Field of the Invention
This invention relates to fatigue crack growth prediction & remote detection system based on IoT technology.
Background of the Invention
US8746077B2: A fatigue sensor for monitoring the health state of structural members is disclosed. The sensor has multiple parallel beams, each sensitive to different levels of fatigue, that are designed to fail prematurely but progressively as the sensor goes through the same fatigue cycles as the structural member it is attached to. Whenever fatigue levels on a particular beam of the sensor exceed the engineered number of fatigue cycles, that particular beam fails and sensor electronics can detect that failure and transmit this information wirelessly when interrogated by an external interrogator. Having multiple beams that fail after different numbers of fatigue cycles enables the health state of the structural member to be monitored, in that unlike normal fracture sensor that sense failure of the structural members after the actual fracture event, the present invention is capable of sensing imminent failure of the structural member before the actual failure occurs.
Research Gap: In the present work the FAC series crack propagation gauge which provides the rate of crack growth as well as the direction duo to loading conditions. Apart from this the feeds from other sensors is also collected so as to analyze the system in totality.
US6443018B1: A multidirectional fatigue damage indicator is disclosed. The fatigue damage indicator is composed of a series of fatigue fuse elements welded to a semicircular assembly frames. The fuse elements have the same fatigue lifetime in each row but have different lifetime from row to row so that it may enable one to monitor the progress of fatigue damage of the structure. A series of fatigue fuse elements are welded to a semicircular assembly frame in circumferential direction and additionally in radial direction. The arrangement in circumferential direction is to cover the changing characteristics of the principal stress directions while that in radial direction is to monitor the actual progress of fatigue damage under combined cyclic loads by watching the sequential fracture of the fuse elements.
Research Gap: It provides a testing facility where the fatigue is analyzed along with the effect of temperature, Vibration etc., the component can be analyzed while it is in service as the analysis is done at a Remote location through IoT application.
US5528151AA: Plurality of fatigue life test strips (16, 18, 20, 22) has each of the strips anchored to a base (12) which is subject to thermal cycling and consequent dimensional change which causes fatigue. The base is, at best, semi conductive, and the strips are conductive. The conductivity of each of the strips is measured by test circuit (52) so that, when one fails due to fatiguing, the failure is signaled.
Research Gap: It provides multiple location test facility within a structure to provide a holistic analysis of the entire machine/ structure. The structural Integrity factor value gives the usability status of structure or machine.
JP2001272319A: To realize a fatigue damage prognosis device and a method therefor, capable of easily and quantitatively measuring a crack length. SOLUTION: This fatigue damage prognosis device has a fatigue sensor having a thin plate sacrificial test piece stuck to a structure to predict fatigue damages, having line symmetrical artificial cracks formed in a stress concentration part in the center of the longitudinal direction, and fatigue gauges, each detecting a crack development state of the artificial crack of the sacrifice test piece, on the basis of a change in an electric resistance value caused by wire breaking of electric resistance wire. The fatigue damage prognosis device comprises the fatigue sensor, a measuring instrument measuring the detection value of the fatigue sensor, a data electric transmission device electrically transmitting the measurement data of the measuring instrument.
Research Gap: FAC Series Crack Gauge measures the crack Propagation and gives the details of the crack present. However, the additional stain gauge Rosettes determines the 3D Strain profile and with the help of 3D image of the Component or Structure and the material details the Stress Profile along the component is made from the FEA which helps in determining the generation of new cracks due to continued fatigue.
US7621193B2: A sensor device for monitoring and testing the integrity of structural elements is disclosed. A frangible membrane including a thin breakable conductor sense loop is bonded to a structural element to be tested. A fracture in the bonded structural element induces a disruption in the both the frangible membrane and the thin breakable conductor sense loop. Measured electrical property change of the disrupted conductor sense loop reveals the fracture in the structural element. Connection to the sensor device may be through a connector or using a wireless reader which remotely energizes the sensor device. The sensor may also be implemented as a gasket and/or employ weep holes to the breakable conductor to reveal possible corrosion as well.
