Modular machinery data collection and analysis system

• US 6,295,510 B1
• Filed: 07/17/1998
• Issued: 09/25/2001
• Est. Priority Date: 07/17/1998
• 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): Hoff, Marc S.
• Assistant Examiner(s): Raymond, Edward
• Application Number:
  US09/118,287
• Time in Patent Office: 1,166 Days
• Field of Search: 702/183, 702/182, 702/81, 702/82, 702/56, 702/57, 310/10, 310/50, 310/53, 324/500, 324/512, 324/513, 324/520, 324/522, 324/772, 340/870.16, 340/825.06, 340/825.16, 340/825.56
• US Class Current: 702/183
• CPC Class Codes: H02K 11/20 for measuring, monitoring, testing, protecting or switching rectifiers H02K11/04; power electronics H02K11/33
• CPC Class Codes: H02K 11/21 Devices for sensing speed or position, or actuated thereby specially adapted for machines having non-mechanical commutating devices H02K29/06, H02K29/14
• CPC Class Codes: H02K 11/25 Devices for sensing temperature, or actuated thereby
• CPC Class Codes: H02K 11/35 Devices for recording or transmitting machine parameters, e.g. memory chips or radio transmitters for diagnosis
• CPC Class Codes: H02P 9/02 Details of the control

Abstract

A dynamoelectric machine diagnostic system is provided. The system includes a docking station coupled to a dynamoelectric machine; a plurality of sensors operatively coupled to the docking station, at least one of the sensors being permanently positioned in the dynamoelectric machine for data gathering; and a diagnostic module, adapted to be received by and coupled to the docking station so that the diagnostic module may collect data output from at least one of the plurality of sensors.

Claims

1. A dynamoelectric machine diagnostic system, comprising:

a docking station coupled to a dynamoelectric machine;

a plurality of sensors operatively coupled to the docking station, at least one of the sensors being positioned within the dynamoelectric machine for data gathering; and

a diagnostic module, adapted to be received by and coupled to the docking station so that the diagnostic module may collect data output from at least one of the plurality of sensors.

2. The system of claim 1, the diagnostic module processing the collected data to facilitate rendering a health assessment of the dynamoelectric machine.

3. The system of claim 1, the diagnostic module generating an FFT of vibration data of the dynamoelectric machine.

4. The system of claim 1, the diagnostic module generating an FFT of current data of the dynamoelectric machine.

5. The system of claim 1, the diagnostic module determining shaft torque and shaft speed of the dynamoelectric machine.

6. The system of claim 1, the diagnostic module determining temperature of the dynamoelectric machine.

7. The system of claim 1, the plurality of sensors including an accelerometer positioned with the dynamoelectric machine.

8. The system of claim 1, the plurality of sensors including an encoder positioned within the dynamoelectric machine.

9. The system of claim 1, the plurality of sensors including an optical sensor positioned within the dynamoelectric machine.

10. The system of claim 1, the plurality of sensors including a current sensor positioned within the dynamoelectric machine.

11. The system of claim 1, the plurality of sensors including a viscosity sensor positioned within the dynamoelectric machine.

12. The system of claim 1, the plurality of sensors including a temperature sensor positioned within the dynamoelectric machine.

13. The system of claim 1, the plurality of sensors including an acoustic sensor positioned within the dynamoelectric machine.

14. The system of claim 1, the plurality of sensors including a flux sensor positioned within the dynamoelectric machine.

15. The system of claim 1, the diagnostic module including a neural network to facilitate processing of the collected data.

16. The system of claim 1, the diagnostic module including an expert system to facilitate processing of the collected data.

17. The system of claim 1, the diagnostic module including an RF section.

18. The system of claim 1, the docking station including an RF section.

19. The system of claim 1, the diagnostic module including a black-box recorder type housing.

20. The system of claim 1, the docking system including a memory, the memory storing design information specific to the dynamoelectric machine.

21. The system of claim 1, the diagnostic module including a memory, the memory storing design information specific to the dynamoelectric machine.

22. A system for load sharing by at least a first and second dynamoelectric machine, comprising:

a first diagnostic module operatively coupled to the first dynamoelectric machine;

a second diagnostic module operatively coupled to the second dynamoelectric machine, the second diagnostic module being operatively coupled to the first diagnostic module;

the first diagnostic module and second diagnostic module coordinating with each other a data collection protocol to collect machine data respectively from the first and second dynamoelectric machines.

23. The system of claim 22, the first diagnostic module and the second diagnostic module communicating via a network.

24. The system of claim 22, the first diagnostic module and the second diagnostic module communicating via a wireless link.

25. A system for diagnosing the health state of a plurality of dynamoelectric machines, comprising:

a host computer operatively coupled to a network backbone;

a plurality of docking stations, each docking station coupled to a respective dynamoelectric machine of the plurality of machines, each docking station operatively coupled to the host computer via the network, each docking station being operatively coupled to at least one machine data collecting sensor positioned within the respective machine; and

a plurality of diagnostic modules, each diagnostic module adapted to be received by and coupled to a respective one of the plurality of docking stations, each diagnostic module collecting data from the respective at least one sensor, each diagnostic module processing the collected data to facilitate diagnosing the health state of the respective machine.

26. A system for determining a health state of a dynamoelectric machine, comprising:

a first docking station coupled to the machine, the first docking station being operatively coupled to a first data collecting sensor positioned in the machine;

a second docking station coupled to the machine, the second docking station being operatively coupled to a second data collecting sensor positioned in the machine;

a first diagnostic module adapted to be coupled to the first docking station, the first diagnostic module receiving data collected by the first sensor;

a second diagnostic module adapted to be coupled to the second docking station, the second diagnostic module receiving data collected by the second sensor, the second diagnostic module being operatively coupled to the first diagnostic module;

wherein the first diagnostic module controls the second diagnostic module.

27. The system of claim 26 the first diagnostic module storing the received data.

28. The system of claim 26 the second diagnostic module storing the received data.

29. The system of claim 26 the first diagnostic module processing the received data.

30. The system of claim 26 the second diagnostic module processing the received data.

31. A dynamoelectric machine diagnostic system, comprising:

a plurality of sensors for internally sensing a plurality of parameters of at least two dynamoelectric machines;

at least two collection means for collecting data related to the sensed parameters of the machines respectively, the at least two collection means coordinating with each other a data collection protocol to collect machine data respectively from the dynamoelectric machines;

coupling means for operatively coupling the plurality of sensors to the at least two collection means; and

processing means for processing the collected data.