Modular monitoring and protection system with open communication backbone

• US 20030212508A1
• Filed: 05/13/2002
• Published: 11/13/2003
• Est. Priority Date: 05/13/2002
• Status: Active Grant

• Current Assignee: Rockwell Automation, Inc.
• Original Assignee: Entek IRD International Corp. (Rockwell Automation, Inc.)
• Inventors: Bibelhausen, David J., Stoutenburg, Donn V., Carle, Patrick F., Kramb, Kevin E., Shupe, Dan R., Lien, Chien-Tan
• Granted Patent: US 6,704,668 B2
• Time in Patent Office: Days
• US Class Current: 702/45
• CPC Class Codes: G05B 23/0216 Human interface functionality, e.g. monitoring system providing help to the user in the selection of tests or in its configuration
• CPC Class Codes: G05B 23/027 Alarm generation, e.g. communication protocol; Forms of alarm
• CPC Class Codes: G05B 23/0289 Reconfiguration to prevent failure, e.g. usually as a reaction to incipient failure detection
• CPC Class Codes: G05B 23/0291 Switching into safety or degraded mode, e.g. protection and supervision after failure

Abstract

A monitoring and protection system is provided which is highly modular and expandable. The system is based upon individual monitoring modules which may be associated with one another in groups at locations or points along a machine system where dynamic operating conditions are to be monitored and controlled. The individual modules communicate between themselves, and with remote modules, via an open industrial data exchange protocol. The modules are thus freed of the need for a backplane or other backbone for mounting and communications purposes. Any number of modules may be positioned at the points of interest along the machine system, from as few as a single module to a large group of modules, with the entire system being expandable and contractible according to the design needs based upon the open industrial data exchange protocol.

Claims

1. A system for monitoring dynamic operating parameters of a mechanical system including at least one powered rotating component, the monitoring system comprising:

at a location proximate to the mechanical system, a first monitoring module configured to be coupled to at least a first sensor at location A and to receive signals therefrom indicative of a first operating parameter of the mechanical system;

a second monitoring module configured to be coupled to at least a second sensor at location A and to receive signals therefrom indicative of a second operating parameter of the mechanical system;

the first and second monitoring modules being further configured to exchange signals with one another in accordance with an open industrial data exchange protocol.

2. The monitoring system of claim 1, wherein the first and second monitoring modules only exchange signals with one another in accordance with the open industrial data exchange protocol.

3. The monitoring system of claim 1, further comprising a central monitoring station distal from location A and coupled to the first and second monitoring modules and configured to exchange data with the first and second modules in accordance with the open industrial data exchange protocol.

4. The monitoring system of claim 1, further comprising a relay controllable to protect a portion of the mechanical system, and wherein the first monitoring module includes a processor configured to open or close the relay in response to the signals from the first sensor.

5. The monitoring system of claim 4, wherein the relay is integrated in the first monitoring module.

6. The monitoring system of claim 4, wherein the first and second monitoring modules and the relay are disposed within an enclosure proximate to location A.

7. The monitoring system of claim 1, further comprising at a location B of the mechanical system distal from location A, and a third monitoring module configured to be coupled to at least a third sensor at location B, to receive signals therefrom indicative of a third operating parameter of the mechanical system, and to exchange signals with the first or second module in accordance with the open industrial data exchange protocol.

8. The monitoring system of claim 7, further comprising a relay controllable to protect a portion of the mechanical system, and wherein the third monitoring module includes a processor configured to open or close the relay in response to the signals from the third sensor.

9. The monitoring system of claim 8, wherein the relay is integrated in the third monitoring module.

10. The monitoring system of claim 7, further comprising a central monitoring station distal from locations A and B, coupled to the first, second and third monitoring modules and configured to exchange data with the first, second and third modules in accordance with the open industrial data exchange protocol.

11. The monitoring system of claim 10, further comprising a gateway coupled to an open industrial data exchange network for exchanging data between at least one of the monitoring modules and a remote component in accordance with a data exchange protocol different from the open industrial data exchange protocol.

12. A system for monitoring dynamic operating parameters of a rotary mechanical system, the monitoring system comprising:

a first monitoring panel including an enclosure disposed proximate to a location A of the rotary mechanical system, a first monitoring module disposed in the enclosure and configured to be coupled to at least a first sensor at location A and to receive signals therefrom indicative of a first operating parameter of the mechanical system, and a second monitoring module disposed in the enclosure and configured to be coupled to at least a second sensor at location A and to receive signals therefrom indicative of a second operating parameter of the mechanical system, the first and second monitoring modules being further configured to exchange signals with one another in accordance with an open industrial data exchange protocol; and

a second monitoring panel including an enclosure disposed proximate to a location B of the rotary mechanical system distal from location A, and a third monitoring module disposed therein and configured to be coupled to at least a third sensor at location B, to receive signals therefrom indicative of a third operating parameter of the mechanical system, and to exchange signals with the first or second module in accordance with the open industrial data exchange protocol.

