Control sequencing and prognostics health monitoring for digital power conversion and load management

• US 7,308,614 B2
• Filed: 04/14/2003
• Issued: 12/11/2007
• Est. Priority Date: 04/30/2002
• Status: Expired due to Fees

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Kojori, Hassan A.
• Primary Examiner(s): Baderman, Scott
• Assistant Examiner(s): LOHN, JOSHUA A
• Application Number:
  US10/412,229
• Publication Number:
  US 20030204777A1
• Time in Patent Office: 1,702 Days
• Field of Search: 714/14, 714/22, 714/47, 713/340
• US Class Current: 714/47.2
• CPC Class Codes: G05B 23/0289 Reconfiguration to prevent failure, e.g. usually as a reaction to incipient failure detection
• CPC Class Codes: G06F 1/26 Power supply means, e.g. regulation thereof for memories G11C
• CPC Class Codes: G06F 11/24 Marginal checking or other specified testing methods not covered by G06F11/26, e.g. race tests

Abstract

An electronics-based system (100) for power conversion and load management provides control sequencing and prognostic health monitoring and diagnostics for fault tolerant operation of the system. The system (100) includes a prognostic health monitoring and diagnostic unit (30) for identifying present out-of-range conditions, overload conditions, and trending violations, for components of the system and a decision making unit (20), which controls transitions between a plurality of operating modes to ensure fail-safe operation without unnecessary tripping, cold-starts or system resets upon the occurrence of certain fault conditions.

Claims

1. An apparatus for control sequencing and prognostic health monitoring of an electrical power system of a vehicle, the electrical power system including power rectification/inversion equipment for AC-DC, DC-AC, and/or AC-DC-AC power conversion and power distribution equipment for distributing converted power to one or more loads of the vehicle, said apparatus comprising:

a data measuring unit for obtaining measurement values of at least one electrical component of the electrical power system;

a prognostic health monitoring and diagnostic unit for identifying out-of-range conditions for said electrical component as a function of said measured values, said prognostic health monitoring and diagnostic unit further identifying overload conditions for said electrical component based on past and present measurement values and identifying trend violations as a function of said measurement values to assess future operation of said electrical component; and

a decision making unit for controlling transition between a plurality of operating modes based on conditions identified by said prognostic health monitoring and diagnostic unit, said decision making unit controlling the transition between said plurality of operating modes to selectively continue operation of said electronics power system of said vehicle in a fail-safe fashion despite conditions identified by said prognostic health monitoring and diagnostic unit and to selectively initiate autonomous restart of said power rectification/inversion equipment following a fault condition identified by said prognostic health monitoring and diagnostic unit.

2. The apparatus according to claim 1, wherein said plurality of operating modes include:

a STOP/READY mode, during which a start-up test sequence is initiated by said decision making unit to confirm overall readiness of said power system;

a transitional STANDBY mode;

a RUN mode, during which said power system is operational; and

a FAULT mode, which is initiated by said decision making unit when said prognostic health monitoring and diagnostic unit identifies an abnormal event.

3. The apparatus according to claim 2, wherein said plurality of operating modes further include:

an ALARM mode, which said decision making unit initiates when said prognostic health monitoring and diagnostic unit detects a condition for said electrical component that is at or near a tolerance level of said electrical component.

4. The apparatus according to claim 3, wherein said decision making unit initiates transition from said STANDBY mode to said RUN mode, said FAULT mode, or said ALARM mode.

5. The apparatus according to claim 3, wherein said decision making unit selectively initiates transition from said STOP/READY mode to said STANDBY mode, said FAULT mode, or said ALARM mode.

6. The apparatus according to claim 3, wherein said decision making unit selectively controls transition from said RUN mode to said ALARM mode, said FAULT mode, said STANDBY mode, or said STOP/READY mode.

7. The apparatus according to claim 3, wherein said decision making unit selectively initiates transition from said FAULT mode to said STANDBY mode or said STOP/READY mode.

8. The apparatus according to claim 1, wherein said decision making unit executes a power sequencing routine to selectively enable Soft-start, Soft-stop, restart, and ride-through for said power system based on results of said prognostic health monitoring and diagnostic unit.

