Modular monitoring and protection system with local protection loop

• US 20030212530A1
• 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 6,711,527 B2
• Time in Patent Office: Days
• US Class Current: 702/188
• CPC Class Codes: G05B 2219/24084 Remote and local monitoring, local result to remote, remote takes action
• CPC Class Codes: G05B 2219/25391 Start, stop sequence of different parts of machine, copier, textile, glass
• CPC Class Codes: G05B 23/0286 Modifications to the monitored process, e.g. stopping operation or adapting control
• CPC Class Codes: G05B 9/02 electric

Abstract

A monitoring and protection system includes monitoring modules that are positioned proximate to locations of interest in a machine system where dynamic operating conditions are monitored. The monitoring modules may be configured to communicate with other modules via an open industrial data exchange protocol. The monitors are also configured to control the operative state of a component such as a relay circuit, either integrated into the monitoring module or provided in a separate relay module. Extremely rapid and versatile response is attained through implementation of a local control loop for control of the state of the relay circuit, which may be complemented by a remote loop that includes a remote monitoring or control system for response to different inputs or conditions.

Claims

1. A monitoring and protection system for a machine, the system comprising:

a sensor disposed at a location with respect to the machine to sense a dynamic operating parameter of the machine during operation;

a central monitoring station disposed remote from the sensor location; and

a monitoring and protection station disposed proximate to the sensor, and including a monitoring module coupled to the sensor to receive and process signals representative of the operating parameter and a relay coupled to a component of the machine and controllable by the monitor to selectively apply or interrupt power to the component based upon the signals and a control loop within the monitoring and protection station, the monitoring and protection station being configured to control the relay independently of the central monitoring station and to report such control to the central monitoring station in accordance with an open industrial data exchange protocol.

2. The system of claim 1, wherein the monitoring and protection station includes a plurality of modules disposed within a common enclosure.

3. The system of claim 2, wherein the plurality of modules are configured to exchange data therebetween in accordance with the open industrial data exchange protocol.

4. The system of claim 1, wherein the monitoring and protection station includes a relay module and wherein the relay is incorporated in the relay module.

5. The system of claim 1, wherein the relay is integrated into the monitoring module.

6. The system of claim 1, wherein the monitoring module is configured to process vibrational data from the sensor to determine a vibration profile, and wherein the relay is controlled at least partially based upon the vibration profile.

7. The system of claim 1, wherein the monitoring module is also configured to control the relay based upon signals received from the central monitoring station.

8. The system of claim 1, wherein the monitoring module is configured to generate an alarm signal based upon the operating parameter.

9. The system of claim 8, wherein the alarm signal is generated in response to controlling a change of state of the relay.

10. The system of claim 1, wherein a change of state of the relay controlled by the monitoring module interrupts power to the machine.

11. A monitoring and protection system for a machine, the system comprising:

a sensor disposed at a location with respect to the machine to sense a dynamic operating parameter of the machine during operation;

a central monitoring station disposed remote from the sensor location; and

a monitoring and protection station disposed proximate to the sensor, and including a monitoring module coupled to the sensor to receive and process signals representative of the operating parameter and a relay coupled to a component of the machine and controllable by the monitoring module to selectively apply or interrupt power to the component based upon the signals, the monitoring and protection station being configured to control the relay in a local control loop within the monitoring and protection station and in a remote control loop in which control signals are received from the central monitoring station.

12. The system of claim 11, wherein the monitoring module is configured to report changes in a state of the relay to the central monitoring station in accordance with an open industrial data exchange protocol.

13. The system of claim 11 wherein the monitoring and protection station includes a plurality of modules disposed within a common enclosure.

14. The system of claim 13, wherein the plurality of modules are configured to exchange data therebetween in accordance with the open industrial data exchange protocol.

15. The system of claim 11, wherein the monitoring and protection station includes a relay module and wherein the relay is incorporated in the relay module.

16. The system of claim 11, wherein the relay is integrated into the monitoring module.

17. The system of claim 11, wherein the monitoring module is configured to process vibrational data from the sensor to determine a vibration profile, and wherein the relay is controlled at least partially based upon the vibration profile.

18. The system of claim 11, wherein the monitoring module is configured to generate an alarm signal based upon the operating parameter.

19. The system of claim 18, wherein the alarm signal is generated in response to controlling a change of state of the relay.

20. The system of claim 11, wherein a change of state of the relay controlled by the monitoring module interrupts power to the machine.

