Route based ultrasonic monitoring system

• US 6,189,384 B1
• Filed: 05/05/1998
• Issued: 02/20/2001
• Est. Priority Date: 05/05/1998
• Status: Active Grant

• Current Assignee: Computational Systems Incorporated (Emerson Electric Company)
• Original Assignee: CSI Technology Incorporated (Emerson Electric Company)
• Inventors: Johnson, William S., Piety, Kenneth R.
• Primary Examiner(s): Williams, Hezron
• Assistant Examiner(s): MILLER, ROSE MARY
• Application Number:
  US09/073,276
• Time in Patent Office: 1,022 Days
• Field of Search: 736/49, 736/58, 736/59, 736/60, 736/61, 73/405.A, 735/84, 735/92
• US Class Current: 73/592
• CPC Class Codes: G01H 1/003 of rotating machines G01H1/10 takes precedence

Abstract

A route based ultrasonic monitoring method for use by an operator in detecting when the ultrasonic sound produced by a device indicates the presence of a leak or machinery defect. The route based ultrasonic monitoring method uses a central processing location to store testing information concerning which machines to test and how to configure a portable ultrasonic sensing device to test them. At the appropriate time, the testing information is loaded from the central processing location into the portable processing and storage unit. The operator is then prompted by the portable processing and storage unit to proceed to a test location. Once at the test location, the portable processing and storage unit provides the testing information to the portable ultrasonic sensing device. The test is then performed by the operator with the portable ultrasonic sensing device and the test results are downloaded from the portable sensing device to the portable processing and storage unit. Once all the tests along a particular route of testing locations have been performed, the test results are downloaded from the portable processing and storage unit to the central processing location. The results of the most current set of tests are then compared to the results of previous tests to determine the presence of any machinery defects.

Claims

1. A route based method of locating mechanical defects, electrical anomalies or leaks producing ultrasonic sound, the steps of the method comprising:

storing a set of instructions including at least a set of measurement locations for performing a series of airborne ultrasonic sound measurements;

directing an operator along a route that includes the measurement locations;

prompting the operator to perform the series of airborne ultrasonic sound measurements along the route of measurement locations;

sensing airborne ultrasonic sound with a non-contact airborne ultrasonic sensor;

producing sensed ultrasonic electrical signals corresponding to the sensed airborne ultrasonic sounds;

producing audible frequency electrical signals derived from the sensed ultrasonic electrical signals;

using the audible frequency electrical signals to produce an audible sound that is related to airborne ultrasonic sound sensed at a location;

locating any mechanical defect, electrical anomaly or leak producing airborne ultrasonic sound in the location based upon at least one of said audible frequency electrical signals and said sensed ultrasonic electrical signals; and

prompting the operator to record information corresponding to said airborne ultrasonic sound from any mechanical defect, electrical anomaly or leak located.

2. The method of claim 1 further comprising:

using the audible frequency electrical signals to produce an audible sound that is related to ultrasonic sound measured at a measurement point;

providing and storing a set of notes describing characteristics of the audible sound; and

prompting the operator to select a note that describes a characteristic of the audible sound; and

storing the selected note.

3. The method of claim 1 further comprising the step of comparing the set of results from the series of ultrasonic sound measurements to a set of results from a previous series of ultrasonic sound measurements along the route of measurement locations in order to determine if any trends in the set of results from the series of ultrasonic measurements exist.

4. The method of claim 1 further comprising the step of providing a set of alarm levels for the series of ultrasonic sound measurements.

5. The method of claim 1 further comprising the step of analyzing the set of results to determine if a machinery defect or leak is present.

6. The method of claim 1 further comprising the step of assigning each measurement location in the route of measurement locations an identification code.

7. The method of claim 1 further comprising visually displaying the results of the series of ultrasonic sound measurements to the operator.

8. The method of claim 1 wherein the step of performing the series of ultrasonic sound measurements further includes taking temperature measurements.

9. The method of claim 1 wherein the step of directing an operator along a route of measurement locations further includes providing the operator the location of the next test to perform.

10. The method of claim 1 wherein the step of prompting the operator to perform a series of ultrasonic sound measurements further includes providing the operator information concerning the type of measurements to be taken and the manner in which the measurements should be taken.

11. A route based method of monitoring and locating equipment failures such as leaks, electrical anomalies or machinery defects that produce airborne ultrasonic sound waves, the steps of the method comprising:

storing test information concerning the type and location of ultrasonic tests to perform in a centrally based storage system;

loading a portion of the test information into a portable testing device;

prompting an operator to perform an airborne ultrasonic test that generates test results with the portable testing device;

storing the test results in the portable testing device;

transferring the test results from the portable testing device to a centrally based storage system; and

determining whether to perform another airborne ultrasonic test based on previous test results.

12. The method of claim 11 further comprising the step of diagnosing equipment failures by comparing the test results of a most recent test to the test results of a previous test.

13. The method of claim 11 further comprising performing a series of tests on a particular piece of equipment over a period of time to obtain a series of test results and identifying trends in the series of test results that indicate a potential equipment failure.

14. The method of claim 11 wherein the step of loading a portion of the test information into a portable testing device further comprises loading configuration information and alarm levels into the portable testing device.

15. The method of claim 14 further comprising the step of calculating the alarm levels for a piece of equipment based on test results received from a prior test performed on the piece of equipment.

