I-Corps: A Smart Sensing System for Online Machine Health Monitoring

这个I-Corps项目的更广泛的影响/商业潜力是开发一种智能传感系统，能够实时、连续地监测机器的健康状况。其目标是通过优化维护计划和消除昂贵的停机检查需求来降低运营成本，同时避免运营期间的灾难性组件故障。 其对碎片和多种油属性的综合监测和实时分析有望改变风电场、运输、制造和国防工业中使用的旋转和往复式机器的状态监测。 沿着高灵敏度和紧凑的尺寸，它将成为一个强大的在线健康监测和寿命预测的工具，轴承，齿轮箱，甚至内燃机。 这个I-Corps项目的基础是开发一个用于在线机器健康监测的智能传感系统。该技术采用独特的感应脉冲传感技术，结合多路复用微流体设备，能够检测单个磨损碎屑（20微米以上），从而能够从一开始就连续监测整个磨损过程。此外，采用实时大数据处理，大大减少了需要分析和存储的数据量，实现了实时在线监控。该系统还使用了一个属性传感阵列，能够精确测量润滑剂的多种特性。 人工神经网络用于从重叠的传感器响应中精确定位单个油的特性，具有高精度和高速度，消除交叉敏感性并提供完整的机器健康信息。该奖项反映了NSF的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估而被认为值得支持。

The broader impact/commercial potential of this I-Corps project is the development of a smart sensing system capable of real-time, continuous condition monitoring of a machine’s health status. The goal is to reduce operation costs by optimizing the maintenance schedule and eliminating the need for costly shutdowns for inspection, while also avoiding catastrophic component failure during operation. Its comprehensive monitoring of both debris and multiple oil properties with real-time analysis is expected to transform condition monitoring of rotating and reciprocating machines used in the wind farm, transportation, manufacturing and defense industries. Along with high sensitivity and compact size, it will be a powerful instrument for online health monitoring and life prognosis for bearings, turbomachinery gearboxes, and even combustion engines. This I-Corps project is based on the development of a smart sensing system for online machine health monitoring. The technology uses a unique inductive pulse sensing technology combined with a multiplexed microfluidic device enabling the detection of individual wear debris (20+ microns), enabling continuous monitoring of the entire wear progression from inception. In addition, real-time big data processing is used to significantly reduce the data size to be analyzed and stored, enabling real-time online monitoring. The system also uses a property-sensing array enabling accurate lubricant measurement of multiple characteristics. The artificial neural network is used to pinpoint individual oil properties from the overlapped sensor responses with high accuracy and speed, eliminating cross-sensitivities and providing complete machine health information.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.