Virtual Sound Sensing for Machinery Predictive Maintenance
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Solution Overview
Problem
Existing vibration and sound monitoring systems for predictive maintenance are costly and prone to noise interference, with vibration data being limited to the vicinity of the sensor and sound data being unreliable at certain frequencies due to standing waves and ambient noise.
Innovation Solution
A method and apparatus that utilizes measured vibration data to indirectly estimate sound data using a pre-measured acoustic transfer function, reducing the need for continuous sound monitoring by minimizing noise interference and optimizing data collection during quiet periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If both sound and vibration sensors are used for monitoring, then monitoring accuracy is improved, but cost increases
Solution Approach 1:
The patent creates a virtual sound sensor by using the acoustic transfer function to transform vibration data into estimated sound data. This copying approach allows the system to obtain sound information without deploying physical sound sensors, thereby maintaining monitoring accuracy while reducing hardware costs and system complexity.
Solution Approach 2:
The patent replaces the need for acoustic sensors (microphones) with a computational approach. By using the acoustic transfer function to process vibration data, the system substitutes physical acoustic measurement with mechanical vibration measurement combined with signal processing, eliminating the need for additional sound sensing hardware.
2Loss of information
If microphones are used for continuous sound monitoring, then sound data availability is improved, but noise interference increases
Solution Approach 1:
The patent introduces the acoustic transfer function as an intermediary that connects vibration data to sound data. This transfer function, pre-measured under quiet conditions, acts as a mediator that allows the system to estimate sound data from vibration data during noisy operational conditions, thereby avoiding direct acoustic measurement that would be contaminated by environmental noise.
Solution Approach 2:
The acoustic transfer function is measured and stored in advance during quiet conditions when no noise interference is present. This preliminary action allows the system to have a clean reference model ready for use during operational monitoring, eliminating the need to perform acoustic measurements in real-time noisy environments.
3Area of stationary object
If microphones are deployed at multiple locations, then sound coverage is improved, but cost and complexity increase
Solution Approach 1:
The patent makes the vibration sensor multi-functional by enabling it to serve both as a vibration monitor and as a virtual sound sensor through the acoustic transfer function. This universality allows a single vibration sensor to provide both vibration and sound information, eliminating the need for separate sound sensors at multiple locations and reducing overall system complexity.
Data Source
AI summary
In example implementations described herein, there are systems and methods for performing predictive maintenance which can include collecting vibration data related to an operation of a first machine during a first time period, computing sound data related to the operation of the first machine during the first time period based on the collected vibration data, and predicting, based on the computed sound data, at least one value associated with a maintenance of the first machine. In some aspects, the systems and methods may further include measuring an acoustic transfer function relating the vibration data related to the operation of the first machine to one or more of the sound pressure data or the particle velocity data.