Wireless collection and analysis of machine data

• US 9,921,136 B2
• Filed: 08/05/2014
• Issued: 03/20/2018
• Est. Priority Date: 08/05/2014
• Status: Active Grant

• Current Assignee: Acoem France
• Original Assignee: 01db-Metravib SAS
• Inventors: Wascat, Bertrand, Poizat, Philippe, Labeyrie, Patrick, Mazoyer, Thierry
• Primary Examiner(s): Marini, Matthew G
• Application Number:
  US14/451,718
• Publication Number:
  US 20160041068A1
• Time in Patent Office: 1,323 Days
• CPC Class Codes: G01D 21/00 Measuring or testing not otherwise provided for
• 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: H04W 4/70 Services for machine-to-machine communication [M2M] or machine type communication [MTC]

Abstract

A sensor unit is configured as a single body, removably mounted in its entirety to a test point location on a machine so machine vibrations propagate into the single body. Within are an accelerometer, circuit board, wireless interface, signal processor, and battery. The sensor unit transmits sensor data wirelessly in real time to a data collection unit. A technician with data collection unit in hand goes from machine to machine, along a route of multiple test point locations on multiple machines, mounting and dismounting the sensor unit and collecting machine vibration data. The sensor unit is configured to reduce frequency response impacts of the mass and volume of the circuit board, wireless interface, signal processor, and battery on dynamic behavior of the sensor unit with respect to machine vibrations to achieve a frequency response rating comparable to a wired sensor.

Claims

1. A machine diagnostic data collection system for collecting vibration data from a rotating machine, the system comprising:

a portable, machine-diagnostic, data collection unit comprising a first wireless data interface, a processor, a memory, a display, an operator input device, and a first battery;

a sensor unit configured as a single body, removably mounted in its entirety to a test point location on the machine in a manner by which machine vibrations propagate into said single body;

wherein the sensor unit comprises a housing, an accelerometer, a second wireless interface, a circuit board, a signal processor, a battery, and an elastomeric member;

wherein the sensor unit is configured to wirelessly link to the portable, machine-diagnostic, data collection unit, and to transmit wirelessly in real time to the portable, machine-diagnostic, data collection unit raw data sensed by the accelerometer;

wherein the elastomeric member is configured to reduce frequency response impacts of mass and volume of the signal processor, circuit board, and battery on dynamic behavior of the sensor unit with respect to machine vibrations by damping vibrations introduced by said circuit board, signal processor, and battery in response to said machine vibrations, thereby vibrationally-decoupling, in part, the sensing component from the signal processor, circuit board, and battery;

wherein the elastomeric member comprises a first elastomeric part, a second elastomeric part and a third elastomeric part;

wherein the first elastomeric part is located at a first end of the circuit board and a first end of the battery toward the sensing component;

wherein the second elastomeric part extends longitudinally along a face of the rechargeable battery;

wherein the third elastomeric part is located at a second end of the circuit board and a second end of the battery away from the accelerometer; and

wherein the first elastomeric part, second elastomeric part and third elastomeric pard are configured to reduce frequency response impacts of mass and volume of the second wireless interface, the signal processor, the circuit board, and the battery on dynamic behavior of the sensor unit with respect to machine vibrations by damping vibrations introduced by said second wireless interface, circuit board, signal processor, and battery in response to said machine vibrations.

2. The machine diagnostic data collection system of claim 1, wherein the accelerometer is a tri-axial accelerometer having one or more sensing components, wherein the first elastomeric part separates each sensing component of said one or more sensing components from said signal processor, circuit board, and battery, and wherein said first elastomeric part, second elastomeric part, and third elastomeric part are configured to vibrationally-decouple, in part, said each one sensing component from the signal processor, circuit board, and battery so that a frequency response rating of the sensor unit is no more than +/−

3 db at 5 kHz on a z-axis.

