Rotating System Digital Twin for Internal Fault Detection
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Solution Overview
Problem
Current methods fail to effectively detect and manage abnormalities in the internal components of rotating systems, such as generators and motors, leading to potential breakdowns and downtime, as they do not provide real-time monitoring capabilities for internal issues.
Innovation Solution
A method and system that utilize a virtual replica of the rotating system, configured with real-time operational data, to simulate its behavior and detect abnormalities in internal components, allowing for timely maintenance and reducing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are positioned to monitor internal components of the rotating system, then measurement precision is improved, but device complexity increases and the system becomes harder to manufacture
Solution Approach 1:
The patent creates a virtual replica (digital twin) of the rotating system that copies the physical system's behavior and characteristics. This virtual model allows monitoring of internal components without physically accessing them, thereby maintaining measurement precision while avoiding the complexity of installing sensors inside the rotating system.
Solution Approach 2:
The patent uses external sensors positioned on the housing or casing as intermediaries to indirectly measure the condition of internal components. The virtual replica model acts as a mediator that translates these external measurements into insights about internal component health, eliminating the need for direct internal sensing.
2Device complexity
If manual testing methods are used to detect internal component abnormalities, then device complexity is reduced, but loss of time increases due to downtime for testing
Solution Approach 1:
The patent enables continuous real-time monitoring of the rotating system through the virtual replica, allowing abnormality detection to occur continuously during operation without stopping the system. This eliminates downtime for testing while maintaining system simplicity by using external sensors and computational modeling.
3Reliability
If real-time monitoring of internal components is implemented, then reliability is improved, but device complexity increases due to additional sensors and systems
Solution Approach 1:
The virtual replica creates a computational copy of the rotating system that can be monitored in real-time. This approach improves reliability by enabling continuous abnormality detection while avoiding the complexity of installing physical sensors inside the rotating components, as the monitoring is performed through software modeling instead.
Solution Approach 2:
The patent replaces the mechanical approach of installing physical sensors inside the rotating system with a computational approach using a virtual replica. This substitution improves reliability through continuous monitoring while reducing device complexity by eliminating the need for internal sensor installation and associated mechanical modifications.
4Productivity
If preventive maintenance is scheduled based on real-time detection, then productivity is improved by reducing downtime, but device complexity increases due to the monitoring system
Solution Approach 1:
The virtual replica enables real-time monitoring of internal component health without requiring complex internal sensor installations. This allows for data-driven preventive maintenance scheduling that improves productivity by reducing unplanned downtime, while the complexity remains manageable through the use of external sensors and computational modeling.
Data Source
AI summary
The present disclosure relates to a system, an apparatus, and a method for managing health condition of at least one rotating system. The method includes receiving, by a processing unit, operational data associated with the rotating system in real-time, from one or more sensing units. The operational data includes parameter values corresponding to an operation of the rotating system. Further, a virtual replica of the rotating system is configured using the operational data. A behavior of the rotating system is simulated on a simulation instance of the rotating system based on the configured virtual replica. The simulation results are analyzed to determine an abnormality in the health condition of the rotating system. The abnormality corresponds to a health status of an internal component of the rotating system. Further, a notification indicating the abnormality is generated, on a Graphical User Interface.