Indicator generating method and predictive maintenance method for failure prediction for a water heating system, such water heating system, and beverage maker
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Solution Overview
Problem
Existing water heating systems in beverage makers, such as those in aircraft galleys, face challenges in predictive maintenance due to the difficulty in detecting degradation and inefficiencies, which can lead to untimely equipment failures and increased operational costs, particularly because they require extensive observability and additional sensor installations.
Innovation Solution
A method and device that generate condition-based and usage-based indicators using power consumption data, specifically the reheating time and frequency, to predict maintenance needs, allowing for predictive maintenance without the need for additional sensors, leveraging existing communication protocols like ARINC 812 and focusing on deriving degradation patterns from minimal measured data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional sensors are installed to detect degradation and improve measurement precision, then the reliability of predictive maintenance improves, but the device complexity and cost increase
Solution Approach 1:
The heating element serves dual purposes: it both heats the water and acts as a sensor through its resistance measurements. The existing heating device automatically provides degradation detection data without requiring separate sensing components, enabling the system to self-monitor its own condition
Solution Approach 2:
The heating element is designed to perform multiple functions simultaneously: thermal heating and condition monitoring. By measuring the resistance of the heating element itself, the system obtains both operational and diagnostic information from a single component
2Measurement precision
If extensive observability and additional sensors are deployed to detect degradation patterns, then the measurement precision improves, but the ease of operation and installation deteriorates
Solution Approach 1:
The heating element inherently provides its own diagnostic information through resistance measurements. The system leverages the heating element's own electrical properties to detect degradation, eliminating the need for separate sensing infrastructure and simplifying installation
Solution Approach 2:
The patent extracts diagnostic capability from a dedicated sensor and instead derives it from the existing heating element's electrical characteristics. By measuring resistance changes in the heating element itself, the system obtains degradation information without adding separate observational components
3Reliability
If multiple sensors and extensive monitoring are implemented to detect heat efficiency issues, then the reliability of failure prediction improves, but the loss of time and resources for setup increases
Solution Approach 1:
The heating element automatically provides degradation detection data through its resistance measurements during normal operation. The system begins monitoring degradation from day one without requiring setup time for installing additional sensors, as the heating element itself serves as the monitoring instrument
Solution Approach 2:
The system establishes degradation monitoring capability before any failure occurs by continuously measuring heating element resistance during normal heating operations. The monitoring infrastructure is already in place and operational from the beginning, eliminating setup delays
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 enables effective predictive maintenance by identifying equipment degradation and heat efficiency issues, reducing the need for extensive sensor installations and improving spares management, thereby minimizing operational interruptions and costs.
Implementation Method 1
a water tank 18 containing water 20 to be heated by a heating device 22
Data Source
AI summary
An indicator generating method for generating an indicator which is suitable for maintenance prediction of a water heating system is proposed. A power state indication device generates a high power consumption signal if a heating device of the water heating system is activated. The time duration of the activation is such an indicator, if no water flow is present. Furthermore, the time interval between subsequent activations is such an indicator. A predictive maintenance method processes these condition-based indicators and determines a remaining useful lifetime according to a predictive maintenance model. The predictive maintenance device outputs a maintenance signal indicating required maintenance, if the remaining useful lifetime drops below a predetermined threshold. The methods may be performed by water heating systems or beverage makers.