Modular monitoring and protection system topology

• US 6,912,484 B2
• Filed: 05/13/2002
• Issued: 06/28/2005
• Est. Priority Date: 05/13/2002
• Status: Active Grant

• Current Assignee: Rockwell Automation, Inc.
• Original Assignee: Entek IRD International Corp. (Rockwell Automation, Inc.)
• Inventors: Kramb, Kevin E., Shupe, Dan R., Lien, Chien-Tan, Bibelhausen, David J., Stoutenburg, Donn V., Carle, Patrick F.
• Primary Examiner(s): Tsai, Carol S. W.
• Application Number:
  US10/144,471
• Publication Number:
  US 20030212529A1
• Time in Patent Office: 1,142 Days
• Field of Search: 702/34, 702/35, 702/47, 702/54, 702/56, 702/57, 702/183, 702/187, 702/188, 702/FOR.155, 702FOR 134-139, 731/68, 736/60, 735/92, 737/78, 735/70, 736/44, 73/18.2, 735/93, 73/18.3, 73/350.9, 73/351.2, 417/1, 417/4, 417/15, 417/17, 417/18, 417/14
• US Class Current: 702/188
• CPC Class Codes: G05B 23/0216 Human interface functionality, e.g. monitoring system providing help to the user in the selection of tests or in its configuration
• CPC Class Codes: G05B 23/027 Alarm generation, e.g. communication protocol; Forms of alarm
• CPC Class Codes: G05B 23/0289 Reconfiguration to prevent failure, e.g. usually as a reaction to incipient failure detection
• CPC Class Codes: G05B 23/0291 Switching into safety or degraded mode, e.g. protection and supervision after failure

Abstract

A monitoring and protection system for a machine system includes monitoring modules or groups of modules positioned at various locations of the machine system at which dynamic operating conditions are monitored. The modules are configured to communicate with one another via an open industrial data exchange protocol. Network media is routed between groups of monitoring modules to establish an overall system topology that is highly distributed and that is not dependent upon routing of multiple signal cables to central monitoring locations or racks.

Claims

1. A distributed system for monitoring dynamic operating conditions of a rotary machine system, comprising:

a first monitoring group including a first sensor for detecting a dynamic operating condition at a first monitoring point of the machine system, and a first condition monitor coupled to the sensor local to the first monitoring point for processing signals from the first sensor;

a second monitoring group including a second sensor for detecting a dynamic operating condition at a second monitoring point of the machine system distal from the first monitoring point, and a second condition monitor coupled to the second sensor local to the second monitoring point for processing signals from the second sensor, and

network media linking the first and second monitoring groups for data exchange therebetween, the network media including data conductors for data exchange in accordance with a predetermined network protocol.

2. The system of claim 1, wherein each of the first and second monitoring groups includes at least one relay controlled by the condition monitor based upon the respective processed signals.

3. The system of claim 2, wherein at least one relay is integrated into the respective condition monitor.

4. The system of claim 2, wherein at least one relay is incorporated in a relay module local to the respective condition monitor.

5. The system of claim 1, further comprising a central monitoring station coupled to the first and second monitoring groups via the network media.

6. The system of claim 5, wherein the central monitoring station is configured for data exchange with the first and second monitoring groups in accordance with the predetermined network protocol.

7. The system of claim 1, further comprising a host monitor coupled to the first and second monitoring groups via the network media.

8. The system of claim 7, wherein the host monitor is configured for data exchange with the first and second monitoring groups in accordance with the predetermined network protocol.

9. The system of claim 1, wherein at least one of the monitoring groups includes a plurality of condition monitors, the plurality of condition monitors being coupled to the network media for data exchange with a distal monitoring group.

10. The system of claim 1, wherein each monitoring group includes a plurality of condition monitors configured to exchange data in accordance with the predetermined network protocol.

11. The system of claim 1, wherein the predetermined network protocol is an open industrial data exchange protocol.

12. The system of claim 1, wherein the media includes power conductors for powering the at least one of the condition monitors or sensors.

13. The system of claim 1, wherein at least one of the condition monitors is configured to process vibrational data from the sensor to determine a vibration profile, and to control a relay at least partially based upon the vibration profile.

