Monitoring system and its use

• US 20030006915A1
• Filed: 08/26/2002
• Published: 01/09/2003
• Est. Priority Date: 02/28/2000
• Status: Abandoned Application

• Current Assignee: Metso Automation OY (Vanowen Group Acquisition Co., Inc.)
• Original Assignee: Metso Automation OY (Vanowen Group Acquisition Co., Inc.)
• Inventors: Lehikoinen, Aki, Mustonen, Harri, Kauppila, Jarmo
• Application Number:
  US10/228,014
• Publication Number:
  US 20030006915A1
• Time in Patent Office: Days
• US Class Current: 340/999
• CPC Class Codes: G05B 23/0213 Modular or universal configuration of the monitoring system, e.g. monitoring system having modules that may be combined to build monitoring program; monitoring system that can be applied to legacy systems; adaptable monitoring system; using different communication protocols
• CPC Class Codes: G07C 3/00 Registering or indicating the condition or the working of machines or other apparatus, other than vehicles

Abstract

An on-line condition monitoring system for the real-time observation of a number of monitored objects comprises a sensor arranged at each object to generate signals representing the condition of the object, a substation for receiving signals from the object at certain measurement intervals and transmitting measurement data to a monitoring unit which has a processing unit and one or more workstations at which the condition of different objects can be observed, and a data network. The substation is further arranged to receive signals during a longer period from an object, which has been put into particular real-time observation. The substation and/or the workstation is arranged to process the signals received by the substation and to generate and present calculation results to the operator. The workstation is arranged by means of real-time signal analysis user interface software to display to the operator the measured signals and the results calculated from them.

Claims

1. A method for monitoring a plurality of monitored objects using an on-line condition monitoring system for the real-time observation of said monitored objects, the method comprising providing a condition monitoring system comprising:

at least one sensor arranged at each monitored object and operable to generate signals representing the condition of said object,

at least one substation operable to receive the signals from the sensor(s) of said one or more monitored objects at certain measurement intervals during a certain measurement period, which signals represent the condition of the monitored objects, so as to generate measurement data, and operable to transmit the measurement data to a monitoring unit,

a monitoring unit, which has

a processing unit for storing and/or for further processing the measurement data obtained from said at least one substation during a certain measurement period, and

one or more workstations at which the condition of the one or more monitored objects is observed on the basis of the measurement data stored in said processing unit, and

a data network for data transmission between the substation, the monitoring unit and the workstation,

the method further comprising;

performing real-time observation of at least one object using at least one substation operable by means of measurement software to receive signals from said object representing the condition of said object during a period that is substantially longer than said certain measurement period,

wherein at least one of said substation and a workstation uses calculation software to process the signals received by the measurement software in the substation so as to generate and present calculation results to the system operator, and

wherein a workstation is operable by means of real-time signal analysis user interface software to display to the operator the measured signals and the results calculated therefrom.

2. The method according to claim 1, wherein the substation is operable by means of the measurement software to transmit measurement signals and/or processed measurement signals to the monitoring unit, substantially at the same rate as the substation receives the measurement signals from a sensor sensing the monitored object.

3. The method according to claim 1, wherein the substation is operable by means of the measurement software to transmit measurement signals and/or processed measurement signals to the monitoring unit as a continuous data flow, the length of which the operator can define.

4. The method according to claim 1, wherein the substation is operable by means of the measurement software to transmit measurement signals and/or calculation results to the monitoring unit as a continuous data flow, wherein a frequency band of the signals in its maximum width extends up to a multiple of 10 kHz.

5. The method according to claim 1, wherein

the signals received by the measurement software in the substation are transmitted as a continuous flow to the workstation, and wherein

the workstation performs a real-time signal analysis calculation on the basis of the signals, which arrive as a continuous flow from the substation, the calculation comprising:

calculation of FFT spectra, and calculation of STA analysis (Synchronized Time Averaging analysis calculation),

calculation from time domain signals or from spectrum representations the RMS-values of the frequency bands, calculation of the signal'"'"'s peak value, and calculation of parameters for failure rates,

and simultaneously the time domain planes of the signals and/or the results calculated from the signals are displayed.

