Rotating Coupling Degradation Tracking With Dual Rotation Sensors
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Solution Overview
Problem
It is challenging to predict the Remaining Useful Life (RUL) of flexible couplings due to the difficulty in determining wear and tear, especially in environments with misalignment, vibration, and varying operating conditions, which can lead to unexpected downtime and failure.
Innovation Solution
A system and method using rotation sensors and fiducial markers to measure parameters like backlash, windup, and inertia, combined with data-driven techniques such as Unscented Kalman Filters and recurrent neural networks, to estimate the degradation and RUL of flexible couplings by tracking changes over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional monitoring methods are used for flexible couplings, then the system is simple and easy to implement, but the ability to predict remaining useful life and detect degradation is insufficient
Solution Approach 1:
The system segments the coupling degradation detection into multiple measurable parameters (backlash, windup, inertia) using separate sensors for each measurement, allowing complex degradation analysis to be broken down into manageable measurement components that can be processed independently and combined for comprehensive assessment
Solution Approach 2:
The patent introduces rotation sensors as intermediary devices that indirectly measure coupling degradation by detecting rotational parameters (backlash, windup, inertia) rather than directly measuring wear or degradation, enabling precise degradation detection through proxy measurements that are easier to obtain accurately
2Reliability
If no real-time monitoring is implemented, then the system operates simply without additional sensors, but unexpected downtime occurs due to inability to predict coupling failure
Solution Approach 1:
The system performs preliminary measurements of backlash, windup, and inertia parameters continuously before actual coupling failure occurs, using rotation sensors to detect early signs of degradation and enable predictive maintenance scheduling based on projected remaining useful life rather than waiting for failure
Solution Approach 2:
The patent implements a feedback loop where rotation sensor measurements are continuously processed to update degradation state estimates and remaining useful life predictions, allowing the system to adapt maintenance schedules based on actual coupling condition rather than fixed intervals, improving reliability while optimizing resource usage
3Loss of information
If multiple rotation sensors and processing systems are added to track coupling health, then degradation can be precisely measured, but the system becomes more complex and costly
Solution Approach 1:
The rotation sensors serve multiple functions simultaneously: measuring backlash, windup, and inertia parameters, as well as providing data for both immediate degradation assessment and long-term remaining useful life prediction, reducing the need for separate specialized sensors for each measurement type
Solution Approach 2:
The patent combines multiple degradation information sources (backlash measurements, windup measurements, inertia measurements) into a unified degradation state estimate and remaining useful life prediction through integrated processing, consolidating what would otherwise require separate analysis systems into a single coherent assessment framework
Data Source
AI summary
A system and method utilize a first rotation sensor that provides a first signal indicative of a first rotation of a first end of a rotating coupling. The rotating coupling has an articulating member mechanically coupling the first end to a second end. A second rotation sensor provides a second signal indicative of a second rotation of the second end of the rotating coupling. A processor is coupled to the first and second rotation sensors and is operable to determine a relationship between the first and second rotations based on the first and second signals. Based on the relationship, the processor estimates at least one of a degradation of and a remaining useful life of the rotating coupling.