21. A monitoring and protection system for a machine, the system comprising:

a central monitoring station disposed remote from the sensor location;

a first sensor disposed at a first location with respect to the machine to sense a first dynamic operating parameter of the machine during operation;

a second sensor disposed at a second location with respect to the machine remote from the first location to sense a second dynamic operating parameter of the machine during operation;

a first monitoring and protection station disposed proximate to the first sensor, and including a first monitoring module coupled to the first sensor to receive and process signals representative of the first operating parameter and a first relay coupled to a first component of the machine and controllable by the monitor to selectively apply or interrupt power to the first component based upon the signals and a control loop within the first monitoring and protection station; and

a second monitoring and protection station disposed proximate to the second sensor, and including a second monitoring module coupled to the second sensor to receive and process signals representative of the second operating parameter and a second relay coupled to a second component of the machine and controllable by the monitor to selectively apply or interrupt power to the second component based upon the signals and a control loop within the second monitoring and protection station;

wherein the monitoring and protection stations are configured to control the respective relay independently of the central monitoring station and to report such control to the central monitoring station in accordance with an open industrial data exchange protocol.

22. The system of claim 21, wherein each monitoring and protection station includes a plurality of modules disposed within a common enclosure.

23. The system of claim 22, wherein the plurality of modules of each monitoring and protection station are configured to exchange data therebetween in accordance with the open industrial data exchange protocol.

24. The system of claim 21, wherein each monitoring and protection station includes a relay module and wherein the relay is incorporated in the respective relay module.

25. The system of claim 21, wherein the relays are integrated into the respective monitoring module.

26. The system of claim 21, wherein each monitoring module is configured to process vibrational data from the respective sensor to determine a vibration profile, and wherein the respective relay is controlled at least partially based upon the vibration profile.

27. The system of claim 21, wherein each monitoring module is also configured to control the respective relay based upon signals received from the central monitoring station.

28. The system of claim 21, wherein each monitoring module is also configured to control the respective relay based at least partially upon signals received from the other monitoring module.

29. The system of claim 21, wherein each monitoring module is configured to generate an alarm signal based upon the operating parameter.

30. The system of claim 29, wherein the alarm signal is generated in response to controlling a change of state of the relay.

31. The system of claim 21, wherein a change of state of the relay controlled by the monitoring module interrupts power to the machine.

32. A monitoring and protection system for a machine, the system comprising:

a central monitoring station disposed remote from the sensor location;

a first sensor disposed at a first location with respect to the machine to sense a first dynamic operating parameter of the machine during operation;

a second sensor disposed at a second location with respect to the machine remote from the first location to sense a second dynamic operating parameter of the machine during operation;

a first monitoring and protection station disposed proximate to the first sensor, and including a first monitoring module coupled to the first sensor to receive and process signals representative of the first operating parameter and a first relay coupled to a first component of the machine and controllable by the monitor to selectively apply or interrupt power to the first component; and

a second monitoring and protection station disposed proximate to the second sensor, and including a second monitoring module coupled to the second sensor to receive and process signals representative of the second operating parameter and a second relay coupled to a second component of the machine and controllable by the monitor to selectively apply or interrupt power to the second component;

wherein the monitoring and protection stations are configured to control the respective relay in a local control loop within the respective monitoring and protection station and in a remote control loop including either the central monitoring station or the other monitoring and protection station.

33. The system of claim 32, wherein each monitoring module is configured to report changes in a state of the respective relay to the central monitoring station in accordance with an open industrial data exchange protocol.

34. The system of claim 32 wherein each monitoring and protection station includes a plurality of modules disposed within a common enclosure.

35. The system of claim 34, wherein the plurality of modules are configured to exchange data therebetween in accordance with the open industrial data exchange protocol.

36. The system of claim 32, wherein each monitoring and protection station includes a relay module and wherein the relay is incorporated in the respective relay module.

37. The system of claim 32, wherein each relay is integrated into the respective monitoring module.

38. The system of claim 32, wherein each monitoring module is configured to process vibrational data from the respective sensor to determine a vibration profile, and wherein each relay is controlled at least partially based upon the respective vibration profile.

39. The system of claim 32, wherein each monitoring module is configured to generate an alarm signal based upon the respective operating parameter.

40. The system of claim 39, wherein the alarm signals are generated in response to controlling a change of state of the respective relay.

41. The system of claim 32, wherein a change of state of the relay controlled by the respective monitoring module interrupts power to the machine.