Motorized system integrated control and diagnostics using vibration, pressure, temperature, speed, and/or current analysis

• US 7,308,322 B1
• Filed: 09/27/2001
• Issued: 12/11/2007
• Est. Priority Date: 09/29/1998
• Status: Expired due to Term

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Discenzo, Frederick M., Chung, Dukki, Zevchek, Joseph K., Bezdicek, Jan, Flek, Ondrej, Sladek, Bohumir, Unsworth, Peter J., Loparo, Kenneth A., Tusla, Petr, Ryba, Jiri, Vetcha, Sarat Babu, Perovic, Dragica Kostic, Perovic, Srdjan, Arkan, Muslum
• Primary Examiner(s): Chang, Jungwon
• Application Number:
  US09/965,545
• Time in Patent Office: 2,266 Days
• Field of Search: 702/182, 702/183, 700/47, 700/48, 700/21, 700/28, 700/71, 700/175, 318/439
• US Class Current: 700/28
• CPC Class Codes: G05B 23/0221 Preprocessing measurements, e.g. data collection rate adjustment; Standardization of measurements; Time series or signal analysis, e.g. frequency analysis or wavelets; Trustworthiness of measurements; Indexes therefor; Measurements using easily measured parameters to estimate parameters difficult to measure; Virtual sensor creation; De-noising; Sensor fusion; Unconventional preprocessing inherently present in specific fault detection methods like PCA-based methods
• CPC Class Codes: G05B 23/0229 knowledge based, e.g. expert systems; genetic algorithms
• CPC Class Codes: G05B 23/0254 based on a quantitative model, e.g. mathematical relationships between inputs and outputs; functions: observer, Kalman filter, residual calculation, Neural Networks

Abstract

Systems and methods are disclosed for controlling, diagnosing and prognosing the health of a motorized system. The systems may comprise a diagnostics system, a prognostic system and a controller, wherein the diagnostics system and/or prognostic system employs a neural network, an expert system, and/or a data fusion component in order to assess and/or prognose the health of the motorized system according to one or more attributes associated therewith. The controller may operate the motorized system in accordance with a setpoint and/or a diagnostics signal from the diagnostics system and/or prognostic information. Also disclosed are methodologies for controlling, diagnosing and prognosing the health of a motorized system, comprising operating a motor in the motorized system in a controlled fashion, diagnosing and/or prognosing the health of the motorized system according to a measured attribute associated with the motorized system, wherein the motor may be operated according to a setpoint and/or the diagnostics signal and/or prognosis.

Claims

1. A method for controlling a motorized system comprising:

measuring an attribute of the motorized system, the attribute comprises at least one of vibration, speed, temperature, pressure, and current in the motorized system;

diagnosing a health of the motorized system based on the measured attribute;

providing a diagnostics signal based on the diagnosed health;

prognosing a state of the motorized system based at least in part on the at least one sensed attribute and/or the diagnosed state;

providing a control signal based at least in part on the diagnosed health and the prognosed state; and

providing a feedback operation that adjusts the control signal to extend the lifetime of the motorized system to a specific time horizon, the control signal is adjusted based upon at least one of reaching a pre-determined pump cavitation amount or reaching a pre-determined pump blockage amount.

2. The method of claim 1, further comprising operating the motorized system according to the diagnostics signal.

3. The method of claim 1, further comprising modifying a setpoint of the motorized system.

4. The method of claim 1, wherein diagnosing the health comprises obtaining a frequency spectrum of the measured attribute and analyzing the frequency spectrum to detect adverse operating conditions.

5. The method of claim 4, wherein analyzing the frequency spectrum comprises analyzing the frequency spectrum to detect faults, component wear and component degradation.

6. The method of claim 5, wherein measuring the attribute comprises measuring an attribute associated with a motorized pump.

7. The method of claim 1, wherein measuring the attribute comprises measuring an attribute associated with a fan.

8. The method of claim 1, wherein measuring the attribute comprises measuring an attribute associated with the motorized system selected from the group comprising motorized pump, fan, conveyor system, compressor, gear box, motion control device, screw pump, mixer, hydraulic machine and pneumatic machine.

9. The method of claim 1, wherein diagnosing the health comprises analyzing an amplitude of a first spectral component of a frequency spectrum at a first frequency.

10. The method of claim 1, wherein providing the control signal comprises providing the control signal to increase cavitation to reduce damage to the motorized system.

11. The method of claim 1, wherein providing the control signal comprises providing the control signal to reduce cavitation to extend an operating lifetime of the motorized system.

12. The method of claim 1, wherein providing the control signal comprises generating the control signal and transmitting the control signal via a wireless network.

