Replacement Part Configuration Using Machine Performance Data
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current predictive maintenance methods focus on timely delivery of identical replacement parts for machines, neglecting the potential for optimized configurations based on operational performance data to enhance durability, energy efficiency, and manufacturing costs.
Innovation Solution
A method that utilizes performance data from monitoring machines to calculate multiple optimized mechanical configurations for replacement parts using modeling algorithms, allowing users to select options based on criteria like lifetime, operating costs, and energy efficiency, and provides description or construction data for manufacturing these optimized parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If identical replacement parts are delivered for replacement during maintenance intervals, then reliability is maintained, but adaptability and optimization potential are lost
Solution Approach 1:
The patent applies parameter changes by modifying the mechanical configuration parameters of replacement parts based on operational performance data. Instead of delivering identical parts, the system calculates optimized configurations that adjust geometric parameters, material properties, or structural characteristics to improve machine efficiency while maintaining reliability requirements.
Solution Approach 2:
The patent implements preliminary action by calculating and preparing optimized replacement part configurations before the parts are physically delivered. The system uses historical performance data to pre-compute optimal designs, so that when parts are replaced, the optimized configurations are already ready, enabling adaptability without delaying maintenance schedules.
2Adaptability or versatility
If multiple optimized configurations are calculated and offered for selection, then adaptability and customization are improved, but device complexity and data processing requirements increase
Solution Approach 1:
The patent applies segmentation by dividing the complex modeling system into modular components: data acquisition modules, performance analysis modules, configuration calculation modules, and selection interface modules. Each module handles a specific aspect of the optimization process, making the overall system more manageable and scalable while providing multiple configuration options.
Solution Approach 2:
The patent uses an intermediary approach by introducing a centralized modeling server that acts as a mediator between performance data sources and configuration output. This intermediary server consolidates the computational complexity, allowing multiple configurations to be generated and managed without proportionally increasing the complexity at each individual interface point.
3Manufacturing precision
If performance data is collected and analyzed to optimize replacement parts, then manufacturing precision and part performance are improved, but loss of time for data collection and processing occurs
Solution Approach 1:
The patent applies preliminary action by continuously collecting and pre-processing performance data during machine operation, so that when a replacement part is needed, the analysis and optimization calculations are already prepared or can be quickly completed. This reduces the time loss at the critical moment of part replacement while maintaining high manufacturing precision.
Solution Approach 2:
The system implements self-service by automatically collecting performance data, analyzing it, and generating optimized configurations without requiring manual intervention. The automated data processing reduces time loss by eliminating human involvement in data collection and initial analysis, allowing the system to serve itself in preparing optimization recommendations.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method for providing a replacement part (1) or for providing description data or construction data (15) for manufacturing a replacement part (1), the replacement part designed for replacing an initial mechanical machine part (2) of a machine (3) for conveying a medium, the initial part (2) having an initial mechanical configuration with initial part description data (4), the method including: - receiving performance data (5) achieved by monitoring the machine (2) during operation with the initial machine part (2) with one or more measuring devices (6), - sending the performance data (5) to a modelling server (7), - calculating on the modelling server (7) multiple optimised mechanical configurations (9) of the replacement part (1) with one or more modelling algorithms (10) based on different optimisation criteria using at least the initial part description data (4) or construction data and the received performance data (5), - providing a selection (11) of several performance options representing the multiple mechanical configurations (9) of the replacement part (1), - receiving an input (13) from a user (14) selecting one of the performance options, - providing the replacement part (1) with the final optimised configuration (9') corresponding to the selected performance option or sending optimised part description data or optimised part construction data (15) for manufacturing the replacement part (1) with the final optimised configuration (9').