Systems and methods for detection and analysis of faulty components in a rotating pulley system

Abstract

A vibration monitoring system described herein is used to detect and analyze mechanical characteristics such as vibrations emanating from a rotating system (including the shaft and bearing system). The analysis of the mechanical characteristics yields decision data as to whether and which component connected with the rotating system is faulty so that it may be replaced. An example of a rotating system would be any of the rotating accessories present in an automotive vehicle.

What is claimed is: 
     
         1 . A vibration monitoring device ( 700 ) for identifying a faulty component in a rotating system, wherein the rotating system comprises a rotating component ( 760 ), the device ( 700 ) comprising:
 (a) a device base ( 710 ), configured for attachment to a distal end ( 761 ) of the rotating component ( 760 );   (b) a housing ( 720 ) comprising:
 i. a first end ( 721 ), attached to the device base ( 710 ); 
 ii. a second end ( 722 ); and 
 iii. a first rotational axis ( 730 ) passing through the two ends; 
   (c) a support platform ( 740 ) having two parallel faces, the platform ( 740 ) disposed within the housing ( 720 ) such that the faces are orthogonal to the rotational axis ( 730 );   (d) a motion sensor ( 750 ) comprising a set of accelerometers ( 755 ) disposed on the support platform ( 740 );   wherein the device ( 700 ) is attached to the distal end ( 761 ) of the rotating component ( 760 ) such that the first rotational axis ( 730 ) is coaxial with a second rotational axis ( 735 ) of the rotating component,   wherein as the component ( 760 ) rotates, it produces one or more vibrations which are measured by the motion sensor ( 750 ),   wherein measurement of the one or more vibrations is effective for the detection of a vibration signal, and   wherein an analysis of the vibration signal is effective for the identification of the faulty component.   
     
     
         2 . The vibration monitoring device of  claim 1 , wherein the support platform ( 470 ) is a printed circuit board (PCB). 
     
     
         3 . The vibration monitoring device of  claim 2 , wherein the PCB comprises a processor unit operatively coupled to the set of accelerometers ( 755 ) and a memory repository operatively coupled to the processor unit. 
     
     
         4 . The vibration monitoring device of  claim 3 , wherein the PCB comprises a wireless transmitter operatively coupled to the processor unit, and a wireless receiver unit, in communication with the wireless transmitter. 
     
     
         5 . The vibration monitoring device of  claim 4 , wherein the processor unit performs a primary analysis of the vibration signal to yield a primary result which is wirelessly communicated by the transmitter to the receiver before a secondary analysis is preformed to determine if the component is faulty. 
     
     
         6 . The vibration monitoring device of  claim 1 , wherein the component ( 760 ) has a reference vibration signature and the analysis identifies a difference between the reference vibration signature and the vibration signal. 
     
     
         7 . The vibration monitoring device of  claim 1 , wherein the rotating system is an automobile engine. 
     
     
         8 . The vibration monitoring device of  claim 1 , device base ( 710 ) comprises a base magnet for magnetic attachment of the device ( 700 ) to a metal portion of the rotating component ( 760 ). 
     
     
         9 . The vibration monitoring device of  claim 1 , wherein the rotating component ( 760 ) is a pulley. 
     
     
         10 . The vibration monitoring device of  claim 1 , wherein the device ( 700 ) comprises a conical mounting adapter ( 770 ) which fits within a rim ( 762 ) of the pulley, wherein the adapter ( 770 ) is seated such that the device ( 700 ) and the pulley are parallel. 
     
     
         11 . The vibration monitoring device of  claim 1 , wherein the adapter ( 770 ) is attached to the device base ( 710 ) using an attachment ring ( 715 ). 
     
     
         12 . The vibration monitoring device of  claim 1 , wherein the rotating component ( 760 ) comprises a male component ( 771 ) which mates with a female slot ( 772 ) of the adapter ( 770 ) in order to align the device ( 700 ) and the component ( 760 ). 
     
     
         13 . The vibration monitoring device of  claim 1 , wherein the rotating component ( 760 ) is a shaft. 
     
