Rotating Machine Abnormality Detection Using Ultrasonic Vibration Analysis
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Solution Overview
Problem
Existing rotating machine abnormality detection methods, such as those using listening rods and vibration analysis, rely heavily on expert judgment and struggle to objectively detect initial abnormalities due to overlapping steady vibrations, making it difficult to identify issues at their onset.
Innovation Solution
A rotating machine abnormality detection device that utilizes ultrasonic wave measuring sections to detect vibrations in the ultrasonic wave band, coupled with control processing to analyze first measurement data for initial abnormalities, and vibration measuring sections to determine abnormality types and degrees based on audible wave band data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If vibration analysis in audible wave band is used to detect rotating machine abnormalities, then the detection can be performed with conventional equipment, but the steady vibration overlaps with abnormal vibrations making it difficult to detect initial abnormalities
Solution Approach 1:
The patent segments the vibration detection into two distinct frequency bands: audible wave band (20-20,000 Hz) for general vibration monitoring and ultrasonic wave band (20,000-1,000,000 Hz) for initial abnormality detection. This segmentation allows each band to serve its specific purpose without interference from overlapping vibrations.
Solution Approach 2:
The patent introduces a new dimension of frequency analysis by adding ultrasonic wave band measurement to the traditional audible wave band measurement. This dimensional expansion enables detection of initial abnormalities that would be masked in the audible band, as ultrasonic vibrations from early-stage abnormalities occur before they become audible.
2Ease of manufacture
If listening rod method is used for abnormality detection, then simple equipment can be used, but the determination accuracy depends on inspector expertise making objective determination difficult
Solution Approach 1:
The patent replaces the mechanical listening rod method with an automated electronic detection system using ultrasonic sensors and signal processing circuits. This substitution eliminates the need for inspector expertise while maintaining objective, reliable detection through electronic measurement and analysis of vibration characteristics in the ultrasonic wave band.
3Extent of automation
If vibration measurement is performed to detect abnormalities, then the detection can be automated, but the frequency band overlap with steady vibration makes initial abnormality detection difficult
Solution Approach 1:
The patent segments the frequency spectrum into audible and ultrasonic bands, assigning the ultrasonic band (20,000-1,000,000 Hz) specifically for detecting initial abnormalities. This segmentation allows automated detection systems to focus on the ultrasonic frequency range where early-stage abnormalities produce distinct signals without overlapping with steady vibrations in the audible band.
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 objective and reliable detection of initial abnormalities in rotating machines by analyzing ultrasonic wave band vibrations and audible wave band changes, reducing reliance on expert judgment and improving early detection capabilities.
Implementation Method 1
measuring a vibration in an ultrasonic wave band caused by the rotary member
Implementation Method 2
vibration measuring sections to determine abnormality types and degrees based on audible wave band data
Data Source
AI summary
A rotating machine abnormality detection device and a rotating machine abnormality detection method according to the present invention are designed to detect an abnormality in a rotating machine including a rotary member rotatable about a predetermined axis, and detect an initial abnormality in the rotating machine based on first measurement data obtained by measuring a vibration in an ultrasonic wave band caused by the rotary member. A rotating machine according to the present invention includes the rotating machine abnormality detection device.