Intermittent Machinery Monitoring via Steady-State Signal Segmentation
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Solution Overview
Problem
Monitoring intermittently operating machinery poses challenges due to short periods of steady state running, which are necessary for effective condition assessment, as existing methods require continuous operation or long durations for statistically significant signal characterization.
Innovation Solution
A method and apparatus that automatically identify and process only steady state operating conditions from sensor signals, allowing for continuous monitoring and statistically significant measurements by excluding interruptions and variations, using preamplifiers, amplifiers, dynamic enveloping circuitry, and digital micro-electronic devices to characterize signals over shorter samples and aggregate them for longer durations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If sensor signals are processed over short periods to accommodate intermittent operation, then the adaptability to intermittent operation is improved, but the statistical significance of the measurement deteriorates
Solution Approach 1:
The patent segments the signal processing into distinct phases: identification phase (detecting start/stop events) and characterization phase (processing signals during steady-state operation). This segmentation allows the system to accumulate statistically significant data from multiple short operational periods while adapting to intermittent operation patterns.
Solution Approach 2:
The system performs preliminary identification of steady-state operating conditions before conducting full signal characterization. By pre-identifying when the machine is in steady-state operation, the system ensures that only statistically significant portions of the signal are processed, maintaining measurement precision despite intermittent operation.
2Productivity
If signal processing includes all operational periods to maximize data collection, then the productivity of monitoring is improved, but the reliability of condition assessment deteriorates due to inclusion of non-representative signals
Solution Approach 1:
The patent extracts and isolates only the steady-state portions of the signal for condition assessment, excluding transient start-up and shutdown periods. This extraction ensures that reliability is maintained by using only representative signals, while productivity is preserved through continuous monitoring during steady-state operation.
Solution Approach 2:
The system uses feedback from the identification phase to control the characterization phase. By continuously monitoring operational status and providing feedback about steady-state conditions, the system dynamically adjusts when to accumulate data, ensuring both reliability through selective processing and productivity through continuous operation during steady-state periods.
3Measurement precision
If the monitoring system requires continuous steady state operation for effective measurement, then the measurement precision is improved, but the adaptability to intermittent operation deteriorates
Solution Approach 1:
The patent implements dynamic signal processing that adapts to changing operational conditions. The system transitions between identification and characterization modes based on real-time detection of steady-state conditions, allowing it to maintain measurement precision during intermittent operation by dynamically adjusting when data accumulation occurs.
Solution Approach 2:
The system employs periodic identification and characterization cycles during intermittent operation. Each operational period undergoes a cycle of identifying steady-state conditions followed by signal characterization, allowing the system to accumulate statistically significant data from multiple periodic operational cycles while adapting to the intermittent nature of the machinery.
Data Source
AI summary
A method of monitoring the mechanical condition of a machine in which statistically significant measurements on a characteristic signal are made over a period of time which can include interruptions and variations in the operation of the machine giving rise to uncharacteristic signals and the processing of the signal during the statistically significant measurement automatically excludes those parts of the signal associated with interruptions and variations in the operation of the machine. The invention also includes apparatus for carrying out the above method including a preamplifier, adapted to provide output to a further amplifier, adapted to provided output to dynamic enveloping circuitry, adapted to provide an output to an analogue to digital converter, adapted to provide an output to a digital micro-electronic device.