Brush holder assembly monitoring apparatus, assembly, system and method

• US 8,825,800 B2
• Filed: 11/26/2013
• Issued: 09/02/2014
• Est. Priority Date: 05/24/2007
• Status: Active Grant

• Current Assignee: Cutsforth Incorporated
• Original Assignee: Cutsforth Incorporated
• Inventors: Cutsforth, Robert S.
• Primary Examiner(s): SHINGLES, KRISTIE D
• Application Number:
  US14/090,508
• Publication Number:
  US 20140077960A1
• Time in Patent Office: 280 Days
• Field of Search: 709/217
• US Class Current: 709/217
• CPC Class Codes: G05B 19/4065 Monitoring tool breakage, life or condition
• CPC Class Codes: G05B 2219/50185 Monitoring, detect failures, control of efficiency of machine, tool life
• CPC Class Codes: G05B 23/0208 characterized by the configuration of the monitoring system
• CPC Class Codes: G05B 23/0218 characterised by the fault detection method dealing with either existing or incipient faults
• CPC Class Codes: G06Q 10/06311 Scheduling, planning or task assignment for a person or group
• CPC Class Codes: G06Q 10/083 Shipping
• CPC Class Codes: G06Q 10/1097 Task assignment
• CPC Class Codes: G06Q 10/20 Administration of product repair or maintenance
• CPC Class Codes: G08B 21/182 Level alarms, e.g. alarms responsive to variables exceeding a threshold
• CPC Class Codes: H01R 39/58 Means structurally associated with the current collector for indicating condition thereof, e.g. for indicating brush wear
• CPC Class Codes: H01R 43/002 Maintenance of line connectors, e.g. cleaning
• CPC Class Codes: H02K 11/20 for measuring, monitoring, testing, protecting or switching rectifiers H02K11/04; power electronics H02K11/33
• CPC Class Codes: H02K 5/14 Means for supporting or protecting brushes or brush holders
• CPC Class Codes: H04L 43/04 Processing captured monitoring data, e.g. for logfile generation
• CPC Class Codes: H04L 43/08 Monitoring or testing based on specific metrics, e.g. QoS, energy consumption or environmental parameters

Abstract

Methods and systems for monitoring a brush holder assembly and/or detecting wear of a brush in a brush holder assembly are disclosed. One method includes sending data from a plurality of remote monitoring locations to a central control unit, where the data may be evaluated in order to monitor states of brushes at a plurality of remote electrical facilities. For example, multiple images of a marker tracking longitudinal movement of the brush may be acquired. A comparison of the images, for example, a comparative imaging technique, such as pixel-by-pixel comparison, may then be performed in order to evaluate a condition of the brush, such as the wear rate, wear state, or life expectancy of the brush.

Claims

1. A method of monitoring a brush holder assembly of an electrical generator including one or more carbon brushes at each of a plurality of remote monitoring locations, the one or more carbon brushes of each brush holder assembly being in contact with a rotating conductive surface to conduct electrical current therefrom, the brush holder assembly permitting linear movement of the one or more carbon brushes toward the rotating conductive surface as the one or more carbon brushes wear, the plurality of remote monitoring locations geographically spaced from one another, the method comprising:

providing a central control unit off-site from and in communication with the plurality of remote monitoring locations;

receiving data from the plurality of remote monitoring locations at the central control unit; and

evaluating the data at the central control unit to monitor states of the carbon brushes in contact with the rotating conductive surface at the plurality of remote monitoring locations to predict an estimated projection of a future condition of the carbon brushes at a future date.

2. The method of claim 1, further comprising the step of alerting personnel of an anomalous or threshold condition at one of the plurality of remote monitoring locations.

3. The method of claim 1, further comprising the step of scheduling maintenance at one of the plurality of remote monitoring locations.

4. The method of claim 1, further comprising the step of routing personnel to one of the plurality of remote monitoring locations.

5. The method of claim 1, further comprising the step of scheduling distribution or delivery of a replacement brush to one of the plurality of remote monitoring locations.

6. The method of claim 1, wherein the plurality of remote monitoring locations are networked with the central control unit.

7. A method of monitoring a condition of a brush of a brush holder assembly of an electrical generator, the method comprising:

providing a processing unit;

receiving a signal representative of a current condition of the brush of the brush holder assembly of the electrical generator at the processing unit; and

evaluating the signal with the processing unit to predict a future occurrence of an anomalous or threshold condition of the brush of the brush holder assembly of the electrical generator.

8. The method of claim 7, further comprising the step of notifying personnel of the anomalous or threshold condition.

9. The method of claim 7, further comprising the step of scheduling maintenance of the electrical generator.

10. The method of claim 7, further comprising the step of routing personnel to the electrical generator.

11. The method of claim 7, further comprising the step of scheduling distribution or delivery of a replacement brush to the electrical generator.

12. The method of claim 7, wherein the step of evaluating the signal with the processing unit includes comparing actual acquired data with modeled data.

13. A system for monitoring the wear of carbon brushes of brush holder assemblies, the system comprising:

a plurality of remote monitoring locations geographically spaced from one another, wherein each remote monitoring location generates data regarding the position of one or more carbon brushes of a brush holder assembly of an electrical generator at the remote monitoring location; and

a central control unit located off-site from the plurality of remote monitoring locations for receiving data from the plurality of remote monitoring locations, the central control unit including a processing unit having a software program configured to predict an estimated projection of a future condition of the carbon brushes at a future date.

14. The system of claim 13, wherein each remote monitoring location has one or more imaging devices for acquiring images of a brush holder assembly.