Method and apparatus for determining an operating point of a work machine

• US 8,763,464 B2
• Filed: 11/18/2011
• Issued: 07/01/2014
• Est. Priority Date: 05/20/2009
• Status: Active Grant

• Current Assignee: KSB AG (Ksb Stiftung)
• Original Assignee: KSB AG (Ksb Stiftung)
• Inventors: Emde, Christoph, Laue, Stefan, Silovic, Marjan
• Primary Examiner(s): SAINT SURIN, JACQUES M
• Application Number:
  US13/300,261
• Publication Number:
  US 20120111114A1
• Time in Patent Office: 956 Days
• Field of Search: 736/59, 736/60, 735/93, 702 41- 44, 702/56
• US Class Current: 73/659
• CPC Class Codes: F04D 15/0088 Testing machines
• CPC Class Codes: F04D 15/0094 Indicators of rotational movement

Abstract

Method and apparatus for determining an operating point of a work machine and/or asynchronous motor driving the same, the operating point being characterized by the power consumed by and/or output rate of the machine, in which one or more operating point-dependent measurement variables of the machine are detected by sensors, and the measured values are evaluated and/or stored during operation of the machine. The operating point is determined without using electric measurement variables of the motor by determining a frequency linearly proportional to the fundamental tone of the machine through signal analysis, especially frequency analysis of a measured mechanical variable selected from pressure, differential pressure, power, vibration, and solid-borne or air-borne sound. From this, the rotational speed of the driving machine is determined, and the operating point characterized by the power consumed by and/or output rate of the machine is determined utilizing the rotational speed/torque relationship of the motor.

Claims

1. A method for determining an operating point of a work machine or of an asynchronous motor driving the such a machine, wherein

the operating point is characterized by a power input of the work machine or by a delivery rate of the work machine;

one or more operating point-dependent measurement variables of the work machine are detected by one or more sensors;

measured values of the variables are evaluated or stored while the work machine is in operation; and

the operating point is determined without the use of electrical measurement variables of the asynchronous drive motor;

said method comprising;

determining a frequency linearly proportional to the rotational sound of the work machine by signal analysis of a measured mechanical variable selected from the group consisting of pressure, differential pressure, force, vibration, solid-borne noise, and airborne noise;

determining the rotational speed (n) of the drive machine from said frequency; and

determining the operating point from the slip-induced rotational speed/torque dependence of the asynchronous motor.

2. The method as claimed in claim 1, wherein the power input (P₂) of the work machine is determined by:

determining the rotational speed/torque characteristic curve (M(n)) of the motor based on at least one motor parameter selected from the group consisting of design power, design rotational speed (n_N), if appropriate synchronous rotational speed (n₀), pull-out torque (M_k), pull-out rotational speed (n_k) and pull-out slip (s_k); and

determining the power input (P₂) or torque (M) of the motor from the determined drive rotational speed (n) and the rotational speed/torque characteristic curve (M(n)) of the motor.

3. The method as claimed in claim 1, wherein said work machine is a centrifugal pump;

said method further comprising determining a delivery rate (Q) of the pump from the rotational speed (n) of the pump drive.

4. The method as claimed in claim 3, wherein the delivery rate (Q) of the pump is determined from the power input (P₂) determined from the rotational speed (n) of the pump drive.

5. The method as claimed in claim 3, wherein the delivery rate (Q) of the pump is determined from:

parameters of the motor, which describe a rotational speed/torque characteristic curve (M(n)) of the motor;

parameters of the pump, which describe a delivery flow/power characteristic curve of the pump; and

the drive rotational speed (n).

6. The method as claimed in claim 3, wherein the delivery rate (Q) of the centrifugal pump is determined from a characteristic curve which represents the load-dependent rotational speed change against the delivery rate (Q) of the pump.

7. The method as claimed in claim 3, wherein the drive rotational speed (n) for determining the operating point of the centrifugal pump, is determined from measurement values of at least one pressure sensor.

