State Detection via Non-Normal Time Rate
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Solution Overview
Problem
Current methods for monitoring machine device deterioration require design drawings and are costly, especially for diverse machine types, as they rely on sensor signal amplitudes that vary by machine size and model, necessitating individual threshold settings and design drawing acquisition.
Innovation Solution
A state detecting system that uses a non-normal time rate, calculated as the ratio of time the sensor signal amplitude exceeds a predetermined normal amplitude within a specified time, allowing for deterioration diagnosis without relying on machine size, model, or design drawings, using a detecting element like a vibration sensor and processing unit for analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensor signal amplitude threshold method is used for deterioration monitoring, then detection capability is improved, but the system requires individual threshold settings for each machine size and model, increasing system complexity and cost
Solution Approach 1:
The patent changes the parameter from absolute amplitude threshold to relative amplitude ratio (amplitude ratio between current signal and reference signal). This transformation makes the detection method scale-invariant, allowing the same threshold to be applied across different machine sizes and models without individual calibration, thus resolving the contradiction between detection precision and system complexity
Solution Approach 2:
The patent creates a universal monitoring system that can be applied to diverse machine types (pumps, motors, compressors, etc.) of various sizes using a single standardized method. The amplitude ratio approach serves multiple functions: it normalizes signals across different scales, eliminates the need for machine-specific calibration, and provides consistent deterioration detection across the entire machine portfolio
2Measurement precision
If design drawing information is required for damage frequency calculation, then diagnosis accuracy is improved, but the cost and time to acquire design drawings increases
Solution Approach 1:
The patent extracts the essential diagnostic information (amplitude characteristics) from the complex design drawing requirements. By focusing only on amplitude ratio measurements rather than requiring full design specifications for damage frequency calculation, the system obtains sufficient diagnostic accuracy without the time-consuming process of acquiring and analyzing complete design drawings
3Measurement precision
If individual threshold settings are made for each machine type, then detection accuracy is improved, but maintenance cost increases
Solution Approach 1:
The patent transforms the detection parameter from absolute amplitude (which requires machine-specific thresholds) to amplitude ratio (which uses universal thresholds). This parameter change enables a single standardized threshold to achieve accurate detection across all machine types, eliminating the need for costly individual threshold calibration and reducing maintenance expenses while preserving detection accuracy
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
This approach enables cost-effective, accurate deterioration monitoring across various machines without the need for design drawings, with high detection accuracy at the initial deterioration stage and flexible threshold settings applicable to multiple machines.
Implementation Method 1
a vibration sensor which is fixed to a rolling bearing or a housing
Data Source
AI summary
One preferable aspect of the present invention is a state detecting system which detects a state of a machine device based on a detection signal from a detecting element provided to the machine device, and is the state detecting system which includes a non-normal time rate detecting unit which detects a rate or a value as a non-normal time rate, the rate being a rate of an integration value of a time during which an amplitude of the detection signal exceeds a predetermined normal amplitude within a predetermined time, and the value being physically equivalent to the rate.