Integrated multi-element lubrication sensor and lubricant health assessment

• US 6,196,057 B1
• Filed: 04/27/1999
• Issued: 03/06/2001
• Est. Priority Date: 04/02/1998
• Status: Expired due to Term

• Current Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Original Assignee: Reliance Electric Technologies LLC (ABB Limited)
• Inventors: Discenzo, Frederick M.
• Primary Examiner(s): Williams, Hezron
• Assistant Examiner(s): WIGGINS, JOHN DAVID
• Application Number:
  US09/300,645
• Time in Patent Office: 679 Days
• Field of Search: 73/54, 73/530.1, 73/530.5, 73/617.1, 73/232, 73/232.1, 73/233.4, 73/233.1, 73/233, 422/68.1, 422/90, 422/82.01
• US Class Current: 73/54.01
• CPC Class Codes: F16C 19/52 with devices affected by abnormal or undesired conditions
• CPC Class Codes: F16C 2233/00 Monitoring condition, e.g. temperature, load, vibration
• CPC Class Codes: F16C 33/667 related to conditioning, e.g. cooling, filtering
• CPC Class Codes: F16C 41/008 Identification means, e.g. markings, RFID-tags; Data transfer means
• CPC Class Codes: F16N 2250/30 Dialectricum
• CPC Class Codes: F16N 2250/36 Viscosity
• CPC Class Codes: F16N 2260/18 necessity of changing oil
• CPC Class Codes: F16N 2270/52 Viscosity
• CPC Class Codes: F16N 2270/54 pH; Acidity
• CPC Class Codes: F16N 2270/56 Temperature
• CPC Class Codes: G01N 11/16 by measuring damping effect upon oscillatory body
• CPC Class Codes: G01N 2291/0226 Oils, e.g. engine oils
• CPC Class Codes: G01N 2291/0256 Adsorption, desorption, surface mass change, e.g. on biosensors
• CPC Class Codes: G01N 2291/02818 Density, viscosity
• CPC Class Codes: G01N 2291/106 one or more transducer arrays
• CPC Class Codes: G01N 29/022 Fluid sensors based on microsensors, e.g. quartz crystal-microbalance [QCM], surface acoustic wave [SAW] devices, tuning forks, cantilevers, flexural plate wave [FPW] devices microdevices per se B81B
• CPC Class Codes: G01N 33/2888 Lubricating oil characteristics, e.g. deterioration lubricating properties G01N33/30
• CPC Class Codes: G01N 33/30 for lubricating properties

Abstract

A multi-element fluid sensor system having a distributed sensor configuration for determining the health state of a fluid. The sensor system includes at least two sensors for collecting data relating to a particular parameter (e.g., pH, temperature, electrical conductivity, chemistry, viscosity) of the fluid. The at least two sensors may be integrated onto a semiconductor base so as to provide for a micro sensor for in situ monitoring of the fluid. The system also includes a data fusion processor operatively coupled to the at least two sensors. The data fusion processor processes the fluid data to at least compensate for information fragmentation attributed to using the at least two sensors. The data fusion processor may condense the data, combine the data, evaluate the data and interpret the data.

Claims

1. A multi-element fluid sensor system, comprising:

at least two sensors, each sensor adapted to collect data relating to a fluid; and

a data fusion processor operatively coupled to the at least two sensors, the data fusion processor processing the fluid data to at least compensate for fragmentation of information attributed to using the at least two sensors.

2. The system of claim 1, the at least two sensors being integrated onto a semiconductor base.

3. The system of claim 1, the data fusion processor condensing the fluid data.

4. The system of claim 1, the data fusion processor combining the fluid data.

5. The system of claim 1, the data fusion processor evaluating the fluid data.

6. The system of claim 1, the data fusion processor interpreting the fluid data.

7. The system of claim 1, the at least two sensors including a pH sensor.

8. The system of claim 1, the at least two sensors including a chemical sensor.

9. The system of claim 1, the at least two sensors including a conductivity sensor.

10. The system of claim 1, the at least two sensors including a temperature sensor.

11. The system of claim 1, the at least two sensors including a viscosity sensor.

12. The system of claim 1 providing for in situ monitoring of the fluid.

13. The system of claim 1, the fluid is one of:

oil, grease, hydraulic fluid, cutting oil/cutting coolant, and biological fluid.