13. The method of claim 1, wherein providing the diagnostic signal comprises generating the diagnostic signal and transmitting the diagnostic signal via a wireless network.

14. The method of claim 1 being implemented on a system connected to the motorized system via a wireless network.

15. The method of claim 1, wherein measuring the attribute comprises receiving measurements from at least one sensor.

16. A control system for controlling a motorized system comprising:

means for measuring an attribute of the motorized system, the measured attribute comprises at least one of vibration, speed, temperature, pressure, and current in the motorized system;

means for diagnosing a health of the motorized system;

means for prognosing a state of the motorized system;

means for providing a control signal based at least in part on both of a diagnosed health and a prognosed state of the motorized system;

means for providing a diagnostic signal; and

means for performing feedback analysis to adjust the control signal to extend motorized system lifetime to a specific time horizon, the control signal is adjusted based upon at least one of reaching a pre-determined pump cavitation amount or reaching a pre-determined pump blockage amount.

17. The control system of claim 16, further comprising:

means for modifying operation of the motorized system based on the diagnostic signal.

18. The control system of claim 16, further comprising:

means for modifying operation of the motorized system based on the control signal.

19. A system comprising:

a motorized system;

a communications link coupled to the motorized system; and

a control system coupled to the communications link comprising;

a controller coupled to the communications link adapted to operate the motorized system in a controlled fashion;

a diagnostics system coupled to the communications link adapted to diagnose the health of the motorized system according to at least one measured attribute associated with the motorized system, the measured attribute comprises at least one of vibration, speed, temperature, pressure, and current in the motorized system;

a prognostics system coupled to the communications link that provides prognoses of future states of the motorized system based at least in part on the at least one sensed attribute and/or and the diagnosed health and provides the prognoses to the control component; and

a feedback analysis component that adjusts the controller via a control signal to increase motorized system life duration to a specific time horizon, the control signal is adjusted based upon at least one of reaching a pre-determined pump cavitation amount or reaching a pre-determined pump blockage amount.

20. The system of claim 19, wherein the motorized system comprises components, devices, subsystems and process controls.

21. The system of claim 20, wherein the components comprise bearings, the devices comprise a motor, pump and fan, the subsystems comprise a motor-drive-pump and process controls comprise a pump fluid control.

22. The system of claim 19, wherein the motorized system comprises a motor and a load, and wherein the load comprises at least one of a valve, a pump, a conveyor roller, a fan, a compressor, and a gearbox.

23. The system of claim 20, wherein the diagnostics system provides a diagnostics signal, and wherein the controller provides a control signal.

24. The system of claim 23, wherein the diagnostics signal represents health of the motorized system and the control signal represents control information for the motorized system.

25. The system of claim 20, wherein the controller provides a control signal, wherein the control signal contains control information for controlling at least one of the components, the devices, the subsystems and the process controls.

26. The system of claim 19, further comprising at least one sensor coupled to the motorized system and the communications link for measuring the at least one measured attribute.

27. The system of claim 19, wherein the communications link is a wired connection.

28. The system of claim 19, wherein the communications link is a wireless connection.

29. The system of claim 19, wherein the communications link is a wireless radio frequency system.

30. The system of claim 19, wherein the communications link is a wireless network.

31. The system of claim 19, wherein the control system is implemented on a computer system.

32. A system to facilitate controlling a motorized system, comprising:

at least one sensor that senses at least one attribute of the motorized system, the attribute comprises at least one of vibration, speed, temperature, pressure, and current in the motorized system;

a diagnostics system that diagnoses a state of the motorized system based at least in part on the at least one sensed attribute;

a prognostic system that makes a prognosis of the motorized system based at least in part on the at least one sensed attribute, the diagnosed state, or both; and

a controller that controls the motorized system via a control signal based at least in part on the diagnosed state;

the diagnostics system further performs at least a second diagnosis of the state of the motorized system after corrective action is taken by the control component and ensures that the motorized system will function until a predetermined time horizon is reached, the control signal is adjusted based upon at least one of reaching a pre-determined pump cavitation amount or reaching a pre-determined pump blockage amount.

33. The system of claim 32, the controller controlling the motorized system based at least in part on the prognosis.

34. The system of claim 33, the controller automatically adjusting operation of the motorized system based at least in part on prognosed future states of the motorized system.

35. The system of claim 32, the prognostic system comprising a non-linear training system.

36. The system of claim 32, the prognostic system inferring future operating states of the motorized system.

37. The system of claim 32, the controller automatically adjusting an operating state of the motorized system based at least in part on the prognosis.

38. The system of claim 32, the controller scheduling preventive maintenance for the motorized system based at least in part on the prognosis.