Expert analysis modules for machine testing

• US 6,549,869 B1
• Filed: 06/20/2000
• Issued: 04/15/2003
• Est. Priority Date: 06/20/2000
• Status: Expired due to Term

• Current Assignee: Computational Systems Incorporated (Emerson Electric Company)
• Original Assignee: CSI Technology Incorporated (Emerson Electric Company)
• Inventors: Rich, Michael D., Reeves, Todd W., Piety, Kenneth R., Edwards, Jason M.
• Primary Examiner(s): ASSOUAD, PATRICK J
• Application Number:
  US09/597,508
• Time in Patent Office: 1,029 Days
• Field of Search: 702/35, 702/36, 702/33, 702/34, 702/122, 702/123, 702/182, 702/183, 702/184, 702/185, 702/56, 340/870.16, 340/500, 340/635
• US Class Current: 702/122
• CPC Class Codes: G01H 1/003 of rotating machines G01H1/10 takes precedence
• CPC Class Codes: G01M 13/028 Acoustic or vibration analysis

Abstract

A hand-held apparatus gathers and analyzes test data associated with rotating electric machines, where the test data is indicative of one or more operational characteristics of the mechanical equipment. The apparatus, which is operable to be carried by an operator from one machine to another along a test route, includes a sensor input port for receiving a sensor signal from a sensor, where the sensor signal is indicative of one or more operational characteristics of the rotating electric machines. The apparatus also includes a signal conditioning circuit for receiving the sensor signal, and for conditioning the sensor signal to produce a conditioned signal which is appropriate in format to be digitally processed. A processor, which is coupled to the signal conditioner, receives and processes the conditioned signal according to processing instructions and processing parameters to produce a test spectrum. The processing parameters determine one or more characteristics of the test spectrum. A memory device, which is coupled to the processor, stores a plurality of executable test expert modules, each containing the processing instructions for processing the conditioned signal in a particular way to determine one or more of the operational characteristics of the rotating electric machines. An operator input device is coupled to the processor for receiving input from the operator to select one of the test expert modules to be executed to process the conditioned signal according to the processing instructions contained in the selected module. The apparatus further includes a display device for displaying the test spectrum to the operator. The test expert modules contain processing instructions for determining whether the processing parameters have been set according to a predetermined configuration for a particular test point on the test route, and for processing the conditioned signal in a way dependent upon whether or not the processing parameters have been set according to such a predetermined configuration.

Claims

1. A hand-held apparatus for gathering and analyzing test data associated with rotating machines, the apparatus operable to be carried by an operator from one machine to another along a test route, the test data indicative of one or more operational characteristics of the rotating machines, the apparatus comprising:

a sensor input port for receiving a sensor signal from a sensor, the sensor signal indicative of one or more operational characteristics of the rotating machines;

signal conditioning means for receiving the sensor signal, and for conditioning the sensor signal to produce a conditioned signal which is appropriate in format to be digitally processed;

a processor coupled to the signal conditioning means for receiving and processing the conditioned signal according to processing instructions and processing parameters to produce a test spectrum, where the processing parameters correspond to one or more characteristics of the test spectrum;

a memory device coupled to the processor for storing a plurality of executable test expert modules, each of the test expert modules containing the processing instructions for processing the conditioned signal in a particular way to determine one or more of the operational characteristics of the rotating machines;

an operator input device coupled to the processor for receiving input from the operator to select one of the test expert modules to be executed to process the conditioned signal according to the processing instructions contained in the test expert module selected; and

a display device for displaying the test results to the operator.

2. The apparatus of claim 1 further comprising the test expert modules containing processing instructions for determining whether the processing parameters have been set according to a predetermined configuration for a particular test point on the test route, and for processing the conditioned signal in a way dependent upon whether or not the processing parameters have been set according to a predetermined configuration for a particular test point on the test route.

3. The apparatus of claim 2 further comprising at least one of the test expert modules containing processing instructions for setting a maximum frequency of the test spectrum based upon whether the processing parameters have been set according to a predetermined configuration for a particular test point on the test route.

4. The apparatus of claim 2 further comprising at least one of the test expert modules containing processing instructions for setting a frequency resolution of the test spectrum based upon whether the processing parameters have been set according to a predetermined configuration for a particular test point on the test route.

5. The apparatus of claim 2 further comprising:

the operator input device further for selecting a frequency within the test spectrum to be a designated frequency; and

at least one of the test expert modules containing processing instructions for setting a maximum frequency of the test spectrum based upon whether the operator has selected a designated frequency.