9. The apparatus according to claim 1, further comprising:

a data management unit for synthesizing data obtained from said data measuring unit and for storing operational threshold values for said electrical component.

10. The apparatus according to claim 9, wherein said data management unit further stores historical data, including results of said prognostic health monitoring and diagnostic unit, and functions as an interface between said decision making unit and an operator interface and/or a higher level control unit.

11. The apparatus according to claim 9, wherein said decision making unit updates reliability data for said component stored in said data management unit in accordance with conditions identified by said prognostic health monitoring and diagnostic unit.

12. The apparatus according to claim 1, further comprising:

a protection unit, which receives measurement values from said data measuring unit and selectively initiates protective action for said electrical component based on said measurement values.

13. The apparatus according to claim 1, wherein said decision making unit determines the cumulative effect of conditions identified by said prognostic health monitoring and diagnostic unit to estimate the remaining time before failure for said component.

14. A method for control sequencing and prognostic health monitoring of an electrical power system of a vehicle, the electrical power system including power rectification/inversion equipment for AC-DC, DC-AC, and/or AC-DC-AC power conversion and power distribution equipment for distributing converted power to one or more loads of the vehicle, said method comprising:

obtaining measurement values of at least one component of the electrical power system;

performing prognostic health monitoring and diagnostics to identify out-of-range conditions for said electrical component as a function of said measured values, overload conditions for said electrical component based on past and present measurement values, and trend violations as a function of said measurement values to assess future operation of said electrical component; and

controlling transition between a plurality of operating modes based on conditions identified by said step of performing prognostic health monitoring and diagnostics, said controlling step controlling the transition between said plurality of operating modes to selectively continue operation of said electronics power system of said vehicle in a fail-safe fashion despite conditions identified by said prognostic health monitoring and diagnostic unit and to selectively initiate autonomous restart of said power rectification/inversion equipment following a fault condition identified by said step of performing prognostic health monitoring and diagnostics.

15. The method according to claim 14, wherein said plurality of operating modes include:

a STOP/READY mode, during which a start-up test sequence is initiated to confirm overall readiness of said power system;

a transitional STANDBY mode;

a RUN mode, during which said power system is operational; and

a FAULT mode, which is initiated when said step of performing prognostic health monitoring and diagnostics identifies an abnormal event.

16. The method according to claim 15, wherein said plurality of operating modes further include:

an ALARM mode, which is initiated when said step of performing prognostic health monitoring and diagnostics detects a condition for said electrical component that is at or near a tolerance level of said electrical component.

17. The method according to claim 16, wherein said step of controlling initiates transition from said STANDBY mode to said RUN mode, said FAULT mode, or said ALARM mode.

18. The method according to claim 16, wherein said step of controlling selectively initiates transition from said STOP/READY mode to said STANDBY mode, said FAULT mode, or said ALARM mode.

19. The method according to claim 16, wherein said step of controlling selectively controls transition from said RUN mode to said ALARM mode, said FAULT mode, said STANDBY mode, or said STOP/READY mode.

20. The method according to claim 16, wherein said step of controlling selectively initiates transition from said FAULT mode to said STANDBY mode or said STOP/READY mode.

21. The method according to claim 14, wherein said step of controlling executes a power sequencing routine to selectively enable Soft-start, Soft-stop, restart, and ride-through for said power system based on results of said step of performing prognostic health monitoring and diagnostics.

22. The method according to claim 14, further comprising:

synthesizing data obtained from said data measuring unit; and

storing operational threshold values for said electrical component.

23. The method according to claim 22, further comprising:

storing historical data, including results of said step of performing prognostic health monitoring and diagnostics.

24. The method according to claim 22, further comprising:

updating reliability data for said component in accordance with conditions identified by said step of performing prognostic health monitoring and diagnostic unit.

25. The method according to claim 14, further comprising:

selectively initiating protective action for said electrical component based on said measurement values.

26. The method according to claim 14, further comprising:

determining the cumulative effect of conditions identified by said step of performing prognostic health monitoring and diagnostics to estimate the remaining time before failure for said component.