Data acquisition system for condition-based maintenance

• US 9,897,516 B2
• Filed: 04/19/2016
• Issued: 02/20/2018
• Est. Priority Date: 11/16/2009
• Status: Active Grant

• Current Assignee: Simmonds Precision Products, Inc. (Raytheon Technologies Corporation d/b/a RTX)
• Original Assignee: Simmonds Precision Products, Inc. (Raytheon Technologies Corporation d/b/a RTX)
• Inventors: Bechhoefer, Eric R., Taylor, John T.
• Primary Examiner(s): Le, John H
• Application Number:
  US15/132,447
• Publication Number:
  US 20170023438A1
• Time in Patent Office: 672 Days
• Field of Search: 702 34, 702113, 702182, 702188, 702189, 73168, 290 44, 290 55, 416 37, 416 40, 700286, 700291, 700297, 714 44
• CPC Class Codes: F03D 17/00 Monitoring or testing of wind motors, e.g. diagnostics testing during commissioning of wind motors F03D13/30
• CPC Class Codes: F03D 7/047 characterised by the controller architecture, e.g. multiple processors or data communications
• CPC Class Codes: F05B 2240/96 as part of a wind turbine farm
• CPC Class Codes: F05B 2270/326 Rotor angle
• CPC Class Codes: F05B 2270/332 Maximum loads or fatigue criteria
• CPC Class Codes: F05B 2270/803 Sampling thereof
• CPC Class Codes: G01M 13/00 Testing of machine parts
• CPC Class Codes: G05B 23/0283 Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL] preventive maintenance, i.e. planning maintenance according to the available resources without monitoring the system G06Q10/06
• CPC Class Codes: Y02E 10/72 Wind turbines with rotation axis in wind direction
• CPC Class Codes: Y02P 80/20 using renewable energy

Abstract

Generally, a system and method consistent with the present disclosure may provide a relatively low cost, relatively robust data acquisition and analysis system useful for condition-based maintenance. The system may be useful for condition-based maintenance in industrial applications, e.g., of equipment and/or machinery. The industrial monitoring system may be used, for example, to monitor a condition of rotating machinery, e.g., a wind turbine. The system and method may include data analysis that may be useful for anticipating a need for maintenance, repair and/or replacement of one or more components.

Claims

1. A data acquisition system for monitoring one or more components of a rotating machine having a plurality of separate components, the data acquisition system comprising:

a plurality of separate sensor modules associated with the machine, each of the plurality of separate sensor modules being associated with a separate respective component of the plurality of separate components of the machine and including;

a sensor configured to detect a parameter associated with a condition of the separate respective component and to provide sensor data based on the detected parameter; and

an interface module coupled to the sensor and configured to receive the sensor data from the sensor and to generate module output data based on the received sensor data, the module output data comprising a representation of the condition of the separate respective component; and

a data bus configured to couple each of the plurality of separate sensor modules to a server, wherein the server is configured to provide an estimate of remaining useful life of a selected one of the separate respective components of the rotating machine to a user.

2. The data acquisition system of claim 1, wherein the data bus is configured to allow transmission of module output data from each of the plurality of separate sensor modules to the server.

3. The data acquisition system of claim 1, wherein the sensor is selected from the group consisting of a tachometer configured to detect a rotational speed of a separate respective component or a component indirectly coupled thereto of the rotating machine and an accelerometer configured to detect vibration of a separate respective component or a component indirectly coupled thereto.

4. The data acquisition system of claim 1, wherein the selected one of the separate respective components is a shaft, a bearing, or a gear.

5. The data acquisition system of claim 1, wherein the data bus is a daisy chain and each of the plurality of separate sensor modules is connected to at most two other sensor modules.

6. The data acquisition system of claim 1, further comprising:

a local data concentrator coupled to each of the plurality of separate sensor modules and configured to provide media access control (MAC) for at least one of the separate sensor modules, to transmit commands to at least one of the separate sensor modules, to receive data from at least one of the separate sensor modules and to provide received data to the server via the data bus.

7. The data acquisition system of claim 6, wherein the data bus is configured to carry power from the local data concentrator to at least one of the separate sensor modules.

8. The data acquisition system of claim 1, wherein at least one of the plurality of separate sensor modules comprises a controller configured to perform floating point calculations in hardware.

9. A system comprising:

a rotating machine; and

a data acquisition system mounted on the rotating machine and configured to monitor components of the rotating machine, the data acquisition system comprising;

a plurality of separate sensor modules, each of the plurality of separate sensor modules being associated with one of a plurality of separate respective components of the rotating machine and including;

a sensor configured to detect a parameter associated with a condition of the separate respective component and to provide sensor data based on the detected parameter; and

an interface module directly coupled to the sensor and configured to receive the sensor data from the sensor and to generate module output data based on the received sensor data, the module output data comprising a representation of the condition of the separate respective component;

a data bus configured to couple each of the plurality of separate sensor modules to a server, wherein the server is configured to provide an estimate of remaining useful life of a selected one of the separate respective components of the rotating machine to a user; and

a local data concentrator coupled to each of the plurality of separate sensor modules and configured to provide media access control (MAC) for at least one of the separate sensor modules, to transmit commands to at least one of the separate sensor modules, to receive data from at least one of the separate sensor modules and to provide received data to the server via the data bus.

10. The system of claim 9, wherein the data bus is configured to allow transmission of the module output data from each of the plurality of separate sensor modules to the server.

11. The system of claim 9, wherein the sensor is selected from the group consisting of a tachometer configured to detect a rotational speed of a separate respective component or a component indirectly coupled thereto of the rotating machine and an accelerometer configured to detect vibration of a separate respective component or a component indirectly coupled thereto.

12. The system of claim 9, wherein the selected one of the separate respective components is a shaft, a bearing, or a gear.

13. The system of claim 9, wherein the rotating machine is selected from the group consisting of a wind turbine, gas turbines and gearboxes associated with ground vehicles, ships and/or aircraft.