3. The machine diagnostic data collection system of claim 1, wherein the sensor unit is a first sensor unit and the accelerometer is a tri-axial accelerometer, and further comprising:

a mounting mechanism having a first threaded member and being fixedly attached to said machine at a first test point position; and

a second sensor unit having a tri-axial accelerometer; and

wherein each one sensor unit of the first sensor unit and second sensor unit have a base portion with a second threaded member adapted to mate to the first threaded member of said mounting member when removably mounted to said mounting member, the second threaded member being indexed with respect to an x-axis, y-axis and z-axis of the tri-axial accelerometer, said tri-axial accelerometer of said one sensor unit being situated in said base portion; and

wherein the first threaded member and the second threaded member are configured so that for each one sensor unit of the first sensor unit and second sensor unit when fully mated to an end of travel position at a prescribed installation torque to the mounting mechanism at said one sensor unit'"'"'s corresponding test point position on said machine, a known repeatable prescribed positioning is achieved in which said x-axis and y-axis of the tri-axial accelerometers are aligned, respectively with an x-axis and y-axis of measurement for the machine, regardless of whether the first sensor unit or the second sensor unit is removably mounted without further individualized referencing of the first sensor unit and second sensor unit at the time of mounting.

4. The machine diagnostic data collection system of claim 1, wherein the sensor unit is a first sensor unit of a plurality of sensor units and the test point location is one of a plurality of test point locations on the machine;

wherein each one sensor unit of the plurality of sensor units is configured as a single body, removably mounted in its entirety to a corresponding one test point location on the machine among said plurality of test point locations in a manner by which machine vibrations propagate into said single body for each one of said plurality of sensor units;

wherein the data collection device is configured to collect machine diagnostic data from each one of the plurality of wireless sensor units in series as part of an automated sequence in which upon completion of data collection from said one sensor unit data collection commences from another sensor unit among the plurality of sensor unit automatically according to an order determined by said automated sequence.

5. The machine diagnostic data collection system of claim 1, wherein the sensor unit is a first sensor unit of a plurality of sensor units and the test point location is one of a plurality of test point locations on the machine;

wherein each one sensor unit of the plurality of sensor units is configured as a single body, removably mounted in its entirety to a corresponding one test point location on the machine among said plurality of test point locations in a manner by which machine vibrations propagate into said single body for each one of said plurality of sensor units; and

wherein the data collection device is configured to collect machine diagnostic data from each one of the plurality of wireless sensor units in parallel.

6. The machine diagnostic data collection system of claim 1, further comprising a machine data diagnostic analysis unit separate from the data collection unit and receiving data from the data collection unit, the machine data diagnostic analysis unit configured for performing vibration data analysis on first data among said received data.

7. The machine diagnostic data collection system of claim 1, wherein the portable, machine-diagnostic, data collection unit further comprises an embedded camera, a pyrometer, and a stroboscope.

8. The machine diagnostic data collection system of claim 1, wherein the portable, machine-diagnostic, data collection unit further comprises an embedded infrared imaging camera.

9. The machine diagnostic data collection system of claim 1, wherein the processor is configured to execute a machine setup module for said machine;

wherein said display is configured to display instructions for collecting data with the sensor unit for the test point location on the machine in accordance with said execution of the machine setup module by the processor;

wherein said display is further configured to display among said instructions a set of standard graphic images, as determined by the processor, depicting alternative positioning of the sensor unit on said machine at said test point location, each one standard graphic image of said set corresponding to a different axial alignment of the sensor unit; and

wherein the processor is further configured to store one of said set of standard graphic images as a default image to be displayed among said instructions for gathering data at said test point location of said machine, said processor being configured to command the display to display said default image.

10. A machine diagnostic data collection system for collecting vibration data from a rotating machine, the system comprising:

a portable, machine-diagnostic, data collection unit comprising a first wireless data interface, a processor, a memory, a display, an operator input device, and a first battery;

a sensor unit configured as a single body, removably mounted in its entirety to a test point location on the machine in a manner by which machine vibrations propagate into said single body;

wherein the sensor unit comprises a housing, an accelerometer, a second wireless interface, a circuit board, a signal processor, and a battery;

wherein the sensor unit is configured to wirelessly link to the portable, machine-diagnostic, data collection unit, and to transmit wirelessly in real time to the portable, machine-diagnostic, data collection unit raw data sensed by the accelerometer;

wherein said processor is configured to execute a machine setup module for said machine;

wherein said display is configured to display instructions for collecting data at said test point location of said machine;

wherein the data collection unit further comprises an embedded camera and a photographic image captured by said camera of the sensor unit as mounted at the test point location on said machine;

wherein the processor is configured to automatically store said captured image with said instructions for collecting data at said test point location of said machine; and

wherein the processor is configured to load said captured photographic image with said instructions as a default image for showing positioning of the sensor unit on said machine at said test point location during a subsequent execution of the machine setup module.

