Acoustic emission severance detector and method

• US 5,905,440 A
• Filed: 12/19/1997
• Issued: 05/18/1999
• Est. Priority Date: 12/19/1997
• Status: Expired due to Term

• Current Assignee: Battelle Memorial Institute, Lamb-Weston, Inc. (Lamb Weston Holdings, Inc.)
• Original Assignee: Battelle Memorial Institute, Lamb-Weston, Inc. (Lamb Weston Holdings, Inc.)
• Inventors: Skorpik, James R., Julian, John, Harris, Joe C.
• Primary Examiner(s): Wu, Daniel J.
• Assistant Examiner(s): PHAM, TOAN NGOC
• Application Number:
  US08/995,237
• Time in Patent Office: 515 Days
• Field of Search: 340/680, 340/679, 340/683, 83/22, 83/24, 83/62, 83/62.1, 83/72, 83/74, 83/81, 83/209, 83/210, 83/211, 83/307, 83/370, 83/371, 83/372, 83/954, 83/955, 73/104, 73/659, 73/660
• US Class Current: 340/680
• CPC Class Codes: B26D 1/553 with a plurality of wire-like cutting members
• CPC Class Codes: B26D 3/185 Grid like cutters
• CPC Class Codes: B26D 3/26 specially adapted for cutting fruit or vegetables, e.g. for onions
• CPC Class Codes: B26D 5/00 Arrangements for operating and controlling machines or devices for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
• CPC Class Codes: G05B 19/4065 Monitoring tool breakage, life or condition
• CPC Class Codes: G05B 2219/37245 Breakage tool, failure
• CPC Class Codes: G05B 2219/37337 Noise, acoustic emission, sound
• CPC Class Codes: G05B 2219/37351 Detect vibration, ultrasound
• CPC Class Codes: G05B 2219/37433 Detected by acoustic emission, microphone
• CPC Class Codes: G05B 2219/37434 Measuring vibration of machine or workpiece or tool
• CPC Class Codes: G05B 2219/50203 Tool, monitor condition tool
• CPC Class Codes: Y10T 83/0443 By fluid application
• CPC Class Codes: Y10T 83/089 Responsive to tool characteristic
• CPC Class Codes: Y10T 83/141 With means to monitor and control operation [e.g., self-regulating means]
• CPC Class Codes: Y10T 83/148 Including means to correct the sensed operation

Abstract

The invention has utility generally for monitoring any part for severance of the part. The invention is specifically useful for monitoring severance of a tension blade in a tension blade grid. For general monitoring of a part, the apparatus has wireless connection between the sensing unit and the control unit. The wireless connection is achieved with a transmit/receive unit using radiofrequency power transfer for electrical power and using infrared transmitters and receivers for signal transfer. For food processing, specifically for a vegetable cutting method employing at least one tension blade in a first tension blade grid through which vegetables are passed for cutting the vegetables wherein the at least one tension blade is severed during the cutting, the invention provides for diverting the vegetables to a second tension blade grid. Diversion is accomplished with an acoustic emission sensor acoustically coupled to the at least one tension blade so that during the vegetable cutting, the acoustic emission sensor detects acoustic energy from tension blade severance. The acoustic energy is converted to an electronic signal that is compared in a microprocessor to a threshold. In a severance condition, an actuator receives an alarm signal from the microprocessor and diverts the vegetables to the second tension blade grid.

Claims

1. For a vegetable cutting method employing at least one tension blade in a first tension blade grid through which vegetables are passed for cutting said vegetables wherein at least one tension blade is severed during the cutting, a method for detecting a severance of the at least one tension blade, comprising the steps of:

(a) acoustically coupling a sensor unit having an acoustic emission sensor to said at least one tension blade, said acoustic emission sensor detecting acoustic signals;

(b) receiving acoustic energy from said at least one tension blade into said acoustic emission sensor during said vegetable cutting, and converting said acoustic energy into an electronic signal; and

(c) analyzing said electronic signal by comparison to a threshold.

