Systems and methods for energy efficient machine condition monitoring of fans, motors, pumps, compressors and other equipment

• US 8,996,335 B2
• Filed: 12/31/2012
• Issued: 03/31/2015
• Est. Priority Date: 12/31/2011
• Status: Active Grant

• Current Assignee: ABet SKF
• Original Assignee: ABet SKF
• Inventors: Boerhout, Johannes I.
• Primary Examiner(s): Charioui, Mohamed
• Assistant Examiner(s): KUAN, JOHN CHUNYANG
• Application Number:
  US13/991,994
• Publication Number:
  US 20140195197A1
• Time in Patent Office: 820 Days
• Field of Search: 702/56, 702/182, 735/93
• US Class Current: 702/182
• CPC Class Codes: G01H 1/003 of rotating machines G01H1/10 takes precedence
• CPC Class Codes: G01M 13/00 Testing of machine parts
• CPC Class Codes: G01M 13/028 Acoustic or vibration analysis
• CPC Class Codes: G01M 7/00 Vibration-testing of structures; Shock-testing of structures G01M9/00 takes precedence
• CPC Class Codes: G01M 99/005 Testing of complete machines, e.g. washing-machines or mobile phones testing of machine parts G01M13/00; testing of electric apparatus or components G01R31/50
• CPC Class Codes: G08C 2201/12 Power saving techniques of remote control or controlled devices
• CPC Class Codes: H04W 52/0261 managing power supply demand, e.g. depending on battery level
• CPC Class Codes: Y02D 30/70 in wireless communication networks

Abstract

Methods and systems to achieve highly efficient rotational machine integrity determinations in which at least one sensor (106) senses indicia (105) such as time-varying rotational indicia from a rotational motive apparatus (103) and a processor (108) may provide many different functions including but not limited to operational function energy apportioning decisional processing, data compression, intelligent hierarchical data ranking, differential data processing, or the like perhaps to generate information (109) such as a rotational integrity abridgment transmissor to which an abridgment transmissor electromagnetic signal (112) may be created and perhaps even transmitted from a rotational motive apparatus to facilitate a machine integrity determination.

Claims

1. A method of high efficiency rotational machine integrity determination comprising steps of:

supplying energy to a rotational motive apparatus;

causing mechanical rotation of a rotational element of said rotational motive apparatus;

low friction supporting said rotational element by a stationary element of said rotational motive apparatus;

causing a time-varying rotational indicia from said rotational motive apparatus;

sensing said time-varying rotational indicia of said rotational motive apparatus;

establishing rotational waveform data from said sensed time-varying rotational indicia;

transforming said rotational waveform data by a programmed processor;

compressing data based on said rotational waveform data with a compression system;

generating a rotational integrity abridgment transmissor in response to said transformed rotational waveform data;

creating an abridgment transmissor electromagnetic signal in response to said rotational integrity abridgment transmissor;

transmitting said abridgment transmissor electromagnetic signal from said rotational motive apparatus to facilitate a machine integrity determination; and

a step of energy apportioning operational functions for said method comprising a step of determining power requirements based on a type of power supply;

wherein said step of compressing said data comprises a step of differentially compressing said data.

2. A method of high efficiency rotational machine integrity determination according to claim 1 wherein said step of energy apportioning operational functions comprises a step of efficiently determining a power requirement for a step selected from a group consisting of:

said step of sensing said time-varying rotational indicia of said rotational motive apparatus;

said step of establishing rotational waveform data from said sensed time-varying rotational indicia;

said step of transforming said rotational waveform data by a programmed processor;

said step of generating a rotational integrity abridgment transmissor in response to said transformed rotational waveform data;

said step of creating an abridgment transmissor electromagnetic signal in response to said rotational integrity abridgment transmissor;

said step of transmitting said abridgment transmissor electromagnetic signal from said rotational motive apparatus to facilitate a machine integrity determination; and

any combination thereof.