Research Gap: The data from the sensors is transmitted through a wireless mode to a Local Controller [19], which in turn sends the Data to Cloud though IoT based technology to an Android or Web based application to a remote location where FEA is done and Structural Integrity Factor is determined.
CN111207992B: The invention discloses a loading frame of a three-station steel rail fatigue testing machine, which relates to the technical field of steel rail and welding joint fatigue testing machines and comprises a bottom plate provided with a deck plate, wherein four stand columns are installed on the deck plate, the tops of the four stand columns are connected with a top plate, three equidistant actuator installation holes are formed in the top plate, and the actuator installation holes are respectively positioned between two adjacent stand columns; the actuators are arranged in the actuator mounting holes and connected with the same hydraulic station; the workbench is arranged on the table top plate between the two adjacent stand columns respectively, the workbench is provided with steel rail supporting parts, and the steel rail supporting parts comprise two steel rail supports which are symmetrically arranged at two ends of the actuator and the horizontal distance of which can be adjusted. The invention integrates three sampling fatigue test pieces of the steel rail and the welding joint into three stations of a test rack to synchronously complete fatigue tests under the same test method, greatly improves the test efficiency, facilitates the adjustment of the bearing position of the steel rail and has high structural strength of the bearing frame.
Research Gap: The system provides the use of IoT enabled sensors where multiple sites of a structure / machine can be analyzed simultaneously for both structural Integrity as well as propagation of the cracks already result due to the nature of fatigue loading conditions of the system being analyzed.
None of the prior art indicate above either alone or in combination with one another disclose what the present invention has disclosed. Present invention is model every computation based on machine attributes is represented as an input-output system. Finite element analysis from the onsite data collected can be performed at a remote location and a structural integrity factor is being evaluated to predict the nature of crack development and the rate of crack propagation. Ultimately, the computations are aggregated by the framework configured by the user to produce an output computation attribute that indicates a machine condition or predicts a machine condition.
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, 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.
Over a period of time the machine components tend to fail due to repetitive loading conditions known as Fatigue. The timely detection of Fatigue crack in a machine component during service is a concern. Various industrial equipment needs continuous monitoring to enhance the safety, reliability, and availability and to decrease the cost of maintenance of modern industrial systems. An IOT framework and a user interface allow a user to configure a machine condition monitoring system. In this model every computation based on machine attributes is represented as an input-output system. A Finite Element Analysis from the onsite data collected can be performed at a remote location and a Structural Integrity Factor is being evaluated to predict the nature of crack development and the rate of Crack Propagation. Ultimately, the computations are aggregated by the framework configured by the user to produce an output computation attribute that indicates a machine condition or predicts a machine condition. The Internet of Things (IoT) has enormous development in recent trends of industrial, environmental, and medical applications. The availability of massive amount of processing power in the cloud, new opportunities have emerged for complete automation of industrial devices.