2. The method as recited in claim 1, further for diverting said vegetables to a second tension blade grid, further comprising the steps of:

(d) sending an alarm signal when said electronic signal exceeds said threshold;

whereupon

(e) diverting said vegetables to said second tension blade grid.

3. The method as recited in claim 1, wherein said threshold is a combination of an amplitude limit and a time duration of said electronic signal in excess of said amplitude limit.

4. The method as recited in claim 1, wherein said sensor unit has a wire coupling to a control unit.

5. The method as recited in claim 1, wherein said sensor unit has a wireless coupling to a control unit through a transmit/receive unit.

6. For a vegetable cutting apparatus employing at least one tension blade in a first tension blade grid through which vegetables are passed for cutting said vegetables wherein said at least one tension blade is severed during the cutting, an apparatus for detecting a severance of the at least one tension blade, comprising:

(a) a sensor unit having an acoustic emission sensor acoustically coupled to said at least one tension blade for receiving acoustic energy from said at least one tension blade into said acoustic emission sensor during said vegetable cutting, and converting said acoustic energy into a first electric signal, said acoustic emission sensor detecting acoustic energy; and

(b) a control unit having a microprocessor connected to said sensor unit for analyzing said electronic signal by comparison to a threshold.

7. The apparatus as recited in claim 6 for further diverting said vegetables to a second tension blade grid, further comprising:

(c) an actuator for receiving an alarm signal from said microprocessor when said electronic signal exceeds said threshold and diverting said vegetables to said second tension blade grid.

8. The apparatus as recited in claim 6, wherein said threshold is a combination of an amplitude limit and a time duration of said electronic signal in excess of said amplitude limit.

9. The apparatus as recited in claim 6, wherein said sensor unit has a wire coupling to the control unit.

10. The apparatus as recited in claim 6, wherein said sensor unit has a wireless coupling to the control unit through a transmit/receive unit.

11. The apparatus as recited in claim 6, wherein said sensor unit has, in addition to the acoustic emission sensor;

(i) an optical signal generator for receiving said first electrical signal and generating an optical signal;

(ii) a first optical window for transmitting the optical signal from the sensor unit; and

(iii) a radiofrequency power receiver for receiving radiofrequency energy and converting the radiofrequency energy to electricity for operating the acoustic emission sensor and the optical signal generator for a wireless coupling to a transmit/receive station.

12. The apparatus as recited in claim 11, wherein the transmit/receive station comprises:

(i) a second optical window for receiving said optical signal from said first optical window together with an optical transducer for converting the optical signal to an electrical signal; and

(ii) a radiofrequency power transmitter for converting electricity into the radiofrequency energy and transmitting the radiofrequency energy to the radiofrequency power receiver.

13. The apparatus as recited in claim 12, wherein the control unit provides the electricity to the radiofrequency power transmitter, and receives the electrical signal from the optical transducer.

14. For a vegetable cutting apparatus employing at least one tension blade in a first tension blade grid through which vegetables are passed for cutting said vegetables wherein said at least one tension blade is severed during said cutting, an apparatus for detecting a severance of the at least one tension blade, comprising:

(a) a sensor unit having

(i) an acoustic emission sensor acoustically coupled to said at least one tension blade for receiving acoustic energy from said at least one tension blade into said acoustic emission sensor during said vegetable cutting, and converting said acoustic energy into a first electric signal, said acoustic emission sensor detecting acoustic energy;

(ii) an optical signal generator for receiving said first electrical signal and generating an optical signal,

(iii) a first optical window for transmitting the optical signal from the sensor unit,

(iv) a radiofrequency power receiver for receiving radiofrequency energy and converting the radiofrequency energy to electricity for operating the acoustic emission sensor and the optical signal generator;

(b) a transmit/receive station spaced apart from said sensor unit having

(i) a second optical window for receiving said optical signal from said first optical window together with an optical transducer for converting the optical signal to an electrical signal,

(ii) a radiofrequency power transmitter for converting electricity into the radiofrequency energy and transmitting the radiofrequency energy to the radiofrequency power receiver; and

(c) a control unit for providing the electricity to the radiofrequency power transmitter, and for receiving the electrical signal from the optical transducer having

(i) a microprocessor within the control unit for analyzing the electrical signal by comparison to a threshold.

