System and method for proactive motor wellness diagnosis

• US 7,075,327 B2
• Filed: 06/02/2004
• Issued: 07/11/2006
• Est. Priority Date: 06/18/2003
• Status: Active Grant

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Eaton Corp. (Wisconsin) (Eaton Corporation PLC.)
• Inventors: Habetler, Thomas G., Dimino, Steven A., Krstic, Slobodan, Liu, Yanzhen, Nowak, Michael P., Obaid, Ramzy R.
• Primary Examiner(s): TANG, MINH NHUT
• Application Number:
  US10/859,506
• Publication Number:
  US 20050007096A1
• Time in Patent Office: 769 Days
• Field of Search: None
• US Class Current: 324/765.01
• CPC Class Codes: G01R 31/343 in operation
• CPC Class Codes: G05B 2219/37351 Detect vibration, ultrasound
• CPC Class Codes: G05B 23/0229 knowledge based, e.g. expert systems; genetic algorithms
• CPC Class Codes: G05B 23/0245 based on a qualitative model, e.g. rule based; if-then decisions
• CPC Class Codes: G05B 23/0254 based on a quantitative model, e.g. mathematical relationships between inputs and outputs; functions: observer, Kalman filter, residual calculation, Neural Networks
• CPC Class Codes: H02H 7/0822 Integrated protection, motor control centres

Abstract

The present invention is directed to a power meter or overload relay including a housing and a plurality of sensors configured to monitor operation of a motor. A processor disposed within the housing and configured to receive operational feedback from the plurality of sensor and proactively determine an operational wellness of the motor from the operational feedback.

Claims

1. A power meter comprising:

a housing;

a plurality of sensors configured to monitor operation of a motor;

a processor disposed within the housing and configured to receive operational feedback from the plurality of sensors and proactively determine an operational wellness of the motor from the operational feedback;

wherein the processor is further configured to generate baseline data from the operational feedback during known healthy operation of the motor; and

wherein the processor is further configured to perform a fast Fourier Transform (FFT) on the operational feedback to compare a frequency spectrum of the operational feedback to the baseline data to determine the operational wellness of the motor.

2. The power meter of claim 1 wherein the processor is further configured to output proactive operational wellness alerts to a display.

3. The power meter of claim 2 wherein the proactive operational alerts include pump cavitation alerts, motor alignment alerts, and motor rotational unbalance alerts.

4. The power meter of claim 2 further comprising a communications interface configured to be connected to a communications bus to communicate the proactive operational alerts to the display.

5. The power meter of claim 1 wherein the plurality of sensors are configured to non-invasively monitor operation of the motor.

6. The power meter of claim 1 wherein the plurality of sensors include a sensor configured to monitor a three-phase current and voltage of the motor.

7. The power meter of claim 1 further comprising a notch filter configured to remove a fundamental frequency of the motor from the operational feedback.

8. The power meter of claim 7 wherein the notch filter is configured to be adaptive to track the fundamental frequency of the motor and an accompanying inverter.

9. The power meter of claim 1 incorporated into a relay.

10. The power meter of claim 1 wherein the operational feedback includes at least one of current data, voltage data, and power data.

11. An overload relay comprising:

a relay housing;

a power meter disposed within the relay housing and configured to receive data from a motor and perform motor fault protection;

a wellness system disposed within the housing and configured to review the data and proactively determine a wellness of the motor to generate condition based maintenance alerts

wherein the wellness system is further configured to communicate the condition based maintenance alerts upon determining an undesirable wellness of the motor; and

wherein the condition based maintenance alerts are communicated over a communications network to an operator display.

12. The overload relay of claim 11 wherein the wellness system is further configured to detect pump cavitation, motor misalignment, and motor rotational unbalance to determine the wellness of the motor.

13. The overload relay of claim 12 wherein pump cavitation, motor misalignment, and motor rotational unbalance are detected non-invasively while the motor is operational.

14. The overload relay of claim 11 wherein the wellness system is further configured to communicate the condition based maintenance alerts without tripping the motor.

15. The overload relay of claim 11 further comprising a circuit configured to perform motor start/stop functions and motor trip/reset functions.

16. The overload relay of claim 11 further comprising a circuit configured to provide feedback regarding trip times and dates and trip causes including at least motor overload, phase unbalance, and ground fault.

17. The overload relay of claim 11 wherein the power meter is further configured to monitor motor phase currents and thermal capacity.

18. A kit configured to retrofit a relay comprising:

a housing having dimensions substantially similar to an overload relay;

an interface configured to receive feedback from a plurality of sensors monitoring a motor;

a wellness system disposed within the housing and configured to receive the feedback from the interface and determine whether preventative maintenance is required on the motor

wherein the wellness system is further configured to compare the feedback to historical data and output preventative maintenance alerts if the feedback is outside a tolerance; and

wherein the preventative maintenance alerts include cavitation alerts, motor alignment alerts, and motor rotational unbalance alerts.

19. The kit of claim 18 further comprising a housing and wherein the interface is disposed within the housing.

20. The kit of claim 19 wherein the housing is configured to be substantially similar to a relay housing configured to not have a wellness system disposed therein.

21. The kit of claim 18 further comprising a communications interface configured to be connected to a communications bus to communicate preventative maintenance alerts to an operator display.

22. The kit of claim 18 wherein the wellness system is further configured to provide non-invasive diagnostic feedback.

23. The kit of claim 18 wherein the wellness system is further configured to operate in a learning mode to populate historical data.

24. The kit of claim 18 wherein the wellness system is configured to perform motor fault signature analysis to diagnose impending motor faults.

25. The kit of claim 24 wherein the impending motor faults include potential cavitation faults and mechanical faults.