Synchronized Drive Abnormality Detection via Cumulative Sum Linearity

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Solution Overview

Problem

Existing methods struggle to accurately detect synchronization deviation between drive mechanisms operating together in industrial machines, which can lead to inaccurate operation of devices like workpiece feeding devices.

Innovation Solution

A method and system that involve acquiring drive data from synchronized drive mechanisms, extracting differences, deriving a cumulative sum, and determining linearity or non-linearity to detect synchronization deviation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional abnormality detection methods using sensors and thresholds are used for each drive mechanism, then individual mechanism abnormalities can be detected, but synchronization deviation between the pair of drive mechanisms cannot be detected

Engineering Contradiction:

Improveabnormality detection capabilityVSAvoidsynchronization deviation information

Core Design Contradiction:

Measurement precisionVSLoss of information

Solution Approach 1:

The patent combines the detection of individual drive mechanism abnormalities with the detection of synchronization deviation by integrating multiple data sources (drive data from both mechanisms and position data) into a unified analysis process that simultaneously evaluates both individual health and coordination accuracy

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent introduces an intermediary analysis process that compares drive data and position data from both mechanisms to detect synchronization deviation, acting as a mediator that translates raw data into synchronization status information without requiring direct modification of the individual detection mechanisms

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If a pair of drive mechanisms operate together in synchronization, then the industrial machine can function efficiently, but synchronization deviation may occur undetected leading to inaccurate operation

Engineering Contradiction:

Improveoperational efficiencyVSAvoidsynchronization accuracy

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent implements feedback by continuously monitoring drive data and position data from both mechanisms, comparing them to detect synchronization deviation, and providing this information back to operators or control systems to maintain operational accuracy and prevent inaccurate operation

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent performs preliminary detection of synchronization deviation before it leads to inaccurate operation by continuously analyzing drive data patterns and position differences, allowing preventive maintenance or adjustment before the deviation causes operational errors

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250264860A1Method and system for determining abnormality in industrial machine

Publication Date: 2025.08.21 KOMATSU SANKI

AI summary

A method of determining synchronization deviation includes acquiring first drive data indicative of a dynamic state of a first drive mechanism, acquiring second drive data indicative of a dynamic state of a second drive mechanism, extracting differences between the first drive data and the second drive data, deriving a cumulative sum of the differences, determining whether the cumulative sum exhibits linearity or non-linearity, and determining that the synchronization deviation has occurred between the first drive mechanism and the second drive mechanism when the cumulative sum exhibits non-linearity.