16. The method of claim 11 further comprising the step of determining when to perform another test on a piece of equipment based on the previous results of tests performed on the piece of equipment.

17. The method of claim 11 wherein the step of prompting the operator to perform a test further comprises providing the operator information concerning the manner in which the test should be performed.

18. The method of claim 11 wherein the step of loading test information into the portable testing device further includes loading configuration information into the portable testing device.

19. A method of monitoring the condition of a plurality of pieces of equipment producing ultrasonic sounds, the steps of the method comprising:

storing a set of predetermined criteria in a digital memory that correspond to acceptable operating conditions of the plurality of pieces of equipment;

performing a set of contact ultrasonic sound measurements on the plurality of pieces of equipment at a plurality of measurement points to obtain a set of ultrasonic test data;

sensing airborne ultrasonic sound at designated locations to locate any mechanical defects, electrical anomalies or leaks producing airborne ultrasonic sound;

storing the set of ultrasonic test data corresponding to the set of ultrasonic sound measurements and the location of any detected mechanical defects, electrical anomalies or leaks in a digital memory; and

comparing the set of ultrasonic test data to the set of predetermined criteria to determine whether additional tests are required.

20. The method of claim 19 wherein the set of predetermined criteria comprises a set of historical and baseline data corresponding to results of past ultrasonic sound measurements.

21. The method of claim 19 further comprising the step of measuring and recording a temperature of a piece of equipment in the plurality of pieces of equipment at a first time and a second time and comparing the temperature at the first time to the temperature at the second time to determine the condition of the equipment.

22. The method of claim 19 further comprising determining a temperature alarm level at which a temperature alarm will be generated and generating a temperature alarm when the temperature alarm level is exceeded.

23. The method of claim 22 wherein the temperature alarm level is based on a previous temperature that was measured and recorded for the piece of equipment.

24. The method of claim 19 further comprising the step of generating ultrasonic alarm levels for a piece of equipment and producing an ultrasonic alarm signal when the ultrasonic sound produced by the piece of equipment exceeds the ultrasonic alarm levels.

25. The method of claim 24 wherein the ultrasonic alarm levels are generated based on the amount of ultrasonic sound previously measured and recorded for a piece of machinery.

26. The method of claim 19 further comprising the step of compiling a list of the location of each piece of equipment to be monitored and the times at which the piece of equipment should be monitored and prompting an operator to monitor the pieces of equipment at the appropriate times.

27. A route based method for ultrasonically monitoring a mechanical system, the steps of the method comprising:

creating a route that contains the location of each machine, device, or area to be tested and the tests to be performed on each machine, device, or area,

storing the route in a central processing location;

assigning each machine to be ultrasonically monitored and each measurement to be taken an identification code and storing the identification code for later reference;

determining alarm levels for each ultrasonic measurement to be taken;

loading a route of the ultrasonic tests to be performed, the alarm levels for each measurement and the configuration information needed to perform the route of ultrasonic tests into a portable processing and storage unit from a central processing location;

loading a list of locations at which to sense airborne ultrasonic sounds into the portable processing and storage unit from the central processing location;

prompting an operator of the portable processing and storage unit to perform a first ultrasonic test with a portable sensing device and the portable processing and storage unit;

providing the configuration information related to the performance of the particular ultrasonic test including the alarm levels for the ultrasonic test from the portable storage and processing unit to the portable sensing means;

performing the ultrasonic test with the portable sensing device by sensing at least ultrasonic sound and obtaining test results;

downloading the ultrasonic test results from the portable sensing device to the portable processing and storage unit;

prompting the operator to perform the next ultrasonic test indicated by the portable processing and storage device;

continuing to perform the ultrasonic tests indicated by the portable processing and storage device in the manner described above until all of the ultrasonic tests on the route of ultrasonic tests have been performed;

transferring the ultrasonic test results stored in the portable processing and storage unit to the central processing station and storing the ultrasonic test results in the central processing station; and

comparing the ultrasonic test results from the most current set of measurements to the stored ultrasonic test results from previous measurements to determine if any trends in the data indicate a condition that warrants performing additional ultrasonic tests.

28. An ultrasonic monitoring apparatus for ultrasonically monitoring a route of machines, devices or areas comprising:

portable ultrasonic sound sensing means having an ultrasonic sensor for sensing at least the amplitude of airborne ultrasonic sound produced by machines in the route of machines;

temperature sensing means for taking temperature readings along the route of machines;

portable processing and storage means for storing the location of the machines in the route of machines, storing and providing configuration and test information concerning the tests to be performed on each machine, device, or area in the route of machines, prompting the operator of the ultrasonic monitoring apparatus to perform a particular test, and receiving test results from the portable ultrasonic sound sensing means;

display means for visually providing testing information to an operator of the apparatus concerning tests to be performed and the results the tests; and

audible indication means for audibly providing testing information to the operator of the apparatus concerning at least the results of the most recent test performed.

29. The apparatus of claim 28 further comprising a central computer for receiving and storing the test results from the portable processing and storage means and analyzing the test results to determine if a machine in the route of machines has a machine defect.

30. The apparatus of claim 29 wherein the central computer further comprises processing means for comparing the test results from the most current set of tests to the test results from previous tests to determine if trends in the test results indicate the presence of a machine defect.