Multi-Axis Vibration Sensor with Dynamic Sampling Rate

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Solution Overview

Problem

Current machinery monitoring systems require extensive training and equipment to diagnose issues, as they are complex and expensive, making it difficult to efficiently detect anomalies in vibrations and other parameters without human intervention.

Innovation Solution

A sensor system with a housing, processor, battery, and communication adapter that automatically switches between different measurement modes based on detected changes or predetermined thresholds, allowing for wireless communication and predictive analysis, enabling cost-effective and efficient monitoring of machinery vibrations and temperature.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If highly precise and complex measuring equipment is used to detect machinery vibrations, then measurement precision is improved, but device complexity increases and requires extensive training

Engineering Contradiction:

Improvevibration detection precisionVSAvoidmeasuring equipment complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent uses accelerometers to create electrical copies of mechanical vibration signals, transforming physical vibration into electrical signals that can be processed and analyzed without requiring complex mechanical measurement equipment

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces complex mechanical measuring equipment with electronic sensors (accelerometers) and signal processing systems, substituting mechanical measurement with electrical signal acquisition and digital analysis

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If trained personnel operate complex measuring equipment to diagnose machinery issues, then measurement precision is improved, but ease of operation deteriorates due to extensive training requirements

Engineering Contradiction:

Improveanomaly detection accuracyVSAvoidequipment operation simplicity

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The system performs self-diagnosis by automatically analyzing vibration signals and identifying anomalies without requiring human expertise in vibration analysis, with the embedded system automatically detecting and reporting machinery issues

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent implements feedback mechanisms where the system continuously monitors vibration signals, compares them against baseline patterns, and automatically alerts operators to anomalies, creating a closed-loop system that reduces the need for human interpretation

Inventive Principle:

Principle #23Feedback

3Reliability

If continuous monitoring of machinery vibrations is performed, then reliability is improved, but use of energy increases due to constant high-rate sampling

Engineering Contradiction:

Improvemachinery monitoring reliabilityVSAvoidsensor power consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent implements dynamic sampling where the sampling rate automatically adjusts based on the vibration signal characteristics - using higher sampling rates when anomalies are detected and lower rates during normal operation, optimizing the balance between monitoring reliability and energy consumption

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system uses periodic sampling at variable intervals rather than continuous sampling, with the sampling frequency dynamically adjusted based on detected vibration patterns, allowing reliable monitoring while reducing overall power consumption

Inventive Principle:

Principle #19Periodic action

4Measurement precision

If high sampling rates are used to capture detailed vibration data, then measurement precision is improved, but loss of substance increases due to larger data storage requirements

Engineering Contradiction:

Improvevibration signal resolutionVSAvoidstorage device capacity

Core Design Contradiction:

Measurement precisionVSLoss of substance

Solution Approach 1:

The patent extracts only the essential features from vibration signals using signal processing techniques such as Fast Fourier Transform (FFT) and envelope analysis, storing only the extracted features rather than raw high-rate data, thereby maintaining diagnostic precision while minimizing storage requirements

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS10697822B2Devices, methods and computer program products providing multi-axis vibrational measurement with predictive analysis

Publication Date: 2020.06.30 PROAXION INC

AI summary

A sensor may include a housing configured to couple to a machine; at least one processor within the housing; a battery within the housing; a communication adapter within the housing and coupled to the at least one processor; and a measurement device within the housing and coupled to the at least one processor and the battery. The communication adapter may be configured to wirelessly connect to a communication network. The measurement device may be configured to: obtain measurements of a physical characteristic of the machine to which the housing is coupled and transmit the measurements via the communication adapter, and automatically switch between a first measurement mode comprising a first sampling rate and a second measurement mode comprising a second sampling rate, different from the first sampling rate, without human intervention.