Relay State Monitoring for Sensorless Instrument Abnormality Detection
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Solution Overview
Problem
Existing methods for detecting abnormalities in instruments connected to relays require direct attachment of sensors, leading to increased costs and labor, and can be difficult to retrofit existing systems. Additionally, these methods increase processing loads by transferring data from the motor side to a monitoring server.
Innovation Solution
An abnormality detection device that acquires the state of a relay connected to an instrument, detects abnormalities based on the relay's state or changes in that state, and notifies users without requiring information from the instrument side. This device uses a detection model learned through machine learning to predict or detect instrument abnormalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is directly attached to the motor to detect load current, then abnormality detection accuracy is improved, but cost and labor increase
Solution Approach 1:
The patent uses the relay as an intermediary component to detect abnormalities in the motor. Instead of attaching sensors directly to the motor, the system monitors the relay's operation state (opening/closing actions) to infer motor abnormalities. The relay serves as a mediator that translates motor status into detectable electrical signals without requiring direct physical contact with the motor or additional sensors on the motor itself.
Solution Approach 2:
The patent replaces the mechanical sensor attachment approach with an electrical monitoring approach. Instead of using physical sensors that require mechanical installation on the motor, the system uses electrical signal analysis from the relay circuit to detect abnormalities. This substitution eliminates the need for mechanical sensor installation while maintaining detection capability.
2Reliability
If a sensor is directly attached to the motor, then abnormality detection capability is improved, but ease of retrofitting existing systems deteriorates
Solution Approach 1:
The relay acts as an accessible intermediary point in the existing electrical circuit that can be monitored without modifying the motor itself. By placing the monitoring system at the relay level rather than requiring motor disassembly or sensor installation, the solution becomes readily applicable to existing systems without extensive retrofitting work.
Solution Approach 2:
The patent creates a universal monitoring solution that works with any motor-relay configuration. The monitoring system detects abnormalities through the relay's electrical characteristics, which are common to all such systems, making the solution broadly applicable across different motor types and existing installations without requiring system-specific customization.
3Measurement precision
If load current detection is performed on the motor side, then abnormality detection accuracy is improved, but processing load on the monitoring server increases
Solution Approach 1:
The patent extracts only the essential abnormality information from the relay's operation state rather than transmitting complete raw data from the motor side. By processing and analyzing the relay signals locally and extracting only relevant abnormality indicators for server analysis, the system reduces the volume of data transmitted and processed by the monitoring server while maintaining detection accuracy.
Solution Approach 2:
The system performs preliminary analysis of the relay operation state before transmitting data to the monitoring server. By pre-processing the signals and identifying potential abnormalities at the relay level first, the system reduces the processing burden on the server by only transmitting relevant abnormality cases rather than all raw operational data.
Data Source
AI summary
An abnormality detection device includes: an acquisition unit configured to acquire a state of a relay that is connected to an instrument to be monitored and controls opening and closing of a circuit to which the instrument is connected; a detector configured to detect an abnormality of the instrument on the basis of the state of the relay or a change in the state of the relay; and a notifying unit configured to notify a user of the abnormality detected by the detector.