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:
An IOT framework and a user interface allow a user to configure a machine condition monitoring system. In this model every computation based on machine attributes is represented as an input-output system. A Finite Element Analysis from the onsite data collected can be performed at a remote location and a Structural Integrity Factor is being evaluated to predict the nature of crack development and the rate of Crack Propagation. Ultimately, the computations are aggregated by the framework configured by the user to produce an output computation attribute that indicates a machine condition or predicts a machine condition. The Internet of Things (IoT) has enormous development in recent trends of industrial, environmental, and medical applications. The availability of massive amount of processing power in the cloud, new opportunities have emerged for complete automation of industrial devices. The above figures show the block diagrams and the process flowchart of the IoT enabled Machine/Equipment Health Monitoring and Preventive Maintenance Suggestion system. [1 – 9] Machine Sensors: These are the integral part of the machine Monitoring Unit, where more than one sensor based on the variables that needs to be monitored as per the rated values by the equipment manufacturer. These variables and the respective sensors can differ from one Test equipment to another for a particular application. Rotating Machine element / Component in service the following sensor used are [1] Machine Vibration sensor, [2] High Speed HD Camera,[3] Material Data Feed , [4] RPM measurement sensor, [5] Strain Gauge Rosettes, [6] FAC Series gauge along with Crack Gauge Adaptor, [7] Ambient TemperatureSensor, [8] Test Subject temperature sensor,[9] Decibel Sensor. [10]. Keyboard: It is a user interface used to feed the Rated Device values as per the prescribed values from the manufacturer. These values are the values specific to the Machine / Structure component under test Like the Input / Output requirement for which the system is supposed to work, Types of load for which the system is designed, Materials specific to the test component etc. [11] Computing Unit: All the sensors employed give their respective inputs to this device. Along with the inputs from the sensors it also receives the data from a user entered Rated Values of the Device. [12] Power Supply 1: This is the power supply unit for the Machine Monitoring Unit which fulfils the power requirements of all the sensors, Keyboard, RF Modem as well as Computing unit. [13] RF Modem-1: This is used to transmit data from the control unit to a Local Controller for further data processing. [14-18] Monitoring Unit: These are the units employed for multiple locations of the same machine / structure for a holistic analysis of the Machine/Structure. Each of these units consists parts from [1-13] which are the sensors or the input feeds.
[19] Local Controller: It comprise of [24] RF Modem which receives the signals from the nearby machine monitoring units, [25] Microcontroller collects the data from RF Modem and stores in [26] Data Storage Device, then gives the modified output through a [27] Wi Fi Modem to Cloud Server. [28] Power Supply -2: It Fulfills the power requirement of all the components of Local Controller i.e. [24], [25], [26] and [27]. The data from the local Controller is feed to the [20] Cloud Server which in turn transmit the data to a [22] Web based application and [21] Android based application so as to monitor the condition of the machine from a remote location and take the necessary action for the machine maintenance.
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.
These and other advantages of the present subject matter would be described in greater detail with reference to the following figures. It should be noted that the description merely illustrates the principles of the present subject matter. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described herein, embody the principles of the present subject matter and are included within its scope.
The Internet of Things (IoT) has enormous development in recent trends of industrial, environmental, and medical applications. The availability of massive amount of processing power in the cloud, new opportunities have emerged for complete automation of industrial devices. The above figures show the block diagrams and the process flowchart of the IoT enabled Machine/Equipment Health Monitoring and Preventive Maintenance Suggestion system. [1 – 9] Machine Sensors: These are the integral part of the machine Monitoring Unit, where more than one sensor based on the variables that needs to be monitored as per the rated values by the equipment manufacturer. These variables and the respective sensors can differ from one Test equipment to another for a particular application. Rotating Machine element / Component in service the following sensor used are [1] Machine Vibration sensor, [2] High Speed HD Camera,[3] Material Data Feed , [4] RPM measurement sensor, [5] Strain Gauge Rosettes, [6] FAC Series gauge along with Crack Gauge Adaptor, [7] Ambient Temperature Sensor, [8] Test Subject temperature sensor,[9] Decibel Sensor. [10]. Keyboard: It is a user interface used to feed the Rated Device values as per the prescribed values from the manufacturer. These values are the values specific to the Machine / Structure component under test Like the Input / Output requirement for which the system is supposed to work, Types of load for which the system is designed, Materials specific to the test component etc. [11] Computing Unit: All the sensors employed give their respective inputs to this device. Along with the inputs from the sensors it also receives the data from a user entered Rated Values of the Device. [12] Power Supply 1: This is the power supply unit for the Machine Monitoring Unit which fulfils the power requirements of all the sensors, Keyboard, RF Modem as well as Computing unit. [13] RF Modem-1: This is used to transmit data from the control unit to a Local Controller for further data processing. [14-18] Monitoring Unit: These are the units employed for multiple locations of the same machine / structure for a holistic analysis of the Machine/Structure. Each of these units consists parts from [1-13] which are the sensors or the input feeds.