6. The method according to claim 1, wherein

at least one substation performs a real-time signal analysis calculation on the basis of the signals received by the measurement software in the substation, the calculation comprising:

calculation of FFT spectra, and calculation of STA analysis (Synchronized Time Averaging analysis calculation),

calculation from time domain signals or from spectrum representations the RMS-values of the frequency bands, calculation of the signal'"'"'s peak value, and calculation of parameters for failure rates,

and simultaneously the at least one substation displays the signals in the time domain and/or the results calculated from the signals, and wherein

the results of the signal analysis calculation are transmitted via the data network to the workstation where said results are displayed to the operator.

7. The method according to claim 1, wherein a substation transmits simultaneously to the workstation data received from one or more sensors.

8. The method according to claim 1, wherein the condition monitoring system is installed in an industrial plant, wherein the system is used to analyse the condition of gears, bearings, pumps, blowers, electrical motors, rolls, and/or turbine generators.

9. A monitoring system for the real-time observation of one or more monitored objects, the monitoring system comprising:

at least one sensor arranged at each monitored object and operable to generate signals representing the condition of said object,

at least one substation operable to receive the signals from the sensor(s) of the one or more monitored objects at certain measurement intervals during a certain measurement period, which signals represent the condition of the one or more monitored objects, so as to generate measurement data, and operable to transmit the measurement data to a monitoring unit,

a monitoring unit, which has

a processing unit for storing and/or for further processing the signals which are obtained from said at least one substation during different measurement periods, and

one or more workstations at which the condition of different objects can be observed on the basis of the measurement data stored in said processing unit, and

a data network for data transmission between the substation, the monitoring unit and the workstation,

wherein the monitoring system further comprises;

measurement software in at least one substation operable to receive from a monitored object, which has been put into particular real-time observation, signals representing the condition of the monitored object during a period that is substantially longer than said certain measurement period,

calculation software in at least one of a substation and a workstation operable to process the signals received by the measurement software in the substation and to generate calculation results, which are presented to the system operator, and

real-time signal analysis user interface software in a workstation operable to disply to the operator the measured signals and the results calculated from them.

10. A monitoring system according to claim 9, wherein the substation is operable by means of the measurement software to transmit measurement signals and/or processed measurement signals to the monitoring unit, substantially at the same rate as the substation receives the measurement signals from a sensor.

11. A monitoring system according to claim 9, wherein the substation is operable by means of the measurement software to transmit measurement signals and/or processed measurement signals to the monitoring unit as a continuous data flow, the length of which the operator can define.

12. A monitoring system according to claim 9, wherein the substation is operable by means of the measurement software to transmit measurement signals and/or calculation results to the monitoring unit as a continuous data flow, whereby a frequency band of the signals in its maximum width extends up to a multiple of 10 kHz.

13. A monitoring system according to claim 9, wherein

the measurement software in the substation is operable to transmit the received signals as a continuous flow from the substation to the workstation, and

the workstation is operable to perform a real-time signal analysis calculation on the basis of the signals, which arrive as a continuous flow from the substation, the calculation comprising:

calculation of FFT spectra, and calculation of STA analysis (Synchronized Time Averaging analysis calculation),

calculation of parameters from the time domain signals or from the spectrum representations, such as the calculation of the RMS-values of the frequency bands, calculation of the signal'"'"'s peak value, and the calculation of parameters for failure rates, and the workstation is operable simultaneously to display the signals in the time domain and/or the results calculated from the signals.

14. A monitoring system according to claim 9, wherein

at least one substation is arranged to perform a real-time signal analysis calculation on the basis of the signals received by the measurement software in the substation, the calculation comprising:

calculation of FFT spectra, and calculation of STA analysis (Synchronized Time Averaging analysis calculation),

calculation of parameters from the time domain signals or from the spectrum representations, such as the calculation of the RMS-values of the frequency bands, calculation of the signal'"'"'s peak value, and the calculation of parameters for failure rates, and wherein

the results of the signal analysis calculation are arranged to be transmitted via the data network to the workstation where they are displayed to the operator.

15. A monitoring system according to claim 9, wherein

a substation is arranged to transmit simultaneously with the aid of the measurement software data received from one or more sensors.

16. A monitoring system according to claim 9, wherein the condition monitoring system comprises sensors, which are mounted in the continuously monitored objects, the sensors being operable to measure at least one of acceleration, velocity, rotation speed, displacement, pressure, temperature, and flow of substances.

17. An on-line condition monitoring system according to claim 9 arranged in an industrial plant, wherein the system is arranged to analyse the condition of gears, bearings, pumps, blowers, electrical motors, rolls, and/or turbine generators.