6. The apparatus of claim 5 further comprising at least one of the test expert modules containing processing instructions for setting a maximum frequency of the test spectrum based upon a value of the designated frequency.

7. The apparatus of claim 2 further comprising:

the operator input device further for selecting a frequency within the test spectrum to be a designated frequency; and

at least one of the test expert modules containing processing instructions for setting a frequency resolution of the test spectrum based upon whether the operator has selected a designated frequency.

8. The apparatus of claim 7 further comprising at least one of the test expert modules containing processing instructions for setting a frequency resolution of the test spectrum based upon a value of the designated frequency.

9. The apparatus of claim 1 further comprising:

the memory device for storing a turning speed detection test expert module having the processing instructions for processing the conditioned signal to determine a detected turning speed of the rotating machine;

the operator input device for receiving from the operator an estimated turning speed of the rotating machine;

the processor for executing the turning speed detection test expert module to analyze the test spectrum based on the estimated turning speed to determine the detected turning speed of the rotating machine;

the display device for displaying the detected turning speed to the operator; and

the operator input device further for receiving input from the operator concerning whether to accept the detected turning speed as being an actual turning speed of the rotating machine.

10. A hand-held apparatus for gathering and analyzing test data associated with rotating machines, the apparatus operable to be carried by an operator from one machine to another along a test route, the test data indicative of one or more operational characteristics of the machines, the apparatus comprising:

a sensor input port for receiving a sensor signal from a sensor, the sensor signal indicative of the actual turning speed of a machine along the route;

signal conditioning means for receiving the sensor signal, and for conditioning the sensor signal to produce a conditioned signal which is appropriate in format to be digitally processed;

an operator input device for receiving from the operator an estimated turning speed of the machine;

a processor coupled to the signal conditioning means for receiving and processing the conditioned signal to determine a detected turning speed of the machine;

a display device for displaying the detected turning speed to the operator; and

the operator input device further for receiving input from the operator concerning whether to accept the detected turning speed as being the actual turning speed of the machine.

11. The apparatus of claim 10 further comprising:

the processor for processing the conditioned signal to produce a test spectrum, and for determining the detected turning speed of the machine based on the test spectrum; and

the display device for displaying the test spectrum to the operator with the detected turning speed marked on the test spectrum.

12. A method for controlling a hand-held machine analyzer to analyze faults in rotating machines, where the analyzer is operable to be carried by an operator from one machine to another along a machine testing route, and where the analyzer includes a sensor for generating sensor signals, conditioning circuits for conditioning the sensor signals to produce conditioned signals appropriate in format to be digitally processed, a processor for processing the conditioned signals according to processing parameters to produce measurement data, a display device for displaying the measurement data to the operator, and an input device for receiving input instructions from the operator, the method comprising:

(a) receiving conditioned signals from the conditioning circuits while the sensor is positioned at a test point on the machine;

(b) processing the conditioned signals according to initial processing parameters to produce initial measurement data;

(c) displaying the initial measurement data to the operator on the display device, where the initial measurement data is indicative of a machine condition;

(d) displaying a list of expert analysis routines from which the operator may select to aid in further analyzing the machine condition;

(e) receiving input instructions from the operator indicating a selected one of the expert analysis routines;

(f) executing the selected expert analysis routine and thereby;

(f1) determining, based on the initial measurement data, subsequent processing parameters to use in subsequent processing of the conditioned signals; and

(f2) processing the conditioned signals according to the subsequent processing parameters determined in step (f1) to produce subsequent measurement data, where the subsequent measurement data is more indicative of the machine condition than is the initial measurement data; and

(g) displaying the subsequent measurement data to the operator on the display device.

13. The method of claim 12 further comprising:

(h) again displaying the list of expert analysis routines from which the operator may select to aid in further analyzing the machine condition;

(i) receiving input instructions from the operator indicating a selected expert analysis routine;

(j) executing the selected expert analysis routine and thereby;

(j1) determining, based on previous measurement data, further processing parameters to use in further processing of the conditioned signals; and

(j2) processing the conditioned signals according to the further processing parameters determined in step (j1) to produce further measurement data, where the further measurement data is further indicative of the machine condition;

(k) displaying the further measurement data to the operator on the display device;

(l) repeating steps (h) through (k) as necessary to further analyze the machine condition.