3. A method of high efficiency rotational machine integrity determination according to claim 1 wherein said step of energy apportioning operational functions comprises a step of evaluating a power supply and determining a power requirement for an element selected from a group consisting of:

computational resources required to establish said rotational waveform data;

computational resources required to transform said rotational waveform data;

computational resources required to generate said rotational integrity abridgment transmissor;

computational resources required to create said abridgment transmissor electromagnetic signal;

computational resources required to transmit said abridgment transmissor electromagnetic signal;

computational resources required to compress;

computational resources required to uncompress;

computational resources required to establish a frequency of transformation;

computational resources required to establish a frequency of transmission;

computational resources required to establish a frequency of sensing;

computational resources required to establish a frequency of establishing rotational waveform data;

computational resources required to establish a frequency of creation of an electromagnetic signal;

computational resources required to establish a compression algorithm;

computational resources required to establish a decompression algorithm;

computational resources required to establish a transmission time;

computational resources required to establish a degree of transformation;

computational resources required to establish a degree of compression;

computational resources required to establish a degree of error detection;

computational resources required to establish a degree of error correction;

computational resources required to establish a degree of error control;

computational resources required to establish an amount of distortion introduced in said rotational abridgment transmissor; and

any combination thereof.

4. A method of high efficiency rotational machine integrity determination according to claim 3 wherein said step of evaluating a power supply and determining a power requirement for said element comprises a step of reducing said power requirement for at least one of said elements.

5. A method of high efficiency rotational machine integrity determination according to claim 1 wherein said step of energy apportioning operational functions for said method comprises a step of determining an enhanced compression power requirement and an enhanced transmission power requirement based on a power supply.

6. A method of high efficiency rotational machine integrity determination according to claim 1 wherein said power supply is selected from a group consisting of a battery, a power plug, a sensor battery, device battery, a remote device battery, and any combination thereof.

7. A method of high efficiency rotational machine integrity determination according to claim 1 wherein said step of differentially compressing said data comprises steps of:

sensing time-varying rotational indicia from at least two sensors;

compressing said time-varying rotational indicia sensed from a first sensor with a first compression system; and

compressing said time-varying rotational indicia sensed from at least one additional sensor with at least one additional compression system that is different from said first compression system.

8. A method of high efficiency rotational machine integrity determination according to claim 1 wherein said step of differentially compressing said data comprises steps of:

compressing at least part of said data with a first compression system; and

compressing at least one additional part of said data with at least one additional compression system.

9. A method of high efficiency rotational machine integrity determination according to claim 1 and further comprising a step of intelligently hierarchically ranking data based on said rotational waveform data.

10. A method of high efficiency rotational machine integrity determination according to claim 9 wherein said step of intelligently hierarchically ranking data based on said rotational waveform data comprises a step of intelligently hierarchically ranking data directly based on said rotational waveform data.

11. A method of high efficiency rotational machine integrity determination according to claim 9 wherein said step of intelligently hierarchically ranking data based on said rotational waveform data comprises a step of intelligently hierarchically ranking data indirectly based on said rotational waveform data.

12. A method of high efficiency rotational machine integrity determination according to claim 9 wherein said step of transforming said rotational waveform data by a programmed processor comprises a step of transforming said rotational waveform data by a programmed processor in response to said step of intelligently hierarchically ranking data based on said rotational waveform data.

13. A method of high efficiency rotational machine integrity determination according to claim 9 and further comprising a step of compressing at least part of said data in response to said step of intelligently hierarchically ranking said data.

14. A method of high efficiency rotational machine integrity determination according to claim 13 wherein said step of compressing at least part of said data in response to said step of intelligently hierarchically ranking said data comprises a step of hierarchically compressing said data until reaching a power requirement threshold.

15. A method of high efficiency rotational machine integrity determination according to claim 1 and further comprising a step of generating differential data based on said rotational waveform data.

16. A method of high efficiency rotational machine integrity determination according to claim 15 wherein said step of generating said differential data comprises a step of generating subtracted data.

17. A method of high efficiency rotational machine integrity determination according to claim 1 wherein said rotational motive apparatus is selected from a group consisting of a rotating pump, a rotating electric motor, a compressor, and a rotating fan.

18. A method of high efficiency rotational machine integrity determination according to claim 1 wherein said step of sensing said time-varying rotational indicia from said rotational motive apparatus comprises a step of on-machine sensing said time-varying rotational indicia from said rotational motive apparatus.

