Integrated control and diagnostics systems

• US 7,538,512 B2
• Filed: 10/31/2007
• Issued: 05/26/2009
• Est. Priority Date: 12/15/1999
• 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): Duda; Rina I
• Application Number:
  US11/933,256
• Publication Number:
  US 20080048603A1
• Time in Patent Office: 573 Days
• Field of Search: 318/609, 318/610, 318/632, 318/432, 318/434, 318/600
• US Class Current: 318/609
• 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. An integrated control and diagnostic system comprising:

a diagnostic module to generate a diagnostic signal indicative of proper operation of a controlled system; and

a control module integrated into the controlled system with the diagnostic module, wherein the control module generates a driving output for the controlled system based on a control optimization algorithm and the diagnostic signal;

wherein the diagnostic signal is utilized to detect and diagnose developing faults before the system become inoperable and to alter the driving output by averting or accommodating the faults according to a model.

2. The system of claim 1, wherein the diagnostic module generates diagnostic signal based on the driving output.

3. The system of claim 1, wherein the control module is associated with at least one controllable parameter, the parameter being controllable in response to the diagnostic signal.

4. The system of claim 1, further comprising at least one sensor embedded into the controlled system to measure parameters associated with the controlled system.

5. The system of claim 4, wherein the parameters associated with the controlled system include at least one of speed, current, voltage, temperature, vibration, magnetic flux, and lubrication characteristics.

6. The system of claim 1, wherein the output is utilized to perform a system simulation.

7. The system of claim 1, wherein the diagnostic module is implemented with application specific integrated circuits.

8. The system of claim 1, wherein the control module includes a velocity feedback loop and a torque feedback loop.

9. The system of claim 1, wherein the control module includes a P-I controller.

10. The system of claim 9, wherein the control module includes an inverter.

11. A control and diagnostic system comprising:

a diagnostic module to produce a diagnostic signal indicative of proper operation of a controlled system; and

a processor to receive the health assessment signal from the diagnostic module, process the health assessment signal, and transmit the processed signal to a control module coupled to the diagnostic module and integrated into the controlled system, wherein the control module generates a driving output based at least in part on the processed signal;

wherein the diagnostic signal is utilized to detect and diagnose developing faults before the system becomes inoperable and to alter the driving output by averting or accommodating the faults according to a model.

12. The system of claim 11, wherein the processor is integrated into the controlled system.

13. The system of claim 11, wherein the processor is integrated into the diagnostic module.

14. The system of claim 11, wherein the processed signal is indicative of changes the control module needs to make to optimize system operation.

15. The system of claim 14, wherein the processed signal is based on the driving output.

16. The system of claim 15, wherein the processed signal is based on at least one optimization parameter input to the processor via auxiliary inputs.

17. The system of claim 16, wherein the at least one optimization parameter relates to at least one of mission requirements, workload schedule, operating environment, and preventative maintenance schedules.

18. The system of claim 11, wherein the processor transmits the diagnostics signal to an external indicator unit.

19. The system of claim 11 wherein the processor transmits the diagnostics signal to an operator.