15. The apparatus as recited in claim 14 for further diverting said vegetables to a second tension blade grid, further comprising:

(d) an actuator for receiving an alarm signal from said microprocessor when said electronic signal exceeds said threshold and diverting said vegetables to said second tension blade grid.

16. The apparatus as recited in claim 14, wherein said acoustic emission sensor has a frequency in a range greater than 100 kHz.

17. For a vegetable cutting apparatus employing at least one tension blade in a first tension blade grid through which vegetables are passed for cutting said vegetables wherein said at least one tension blade is severed during the cutting, an apparatus for diverting said vegetables to a second tension blade grid, comprising:

(a) a sensor unit having

(i) an acoustic emission sensor acoustically coupled to said at least one tension blade for receiving acoustic energy from said at least one tension blade into said acoustic emission sensor during said vegetable cutting, and converting said acoustic energy into a first electric signal, said acoustic emission sensor detecting acoustic energy;

(ii) an optical signal generator for receiving said first electrical signal and generating an optical signal,

(iii) a first optical window for transmitting the optical signal from the sensor unit,

(iv) a radiofrequency power receiver for receiving radiofrequency energy and converting the radiofrequency energy to electricity for operating the acoustic emission sensor and the optical signal generator;

(b) a transmit/receive station spaced apart from said sensor unit having

(i) a second optical window for receiving said optical signal from said first optical window together with an optical transducer for converting the optical signal to an electrical signal,

(ii) a radiofrequency power transmitter for converting electricity into the radiofrequency energy and transmitting the radiofrequency energy to the radiofrequency power receiver; and

(c) a control unit for providing the electricity to the radiofrequency power transmitter, and for receiving the electrical signal from the optical transducer having

(i) a microprocessor within the control unit for analyzing the electrical signal by comparison to a threshold,

(d) an actuator for receiving an alarm signal from said microprocessor when said electronic signal exceeds said threshold and diverting said vegetables to said second tension blade grid.

18. The apparatus as recited in claim 17, wherein said acoustic emission sensor has a frequency in a range greater than 100 kHz.

19. An apparatus for detecting severance of a part, comprising:

(a) a sensor unit having

(i) an acoustic emission sensor acoustically coupled to said part for receiving acoustic energy from said part into said acoustic emission sensor during use of said part, and converting said acoustic energy into a first electrical signal, said acoustic emission sensor detecting acoustic energy,

(ii) an optical signal generator for receiving said first electrical signal and generating an optical signal,

(iii) a first optical window for transmitting the optical signal from the sensor unit,

(iv) a radiofrequency power receiver for receiving radiofrequency energy and converting the radiofrequency energy to electricity for operating the acoustic emission sensor and the optical signal generator;

(b) a transmit/receive station spaced apart from said sensor unit having

(i) a second optical window for receiving said optical signal from said first optical window together with an optical transducer for converting the optical signal to an electrical signal,

(ii) a radiofrequency power transmitter for converting electricity into the radiofrequency energy and transmitting the radiofrequency energy to the radiofrequency power receiver; and

(c) a control unit for providing the electricity to the radiofrequency power transmitter, and for receiving the electrical signal from the optical transducer having

(i) a microprocessor within the control unit for analyzing the electrical signal by comparison to a threshold.

20. The apparatus as recited in claim 19, wherein said acoustic emission sensor has a frequency in a range greater than 100 kHz.