Method, system and computer program for fault detection in a machine
Method, system and computer program for fault detection in a machine
 CN 105,466,707 B
 Filed: 09/15/2015
 Issued: 09/03/2021
 Est. Priority Date: 09/15/2014
 Status: Active Grant
First Claim
1. A method for condition monitoring of a machine, comprising:
 obtaining a first set of data observations corresponding to a first pair of machine condition parameters, the first pair of machine condition parameters comprising two different machine condition parameters;
determining a first correlation coefficient corresponding to the first pair of machine condition parameters based on the first set of data observations;
determining a first pvalue corresponding to the first pair of machine condition parameters based on the first correlation coefficient; and
selecting at least one condition monitoring activity for execution from a plurality of available condition monitoring activities, wherein the selection of the condition monitoring activity is based on;
at least the first pvalue; and
one or more defined selection rules that are,wherein the selection rule is defined as follows;
in response to (i) the first pair of machine condition parameters including a related pair of variables and (ii) the first pvalue being greater than a first predetermined pvalue limit, orIn response to (iii) the first pair of machine condition parameters comprising an uncorrelated pair of variables and (iv) the first pvalue being less than or equal to a first predetermined pvalue limit,the selected condition monitoring behavior is a condition monitoring behavior configured to be executed in response to a detected fault condition.
Chinese PRB Reexamination
Abstract
The present invention provides a method, system, and computer program product for condition monitoring of a machine. Condition monitoring of a machine according to the present disclosure may include (i) obtaining a first set of data observations corresponding to a first pair of machine condition parameters, (ii) determining a first correlation coefficient corresponding to the first pair of machine condition parameters based on the first set of data observations, (iii) determining a first pvalue corresponding to the first pair of machine condition parameters based on the first correlation coefficient, and (iv) selecting at least one condition monitoring activity for execution from a plurality of available condition monitoring activities, wherein the selection of the condition monitoring activity is based on the at least first pvalue and one or more defined selection rules.
25 Claims

1. A method for condition monitoring of a machine, comprising:

obtaining a first set of data observations corresponding to a first pair of machine condition parameters, the first pair of machine condition parameters comprising two different machine condition parameters; determining a first correlation coefficient corresponding to the first pair of machine condition parameters based on the first set of data observations; determining a first pvalue corresponding to the first pair of machine condition parameters based on the first correlation coefficient; and selecting at least one condition monitoring activity for execution from a plurality of available condition monitoring activities, wherein the selection of the condition monitoring activity is based on; at least the first pvalue; and one or more defined selection rules that are, wherein the selection rule is defined as follows; in response to (i) the first pair of machine condition parameters including a related pair of variables and (ii) the first pvalue being greater than a first predetermined pvalue limit, or In response to (iii) the first pair of machine condition parameters comprising an uncorrelated pair of variables and (iv) the first pvalue being less than or equal to a first predetermined pvalue limit, the selected condition monitoring behavior is a condition monitoring behavior configured to be executed in response to a detected fault condition.


2. The method of claim 1, wherein the condition monitoring activities structured to be performed in response to the detected fault condition include any one or more of:

signaling a detected fault condition; modifying an operating state of the machine; activating a condition monitoring program in response to a detected fault condition; triggering one or more of an alarm, a warning, a manual inspection, and a sensorbased test; triggering online vibration analysis; and performing at least one additional test related to an operating condition of the machine.


3. The method of claim 1, wherein the first predetermined pvalue limit is any value between 0.01 and 0.05.

4. The method of claim 1, further comprising:

obtaining a second set of data observations corresponding to a second pair of machine condition parameters; determining a second correlation coefficient corresponding to the second pair of machine condition parameters based on the second set of data observations; and determining a second pvalue corresponding to the second pair of machine condition parameters based on the second correlation number; wherein condition monitoring behavior is selected for execution additionally based on at least the second pvalue.


5. The method of claim 4, wherein the machine comprises a centrifugal pump system, and wherein:

the first pair of machine condition parameters is a related pair of variables including current and discharge pressure; the second pair of machine condition parameters is a correlated pair of variables including current and outflow rate; and
isIn response to the first pvalue being greater than a first predetermined pvalue limit or the second pvalue being greater than a second predetermined pvalue limit, the selected condition monitoring action is a condition monitoring action configured to be performed in response to a detected fault condition.


6. The method of claim 4, wherein the machine comprises a centrifugal pump system, and wherein:

the first pair of machine condition parameters is an uncorrelated pair of variables including current and sensed bearing temperature; the second pair of machine condition parameters is a uncorrelated pair of variables including current and sensed vibration characteristics; and
isIn response to the first pvalue being less than or equal to a first predetermined pvalue limit or the second pvalue being less than or equal to a second predetermined pvalue limit, the selected condition monitoring behavior is a condition monitoring behavior configured to be executed in response to a detected fault condition.


