Integrated control and diagnostics system

• US 7,301,296 B1
• Filed: 09/04/2003
• Issued: 11/27/2007
• Est. Priority Date: 07/23/2001
• Status: Expired due to Fees

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Discenzo, Frederick M.
• Primary Examiner(s): Donovan; Lincoln
• Assistant Examiner(s): Smith; Tyrone
• Application Number:
  US10/654,776
• Time in Patent Office: 1,545 Days
• Field of Search: 318/439, 318/138, 318/254, 318/432, 318/434, 318/609, 318/610, 318560-600, 318466-469, 701 29- 43
• US Class Current: 318/400.04
• CPC Class Codes: G05B 19/4063 Monitoring general control system G05B19/4062 takes precedence
• CPC Class Codes: G05B 2219/33299 Real time, online diagnostic, integrated in normal control system
• CPC Class Codes: G05B 2219/34427 Diagnostic, monitoring incorporated in controller
• CPC Class Codes: H02H 7/0844 Fail safe control, e.g. by comparing control signal and controlled current, isolating motor on commutation error
• CPC Class Codes: H02P 29/032 Preventing damage to the motor, e.g. setting individual current limits for different drive conditions

Abstract

An integrated control and diagnostics system for a controlled system (e.g., a motor) includes a diagnostics module and a controller coupled to the motor. To optimize operation, the diagnostics information signal is used to modify the control provided by the controller as required. Moreover, the output of the control module is coupled to the diagnostics module so that the health assessment made by the diagnostics module can be based at least in part on the output of the controller. The invention uses a model-based diagnostics approach that allows integration of control algorithms with diagnostics algorithms to intelligently trade off optimizing performance to avert or accommodate failures, and to meet performance requirements in a wide range of applications.

Claims

1. A control and diagnostic system comprising:

a diagnostic module to produce a health assessment signal indicative of the health of a controlled system;

a control module to generate a driving output based at least in part on a processed signal that is indicative of changes the control module needs to make to optimize system operation, the control module coupled to the diagnostic module and integrated into the controlled system;

a processor to receive the health assessment signal from the diagnostic module, generate the processed signal based at least in part on the health assessment signal, a driving output, and an optimization parameter, and transmit the processed signal to the control module, the optimization parameter input to the processor relates to at least one of mission requirements, workload schedule, operating environment, and preventative maintenance schedules; and

a supervisory system that utilizes an adaptive model associated with the controlled unit, and sub-modules including at least one of an evaluation module, an action planning module, a simulation/forecasting module, and a schedule module to optimize system operation.

2. The system of claim 1, the processor is integrated into the controlled system.

3. The system of claim 1, the processor is integrated into the diagnostic module.

4. The system of claim 1, the processor transmits the health assessment signal to an external indicator unit.

5. The system of claim 1, the processor transmits the health assessment signal to an operator.

6. The system of claim 1, the health assessment signal is generated in response to at least one signal generated by a sensor that monitors at least one parameter of associated with the controlled system.

7. The system of claim 1, further comprising an enhancement module that generates an evolving set of design rules based on a plurality of health assessment signals to facilitate design of an improved version of the system in the future.

8. The system of claim 7, further comprising a model embedded in a memory of the enhancement module to generate the evolving set of design rules.

9. An integrated control and diagnostic system comprising:

a diagnostic module to produce a state signal indicative of the state of a controlled unit;

a controller integrated together with the diagnostic module and contained within the controlled unit to generate a driving signal based at least in part on a processed signal based on at least one optimization parameter input to a processor via auxiliary inputs, the at least one optimization parameter relates to at least one of mission requirements, workload schedule, operating environment, and preventative maintenance schedules; and

a supervisory system that utilizes the state signal and driving signal to simulate system operation and, in conjunction with operational objectives, to modify the driving signal for one or more controlled units, the supervisory system includes a plurality of operator inputs including at least one of a set point, goals, spare parts inventory, and costs and further utilizes an adaptive model associated with the controlled unit, and sub-modules including at least one of an evaluation module, an action planning module, a simulation/forecasting module, and a schedule module to optimize system operation.

10. The system of claim 9, the supervisory system comprises a processor integrated with the controller and diagnostic module.

11. The system of claim 9, the controlled unit is a motor.

19. The system of claim 9, the supervisory system includes a plurality of operator inputs.

20. The system of claim 19, the operator inputs include at least one of a set point, goals, spare parts inventory, and costs.

12. A control and diagnostic system comprising:

a diagnostic module to produce a health assessment signal indicative of the health of a controlled system;

a control module coupled to the diagnostic module and integrated into the controlled system that generates a driving output based at least in part on a processed signal;

a processor to receive the health assessment signal from the diagnostic module, generate a processed signal based at least in part on the health assessment signal, transmit the processed signal to the control module, and dynamically alter parameters to prove or disprove diagnostic information generated by the diagnostics module, the processed signal based on at least one optimization parameter input to the processor via auxiliary inputs, the at least one optimization parameter relates to at least one of mission requirements, workload schedule, operating environment, and preventative maintenance schedules, the processor further transmits the health assessment signal to an external indicator unit; and

a supervisory system that utilizes an adaptive model associated with the controlled unit, and sub-modules including at least one of an evaluation module, an action planning module, a simulation/forecasting module, and a schedule module to optimize system operation.

13. The system of claim 12, the processor is integrated into the controlled system.

14. The system of claim 12, the processor is integrated into the diagnostic module.

15. The system of claim 12, the driving output is indicative of changes the control module needs to make to optimize system operation.

16. The system of claim 15, the processed signal is based on the driving output.

17. An integrated control and diagnostic system comprising:

a diagnostic module to produce a state signal indicative of the state of a controlled unit;

a controller integrated together with the diagnostic module and contained within the controlled unit to generate a driving signal; and

a supervisory system that utilizes the state signal and driving signal in conjunction with operational objectives to modify the driving signal for one or more controlled units, the supervisory system dynamically alters parameters to prove or disprove diagnostic information produced by the diagnostic module and utilizes an adaptive model associated with the controlled unit with sub-modules including at least one of an evaluation module, an action planning module, a simulation/forecasting module, and a schedule module to optimize the system operation.

18. The system of claim 17, the supervisory system comprises a processor integrated with the controller and diagnostic module.

21. The system of claim 17, the controlled unit is a motor.