Description:FIELD OF THE INVENTION
This invention relates to Development of a Real-Time Health Monitoring System for Machines
BACKGROUND OF THE INVENTION
In industrial environments, the absence of real-time monitoring systems results in an increased risk of machinery breakdowns and safety hazards. Reactive maintenance approaches exacerbate downtime and operational inefficiencies. Therefore, there is a critical need for an innovative monitoring solution that continuously tracks machine health, analyses data in real-time, and provides early alerts to optimize maintenance schedules and ensure workplace safety, ultimately driving productivity and cost savings.
CA3007519 Systems and methods for estimating engine and electrical machine health are provided. The systems and methods therefore include features that provide for improved health estimates of one or more engines and/or electrical machines of one or more engines having an electrical machine embedded therein or coupled thereto. In particular, the systems and methods therefore include features for utilizing sensed or measured operating parameters of the electrical machines and/or operating parameters of the prime mover to estimate the health of the prime mover and/or the electrical machines embedded therein or coupled thereto.
RESEARCH GAP:
• The overall health of the machine is observed by using a variety of sensors.
• Emergency notification is generated if a defect is observed in the readings.
• Direct connection with cloud served.
• 24/7 health monitoring.
US11493379B2 A system for monitoring at least one machine including a plurality of magnetic sensors synchronously sensing magnetic fields emitted by at least one machine, along a corresponding plurality of channels and outputting magnetic field emission signals corresponding to the magnetic fields, a signal analyzer receiving at least a portion of the magnetic field emission signals, performing analysis thereof, and providing an output based on the analysis, the output including at least an indication of a condition of the at least one machine, and a control module receiving the indication of the condition and initiating at least one of a repair event on the at least one machine, an adjustment to a maintenance schedule of the at least one machine and an adjustment to an operating parameter of the at least one machine based on the indication, whereby efficacy of the at least one machine is improved.
RESEARCH GAP:
• A variety of sensors can be added to monitor the overall health of the machine.
• Direct connection with the cloud server.
• The user is notified whenever a defect is noticed by the system.
None of the prior art indicate above either alone or in combination with one another disclose what the present invention has disclosed. This invention relates to Development of a Real-Time Health Monitoring System for Machines.
SUMMARY OF THE INVENTION
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention.
This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.
To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.
In this invention, we've suggested a system that offers the ability to continually monitor a machine in real-time and continuously generate output that shows the health of the machine based on multiple sensors for different parts of the machine.
BRIEF DESCRIPTION OF THE DRAWINGS
The illustrated embodiments of the subject matter will be understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:
Figure 1. The system of sensor for monitoring health
Figure 2. The Entire Health Monitoring system
The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION OF THE INVENTION
The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a",” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
In addition, the descriptions of "first", "second", “third”, and the like in the present invention are used for the purpose of description only, and are not to be construed as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Thus, features defining "first" and "second" may include at least one of the features, either explicitly or implicitly.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
In this invention, we've suggested a system that offers the ability to continually monitor a machine in real-time and continuously generate output that shows the health of the machine based on multiple sensors for different parts of the machine.
During the sensor data acquisition phase, a wide range of sensors are carefully attached to different vital parts of the mechanical apparatus to record a wide range of operating parameters that are essential for health monitoring. These sensors have a wide range of features that are customized to the characteristics of the components that are being observed. Thermal sensors (101) are positioned carefully to measure differences in thermal profiles for temperature assessment. This allows for careful monitoring of any overheating or cooling anomalies that may indicate underlying problems. Vibratory sensors (102) are carefully incorporated to monitor mechanical vibrations, giving important information about the machine's structural integrity and operational stability. These sensors are skilled at detecting even the smallest oscillations and tremors. Acoustic sensors (103) are carefully calibrated to identify auditory signatures and are strategically used to record sound emissions. This allows for the detection of unusual noises that may indicate component failure or deterioration. Furthermore, specialized electrical analysis sensors (104) are used to examine electrical parameters, making it easier to identify aberrations like voltage fluctuations or irregular current flows that could indicate upcoming electrical faults or failures. Together, these sensors function round the clock, gathering and sending real-time information on temperature, vibration, sound, electrical signals, and other relevant parameters to the data acquisition system. There, the gathered information is carefully processed and analysed to identify trends, abnormalities, and possible problems. This well-planned sensor deployment approach guarantees thorough health monitoring of the mechanical machine, enabling preventive maintenance and providing protection against unplanned downtime or catastrophic breakdowns. All the information gathered by the sensors is sent to the microcontroller (105) and then from it, it is sent to the main computing unit (106).
A mechanical machine health monitoring system is a comprehensive solution that is intended to provide ongoing watchfulness over the machine's operation. Using an advanced data processing and analysis framework, the system uses algorithms to examine collected sensor data in real-time and display it in a display unit (108). These algorithms painstakingly identify patterns, trends, or anomalies in the data, acting as early warning systems for possible problems with the machine's condition. Every sensor is given a unique pattern, and when these patterns diverge, alarms are sent out to indicate possible issues with the related component. When an anomalous pattern appears, a message is immediately created to notify the selected staff who are in charge of keeping an eye on the machine's health. To ensure that pertinent stakeholders are informed as soon as possible, these notifications are distributed via a variety of communication channels, such as visual displays, auditory alarms, email notifications, or mobile app alerts. Moreover, the alerts not only indicate the identified problem but also offer comprehensive details on the impacted element, facilitating focused action and prompt resolution. The system functions flawlessly, maximizing operational efficiency and avoiding downtime by continuously monitoring the machine's health, proactively recognizing anomalies, and permitting prompt steps to manage risks. All the data gathered by the system is at the same time, stored in the cloud (109) for storing and future analysation.
ADVANTAGES OF THE INVENTION
• This enables proactive maintenance and intervention before problems escalate, minimizing downtime and costly repairs.
• By identifying patterns and trends indicative of component deterioration or malfunction, the system facilitates preventive maintenance scheduling.
• With 24/7 monitoring capabilities, the system ensures optimal operational efficiency by promptly addressing emerging issues.
• Timely detection of potential issues through continuous monitoring enhances workplace safety by mitigating the risk of accidents or equipment failures.
• Data is stored in cloud server for future analysation.
, Claims:1. A real-time mechanical machine health monitoring system, comprising: thermal sensor, vibratory sensor, acoustic sensor, electrical analysis sensor, computing unit and display unit.
2. The system as claimed as claim 1, wherein the thermal sensors (101) positioning carefully to measure differences in thermal profiles for temperature assessment.
3. The system as claimed as claim 1, wherein the system uses algorithms to examine collected sensor data in real-time and display it in a display unit (108).
4. The system as claimed as claim 1, wherein the Vibratory sensors (102) incorporated to monitor mechanical vibrations, giving important information about the machine's structural integrity and operational stability.
5. The system as claimed as claim 1, wherein the Acoustic sensors (103) calibrating to identify auditory signatures and are strategically used to record sound emissions.
6. The system as claimed as claim 1, wherein the electrical analysis sensors (104) are used to examine electrical parameters, making it easier to identify aberrations like voltage fluctuations or irregular current flows that could indicate upcoming electrical faults or failures.