11. A machine diagnostic data collection system for collecting vibration data from a rotating machine, the system comprising:

a portable, machine-diagnostic, data collection unit comprising a first wireless data interface, a processor, a memory, a display, an operator input device, and a first battery;

a sensor unit configured as a single body, removably mounted in its entirety to a test point location on the machine in a manner by which machine vibrations propagate into said single body;

wherein the sensor unit comprises a housing, an accelerometer, a second wireless interface, a circuit board, a signal processor, a battery, and an elastomeric member;

wherein the sensor unit is configured to wirelessly link to the portable, machine-diagnostic, data collection unit, and to transmit wirelessly in real time to the portable, machine-diagnostic, data collection unit raw data sensed by the accelerometer;

wherein the elastomeric member is configured to reduce frequency response impacts of mass and volume of the signal processor, circuit board, and battery on dynamic behavior of the sensor unit with respect to machine vibrations by damping vibrations introduced by said circuit board, signal processor, and battery in response to said machine vibrations, thereby vibrationally-decoupling, in part, the sensing component from the signal processor, circuit board, and battery;

wherein the sensor unit further comprises;

a base portion comprising a base member and the accelerometer; and

an upper portion comprising the signal processor, the second wireless interface, and the battery, said elastomeric member comprising a first elastomeric part separating the base member and a sensing component of the accelerometer, from the signal processor, the battery, and the second wireless interface of the upper portion; and

wherein the housing comprises a base portion housing circumferentially surrounding the base member along a length of the base member, and an upper portion housing circumferentially surrounding the second wireless interface, signal processor and battery;

wherein the base portion housing and upper portion housing adjoin to form respective lower and upper length portions of the cylindrical body;

wherein the signal processor is electrically coupled to the accelerometer and samples an output signal of the accelerometer;

wherein the second wireless interface is electrically coupled to the signal processor and is configured to transmit wirelessly raw sensor data obtained by the signal processor from the sampled output signal;

wherein the base portion is configured to be located closer to the machine than the upper portion and to receive machine vibrations propagating from the machine to the sensor unit.

12. The machine diagnostic data collection system of claim 11, wherein the elastomeric member further comprises a second elastomeric part and a third elastomeric part;

wherein the second elastomeric part extends longitudinally along a face of the battery;

wherein the third elastomeric part is located at a second end of the circuit board and a second end of the battery away from the accelerometer;

wherein the first elastomeric part, second elastomeric part and third elastomeric pard are configured to reduce frequency response impacts of mass and volume of the second wireless interface, the signal processor, the circuit board, and the battery on dynamic behavior of the sensor unit with respect to machine vibrations by damping vibrations introduced by said second wireless interface, circuit board, signal processor, and battery in response to said machine vibrations.

13. The machine diagnostic data collection system of claim 12, wherein the accelerometer is a tri-axial accelerometer having one or more sensing components,

wherein the first elastomeric part separates each sensing component of said one or more sensing components from said signal processor, circuit board, and battery, and

wherein said first elastomeric part, second elastomeric part, and third elastomeric part are configured to vibrationally-decouple, in part, said each one sensing component from the signal processor, circuit board, and battery so that a frequency response rating of the accelerometer sensor device is no more than +/−

3 db at 5 kHz on a z-axis.

14. The machine diagnostic data collection system of claim 12, wherein the upper portion housing has a profile in the longitudinal direction comprising a first curved portion nearest the base portion housing and a second straight or angled portion farthest from the base portion housing, wherein the first curved portion has a backward-S shape with a convex portion longer than a concave portion, and wherein a length from a maximum trough depth of the concave portion to a distal end of the upper portion housing is 20-30% of an entire longitudinal length of the upper portion housing.

15. The machine diagnostic data collection system of claim 11, wherein the upper portion further comprises a cap member mating to the upper portion housing and at which is situated an antenna.