7. The method of claim 4, further comprising:

obtaining a third set of data observations corresponding to a third pair of machine condition parameters; and determining a third correlation coefficient corresponding to the third pair of machine condition parameters based on the third set of data observations; determining a third pvalue corresponding to the third pair of machine condition parameters based on the third phase relationship number; wherein condition monitoring behavior is selected for execution additionally based on at least the third pvalue.


8. The method of claim 7, wherein the machine comprises a centrifugal pump system, and wherein:

the first pair of machine condition parameters is a related pair of variables comprising an outlet flow rate and an inlet valve position; the second pair of machine condition parameters is a related pair of variables comprising an outflow rate and a discharge valve position; the third pair of machine condition parameters is a related pair of variables including an outflow rate and an inflow rate; and
isIn response to the first pvalue being greater than a first predetermined pvalue limit, the second pvalue being greater than a second predetermined pvalue limit, and the third pvalue being greater than a third predetermined pvalue limit, the selected condition monitoring action is a condition monitoring action configured to be performed in response to a detected fault condition.


9. A method for condition monitoring of a centrifugal pump system, comprising:

based on the data observations, obtaining; a first pvalue corresponding to a first pair of machine condition parameters including a current and a discharge pressure; a second pvalue corresponding to a second pair of machine condition parameters including a correlation of current and outflow rate, a third pvalue corresponding to a third pair of machine condition parameters including no correlation of current and sensed bearing temperature, a fourth pvalue corresponding to a fourth unrelated pair of machine condition parameters including current and sensed vibration characteristics, a fifth pvalue corresponding to a fifth pair of machine condition parameters including an associated outlet flow rate and an inlet valve position, a sixth pvalue corresponding to a sixth pair of machine condition parameters including a correlation of the outflow rate and the discharge valve position, an A seventh pvalue corresponding to a seventh pair of machine condition parameters including a correlation of the outflow rate and the inflow rate; selecting a first condition monitoring activity for execution from a plurality of available condition monitoring activities, wherein; in response to (i) the first pvalue being greater than a first predetermined pvalue limit, or (ii) the second pvalue being greater than a second predetermined pvalue limit; and
(ii) the third pvalue is less than or equal to a third predetermined pvalue limit, or the fourth pvalue is less than or equal to a fourth predetermined pvalue limit, the selected first condition monitoring activities comprising condition monitoring activities configured to be performed in response to a detected fault condition;
orIn response to (iii) the first pvalue being greater than a first predetermined pvalue limit, or the second pvalue being greater than a second predetermined pvalue limit; and
(iv) the third pvalue is greater than a third predetermined pvalue limit and the fourth pvalue is greater than a fourth predetermined pvalue limit, the selected first condition monitoring behavior comprising;comparing the detected bearing temperature to a recommended operating temperature; comparing the detected vibration characteristic to a recommended vibration characteristic limit; and selecting a second condition monitoring act for execution from the plurality of available condition monitoring acts in response to the detected bearing temperature exceeding the recommended operating temperature or the detected vibration characteristic exceeding a recommended vibration characteristic limit, wherein the second condition monitoring act comprises a condition monitoring act configured to be executed in response to the detected fault condition; or In response to the first pvalue being less than or equal to a first predetermined pvalue limit and the second pvalue being less than or equal to a second predetermined pvalue limit, the selected first condition monitoring behavior comprises; comparing the observed maximum outflow rate to the observed minimum outflow rate; and in response to the maximum outflow rate exceeding more than a predetermined first outflow change limit than the minimum outflow rate, determining (a) whether the fifth pvalue is greater than a fifth predetermined pvalue limit, (b) whether the sixth pvalue is greater than a sixth predetermined pvalue limit, and (c) whether the seventh pvalue is greater than a seventh predetermined pvalue limit.


10. The method of claim 9, wherein any of the first through seventh predetermined pvalue limits comprises any value between 0.01 and 0.05.

11. The method of claim 9, wherein in response to (a) the fifth pvalue being greater than the fifth predetermined pvalue limit, (b) the sixth pvalue being greater than the sixth predetermined pvalue limit, and (c) the seventh pvalue being greater than the seventh predetermined pvalue limit, the method further comprises:

in response to the detected decrease in outflow rate exceeding a predetermined second outflow change limit, selecting a third condition monitoring action for execution from the plurality of available condition monitoring actions, wherein the third condition monitoring action comprises a condition monitoring action configured to be executed in response to a detected exhaust recirculation failure or filter plugging failure;
orIn response to detecting the observed outflow rate and the observed oscillation in the exhaust pressure, selecting a fourth condition monitoring action for execution from the plurality of available condition monitoring actions, wherein the fourth condition monitoring action comprises a condition monitoring action configured to be executed in response to the detected cavitation fault.


