Working Machine Structural Part Condition Assessment via Position Comparison
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Solution Overview
Problem
Traditional methods for inspecting the condition of working machines, such as wear and clearance in joints, require a clean, controlled environment and often result in maintenance breaks, leading to less frequent inspections and increased risks of unplanned breakdowns.
Innovation Solution
A method that compares the actual position or state of motion of a structural part to a computational position or state of motion, determined using a computational model, allowing for on-site condition assessment during normal operation without additional equipment, enabling early detection of wear and planned maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional inspection methods are used to determine the condition of a working machine, then measurement accuracy is improved, but productivity deteriorates due to maintenance breaks and transportation requirements
Solution Approach 1:
The working machine performs self-inspection by using its own control system and sensors to monitor its structural parts during normal operation. The control system determines the actual position of structural parts and compares it with the computational model, enabling the machine to assess its own condition without external inspection equipment or maintenance breaks.
Solution Approach 2:
The control system serves multiple functions: it controls the working machine's operation, stores the computational model, processes sensor data, and performs condition assessment. This multi-functionality eliminates the need for separate inspection equipment and allows continuous operation while monitoring machine health.
2Reliability
If traditional inspection methods are used, then reliability is improved through thorough condition assessment, but loss of time increases due to transportation and maintenance breaks
Solution Approach 1:
The condition assessment process operates continuously during the working machine's normal operation. Sensors continuously monitor the actual position of structural parts, and the control system continuously compares this data with the computational model, enabling ongoing reliability assessment without interrupting the machine's useful work.
Solution Approach 2:
The system performs preliminary detection of wear and loosening by continuously monitoring structural part positions. By detecting degradation trends early during normal operation, the system enables planned maintenance before failures occur, reducing emergency repairs and downtime.
3Measurement precision
If equipment is added for condition monitoring, then measurement capability is improved, but device complexity increases
Solution Approach 1:
The control system is designed to perform both operational control and condition monitoring functions. It stores the computational model of the working machine, processes sensor data from structural parts, and performs condition assessment, thereby eliminating the need for separate dedicated monitoring equipment and reducing overall system complexity.
Data Source
AI summary
A condition of at least one structural part (11) of a working machine (10) is determined by determining a computational position of the first structural part (11′) on the basis of the computational model of the working machine (10) and determining an actual position of the first structural part (11′) by detecting means (22). The condition of the at least one structural part (11) is determined on the basis of the difference between the computational position of the first structural part (11′) and the actual position of the first structural part (11′).