System for monitoring plant equipment
First Claim
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1. A monitoring system for cement manufacturing, the system comprising:
- (a) a first cement manufacturing machine;
(b) at least a first sensor coupled to the first machine operably sensing a movement condition associated with a portion of the first machine;
(c) at least a second cement manufacturing machine located remotely from and performing a different manufacturing operation than the first machine;
(d) at least a second sensor coupled to the second machine operably sensing a movement condition associated with a portion of the second machine;
(e) a central computer operably receiving signals from the first and second sensors while being remotely located from the first and second machines;
(f) software instructions used by the central computer to automatically perform substantially real-time calculations based at least in part on signals from the sensors to determine and report operating problems with sensed portions of the machines; and
(g) a hand-held and portable electronic data collector operable to receive signals through the central computer from a third sensor coupled to a third remotely located cement manufacturing machine, the hand-held data collector operably interfacing with the central computer to transfer sensor data to an offline database.
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Abstract
A system for monitoring plant equipment is provided. Another aspect provides an automated analysis system wherein software instructions operably compare sensor data to predefined valves and determine mechanical problems in multiple machines. In another aspect, a cement manufacturing system includes sensors for sensing movement conditions of cement making machines. A further aspect provides a central computer connected to vibration sensors associated with cement making machines, where software instructions perform real-time comparisons and machine performance determinations, based at least in part on sensed signals.
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Citations
50 Claims
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1. A monitoring system for cement manufacturing, the system comprising:
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(a) a first cement manufacturing machine; (b) at least a first sensor coupled to the first machine operably sensing a movement condition associated with a portion of the first machine; (c) at least a second cement manufacturing machine located remotely from and performing a different manufacturing operation than the first machine; (d) at least a second sensor coupled to the second machine operably sensing a movement condition associated with a portion of the second machine; (e) a central computer operably receiving signals from the first and second sensors while being remotely located from the first and second machines; (f) software instructions used by the central computer to automatically perform substantially real-time calculations based at least in part on signals from the sensors to determine and report operating problems with sensed portions of the machines; and (g) a hand-held and portable electronic data collector operable to receive signals through the central computer from a third sensor coupled to a third remotely located cement manufacturing machine, the hand-held data collector operably interfacing with the central computer to transfer sensor data to an offline database. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A monitoring system for cement manufacturing, the system comprising:
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(a) a first cement manufacturing machine; (b) at least a first sensor coupled to the first machine operably sensing a movement condition associated with a portion of the first machine; (c) at least a second cement manufacturing machine located remotely from and performing a different manufacturing operation than the first machine; (d) at least a second sensor coupled to the second machine operably sensing a movement condition associated with a portion of the second machine; (e) a central computer operably receiving signals from the first and second sensors while being remotely located from the first and second machines; (f) software instructions used by the central computer to automatically perform substantially real-time calculations based at least in part on signals from the sensors to determine and report operating problems with sensed portions of the machines; wherein the first sensor operably senses vibration of a bearing assembly in the first machine, and the central computer automatically compares real-time sensed vibrational values to target values and automatically activates an alarm indicator if the compared value difference exceeds an alarm limit. - View Dependent Claims (8, 9, 10, 11, 12)
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13. A monitoring system for cement manufacturing, the system comprising:
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(a) a kiln; (b) a crusher; (c) a separator; (d) a fan; (e) sensors detecting movement-related characteristics of the kiln, crusher, separator and fan; (f) a central processing unit receiving substantially real-time and continuous signals from the sensors and using the signals to determine if any undesirable conditions are present with regard to the kiln, crusher, separator and fan, and to identify one or more likely causes of the undesirable conditions; and (g) at least a first switch matrix and a multiplexer connecting the sensors to the central processing unit to provide at least a sixty-four channel data acquisition device. - View Dependent Claims (14, 15, 16, 17)
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18. A monitoring system for cement manufacturing, the system comprising:
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(a) a kiln; (b) a crusher; (c) a separator; (d) a fan; (e) sensors detecting movement-related characteristics of the kiln, crusher, separator and fan; (f) a central processing unit receiving substantially real-time and continuous signals from the sensors and using the signals to determine if any undesirable conditions are present with regard to the kiln, crusher, separator and fan, and to identify one or more likely causes of the undesirable conditions; and (g) a display visually showing a simulated representation of the kiln, crusher, separator and fan, and an indication feature based on the sensor signals associated therewith. - View Dependent Claims (19, 20, 21)
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22. A monitoring system for cement manufacturing, the system comprising:
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(a) a kiln; (b) a crusher; (c) a separator; (d) a fan; (e) sensors detecting movement-related characteristics of the kiln, crusher, separator and fan; (f) a central processing unit receiving substantially real-time and continuous signals from the sensors and using the signals to determine if any undesirable conditions are present with regard to the kiln, crusher, separator and fan, and to identify one or more likely causes of the undesirable conditions; and (g) a hand-held electronic data collector operable to communicate with the central processing unit to download sensor data from a remotely located cement manufacturing machine. - View Dependent Claims (23, 24)
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25. A monitoring system for cement manufacturing, the system comprising:
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(a) a kiln; (b) a crusher; (c) a separator; (d) a fan; (e) sensors detecting movement-related characteristics of the kiln, crusher, separator and fan; and (f) a central processing unit receiving substantially real-time and continuous signals from the sensors and using the signals to determine if any undesirable conditions are present with regard to the kiln, crusher, separator and fan, and to identify one or more likely causes of the undesirable conditions; wherein the sensors include at least three differently oriented vibration sensors located adjacent the kiln. - View Dependent Claims (26, 27)