14. The method of claim 12 wherein the sensor is a vibration sensor, the conditioned signals are vibration signals, and the initial measurement data represent an initial vibration frequency spectrum, and wherein:

step (b) includes processing the vibration signals using an initial number of lines of resolution;

step (e) includes receiving input instructions from the operator indicating selection of a high-resolution expert analysis routine;

step (f1) includes determining a subsequent number of lines of resolution based upon the initial measurement data; and

step (f2) includes processing the vibration signals to produce a high-resolution vibration frequency spectrum having the subsequent number of lines of resolution determined in step (f1), where the subsequent number of lines of resolution of the high-resolution vibration frequency spectrum is greater than the initial number of lines of resolution of the initial vibration frequency spectrum.

15. The method of claim 12 wherein the sensor is a vibration sensor, the conditioned signals are vibration signals, and the initial measurement data represent an initial vibration frequency spectrum, and wherein:

step (e) further includes receiving an input instruction from the operator indicating a marked frequency within the initial vibration frequency spectrum;

step (f1) includes determining a subsequent maximum frequency based upon the marked frequency; and

step (f2) includes processing the vibration signals to produce a subsequent vibration frequency spectrum having the subsequent maximum frequency.

16. The method of claim 12 wherein the sensor is a vibration sensor, the conditioned signals are vibration signals, and the initial measurement data represent an initial vibration frequency spectrum, and wherein:

step (e) includes receiving input instructions from the operator indicating selection of a bump-test expert analysis routine;

step (a) includes receiving initial vibration signals after the machine has been impacted near the test point on the machine;

step (b) includes processing the vibration signals according to bump-test processing parameters to produce the initial vibration spectrum;

step (e) further includes receiving an input instruction from the operator indicating a marked frequency within the initial vibration frequency spectrum;

step (f1) includes determining a subsequent maximum frequency based upon the marked frequency;

step (a) includes receiving subsequent vibration signals after the machine has again been impacted near the test point on the machine; and

step (f2) includes processing the subsequent vibration signals to produce a subsequent vibration frequency spectrum having the subsequent maximum frequency.

17. The method of claim 12 wherein the sensor is a vibration sensor, the conditioned signals are vibration signals, and the initial measurement data represent an initial vibration frequency spectrum, further comprising:

step (e) including receiving input instructions from the operator indicating selection of a peak phase coast-down expert analysis routine;

step (a) including receiving vibration signals after power to the machine has been removed and as the machine is allowed to coast to a stop;

(h) receiving a tachometer signal indicative of rotational speed of the machine as the machine coasts to a stop;

step (f2) including processing the tachometer and vibration signals to produce vibration amplitude and phase data as a function of the rotational speed of the machine; and

step (g) including displaying the vibration amplitude and phase data to the operator on the display device.

18. The method of claim 12 further comprising:

(h) associating a label field with the subsequent measurement data, where the label field indicates which expert analysis routine was executed to produce the subsequent measurement data; and

(i) storing the subsequent measurement data and the label field on a storage medium.

19. The method of claim 12 wherein the sensor is a vibration sensor, the conditioned signals are vibration signals, and the initial measurement data represent an initial vibration frequency spectrum, and wherein:

step (e) includes receiving input instructions from the operator indicating selection of an expert analysis routine for further analyzing peaks in the initial vibration spectrum;

step (f2) includes processing the subsequent vibration signals to determine a peak vibration amplitude value during a predetermined sample time period; and

step (g) includes displaying the peak vibration amplitude value to the operator on the display device.

20. A method for controlling a hand-held machine analyzer operable to be carried by an operator from one machine to another along a machine testing route, and where the analyzer includes a sensor for generating sensor signals, conditioning circuits for conditioning the sensor signals to produce conditioned signals appropriate in format to be digitally processed, a processor for processing the conditioned signals according to processing parameters to produce measurement data, a display device for displaying the measurement data to the operator, and an input device for receiving input instructions from the operator, the method comprising:

(a) querying the operator to provide an estimated turning speed of the machine;

(b) receiving from the operator an estimated turning speed of the machine;

(c) receiving conditioned signals from the conditioning circuits while the sensor is positioned at a test point on the machine;

(d) analyzing the measurement data based on the estimated turning speed to determine a detected turning speed of the machine;

(e) displaying the detected turning speed to the operator on the display device; and

(f) receiving input from the operator concerning whether to accept the detected turning speed as being an actual turning speed of the machine.