Modular equipment dynamic condition monitoring system with multiple processors

• US 6,768,949 B2
• Filed: 05/13/2002
• Issued: 07/27/2004
• 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., Kramb, Kevin E., Shupe, Dan R., Trumpy, David P.
• Primary Examiner(s): Bui, Bryan
• Application Number:
  US10/144,550
• Publication Number:
  US 20030212500A1
• Time in Patent Office: 806 Days
• Field of Search: 702/182, 702/186, 702/33, 702/34, 702/35, 702/36, 702/56-57, 702/77, 702/91, 702/104, 702/113, 702/116, 702/168, 702/188-190, 735/70, 735/93, 736/02, 736/49, 736/60, 736/61, 736/62
• US Class Current: 702/33
• CPC Class Codes: G01H 1/003 of rotating machines G01H1/10 takes precedence
• CPC Class Codes: G05B 2219/24084 Remote and local monitoring, local result to remote, remote takes action

Abstract

A monitoring and protection technique for machine systems includes providing multiple processors within a monitoring module. A first processor generally performs management functions, such as data communications control, memory management, and so forth. A second processor performs complex calculations that provide data to the first processor. The module may be specifically adapted to applications, such as vibration monitoring, in which case the second processor may perform analysis of received signals to derive vibrational data that forms the basis for decisions for energizing or de-energizing relay circuitry used to control the machine system or an alarm.

Claims

1. A module for monitoring dynamic operating parameters of a machine system, the module comprising:

a first processor for managing at least transmission of data to a remote device;

a memory circuit for storing configuration parameters of the module; and

a second processor for receiving and processing signals from a sensor representative of a dynamic operating parameter of the machine system and for performing computations based on the received signals and the configuration parameters stored in the memory circuit.

2. The module of claim 1, wherein the second processor is dedicated to performing the computations.

3. The module of claim 1, wherein the computations performed by the second processor include a fast Fourier transform.

4. The module of claim 3, wherein the fast Fourier transform derives vibrational data from the received signals.

5. The module of claim 4, wherein at least one of the first and second processors is configured to output an alarm signal based upon the vibrational data.

6. The module of claim 1, wherein the first processor is configured to transmit data to a remote device in accordance with an open industrial data exchange protocol.

7. The module of claim 1, wherein the first processor is configured to control a state change in a relay powering a component of the system based upon computations performed by the second processor.

8. The module of claim 7, wherein module includes the relay controlled by the first processor.

9. A module for monitoring dynamic operating parameters of a machine system, the module comprising:

a sensor interface for receiving signals from a sensor representative of a dynamic operation parameter of the machine system;

a memory circuit for storing configuration parameters of the module;

a first processor for managing at least transmission of data to a remote device; and

a second processor for receiving the signals and for performing computations based on the received signals and the configuration parameters stored in the memory circuit, including a fast Fourier transform of the signals to derive vibrational data from the received signals.

10. The module of claim 9, wherein at least one of the first and second processors is configured to output an alarm signal based upon the vibrational data.

11. The module of claim 9, wherein the first processor is configured to transmit data to a remote device in accordance with an open industrial data exchange protocol.

12. The module of claim 9, wherein the first processor is configured to control a state change in a relay powering a component of the system based upon computations performed by the second processor.

13. The module of claim 12, wherein module includes the relay controlled by the first processor.

14. A modular monitoring system for monitoring dynamic operating parameters of a machine system, the monitoring system comprising:

a plurality of sensors for detecting dynamic operating parameters of the machine system at a desired location and for generating signals representative thereof; and

a plurality of monitoring modules, each module being coupled to at least one sensor and including a memory circuit for storing configuration parameters of the module and a processor for managing at least transmission of data to a remote device, at least one of the modules further comprising a second processor for receiving the signals and for performing computations based on the received signals and the configuration parameters stored in the memory circuit, including a fast Fourier transform of the signals to derive vibrational data from the received signals, wherein the modules are configured to exchange data with one another in accordance with an open industrial data exchange protocol.

15. The monitoring system of claim 14, wherein the module having the further processor is configured to output an alarm signal based upon the vibrational data.

16. The monitoring system of claim 14, wherein the first processor is configured to transmit data to a remote device in accordance with the open industrial data exchange protocol.

17. The monitoring system of claim 14, wherein the module having the further processor is configured to control a state change in a relay powering a component of the system based upon computations performed by the second processor.

18. The monitoring system of claim 17, wherein module having the further processor includes the controlled relay.

19. The monitoring system of claim 17, further comprising a separate relay module including the controlled relay.

20. A method for monitoring dynamic operating parameters of a machine system, the method comprising:

detecting a dynamic operation parameter of the machine system and generating a signal representative thereof;

applying the signal to a monitoring module including first and second processors, the first processor managing at least transmission of data to a remote device, the second processor receiving the signal and processing the signal;

deriving vibrational data for the machine system in the second processor; and

generating output signals from the first processor based upon the vibrational data.

21. The method of claim 20, wherein the output signals from the first processor are applied to a relay to control the state of the relay.

22. The method of claim 20, wherein the output signals include an alarm signal.

23. The method of claim 20, wherein the output signals include data transmitted to a remote device in accordance with an open industrial data exchange protocol.

24. A method for monitoring dynamic operating parameters of a machine system, the method comprising:

detecting a dynamic operation parameter of the machine system and generating a signal representative thereof;

applying the signal to a monitoring module including first and second processors, the first processor managing at least transmission of signals to a remote device, the seconds processor receiving the signal and processing the signal;

deriving vibrational data for the machine system in the second processor;

generating output signals from the first processor based upon the vibrational data; and

transmitting data to a remote device based on the output signals in accordance with an open industrial data exchange protocol.

25. The method of claim 24, wherein the output signals include an alarm signal.

26. The method of claim 24, wherein the output signals from the first processor are applied to a relay to control the state of the relay.

27. The method of claim 26, wherein the output signals controlling the state of the relay are based upon control logic within the module.

28. The method of claim 26, wherein the output signals controlling the state of the relay are based at least partially upon signals received from the remote device.