emanating condition including any possible faults by way of the processed sound signal.