Diagnostic rule tool condition monitoring system
First Claim
1. A method for monitoring the condition of an electric powered tool, comprising:
- measuring a power consumption signal of the tool while performing a cyclical task;
analyzing selected feature components of the power consumption signal and establishing an initial power threshold tolerance band of predetermined value in a learning mode of the tool;
continuing to use the tool in a monitoring mode while performing the cyclic task and monitoring a plurality of selected feature components of the power consumption signal;
comparing the monitored power consumption signal with the initial power threshold tolerance band and based on the comparison, diagnosing the condition of the tool;
designating at least one combination of the plurality of selected feature components of the power consumption signal as a relearning code representative of a condition of tool wear; and
during the monitoring of said power consumption signal, comparing the monitored power consumption signal to the relearning code and, in response to a detection that the monitored power consumption signal corresponds to said relearning code, recalculating and adjusting the initial power threshold tolerance band while operating in a relearning mode of the tool.
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Abstract
A tool condition monitoring system monitors the power consumption of a tool during performance of a cyclical task. The system monitors a plurality of characteristics of the power consumption and diagnoses the condition of the tool based upon the plurality of characteristics. A rule base of the plurality of characteristics is generated in a learning mode by acquiring a tool of known condition for a plurality of cycles. In monitor mode, the system monitors the power consumption of a tool and diagnosis the condition of the tool by indexing the rule base based upon the plurality of characteristics monitored. In addition, a method is disclosed wherein the band may be modified for accommodating tool wear and avoiding nuisance detection such that the system can keep monitoring in tool'"'"'s lifetime.
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Citations
13 Claims
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1. A method for monitoring the condition of an electric powered tool, comprising:
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measuring a power consumption signal of the tool while performing a cyclical task;
analyzing selected feature components of the power consumption signal and establishing an initial power threshold tolerance band of predetermined value in a learning mode of the tool;
continuing to use the tool in a monitoring mode while performing the cyclic task and monitoring a plurality of selected feature components of the power consumption signal;
comparing the monitored power consumption signal with the initial power threshold tolerance band and based on the comparison, diagnosing the condition of the tool;
designating at least one combination of the plurality of selected feature components of the power consumption signal as a relearning code representative of a condition of tool wear; and
during the monitoring of said power consumption signal, comparing the monitored power consumption signal to the relearning code and, in response to a detection that the monitored power consumption signal corresponds to said relearning code, recalculating and adjusting the initial power threshold tolerance band while operating in a relearning mode of the tool. - View Dependent Claims (2, 3, 4)
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5. A method of monitoring a tool operation, comprising:
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operating a tool in a learning mode while measuring defined operational characteristics of the tool;
analyzing the measured operational characteristics and calculating an initial operational tolerance band representative of a desired operating performance of the tool;
further operating the tool in a production mode while monitoring the operational characteristics of the tool;
designating at least certain operational characteristics as relearning code characteristics representative of a condition of the tool when experiencing tool wear;
while operating the tool in the production mode, comparing the monitored operational characteristics with the relearning code characteristics and, in response to detection that the monitored operational characteristics correspond to the relearning load characteristics, recalculating and adjusting the initial operational tolerance band in a relearning mode of the tool. - View Dependent Claims (6, 7, 8, 9, 10, 11, 12)
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13. A method of monitoring a tool operation comprising the steps of:
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1) operating said tool in a learning mode and capturing samples of selected operational characteristics associated with an operation cycle of said tool;
2) analyzing said capture sample characteristics to define an operational tolerance band having an upper limit and a lower limit of expected operation;
3) defining an extreme upper limit and an extreme lower limit relation to a standard deviation difference between said upper band limit and said lower band limit;
4) operating said tool in a production mode;
5) capturing selected operational characteristics of each operational cycle of said tool during said production mode;
6) storing some of said captured operational characteristics to define relearning code characteristics of said tool;
7) comparing said captured operational characteristics of each operational cycle to said stored relearning code characteristics; and
8) adjusting said upper band limit and said lower band limits within said extreme upper and lower limits should said captured operational characteristics match said relearning code characteristics.
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Specification