Tie Rod Fatigue Warning Using Power Cylinder Oil Pressure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current monitoring methods for the tie rod in diameter expanding machines are inefficient, relying on experience and requiring repeated disassembly for damage detection, which prolongs processing time and reduces efficiency.
Innovation Solution
An early warning method based on oil pressure data from a power cylinder, utilizing an oil pressure sensor connected to a microcomputer, which collects real-time data, calculates a health indicator for the tie rod, and raises an alarm if the indicator falls below a certain threshold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional monitoring methods are used to detect tie rod damage, then damage detection can be performed, but repeated disassembly is required which greatly extends processing time and reduces processing efficiency
Solution Approach 1:
The patent replaces the mechanical disassembly-based detection system with a sensor-based monitoring system. Oil pressure sensors and displacement sensors substitute for physical inspection methods, enabling non-intrusive real-time monitoring of tie rod health status without requiring repeated disassembly operations.
Solution Approach 2:
The patent introduces oil pressure and displacement as intermediary parameters to indirectly monitor tie rod health. Instead of directly inspecting the tie rod, the system measures oil pressure changes and piston displacement, which serve as proxies for tie rod condition, thereby avoiding direct mechanical intervention.
2Productivity
If traditional monitoring methods are used based on processing experience, then operation can continue, but there is a lack of technologies that can directly reflect the fatigue damage state of the tie rod
Solution Approach 1:
The patent implements a feedback mechanism where sensor data on oil pressure and displacement are continuously fed into a monitoring system that calculates tie rod health status. This closed-loop feedback provides real-time information on fatigue damage accumulation, enabling informed operational decisions while maintaining continuous production.
Solution Approach 2:
The patent replaces experience-based subjective assessment with objective sensor-based measurement systems. Electrical sensors substitute for human expertise, providing quantifiable data on tie rod health status that directly reflects fatigue damage without relying on operator experience.
3Reliability
If repeated detachment of the tie rod is performed for damage detection, then damage can be detected, but processing time is greatly extended
Solution Approach 1:
The patent enables continuous monitoring of tie rod health through permanently installed sensors that operate throughout the entire production cycle. The monitoring action continues uninterrupted without requiring periodic shutdowns or disassembly, maintaining both detection reliability and production continuity simultaneously.
Solution Approach 2:
The patent performs preliminary installation of sensors during initial setup, enabling ongoing monitoring without future disassembly. The monitoring capability is established in advance, eliminating the need for repeated detachment operations while maintaining reliable damage detection throughout the tie rod's service life.
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 method allows for real-time monitoring of the tie rod's health state without disassembly, improving processing efficiency and providing timely warnings for fatigue damage, thus enhancing safety and reducing downtime.
Implementation Method 1
installing an oil pressure sensor on the power cylinder; connecting the oil pressure sensor with a microcomputer; and collecting oil pressure data of the power cylinder in real time
Data Source
AI summary
The present disclosure describes an early warning method for assessing the fatigue damage state of a tie rod of a diameter expanding machine, based on the oil pressure of a power cylinder. (1) An oil pressure sensor is installed on the power cylinder, and collects oil pressure data in real time. (2) Required parameters are input into an early warning system. (3) A health state indicator function model of the tie rod is constructed. (4) Calculating the constant term in a linear equation allows for the construction of a tie rod S-N fatigue curve equation at a 95% confidence level. (5) A cumulative damage factor and a current health indicator of the tie rod are calculated. (6) If the early warning system determines that the current health indicator of the tie rod is 60.5 or lower, an alarm is triggered.