Condition monitoring parameter normalization system and method

• US 8,290,630 B2
• Filed: 09/30/2008
• Issued: 10/16/2012
• Est. Priority Date: 09/30/2008
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Lakomiak, Jason E., Lanthier, Gilles
• Primary Examiner(s): Ali, Mohammad
• Assistant Examiner(s): Booker, Kelvin
• Application Number:
  US12/242,724
• Publication Number:
  US 20100082158A1
• Time in Patent Office: 1,477 Days
• Field of Search: 700/280, 700/275, 700/90, 702/54, 702/56, 702/77, 73/14.8, 73/14.6, 73/18.2, 736/49
• US Class Current: 700/280
• CPC Class Codes: B23Q 17/12 for indicating or measuring vibration
• CPC Class Codes: G01H 1/003 of rotating machines G01H1/10 takes precedence
• CPC Class Codes: G05B 2219/35379 Conversion, normalize
• CPC Class Codes: G05B 2219/37434 Measuring vibration of machine or workpiece or tool
• CPC Class Codes: G05B 2219/37493 Use of different frequency band pass filters to separate different signals
• CPC Class Codes: G05B 23/0216 Human interface functionality, e.g. monitoring system providing help to the user in the selection of tests or in its configuration
• CPC Class Codes: G05B 23/0221 Preprocessing measurements, e.g. data collection rate adjustment; Standardization of measurements; Time series or signal analysis, e.g. frequency analysis or wavelets; Trustworthiness of measurements; Indexes therefor; Measurements using easily measured parameters to estimate parameters difficult to measure; Virtual sensor creation; De-noising; Sensor fusion; Unconventional preprocessing inherently present in specific fault detection methods like PCA-based methods
• CPC Class Codes: G05B 23/0272 Presentation of monitored results, e.g. selection of status reports to be displayed; Filtering information to the user

Abstract

In one embodiment, the disclosed method includes controlling operation of a machine system via actuators and a first set of signals received from sensors, receiving a second signal from a vibration sensor, calculating vibration parameters based on the second signal. The method further includes the steps of normalizing each of the vibration parameters and presenting the normalized vibration parameters in an operator interface. In another embodiment, the system includes a controller configured to receive sensor signals from a machine system and to control operation of the machine system via actuators. The system also includes a condition monitoring user interface configured to display normalized vibration parameters for the machine system.

Claims

1. A method for vibration condition monitoring and controlling a machine system, comprising:

controlling operation of a machine system via sending control commands to actuators and receiving a first signal from at least one sensor, the controlled machine system producing vibration during operation;

receiving a second signal from a vibration sensor coupled to the machine system and detecting the vibration produced;

calculating vibration parameters based on the second signal;

normalizing each of the vibration parameters, wherein normalizing each of the vibration parameters comprises scaling each of the vibration parameters; and

presenting the normalized vibration parameters in an operator interface during controlled operation of the machine system.

2. The method of claim 1, wherein the vibration parameters are scaled with respect to alarms for specific vibration frequency bands.

3. The method of claim 2, wherein the alarms are determined by a selection of a system type, the system type corresponding to specific machine component combination.

4. The method of claim 2, wherein the normalized vibration parameters are displayed along with alarms for each normalized vibration parameter.

5. The method of claim 1, wherein presenting the normalized vibration parameters comprises presenting an overall vibration parameter, an unbalance parameter, a looseness parameter, a misalignment parameter, or a bearing parameter.

6. The method of claim 1, wherein calculating the vibration parameters comprises calculating a fast Fourier transform or a spike energy value.

7. The method of claim 1, wherein the vibration sensor comprises an accelerometer.

8. The method of claim 1, comprising presenting diagnostic information that includes status information and system faults.

9. The method of claim 8, wherein the presenting diagnostic information comprises prioritizing the information and faults in order of importance to an operator.

10. A machine control and condition monitoring system, comprising:

a controller configured to receive sensor signals from a machine system and to control operation of the machine system via actuators;

wherein the controller processes vibration measurement data and calculates the normalized vibration parameters; and

wherein normalizing each of the vibration parameters comprises scaling each of the vibration parameters; and

a condition monitoring user interface configured to display normalized vibration parameters for the machine system during controlled operation of the machine system.

11. The system of claim 10, wherein the vibration measurement data is from an accelerometer.

12. The system of claim 10, wherein the calculations of the normalized parameters are based upon a selection of a system type, the system type corresponding to specific machine component combination.

13. The system of claim 10, wherein the normalized vibration parameters comprise an overall vibration parameter, an unbalance parameter, a looseness parameter, a misalignment parameter, or a bad bearing parameter.

14. The system of claim 10, wherein the condition monitoring user interface is also configured to display diagnostic information including status information and system faults.

15. The method of claim 14, wherein the condition monitoring user interface is configured to display the diagnostic information prioritized in order of importance to an operator.

16. A machine system controller, comprising:

computer code to control operation of a machine system via actuators;

computer code to perform vibration monitoring of the machine system;

wherein the vibration monitoring computer code comprises code to process vibration measurement data and calculate the normalized vibration parameters; and

wherein normalizing each of the vibration parameters comprises scaling each of the vibration parameters; and

a vibration monitoring user interface configured to display normalized vibration parameters for the machine system during controlled operation of the machine system.

17. The system of claim 16, wherein the vibration measurement data is from an accelerometer.

18. The system of claim 16, wherein the normalized vibration parameters are scaled with respect to alarms for specific vibration frequency bands.

19. The system of claim 16, wherein the normalized vibration parameters comprise an overall vibration parameter, an unbalance parameter, a looseness parameter, a misalignment parameter, or a bearing parameter.

20. The system of claim 16, wherein the vibration monitoring user interface is also configured to display diagnostic information including status information and system faults.

21. The system of claim 20, wherein the diagnostic information is prioritized in order of importance to an operator.