13. The monitoring system of claim 12, wherein at least one of the first, second and third monitoring modules is configured to control a relay in response to signals received from the respective sensor.

14. The monitoring system of claim 13, wherein the relay is integrated in the respective monitoring module.

15. The monitoring system of claim 13, wherein the relay is incorporated into a relay module within the enclosure of the controlling monitoring module.

16. The monitoring system of claim 13, wherein the first and second monitoring modules exchange signals with one another only in accordance with the open industrial data exchange protocol.

17. The monitoring system of claim 13, wherein the monitoring modules of the first and second monitoring panels exchange signals with one another only in accordance with the open industrial data exchange protocol.

18. The monitoring system of claim 13, further comprising a central monitoring station distal from locations A and B, coupled to the first, second and third monitoring modules and configured to exchange data with the first, second and third modules in accordance with the open industrial data exchange protocol.

19. The monitoring system of claim 18, further comprising a gateway coupled either to the first and second monitoring modules, to the third monitoring module or to the central monitoring station for exchanging data with a remote component in accordance with a data exchange protocol different from the open industrial data exchange protocol.

20. A system for monitoring dynamic operating parameters of a rotary mechanical system, the monitoring system comprising:

a first monitoring group proximate to a location A of the rotary mechanical system, the first monitoring group including a first monitoring module configured to be coupled to at least a first sensor at location A and to receive signals therefrom indicative of a first operating parameter of the mechanical system, and a second monitoring module configured to be coupled to at least a second sensor at location A and to receive signals therefrom indicative of a second operating parameter of the mechanical system, the first and second monitoring modules being further configured to exchange signals with one another in accordance with an open industrial data exchange protocol;

a second monitoring group proximate to a location B of the rotary mechanical system distal from location A, the second monitoring group including a third monitoring module configured to be coupled to at least a third sensor at location B, to receive signals therefrom indicative of a third operating parameter of the mechanical system, and to exchange signals with the first or second module in accordance with the open industrial data exchange protocol; and

a central monitoring station distal from locations A and B, coupled to the first, second and third monitoring modules and configured to exchange data with the first, second and third modules in accordance with the open industrial data exchange protocol.

21. The monitoring system of claim 20, wherein at least one of the first, second and third monitoring modules is configured to control a relay in response to signals received from the respective sensor.

22. The monitoring system of claim 21, wherein the relay is integrated in the respective monitoring module.

23. The monitoring system of claim 20, wherein the first and second monitoring modules exchange signals with one another only in accordance with the open industrial data exchange protocol.

24. The monitoring system of claim 20, wherein the monitoring modules of the first and second monitoring panels exchange signals with one another only in accordance with the open industrial data exchange protocol.

25. The monitoring system of claim 20, wherein the monitoring modules of the first and second monitoring panels exchange data with the central monitoring station only in accordance with the open industrial data exchange protocol.

26. The monitoring system of claim 20, further comprising a gateway coupled either to the first and second monitoring modules, to the third monitoring module or to the central monitoring station for exchanging data with a remote component in accordance with a data exchange protocol different from the open industrial data exchange protocol.

27. An instrumented rotary mechanical system comprising:

rotary equipment including a plurality of monitoring points comprising at least two monitoring locations A and B distal from one another;

a first monitoring group disposed proximate to location A, the first monitoring group including a first monitoring module configured to be coupled to at least a first sensor at location A and to receive signals therefrom indicative of a first operating parameter of the mechanical system, and a second monitoring module configured to be coupled to at least a second sensor at location A and to receive signals therefrom indicative of a second operating parameter of the mechanical system, the first and second monitoring modules being further configured to exchange signals with one another in accordance with an open industrial data exchange protocol;

a second monitoring group disposed proximate to a location B, the second monitoring group including a third monitoring module configured to be coupled to at least a third sensor at location B, to receive signals therefrom indicative of a third operating parameter of the mechanical system, and to exchange signals with the first or second module in accordance with the open industrial data exchange protocol; and

a central monitoring station distal from locations A and B, coupled to the first, second and third monitoring modules and configured to exchange data with the first, second and third modules in accordance with the open industrial data exchange protocol.

28. The monitoring system of claim 27, wherein at least one of the first, second and third monitoring modules is configured to control a relay in response to signals received from the respective sensor.

29. The monitoring system of claim 28, wherein the relay is integrated in the respective monitoring module.

30. The monitoring system of claim 27, wherein the first and second monitoring modules exchange signals with one another only in accordance with the open industrial data exchange protocol.

