Rotating Shaft Condition Analysis with Constant-Per-Revolution Sampling
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Solution Overview
Problem
Existing machine condition monitoring technologies face challenges in accurately analyzing the condition of machines with rotating parts, particularly those with variable speeds, due to high noise levels and the need for individual filter adjustments in vibration sensors, which can lead to unreliable and time-consuming measurements.
Innovation Solution
A condition analyzing system that employs a Shock Pulse Measurement sensor with a predetermined mechanical resonance frequency, allowing for repeatable measurement results independent of the physical path, and a digital signal processing system that includes a pre-processor and evaluator to enhance repetitive signal patterns and reduce noise, enabling early detection of incipient damage in machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If individual filter adjustments are made in vibration sensors to reduce noise, then measurement precision may improve, but device complexity and time consumption increase
Solution Approach 1:
The patent changes the fundamental parameter of the sensor system by using a shock pulse sensor with predetermined mechanical resonance frequency instead of adjustable vibration sensors. This eliminates the need for individual filter adjustments while maintaining measurement precision through the sensor's inherent frequency-selective properties.
Solution Approach 2:
The patent extracts and eliminates the complex adjustable filter components from the measurement system. By using a shock pulse sensor that inherently filters vibrations through its mechanical resonance frequency, the system removes the need for separate filter adjustment mechanisms, thereby reducing device complexity.
2Measurement precision
If individual filter adjustments are made in vibration sensors to reduce noise, then measurement precision may improve, but time consumption increases
Solution Approach 1:
The shock pulse sensor is pre-configured with a predetermined mechanical resonance frequency during manufacturing. This preliminary action eliminates the need for time-consuming field adjustments and filter settings, allowing immediate use while maintaining measurement precision.
Solution Approach 2:
The sensor performs self-filtering through its inherent mechanical resonance frequency, automatically rejecting unwanted vibrations without requiring external adjustment or calibration. This self-service capability eliminates time consumption associated with manual filter adjustments.
3Reliability
If shock pulse measurement is used to reduce noise interference, then reliability improves, but adaptability decreases
Solution Approach 1:
The shock pulse sensor with predetermined mechanical resonance frequency serves multiple functions: it detects shock pulses, filters vibrations through its resonance frequency, and provides reliable measurements across different machine types. This universal sensor design maintains reliability while adapting to various monitoring applications without requiring individual adjustments.
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
The system provides reliable and efficient condition monitoring by simplifying signal processing, reducing noise interference, and enabling early detection of machine damage, even in noisy environments, with consistent results across different measurement setups.
Implementation Method 1
a Shock Pulse Measurement sensor with a predetermined mechanical resonance frequency, allowing for repeatable measurement results independent of the physical path
Implementation Method 2
a digital signal processing system that includes a pre-processor and evaluator to enhance repetitive signal patterns and reduce noise
Data Source
Figure 1
Figure 2A
Figure 2B~2C
AI summary
A method for analysing the condition of a machine having a rotating shaft, comprising: generating an analogue electric measurement signal (SEA) dependent on mechanical vibrations emanating from rotation of said shaft; sampling said analogue measurement signal at a sampling frequency (fS) so as to generate a digital measurement data signal (SMD) in response to said received analogue measurement data; performing a decimation of the digital measurement data signal (SMD) so as to achieve a digital signal (SRED) having a reduced sampling frequency (fSR1, fSR2); wherein said decimation includes the step of controlling the reduced sampling frequency (fSR1, fSR2) such that the number of sample values per revolution of the shaft (8) is kept at a substantially constant value; and receiving said digital signal (SRED2) at an an enhancer input performing a correlation in said enhancer so as to produce an output signal sequence (O) wherein repetitive signals amplitude components are amplified in relation to stochastic signal components performing a condition analysis function (F1, F2, Fn) for analysing the condition of the machine dependent on said digital signal (SRED) having a reduced sampling frequency (fSR1, fSR2).