     
         14 . The vibration monitoring device of  claim 1 , wherein the device base ( 710 ) comprises a threaded nut allowing attachment to the rotating component ( 760 ) by replacement of an existing nut. 
     
     
         15 . The vibration monitoring device of  claim 1 , wherein an alignment aide ( 400 ) is used to position the device onto the center of an accessible end of the rotating component ( 760 ). 
     
     
         16 . The vibration monitoring device of  claim 1 , wherein the alignment aide ( 400 ) comprises a ring ( 405 ) having a center aperture ( 404 ), and a plurality of hinged spring-loaded arms ( 401 ) disposed equidistantly on the ring ( 405 ) which are expandable and retractable,
 wherein to attach the device ( 700 ) to the center of the accessible end of the rotating component ( 760 ), the hinged spring-loaded arms ( 401 ) expand and retract concentrically to contact a circumference of the device ( 700 ), wherein the center aperture ( 404 ) aides in aligning the device ( 700 ) with the center of the rotating component ( 760 ).   
     
     
         17 . The vibration monitoring device of  claim 1 , wherein the accelerometers ( 755 ) are concentrically positioned about the rotational axis ( 730 ) of the device ( 700 ) such that the accelerometers ( 755 ) are equally spaced about the rotational axis ( 730 ). 
     
     
         18 . The vibration monitoring device of  claim 1 , wherein an energy harvesting mechanism harvests a rotational energy generated by the rotating component ( 760 ) and converts said rotational energy into an electrical energy which powers the device ( 700 ). 
     
     
         19 . A rotating system configured for identification of a faulty component, the system comprising:
 (a) a rotating component ( 760 ), having a second rotational axis ( 735 ) and an accessible distal end ( 761 );   (b) a device base ( 710 ), configured for attachment to the distal end ( 761 ) of the rotating component ( 760 );   (c) a housing ( 720 ) comprising:
 i. a first end ( 721 ), attached to the device base ( 710 ); 
 ii. a second end ( 722 ); and 
 iii. a first rotational axis ( 730 ) passing through the two ends; 
   (d) a support platform ( 740 ) having two parallel faces, the platform ( 740 ) disposed within the housing ( 720 ) such that the faces are orthogonal to the rotational axis ( 730 );   (e) a motion sensor ( 750 ) comprising a set of accelerometers ( 755 ) disposed on the support platform ( 740 );   wherein the device ( 700 ) is attached to the distal end ( 761 ) of the rotating component ( 760 ) such that the first rotational axis ( 730 ) is coaxial with a second rotational axis ( 735 ) of the rotating component,   wherein as the component ( 760 ) rotates, it produces one or more vibrations which are measured by the motion sensor ( 750 ),   wherein measurement of the one or more vibrations is effective for the detection of a vibration signal, and   wherein an analysis of the vibration signal is effective for the identification of the faulty component.   
     
     
         20 . A method for identifying a faulty component in a rotating system, wherein the rotating system comprises a rotating component ( 760 ), the method comprising:
 a) providing a vibration monitoring device ( 700 ) comprising:
 i. a device base ( 710 ), configured for attachment to a distal end ( 761 ) of the rotating component ( 760 ); 
 ii. a housing ( 720 ) comprising:
 1. a first end ( 721 ), attached to the device base ( 710 ); 
 2. a second end ( 722 ); and 
 3. a first rotational axis ( 730 ) passing through the two ends; 
 
 iii. a support platform ( 740 ) having two parallel faces, the platform ( 740 ) disposed within the housing ( 720 ) such that the faces are orthogonal to the first rotational axis ( 730 ); and 
 iv. a motion sensor ( 750 ) comprising a set of accelerometers ( 755 ) disposed on the support platform ( 740 ); 
   b) attaching the vibration device ( 700 ) to the distal end ( 610 ) of the rotating component ( 760 ) such that the first rotational axis ( 730 ) is coaxial with a second rotational axis ( 735 ) of the rotating component ( 760 );   c) rotating the component ( 700 ) such that it produces one or more vibrations which are detected by the motion sensor ( 750 );   d) measuring the vibrations by the motion sensor ( 750 ) to detect a vibration signal; and   e) analyzing the vibration signal, wherein the analysis is effective for the identification of the faulty component.