12. A system for condition monitoring of a machine, comprising:

a processorimplemented data analysis and heuristic controller configured to; obtaining a first set of data observations corresponding to a first pair of machine condition parameters, the first pair of machine condition parameters comprising two different machine condition parameters; determining a first correlation coefficient corresponding to the first pair of machine condition parameters based on the first set of data observations; determining a first pvalue corresponding to the first pair of machine condition parameters based on the first correlation coefficient; and
isSelecting at least one condition monitoring activity for execution from a plurality of available condition monitoring activities, wherein the selection of the condition monitoring activity is based on; at least the first pvalue; and one or more defined selection rules that are, wherein the selection rules are retrieved from a database and defined as follows; in response to (i) the first pair of machine condition parameters including a related pair of variables and (ii) the first pvalue being greater than a first predetermined pvalue limit, or In response to (iii) the first pair of machine condition parameters comprising an uncorrelated pair of variables and (iv) the first pvalue being less than or equal to a first predetermined pvalue limit, the selected condition monitoring behavior is a condition monitoring behavior configured to be executed in response to a detected fault condition.


13. The system of claim 12, comprising at least one of:

a pump diagnostic interface configured to receive and communicate information related to an operating state of the machine to a user or device; a preprocessing engine configured to optimize information from one or more sensors for data analysis; and a trigger controller configured to signal or effect a state change in the machine.


14. The system of claim 12, wherein the condition monitoring action configured to be performed in response to the detected fault condition comprises any one or more of:

signaling a detected fault condition; modifying an operating state of the machine; activating a condition monitoring program in response to a detected fault condition; triggering one or more of an alarm, a warning, a manual inspection, and a sensorbased test; triggering online vibration analysis; and performing at least one additional test related to an operating condition of the machine.


15. The system of claim 12, wherein the first predetermined pvalue limit is any value between 0.01 and 0.05.

16. The system of claim 12, wherein the data analysis and heuristics controller is further configured to:

obtaining a second set of data observations corresponding to a second pair of machine condition parameters; determining a second correlation coefficient corresponding to the second pair of machine condition parameters based on the second set of data observations; and determining a second pvalue corresponding to the second pair of machine condition parameters based on the second correlation number; wherein condition monitoring behavior is selected for execution additionally based on at least the second pvalue.


17. The system of claim 16, wherein the machine comprises a centrifugal pump system, and wherein:

the first pair of machine condition parameters is a related pair of variables including current and discharge pressure; the second pair of machine condition parameters is a correlated pair of variables including current and outflow rate; and
isIn response to the first pvalue being greater than a first predetermined pvalue limit or the second pvalue being greater than a second predetermined pvalue limit, the selected condition monitoring action is a condition monitoring action configured to be performed in response to a detected fault condition.


18. The system of claim 16, wherein the machine comprises a centrifugal pump system, and wherein:

the first pair of machine condition parameters is an uncorrelated pair of variables including current and sensed bearing temperature; the second pair of machine condition parameters is a uncorrelated pair of variables including current and sensed vibration characteristics; and
isIn response to the first pvalue being less than or equal to a first predetermined pvalue limit or the second pvalue being less than or equal to a second predetermined pvalue limit, the selected condition monitoring behavior is a condition monitoring behavior configured to be executed in response to a detected fault condition.


19. The system of claim 16, wherein the data analysis and heuristics controller is further configured to:

obtaining a third set of data observations corresponding to a third pair of machine condition parameters; and determining a third correlation coefficient corresponding to the third pair of machine condition parameters based on the third set of data observations; determining a third pvalue corresponding to the third pair of machine condition parameters based on the third phase relationship number; wherein condition monitoring behavior is selected for execution additionally based on at least the third pvalue.


20. The system of claim 19, wherein the machine comprises a centrifugal pump system, and wherein:

the first pair of machine condition parameters is a related pair of variables comprising an outlet flow rate and an inlet valve position; the second pair of machine condition parameters is a related pair of variables comprising an outflow rate and a discharge valve position; the third pair of machine condition parameters is a related pair of variables including an outflow rate and an inflow rate; and
isIn response to the first pvalue being greater than a first predetermined pvalue limit, the second pvalue being greater than a second predetermined pvalue limit, and the third pvalue being greater than a third predetermined pvalue limit, the selected condition monitoring action is a condition monitoring action configured to be performed in response to a detected fault condition.