14. A distributed system for monitoring dynamic operating conditions of a rotary machine system, comprising:

a first monitoring group including a first sensor for detecting a dynamic operating condition at a first monitoring point of the machine system, and a first condition monitor coupled to the sensor local to the first monitoring point for processing signals from the first sensor;

a second monitoring group including a second sensor for detecting a dynamic operating condition at a second monitoring point of the machine system distal from the first monitoring point, and a second condition monitor coupled to the second sensor local to the second monitoring point for processing signals from the second sensor; and

network media linking the first and second monitoring groups for data exchange therebetween, the network media including data conductors for data exchange in accordance with a predetermined network protocol; and

a central monitoring station coupled to the first and second monitoring groups via the network media, the central monitoring station being configured for data exchange with the first and second monitoring groups in accordance with the predetermined network protocol.

15. The system of claim 14, wherein each of the first and second monitoring groups includes at least one relay controlled by the condition monitor based upon the respective processed signals.

16. The system of claim 15, wherein at least one relay is integrated into the respective condition monitor.

17. The system of claim 15, wherein at least one relay is incorporated in a relay module local to the respective condition monitor.

18. The system of claim 14, wherein at least one of the monitoring groups includes a plurality of condition monitors, the plurality of condition monitors being coupled to the network media for data exchange with a distal monitoring group.

19. The system of claim 14, wherein each monitoring group includes a plurality of condition monitors configured to exchange data in accordance with the predetermined network protocol.

20. The system of claim 14, wherein the predetermined network protocol is an open industrial data exchange protocol.

21. The system of claim 14, wherein the media includes power conductors for powering the at least one of the condition monitors or sensors.

22. A distributed system for monitoring dynamic operating conditions of a rotary machine system, comprising:

a plurality of monitoring groups disposed at different locations with respect to the machine system, each monitoring group including a sensor for detecting a dynamic operating condition at a respective monitoring point of the machine system, and a condition monitor coupled to the respective sensor local to the respective monitoring point for processing signals therefrom;

a central monitoring station coupled to the monitoring groups and configured for data exchange with the first and second monitoring groups in accordance with the predetermined network protocol; and

network media linking the monitoring groups for data exchange therebetween and linking the monitoring groups to the central monitoring station, the network media including data conductors for data exchange in accordance with a predetermined network protocol.

23. The system of claim 22, wherein the network media is configured to transmit data and power to at least one of the condition monitors.

24. The system of claim 22, wherein at least one of the condition monitors is configured to process vibrational data from the sensor to determine a vibration profile, and to control a relay at least partially based upon the vibration profile.

25. The system of claim 22, wherein each of the monitoring groups includes at least one relay controlled by the condition monitor based upon the respective processed signals.

26. The system of claim 25, wherein at least one relay is integrated into the respective condition monitor.

27. The system of claim 25, wherein at least one relay is incorporated in a relay module local to the respective condition monitor.

28. The system of claim 22, wherein at least one of the monitoring groups includes a plurality of condition monitors, the plurality of condition monitors being coupled to the network media for data exchange with a distal monitoring group.

29. A distributed system for monitoring dynamic operating conditions of a rotary machine system, comprising:

a plurality of monitoring groups disposed at different locations with respect to the machine system, each monitoring group including a sensor for detecting a dynamic operating condition at a respective monitoring point of the machine system, and a condition monitor coupled to the respective sensor local to the respective monitoring point for processing signals therefrom;

a central monitoring station coupled to the monitoring groups and configured for data exchange with the first and second monitoring groups in accordance with the predetermined network protocol; and

network media linking the monitoring groups for data exchange therebetween and linking the monitoring groups to the central monitoring station, the network media including data conductors for data exchange in accordance with a predetermined network protocol, and power conductors for applying power to at least one of the condition monitors.

30. The system of claim 29, wherein at least one of the condition monitors is configured to process vibrational data from the sensor to determine a vibration profile, and to control a relay at least partially based upon the vibration profile.

31. The system of claim 29, wherein each of the monitoring groups includes at least one relay controlled by the condition monitor based upon the respective processed signals.

32. The system of claim 31, wherein at least one relay is integrated into the respective condition monitor.

33. The system of claim 31, wherein at least one relay is incorporated in a relay module local to the respective condition monitor.

34. The system of claim 29, wherein at least one of the monitoring groups includes a plurality of condition monitors, the plurality of condition monitors being coupled to the network media for data exchange with a distal monitoring group.