14. The system of claim 1 wherein the fluid is employed to lubricate at least one bearing of a dynamoelectric machine.

15. The system of claim 1 used in a forced lube system.

16. The system of claim 1 used in a gear box.

17. The system of claim 1 used in connection with hydrodynamic bearings.

18. The system of claim 1 used in connection with a bearing system.

19. A fluid sensing system, comprising:

at least a distributed set of two sensors integrated onto a semiconductor, base, the sensors respectively collecting data relating to a fluid; and

a data fusion processor also integrated onto the semiconductor base and being operatively coupled to the at least two sensors, the data fusion processor processing the fluid data to at least compensate for fragmentation and overlap of the fluid data attributed to using the at least two sensors.

20. The system of claim 19 used to provide in situ monitoring of the fluid.

21. The system of claim 19, the data fusion processor condensing the fluid data.

22. The system of claim 19, the data fusion processor combining the fluid data.

23. The system of claim 19, the data fusion processor evaluating the fluid data.

24. The system of claim 19, the data fusion processor interpreting the fluid data.

25. The system of claim 19 the at least two sensors including a pH sensor.

26. The system of claim 19 the at least two sensors including a chemical sensor.

27. The system of claim 19 the at least two sensors including a conductivity sensor.

28. The system of claim 19 the at least two sensors including a temperature sensor.

29. The system of claim 19 the at least two sensors including a viscosity sensor.

30. A distributed sensor system for in situ monitoring of a lubricant employed in a dynamoelectric machine, comprising:

a plural sensor means for collecting data for a plurality of parameters relating to the health of the lubricant; and

an algorithmic processing means for fusing the data to at least compensate for fragmentation and overlap of information between the data for the plurality of parameters.

31. A distributed sensor method for in situ monitoring a lubricant, in terms of any data, information or parameter that corresponds to a health state or quality level for said lubricant comprising the steps of:

using a distributed set of at least two sensors to collect a sum of data relating to the health state of the lubricant while the lubricant is being used; and

using a data via an algorithm implementation to at least compensate for any information fragmentation or fusion fusion system to process the data.

32. A lubrication sensor for assessing a quality, condition or health state in a lubrication application comprising:

a distributed set of at least two sensors, each sensor adapted to collect data relating to a lubricant; and

a data fusion processor operatively coupled to the at least two sensors, the data fusion processor processing the lubricant data via an algorithm implementation to at least compensate for fragmentation and/or overlap of information attributed to using the at least two sensors.

33. A lubrication sensor for use in connection with a dynamoelectric machine, comprising:

a set of distributed sensors including at least two of the following sensing devices adapted to collect data relating to a lubricant;

a temperature sensor for sensing temperature of the lubricant;

a viscosity sensor for sensing viscosity of the lubricant;

a chemical sensor for sensing chemical parameters of the lubricant;

a conductivity sensor for sensing electrical conductivity of the lubricant;

a pressure sensor for sensing lubricant pressure;

a shear viscosity sensor for sensing lubricant shear; and

a density sensor for sensing lubricant density; and

a pH sensor for sensing lubricant pH; and

a data fusion processor operatively coupled to the at least two sensing devices, the data fusion processor processing the lubricant data via an algorithm implementation to at least compensate for fragmentation and/or overlap of information attributed to using the at least two sensing devices.

34. A multi-element fluid sensor system having a distributed sensor configuration comprising:

a first sensor adapted to collect data relating to a fluid;

a second sensor substantially identical to the first sensor, the second sensor providing redundancy in collecting the fluid data via an algorithm implementation to at least compensate for any information fragmentation or fusion; and

a data fusion processor operatively coupled to the first and second sensors, the data fusion processor processing the fluid data;

wherein the employment of the second sensor facilitates fluid data reliability and accuracy.