21. A system for condition monitoring of a centrifugal pump system, comprising:

a processorimplemented data analysis and heuristic controller configured to; obtaining, based on data observations received from one or more sensors; a first pvalue corresponding to a first pair of machine condition parameters including a current and a discharge pressure; a second pvalue corresponding to a second pair of machine condition parameters including a correlation of current and outflow rate; a third pvalue corresponding to a third unrelated pair of machine condition parameters including current and detected bearing temperature; a fourth pvalue corresponding to a fourth unrelated pair of machine condition parameters including current and detected vibration characteristics; a fifth pvalue corresponding to a fifth pair of machine condition parameters including an associated outlet flow rate and an inlet valve position; a sixth pvalue corresponding to a sixth pair of machine condition parameters including an associated outflow rate and exhaust valve position; and a seventh pvalue corresponding to a seventh pair of machine condition parameters including a correlation of the outflow rate and the inflow rate; selecting a first condition monitoring activity for execution from a plurality of available condition monitoring activities, wherein; in response to (i) the first pvalue being greater than a first predetermined pvalue limit, or (ii) the second pvalue being greater than a second predetermined pvalue limit; and
(ii) the third pvalue is less than or equal to a third predetermined pvalue limit, or the fourth pvalue is less than or equal to a fourth predetermined pvalue limit, the selected first condition monitoring activities comprising condition monitoring activities configured to be performed in response to a detected fault condition;
orIn response to (iii) the first pvalue being greater than a first predetermined pvalue limit, or the second pvalue being greater than a second predetermined pvalue limit; and
(iv) the third pThe value is greater than a third predetermined pvalue limit and the fourth pvalue is greater than a fourth predetermined pvalue limit, the selected first condition monitoring action comprising; comparing the detected bearing temperature to a recommended operating temperature; comparing the detected vibration characteristic to a recommended vibration characteristic limit; and selecting a second condition monitoring behavior for execution from the plurality of available condition monitoring behaviors in response to the detected bearing temperature exceeding the recommended operating temperature or the detected vibration characteristic exceeding the recommended vibration characteristic limit, wherein the second condition monitoring behavior comprises a condition monitoring behavior configured to be executed in response to the detected fault condition; or In response to the first pvalue being less than or equal to a first predetermined pvalue limit and the second pvalue being less than or equal to a second predetermined pvalue limit, the selected first condition monitoring behavior comprises; comparing the observed maximum outflow rate to the observed minimum outflow rate; and in response to the maximum outflow rate exceeding more than a predetermined first outflow change limit than the minimum outflow rate, determining (a) whether the fifth pvalue is greater than a fifth predetermined pvalue limit, (b) whether the sixth pvalue is greater than a sixth predetermined pvalue limit, and (c) whether the seventh pvalue is greater than a seventh predetermined pvalue limit.


22. The system of claim 21, comprising at least one of:

a pump diagnostic interface configured to receive and communicate information related to an operational state of the centrifugal pump system to a user or device; a preprocessing engine configured to optimize information received from one or more sensors for data analysis; and a trigger controller configured to signal or effect a state change in the centrifugal pump system.


23. The system of claim 21, wherein any of the first through seventh predetermined pvalue limits comprises any value between 0.01 and 0.05.

24. The system of claim 21, wherein the data analysis and heuristics controller is configured to, in response to (a) the fifth pvalue being greater than the fifth predetermined pvalue limit, (b) the sixth pvalue being greater than the sixth predetermined pvalue limit, and (c) the seventh pvalue being greater than the seventh predetermined pvalue limit, cause the system to:

in response to the detected decrease in outflow rate exceeding a predetermined second outflow change limit, selecting a third condition monitoring action for execution from the plurality of available condition monitoring actions, wherein the third condition monitoring action comprises a condition monitoring action configured to be executed in response to a detected exhaust recirculation fault or filter plugging fault;
orIn response to the observed outflow rate and the detected oscillation in the observed discharge pressure, selecting a fourth condition monitoring action for execution from the plurality of available condition monitoring actions, wherein the fourth condition monitoring action comprises a condition monitoring action configured to be executed in response to the detected cavitation fault.


25. A computer program product for condition monitoring of a machine, comprising a nontransitory computer readable storage medium having program code stored therein, the program code comprising computer readable instructions for:

obtaining a first set of data observations corresponding to a first pair of machine condition parameters, the first pair of machine condition parameters comprising two different machine condition parameters; determining a first correlation coefficient corresponding to the first pair of machine condition parameters based on the first set of data observations; determining a first pvalue corresponding to the first pair of machine condition parameters based on the first correlation coefficient; and selecting at least one condition monitoring activity for execution from a plurality of available condition monitoring activities, wherein the selection of the condition monitoring activity is based on; at least the first pvalue; and one or more defined selection rules that are, wherein the selection rule is defined as follows; in response to (i) the first pair of machine condition parameters including a related pair of variables and (ii) the first pvalue being greater than a first predetermined pvalue limit, or In response to (iii) the first pair of machine condition parameters comprising an uncorrelated pair of variables and (iv) the first pvalue being less than or equal to a first predetermined pvalue limit, the selected condition monitoring behavior is a condition monitoring behavior configured to be executed in response to a detected fault condition.

Specification(s)