16. A method of collecting machine diagnostic data from each one machine of a plurality of machines using a machine diagnostic data collection system comprising:

a portable data collection unit comprising a first wireless interface, a processor, a memory, a display, and an operator input device;

a sensor unit configured as a single body, removably mounted in its entirety to a test point location on said one machine in a manner by which machine vibrations propagate into said single body;

wherein the sensor unit comprises within said single body an accelerometer, a second wireless interface, a circuit board, a signal processor, and a battery;

wherein the second wireless interface is configured to transmit wirelessly in real time to the first wireless interface raw data sensed by the accelerometer;

wherein the sensor unit further comprises an elastomeric member separating a sensing component of the accelerometer from the circuit board, signal processor, and battery, the elastomeric member being configured to reduce frequency response impacts of mass and volume of the signal processor the circuit board, and the battery on dynamic behavior of the sensor unit with respect to machine vibrations by damning vibrations introduced by said circuit board signal processor, and battery in response to said machine vibrations, thereby vibrationally-isolating, in part, the sensing component from the signal processor, circuit board, and batter;

the method comprising the steps of;

removably mounting the sensor unit as said single body at a location of a test point on said one machine in a manner by which machine vibrations propagate into said single body;

receiving said machine vibrations at the sensor unit;

damping vibrations introduced by said circuit board, signal processor, and battery in response to said machine vibrations with said elastomeric member to vibrationally decouple, in part, said sensing component from the circuit board, the signal processor, and the battery, thereby reducing frequency response impacts of mass and volume of the the signal processor, the circuit board, and the battery on dynamic behavior of the sensor unit with respect to machine vibrations;

transmitting a wireless signal from the sensor unit to the portable data collection unit as part of a communication protocol for establishing a wireless data communication link between said sensor unit and said portable data collection unit;

sensing said machine vibrations with said accelerometer;

streaming raw sensor data sensed by the accelerometer to the second wireless interface using the signal processor;

transmitting said raw sensor data from said second wireless interface to said portable data collection unit;

discontinuing said streaming of raw sensor data;

dismounting the sensor unit from the machine; and

repeating each step of said method for another machine among the plurality of machines for which vibration data is to be collected; and

wherein a mounting mechanism having a first threaded member is fixedly attached to said one machine;

wherein the accelerometer is a tri-axial accelerometer;

wherein the sensor unit is a first sensor unit and has a first base portion with a second threaded member that mates to the first threaded member;

wherein said removably mounting comprises screwing the first sensor unit onto said mounting mechanism to an end of travel of the second threaded member along the first threaded member to a prescribed torque to achieve a known repeatable prescribed relative position between the first sensor unit and said one machine, in which an x-axis and y-axis of the tri-axial accelerometer are aligned, respectively with an x-axis and y-axis of measurement of said one machine; and

wherein said sensing vibration of the machine with said accelerometer, comprises sensing said vibration while said x-axis and y-axis the tri-axial accelerometer are aligned, respectively with said x-axis and y-axis of measurement of said one machine; and

further comprising removing said first sensor unit from the machine;

removably mounting a second sensor unit different from the first sensor unit to the mounting mechanism of said one machine at another time;

wherein said second sensor unit is manufactured to have a same indexing of the second sensor unit'"'"'s x-axis and y-axis to a third threaded member of the second sensor unit as the first sensor unit'"'"'s x-axis and y-axis to the first sensor unit'"'"'s second threaded member, whereby said first sensor unit and second sensor unit are interchangeably mounted to said mounting mechanism and achieve a same circumferential reference position when screwed onto the mounting mechanism to a prescribed torque without further individualized referencing at the time of mounting;

said removably mounting said second sensor unit to said mounting mechanism thereby achieving a same known repeatable prescribed relative position between the second sensor unit and said one machine as achieved when mounting the first sensor unit to the mounting mechanism of said one machine so that said second sensor unit'"'"'s x-axis and y-axis are aligned, respectively with said x-axis and y-axis of measurement of said one machine.