8. The method as claimed in claim 1, wherein the drive rotational speed (n) for determining the operating point of the work machine or of the asynchronous motor driving the work machine, is determined from measured values measured by at least one solid-borne noise sensor or airborne noise sensor.

9. A method for monitoring the operating point of a work machine or an asynchronous motor driving a work machine;

said method further comprising detecting a faulty operating state comprising an overload or an underload of the work machine or the asynchronous motor based on determination of an operating point according to claim 1, wherein the determined operating point is located outside a stipulated range.

10. An apparatus for determining or monitoring an operating point of a work machine or an asynchronous motor driving a work machine, wherein

said operating point is characterized by a power input of the work machine or a delivery rate of the work machine;

said apparatus comprises at least one input for detection of operating point-dependent measurement variables, and a data store for storing technological data of the work machine or the asynchronous motor driving the work machine; and

wherein said apparatus

determines a frequency linearly proportional to the rotational sound of the work machine through signal analysis of a measured mechanical variable selected from the group consisting of pressure, differential pressure, force, vibration, solid-borne noise and airborne noise;

determines the rotational speed (n) of the drive machine from the determined frequency, and

determines, and optionally monitors, the operating point from non-electrical measurement variables and from the slip-induced rotational speed/torque dependence of the asynchronous motor.

11. The apparatus as claimed in claim 10, wherein the power input of the work machine is determined by:

determining the rotational speed/torque characteristic curve (M(n)) of the motor from stipulated motor parameters selected from the group consisting of design power (P_2N), design rotational speed (n_N), if appropriate synchronous rotational speed (n₀), pull-out torque (M_k), pull-out rotational speed (n_k) and pull-out slip (s_k); and

determining the power input (P₂) or torque (M) of the motor from the drive rotational speed (n) and the rotational speed/torque characteristic curve (M(n)) of the motor.

12. The apparatus as claimed in claim 10, wherein the work machine is a centrifugal pump, and the operating point determination involves determining a delivery rate (Q) of the pump from the drive rotational speed (n).

13. The apparatus as claimed in claim 12, wherein the apparatus determines the delivery rate (Q) of the centrifugal pump from the power input (P₂) determined from the drive rotational speed (n).

14. The apparatus as claimed in claim 12, wherein the apparatus determines the delivery rate (Q) of the centrifugal pump from

parameters of the motor, which describe a rotational speed/torque characteristic curve (M(n)) of the motor;

parameters of the pump, which describe a delivery flow/power characteristic curve of the pump; and

the drive rotational speed (n).

15. The apparatus as claimed in claim 12, wherein the apparatus determines the delivery rate (Q) of the centrifugal pump from a characteristic curve which represents the load-dependent rotational speed change plotted verses the delivery rate (Q) of the pump.

16. The apparatus as claimed in claim 10, wherein:

the apparatus comprises at least one signal input for a pressure sensor; and

from measurement values of a connected pressure sensor determines the drive rotational speed (n) for the purpose of determining the operating point of the work machine.

17. The apparatus as claimed in claim 10, wherein the apparatus comprises at least one signal input for a connected solid-borne noise or airborne noise sensor, and determines the drive rotational speed (n) for determining the operating point of the work machine or of the asynchronous motor driving the work machine from measured values measured by the connected solid-borne noise or airborne noise sensor.

18. The apparatus as claimed in claim 10, wherein the apparatus is connected to a microphone or comprises an integrated microphone for detecting operating point-dependent measurement variables.

19. The apparatus as claimed in claim 18, wherein the apparatus comprises a mobile telephone for detecting operating noises of the work machine and for determining and optionally monitoring an operating point.

20. The apparatus as claimed in claim 18, wherein the determination and optional monitoring of the operating point of the work machine is carried out remotely at a location other than the location of the work machine via a telecommunication device and telecommunication network.