19. A high efficiency rotational machine integrity determination system comprising:

a time-varying rotational indicia sensor responsive to a rotational motive apparatus;

rotational waveform data established by said time-varying rotational indicia sensor;

a programmed rotational waveform data transformation processor;

a data compression system;

a rotational integrity abridgment transmissor generated by said programmed rotational waveform data transformation processor;

an abridgment transmissor electromagnetic signal of said rotational integrity abridgment transmissor;

an abridgment transmissor electromagnetic signal transmitter capable of transmitting said abridgment transmissor electromagnetic signal from said rotational motive apparatus to facilitate a machine integrity determination based on said rotational integrity abridgment transmissor; and

an operational function energy apportioning decisional processor comprising a power supply evaluator and a power consumption determinater;

wherein said data compression system comprises a differential data compression system.

20. A high efficiency rotational machine integrity determination system according to claim 19 wherein said power consumption determinater is selected from a group consisting of a time-varying rotation indicia sensor power consumption determinater, a programmed rotational waveform data transformation processor power consumption determinater, and an abridgment transmissor electromagnetic signal transmitter power consumption determinater.

21. A high efficiency rotational machine integrity determination system according to claim 19 wherein said power consumption determinater is configured to determine power consumption for an element selected from a group consisting of:

computational resources required to establish said rotational waveform data;

computational resources required to transform said rotational waveform data;

computational resources required to generate said rotational integrity abridgment transmissor;

computational resources required to create said abridgment transmissor electromagnetic signal;

computational resources required to transmit said abridgment transmissor electromagnetic signal;

computational resources required to compress;

computational resources required to uncompress;

computational resources required to establish a frequency of transformation;

computational resources required to establish a frequency of transmission;

computational resources required to establish a frequency of sensing;

computational resources required to establish a frequency of establishing rotational waveform data;

computational resources required to establish a frequency of creation of an electromagnetic signal;

computational resources required to establish a compression algorithm;

computational resources required to establish a decompression algorithm;

computational resources required to establish a transmission time;

computational resources required to establish a degree of transformation;

computational resources required to establish a degree of compression;

computational resources required to establish a degree of error detection;

computational resources required to establish a degree of error correction;

computational resources required to establish a degree of error control;

computational resources required to establish an amount of distortion introduced in said rotational abridgment transmissor; and

any combination thereof.

22. A high efficiency rotational machine integrity determination system according to claim 19 wherein said power consumption determinater is based on said power supply evaluator.

23. A high efficiency rotational machine integrity determination system according to claim 19 wherein said power supply evaluator comprises an evaluator of an element selected from a group consisting of a battery, a power plug, a sensor battery, device battery, a remote device battery, and any combination thereof.

24. A high efficiency rotational machine integrity determination system according to claim 19 wherein said operational function energy apportioning decisional processor comprises a reduced power consumption element.

25. A high efficiency rotational machine integrity determination system according to claim 19 wherein said differential data compression system comprises at least two different compression systems.

26. A high efficiency rotational machine integrity determination system according to claim 25 wherein each of said at least two different compression systems are differentially responsive to at least two different time-varying rotational indicia sensors.

27. A high efficiency rotational machine integrity determination system according to claim 19 wherein said differential data compression system comprises a first partial data compression system and at least one additional partial data compressions system that is different from said first partial data compression system.

28. A high efficiency rotational machine integrity determination system according to claim 19 and further comprising a compression power consumption threshold.

29. A high efficiency rotational machine integrity determination system according to claim 19 and further comprising an intelligent hierarchical data ranking element responsive to said rotational waveform data.

30. A high efficiency rotational machine integrity determination system according to claim 29 wherein said intelligent hierarchical data ranking element comprises an intelligent hierarchical data ranking decisional processor.

31. A high efficiency rotational machine integrity determination system according to claim 29 wherein said programmed rotational waveform data transformation processor is responsive to said intelligent hierarchical data ranking element.

32. A high efficiency rotational machine integrity determination system according to claim 29 and further comprising a data compression system responsive to said intelligent data ranking element.

33. A high efficiency rotational machine integrity determination system according to claim 29 and further comprising a partial data compression system responsive to said intelligent data ranking element.

34. A high efficiency rotational machine integrity determination system according to claim 19 and further comprising differential data generated by a differential data processor.

35. A high efficiency rotational machine integrity determination system according to claim 34 wherein said differential data comprises subtracted data.