31. The monitoring system of claim 27, wherein the monitoring modules of the first and second monitoring panels exchange signals with one another only in accordance with the open industrial data exchange protocol.

32. The monitoring system of claim 27, wherein the monitoring modules of the first and second monitoring panels exchange data with the central monitoring station only in accordance with the open industrial data exchange protocol.

33. The monitoring system of claim 27, further comprising a gateway coupled either to the first and second monitoring modules, to the third monitoring module or to the central monitoring station for exchanging data with a remote component in accordance with a data exchange protocol different from the open industrial data exchange protocol.

34. A method for monitoring dynamic operating parameters of a rotary mechanical system, the monitoring system comprising:

coupling a first monitoring module to a second monitoring module for data exchange therebetween within an enclosure disposed proximate to a location A of the rotary mechanical system;

monitoring via the first monitoring module signals from at least a first sensor at location A indicative of a first operating parameter of the mechanical system;

monitoring via the second monitoring module signals from at least a second sensor at location A indicative of a second operating parameter of the mechanical system; and

exchanging signals between the first and second monitoring modules in accordance with an open industrial data exchange protocol.

35. The method of claim 34, wherein the monitoring modules exchange signals only in accordance with the open industrial exchange protocol.

36. The method of claim 34, further comprising exchanging data between the first and second monitoring modules and a further monitoring module proximate to a location B distal from location A in accordance with the open industrial exchange protocol.

37. The method of claim 34, further comprising exchanging data between the first and second monitoring modules and a central monitoring station distal from location A in accordance with the open industrial exchange protocol.

38. The method of claim 34, further comprising processing signals from the first or the second sensor in the first or second monitoring module, respectively, and controlling a relay for powering at least one component of the mechanical system based upon the sensor signals.

39. The method of claim 38, wherein the relay is integrated into the respective first or second monitoring module.

40. A method for monitoring dynamic operating parameters of a rotary mechanical system, the monitoring system comprising:

coupling a first monitoring module to a second monitoring module for data exchange therebetween within an enclosure disposed proximate to a location A of the rotary mechanical system;

coupling a third monitoring module to the first and second monitoring modules within an enclosure disposed proximate to a location B of the rotary mechanical system distal from location A;

monitoring via the first monitoring module signals from at least a first sensor at location A indicative of a first dynamic operating parameter of the mechanical system;

monitoring via the second monitoring module signals from at least a second sensor at location A indicative of a second dynamic operating parameter of the mechanical system;

monitoring via the third monitoring module signals from at least a third sensor at location B indicative of a third dynamic operating parameter of the mechanical system; and

exchanging signals between the first and second monitoring modules, and between the first and second monitoring modules and the third monitoring module in accordance with an open industrial data exchange protocol.

41. The method of claim 40, wherein the monitoring modules exchange signals only in accordance with the open industrial exchange protocol.

42. The method of claim 40, further comprising exchanging data between the first, second and third monitoring modules and a central monitoring station distal from locations A and B in accordance with the open industrial exchange protocol.

43. The method of claim 40, further comprising processing signals from the first, the second or the third sensor in the respective first, second or third monitoring module, respectively, and controlling a relay for powering at least one component of the mechanical system based upon the sensor signals.

44. The method of claim 43, wherein the relay is integrated into the respective first, second or third monitoring module.

45. A method for monitoring dynamic operating parameters of a rotary mechanical system, the monitoring system comprising:

coupling a first monitoring module to a second monitoring module for data exchange therebetween within an enclosure disposed proximate to a location A of the rotary mechanical system;

coupling a third monitoring module to the first and second monitoring modules within an enclosure disposed proximate to a location B of the rotary mechanical system distal from location A;

coupling the first, second and third modules to a central monitoring station distal from locations A and B;

monitoring via the first monitoring module signals from at least a first sensor at location A indicative of a first dynamic operating parameter of the mechanical system;

monitoring via the second monitoring module signals from at least a second sensor at location A indicative of a second dynamic operating parameter of the mechanical system;

monitoring via the third monitoring module signals from at least a third sensor at location B indicative of a third dynamic operating parameter of the mechanical system; and

exchanging signals between the first and second monitoring modules, and between the first and second monitoring modules and the third monitoring module, and between the modules and the central monitoring station in accordance with an open industrial data exchange protocol.

46. The method of claim 45, wherein the monitoring modules exchange signals only in accordance with the open industrial data exchange protocol.

47. The method of claim 45, wherein the monitoring modules exchange data with the central monitoring station only in accordance with the open industrial data exchange protocol.

48. The method of claim 45, further comprising processing signals from the first, the second or the third sensor in the respective first, second or third monitoring module, respectively, and controlling a relay for powering at least one component of the mechanical system based upon the sensor signals.

49. The method of claim 48, wherein the relay is integrated into the respective first, second or third monitoring module.