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28. A monitoring system for cement manufacturing, the system comprising:
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(a) a kiln; (b) a crusher; (c) a separator; (d) a fan; (e) sensors detecting movement-related characteristics of the kiln, crusher, separator and fan; (f) a central processing unit receiving substantially real-time and continuous signals from the sensors and using the signals to determine if any undesirable conditions are present with regard to the kiln, crusher, separator and fan, and to identify one or more likely causes of the undesirable conditions; and (g) an evolutionary learning program being used by the central processing unit to automatically adapt its undesirable condition determination through repeated use over time. - View Dependent Claims (29, 30, 31)
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32. A monitoring system for cement manufacturing, the system comprising:
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(a) a kiln; (b) a crusher; (c) a separator; (d) a fan; (e) sensors detecting movement-related characteristics of the kiln, crusher, separator and fan; (f) a central processing unit receiving substantially real-time and continuous signals from the sensors and using the signals to determine if any undesirable conditions are present with regard to the kiln, crusher, separator and fan, and to identify one or more likely causes of the undesirable conditions; wherein the central processing unit uses at least one of the sensor signals to automatically determine if a mechanically unbalanced movement condition exists. - View Dependent Claims (33, 34, 35)
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36. A computer program, stored in memory, comprising:
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a set of instructions receiving substantially real-time vibration sensor data in cement making machinery; a set of instructions comparing the real-time sensor data to target sensor data; a set of instructions automatically determining if an undesirable condition exists in the cement making machinery, and automatically identifying and reporting a potential cause of the undesirable condition based at least in part on the data comparison and determination; and a set of instructions automatically determining if an undesired rotational imbalance is occurring in the cement making machinery. - View Dependent Claims (37)
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38. A computer program, stored in memory, comprising:
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a set of instructions receiving substantially real-time vibration sensor data in cement making machinery; a set of instructions comparing the real-time sensor data to target sensor data; a set of instructions automatically determining if an undesirable condition exists in the cement making machinery, and automatically identifying and reporting a potential cause of the undesirable condition based at least in part on the data comparison and determination; and a set of instructions automatically determining if an undesired bearing condition is occurring in the cement making machinery. - View Dependent Claims (39)
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40. A computer program, stored in memory, comprising:
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a set of instructions receiving substantially real-time vibration sensor data in cement making machinery; a set of instructions comparing the real-time sensor data to target sensor data; a set of instructions automatically determining if an undesirable condition exists in the cement making machinery, and automatically identifying and reporting a potential cause of the undesirable condition based at least in part on the data comparison and determination; and a set of instructions analyzing analog data from at least fifty vibrational sensors associated with multiple cement making machines in a substantially real-time and continuous manner. - View Dependent Claims (41, 42)
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43. A computer program, stored in memory, comprising:
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a set of instructions receiving substantially real-time vibration sensor data in cement making machinery; a set of instructions comparing the real-time sensor data to target sensor data; a set of instructions automatically determining if an undesirable condition exists in the cement making machinery, and automatically identifying and reporting a potential cause of the undesirable condition based at least in part on the data comparison and determination; and a set of instructions visually displaying a simulated representation of the cement making machinery and an indication image of the sensor data. - View Dependent Claims (44)
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45. A method of using and monitoring machines to manufacture cement, the method comprising:
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(a) moving a portion of a first machine; (b) detecting a characteristic associated with the movement of step (a); (c) moving a portion of a second machine remotely located relative to the first machine; (d) detecting a characteristic associated with the movement of step (c); (e) moving a portion of a third machine remotely located relative to the first and second machines; (f) detecting a characteristic associated with the movement of step (e); (g) making cement with the machines; (h) substantially simultaneously using remotely located software instructions to automatically determine if an undesirable mechanical condition exists in the first, second and third machines based at least in part on the detected characteristics, and if so, automatically identifying a probable cause; and (i) using an evolutionary learning calculation to assist in making the probable cause identification. - View Dependent Claims (46, 47)
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48. A method of using and monitoring machines to manufacture cement, the method comprising:
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(a) moving a portion of a first machine; (b) detecting a characteristic associated with the movement of step (a); (c) moving a portion of a second machine remotely located relative to the first machine; (d) detecting a characteristic associated with the movement of step (c); (e) moving a portion of a third machine remotely located relative to the first and second machines; (f) detecting a characteristic associated with the movement of step (e); (g) making cement with the machines; (h) substantially simultaneously using remotely located software instructions to automatically determine if an undesirable mechanical condition exists in the first, second and third machines based at least in part on the detected characteristics, and if so, automatically identifying a probable cause; (i) rotating a hollow tube of a cement kiln machine; (j) energizing a motor to rotate a transmission which rotates the tube; (k) supporting the transmission with a stationary block and a bearing assembly located between the transmission and the block; (l) heating crushed rock in the kiln to make clinker; (m) receiving signals from a first set of sensors located adjacent the block and operably sensing vibrations of at least one of;
(a) the tube, (b) the transmission, and (c) the bearing assembly;(n) receiving signals from a second set of sensors located adjacent the motor and operably sensing vibrations of at least one of;
(a) the motor and (b) the transmission;(o) using the software instructions to determine if an undesired rotational imbalance is occurring within the kiln machine and if an undesired rotational bearing condition is occurring within the kiln machine; and (p) visually displaying a simulated representation of the kiln machine and a sensor indication image. - View Dependent Claims (49, 50)
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Specification