17. A method of collecting machine diagnostic data from each one machine of a plurality of machines using a machine diagnostic data collection system comprising:

a portable data collection unit comprising a first wireless interface, a processor, a memory, a display, and an operator input device;

a sensor unit configured as a single body, removably mounted in its entirety to a test point location on said one machine in a manner by which machine vibrations propagate into said single body;

wherein the sensor unit comprises within said single body an accelerometer, a second wireless interface, a circuit board, a signal processor, and a battery;

wherein the second wireless interface is configured to transmit wirelessly in real time to the first wireless interface raw data sensed by the accelerometer;

wherein the sensor unit further comprises an elastomeric member separating a sensing component of the accelerometer from the circuit board, signal processor, and battery, the elastomeric member being configured to reduce frequency response impacts of mass and volume of the signal processor, the circuit board, and the battery on dynamic behavior of the sensor unit with respect to machine vibrations by damping vibrations introduced by said circuit board, signal processor, and battery in response to said machine vibrations, thereby vibrationally-isolating, in part, the sensing component from the signal processor, circuit board, and battery;

the method comprising the steps of;

removably mounting the sensor unit as said single body at a location of a test point on said one machine in a manner by which machine vibrations propagate into said single body;

receiving said machine vibrations at the sensor unit;

damping vibrations introduced by said circuit board, signal processor, and battery in response to said machine vibrations with said elastomeric member to vibrationally decouple, in part, said sensing component from the circuit board, the signal processor, and the battery, thereby reducing frequency response impacts of mass and volume of the the signal processor, the circuit board, and the battery on dynamic behavior of the sensor unit with respect to machine vibrations;

transmitting a wireless signal from the sensor unit to the portable data collection unit as part of a communication protocol for establishing a wireless data communication link between said sensor unit and said portable data collection unit;

sensing said machine vibrations with said accelerometer;

streaming raw sensor data sensed by the accelerometer to the second wireless interface using the signal processor;

transmitting said raw sensor data from said second wireless interface to said portable data collection unit;

discontinuing said streaming of raw sensor data;

dismounting the sensor unit from the machine; and

repeating each step of said method for another machine among the plurality of machines for which vibration data is to be collected; and

further comprising after said mounting and before said dismounting of the sensor unit from said location on said machine, the steps of;

capturing, with a camera embedded in said portable, machine-diagnostic, data collection unit, a photographic image of the sensor unit as mounted at said location on said machine; and

automatically storing said captured image with instructions for gathering data at said location of said machine; and

further comprising after said dismounting during a setup operation for a subsequent collection of machine vibration data from said location at said machine;

displaying at said display instructions for gathering data at said location of said machine; and

automatically displaying said captured photographic image among said instructions as a default image for showing positioning of the sensor unit on said machine at said location.

18. A method of collecting machine diagnostic data from each one machine of a plurality of machines using a machine diagnostic data collection system comprising:

a portable data collection unit comprising a first wireless interface, a processor, a memory, a display, and an operator input device;

a sensor unit configured as a single body, removably mounted in its entirety to a test point location on said one machine in a manner by which machine vibrations propagate into said single body;

wherein the sensor unit comprises within said single body an accelerometer, a second wireless interface, a circuit board, a signal processor, and a battery;

wherein the second wireless interface is configured to transmit wirelessly in real time to the first wireless interface raw data sensed by the accelerometer;

wherein the sensor unit further comprises an elastomeric member separating a sensing component of the accelerometer from the circuit board, signal processor, and battery, the elastomeric member being configured to reduce frequency response impacts of mass and volume of the signal processor, the circuit board, and the battery on dynamic behavior of the sensor unit with respect to machine vibrations by damping vibrations introduced by said circuit board, signal processor, and battery in response to said machine vibrations, thereby vibrationally-isolating, in part, the sensing component from the signal processor, circuit board, and battery;

the method comprising the steps of;

removably mounting the sensor unit as said single body at a location of a test point on said one machine in a manner by which machine vibrations propagate into said single body;

receiving said machine vibrations at the sensor unit;

damping vibrations introduced by said circuit board, signal processor, and battery in response to said machine vibrations with said elastomeric member to vibrationally decouple, in part, said sensing component from the circuit board, the signal processor, and the battery, thereby reducing frequency response impacts of mass and volume of the the signal processor, the circuit board, and the battery on dynamic behavior of the sensor unit with respect to machine vibrations;

transmitting a wireless signal from the sensor unit to the portable data collection unit as part of a communication protocol for establishing a wireless data communication link between said sensor unit and said portable data collection unit;

sensing said machine vibrations with said accelerometer;

streaming raw sensor data sensed by the accelerometer to the second wireless interface using the signal processor;

