System and method for proactive motor wellness diagnosis based on potential cavitation faults
First Claim
1. A controller configured to detect indicia of motor faults and having a processor configured to:
- determine motor parameters of a given motor;
generate a set of baseline data for the given motor;
acquire current data from the given motor during operation;
isolate sidebands within the current data;
map the current data within the sidebands to one of a plurality of bins;
compare the current data within the sidebands to baseline data from the set of baseline data associated with the bin; and
determine a predictive fault index of the given motor prior to an actual fault occurrence.
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Accused Products
Abstract
The present invention is directed to system and method for determining motor wellness based on potential faults including cavitation faults. Specifically, a controller configured to detect indicia of motor faults. The controller includes a processor configured to determine motor parameters of a given motor, generate a set of baseline data for the given motor, and acquire current data from the given motor during operation. The processor is also caused to isolate sidebands within the current data and map the current data within the sidebands to one of a plurality of bins. The processor is caused to compare the current data within the sidebands to baseline data from the set of baseline data associated with the bin and determine a predictive fault index of the given motor prior to an actual fault occurrence.
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Citations
39 Claims
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1. A controller configured to detect indicia of motor faults and having a processor configured to:
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determine motor parameters of a given motor;
generate a set of baseline data for the given motor;
acquire current data from the given motor during operation;
isolate sidebands within the current data;
map the current data within the sidebands to one of a plurality of bins;
compare the current data within the sidebands to baseline data from the set of baseline data associated with the bin; and
determine a predictive fault index of the given motor prior to an actual fault occurrence. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21)
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22. A method of monitoring a motor for potential faults comprising:
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receiving current data from an operating motor;
performing at least one FFT on the current data to generate frequency spectrum data;
isolating sidebands within the frequency spectrum data based on a system frequency of the operating motor;
accumulating spectrum components of the frequency spectrum data within sidebands;
for a predetermined period, generating baseline data from the accumulated spectrum components;
after the predetermined period, comparing the spectrum components to the baseline; and
determining a noise pattern indicative of potential faults due to pump cavitation within the spectrum components. - View Dependent Claims (23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34)
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35. A computer readable storage medium having stored thereon a computer program comprising instructions which, when executed by at least one processor, cause the at least one processor to:
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determine a load on a motor;
receive operational current data from the motor;
perform at least two FFTs on the operational current data to generate frequency spectrum data;
average the frequency spectrum data;
define sidebands of the system frequency of the motor;
sum the frequency spectrum data within sidebands to generate a cavitation fault index;
map the cavitation fault index to a load bin from a plurality of load bins based on the load on the motor;
if in a learning mode, average the cavitation fault index with baseline data associated with the load bin; and
if not in the learning mode, compare the cavitation fault index to the baseline data associated with the load bin to determine an impending cavitation fault before a fault occurrence. - View Dependent Claims (36, 37, 38, 39)
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Specification