Machine Failure Localization Using Vibration Frequency Matching
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Solution Overview
Problem
Conventional methods for detecting failures in machine mechanisms often fail to detect all failures and require extensive time to identify locations, especially when specialized frequency component analysis is not applicable to various types of failures.
Innovation Solution
A device and method that utilize a storage unit to correlate specific frequency bands with event codes, an input unit to receive vibration data, and an output unit to match these bands with machine vibrations, specifying failure locations and outputting event codes, along with a correlating unit to store information on countermeasures, enabling efficient detection of various failure locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional alarm detection methods are used, then controller errors and motor overload problems can be detected, but many failures in mechanism units cannot be detected and require considerable time to track
Solution Approach 1:
The patent replaces conventional mechanical alarm detection methods with vibration-based detection. By acquiring vibration data from the mechanism unit and analyzing frequency components, the system can detect various types of failures (including those not detectable by conventional methods) and quickly identify failure locations through pattern matching with stored vibration patterns.
Solution Approach 2:
The patent changes the detection parameter from general alarm signals to specific vibration frequency components. By extracting and analyzing frequency components from vibration data, the system can identify specific failure modes and locations, significantly improving both detection reliability and reducing troubleshooting time.
2Measurement precision
If specialized frequency component analysis is used, then specific failures can be detected, but it is difficult to specify locations of various failures
Solution Approach 1:
The patent creates a universal failure detection system that can handle various types of failures. By storing multiple types of vibration data patterns in the storage unit and matching acquired vibration data against these patterns, the system can detect and identify locations of different failure modes (abnormal vibration, noise, overheating, etc.) using a single unified approach.
Solution Approach 2:
The patent performs preliminary action by pre-storing vibration data patterns and frequency component information for various failure modes in the storage unit before actual failure detection. This pre-prepared database enables rapid matching and identification when failures occur, making the system both precise and versatile across different failure types.
3Ease of operation
If conventional alarm systems are used, then basic error detection is achieved, but extensive manual tracking is required to identify specific failure locations
Solution Approach 1:
The patent implements feedback by comparing acquired vibration data with stored vibration patterns and frequency information. The system automatically identifies matching patterns and outputs failure location information, providing immediate feedback that eliminates manual tracking and significantly reduces the time needed to identify specific failure locations.
Solution Approach 2:
The patent enables the system to self-diagnose failures by automatically analyzing vibration data, matching it against stored patterns, and identifying failure locations without requiring manual intervention. The failure location specifying unit automatically determines and outputs the cause of abnormal operation, making the system self-sufficient in troubleshooting.
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 allows for the efficient and accurate specification of multiple failure locations in machine mechanisms, reducing the time required to track failures and eliminating the need for specialized sensors, by correlating vibration frequencies with pre-stored event codes and countermeasures.
Implementation Method 1
a vibration sensor that detects vibration frequencies generated by the machine mechanism unit
Data Source
AI summary
A failure location specifying device, a failure location specifying method, and a failure location specifying program capable of specifying locations of various failures occurring in a mechanism unit of a machine efficiently are provided. A failure location specifying device includes: a failure history database that stores a specific frequency band occurring resulting from a failure of a machine in correlation with at least an event code indicating a location of the failure; an input unit that receives data related to vibration during operation of the machine as an input; and an output unit that matches the specific frequency band to a frequency included in the data related to vibration to specify the location of the failure and outputs the event code.