transmitting said raw sensor data from said second wireless interface to said portable data collection unit;

discontinuing said streaming of raw sensor data;

dismounting the sensor unit from the machine; and

repeating each step of said method for another machine among the plurality of machines for which vibration data is to be collected; and

wherein the data collection unit further comprises an embedded camera, and the method further comprising;

storing in memory a set of non-photographic standard graphic images, in which each standard graphic image of the set depicts a different mounting orientation of the sensor unit relative to a machine mount;

storing in memory data collection instructions associated with the test point;

as part of a machine diagnostic data collection first route including said location of said test point on said rotating machine, displaying on the display said data collection instructions associated with said test point and including on the display with said data collection instructions an image area occupying less than an entirety of the touchscreen within which a default image is displayed, wherein said default image is one of a placeholder image, an image from among said set of standard graphic images, or a photographic image of the sensor unit mounted at said location;

while the sensor unit is removably mounted to said location during performance of said machine diagnostic data collection first route, capturing a photographic image of a field of view of the embedded camera;

receiving from the user input device an indication that the photographic image is for data collection instruction;

setting by said processor said captured photographic image as the default image, and during a subsequent performance of a second route that includes said location of said test point of said rotating machine, displaying on the touchscreen said data collection instructions associated with said test point and including on the touchscreen with said data collection instructions in said image area occupying less than said entirety of the touchscreen said captured photographic image;

receiving from the user input device an indication that the photographic image is for storage as a data collection result;

storing said processor said captured photographic image among data collection results for the machine; and

receiving machine vibration data from said sensor unit into said data collection interface.

19. A machine diagnostic data collection system for collecting vibration data from a rotating machine, the system comprising:

a portable data collection unit comprising a first wireless interface, a processor, memory, a display, and an operator input device;

a sensor unit configured as a single body, removably mounted in its entirety to a test point location on the machine in a manner by which machine vibrations propagate into said single body;

wherein the sensor unit comprises within said single body an accelerometer, a second wireless interface, a circuit board, a signal processor, and a battery;

wherein the second wireless interface is configured to transmit wirelessly in real time to the first wireless interface raw data sensed by the accelerometer;

wherein the sensor unit further comprises an elastomeric member separating a sensing component of the accelerometer from the circuit board, signal processor, and battery, the elastomeric member being configured to reduce frequency response impacts of mass and volume of the signal processor the circuit board, and the battery on dynamic behavior of the sensor unit with respect to machine vibrations by damping vibrations introduced by said circuit board, signal processor, and battery in response to said machine vibrations, thereby vibrationally-isolating, in part, the sensing component from the signal processor, circuit board and battery;

wherein the elastomeric member comprises a first elastomeric part, a second elastomeric part and a third elastomeric part;

wherein the first elastomeric part separates the sensing component of the accelerometer from the circuit board, signal processor, battery, and second wireless interface, the first elastomeric part located at a first end of the circuit board and a first end of the battery;

wherein the second elastomeric part extends longitudinally along a face of the rechargeable battery;

wherein the third elastomeric part is located at a second end of the circuit board and a second end of the battery away from the accelerometer;

wherein the first elastomeric part, second elastomeric part and third elastomeric pard are configured to reduce frequency response impacts of mass and volume of the second wireless interface, the signal processor, the circuit board, and the battery on dynamic behavior of the sensor unit with respect to machine vibrations by damping vibrations introduced by said second wireless interface, circuit board, signal processor, and battery in response to said machine vibrations; and

wherein the sensor unit has a frequency response rating of no more than +/−

3 db at 5 kHz on a z-axis.

20. The machine diagnostic data collection system of claim 19, wherein the sensor unit is a first sensor unit and further comprising a second sensor unit of a same construction removably mounted in its entirety to a second test point location on the machine, wherein said accelerometer of each one of said first and second sensor unit is a tri-axial accelerometer;

and

wherein said first and second sensor unit are manufactured to have a threaded unit for mounting the respective sensor unit to the machine, the threaded unit having a same indexing of an x-axis and y-axis, whereby said first sensor unit and second sensor unit are interchangeably mounted to said machine and achieve a same circumferential reference position when screwed onto a mounting mechanism to a prescribed torque without further individualized referencing at the time of mounting.