[19] Local Controller: It comprise of [24] RF Modem which receives the signals from the nearby machine monitoring units, [25] Microcontroller collects the data from RF Modem and stores in [26] Data Storage Device, then gives the modified output through a [27] Wi Fi Modem to Cloud Server. [28] Power Supply -2: It fulfills the power requirement of all the components of Local Controller i.e. [24], [25], [26] and [27]. The data from the local Controller is feed to the [20] Cloud Server which in turn transmit the data to a [22] Web based application and [21] Android based application so as to monitor the condition of the machine from a remote location and take the necessary action for the machine maintenance.
ADVANTAGES OF THE INVENTION:
• This is a robust system designed for prediction & detection of Fatigue Crack Growth (FCG) and its Propagation in the components/ elements of machines and structures respectively for strength & material integrity while they are operating.
• Determination of parameters like Crack Tip Opening Displacement (CTOD) & Crack Tip Advancement (CTA) for cyclic loading during the fatigue analysis of the system being evaluated.
• Analysis of FCG based on the effect of number of cycles (N), Load Ratio (R) and Stress Intensity Factor Range (?K) is being evaluated to enhance the understanding of nature of Fatigue Crack Growth Mechanism.
• The design facilitates to monitor the equipment from any remote location.
• The equipment is equipped with High Speed HD Camera which can create the 3D Image of the Test Component which could then be utilized for the FEA analysis being done at a remote location. Analysis details can be then shared on the either the Android / Web Based application.
• The specialty of this equipment is that, it shows the Structural Integrity Factor on the dashboard along with the graphical representation of contours of plastic strain distribution & hydrostatic stress distribution ahead of the crack tip region to help assess the damage caused to the structural element/machine component under the given working conditions.
• The foremost advantage of the system is it facilitates real time monitoring from any location as the data is accessible from web or android device.

Claims:

1. A Fatigue crack growth prediction & remote detection system based on IoT technology system to monitor the movement of the machine parts during machining system is comprising: Vibration sensor (1); High speed HD Camera (2); Material Data (3); RPM sensor (4); Strain Gauge Rosettes Output (5); FAC Series Gauge along with Crack Gauge adaptor (6); Ambient Temperature sensor (7); Test Subject Temperature sensor (8); Decibel sensor (9); Keyboard user input parameter (10); Computing unit (11); Power supply (12); RF Modem (13); Local controller (19); Cloud server (20); Android & web application (21 &22); RF &Wi-Fi modem (24&27); Microcontroller (25); Data Storage (26); Machine monitoring (14 to 18);
2. The system is claimed in claim 1, wherein which is consist of [1] machine vibration sensor, [2] high speed HD camera, [3] material data feed, [4] rpm measurement sensor, [5] strain gauge rosettes, [6] FAC series gauge along with crack gauge adaptor, [7] ambient temperature sensor, [8] test subject temperature sensor, [9] decibel sensor. [10].
3. The system is claimed in claim 1, wherein which is consist of keyboard: it is a user interface used to feed the rated device values as per the prescribed values from the manufacturer; and said values are the values specific to the machine / structure component under test like the input / output requirement for which the system is supposed to work, types of load for which the system is designed, materials specific to the test component.
4. The system is claimed in claim 1, wherein which is consist of [11] computing unit: all the sensors employed give their respective inputs to this device; along with the inputs from the sensors it also receives the data from a user entered rated values of the device.
5. The system is claimed in claim 1, wherein which is consist of [12] power supply 1: this is the power supply unit for the machine monitoring unit which fulfils the power requirements of all the sensors, keyboard, RF modem as well as computing unit.
6. The system is claimed in claim 1, wherein which is consist of [13] RF modem-1: this is used to transmit data from the control unit to a local controller for further data processing.
7. The system is claimed in claim 1, wherein which is consist of [14-18] monitoring unit: these are the units employed for multiple locations of the same machine / structure for a holistic analysis of the machine/structure.