Patent Application
20210041327
The present disclosure relates to a system and method for acquiring vibration-related information associated with operation of a rotary machine, and more particularly, to a portable system and method for acquiring vibration-related information associated with operation of a rotary machine.
Early detection of a mechanical problem with a machine may reduce the likelihood, or prevent, more significant and/or more costly damage to the machine. For example, failure of a particular component of a machine may result in damage to additional components of the machine. Thus, if a problem with the particular component is identified prior to its failure, it may reduce or prevent damage to the additional components of the machine, thereby reducing down time and/or repair costs. Moreover, for the purpose of identifying potential problems before component failure occurs, it may be necessary for inspection of the machine at a service location remote from where the machine is being used. However, it may not be practical, or it may be costly and time consuming, for some types of machines to be transported to a service location remote from a location where the machine is being used. For example, when the machine is large or must be placed on a trailer or cargo carrier to be transported to a service location for evaluation of the condition of the machine, it may be prohibitively costly or time consuming to do so. As a result, it may be desirable to develop a way to evaluate operation of a machine to identify potential problems with the machine prior to failure of major components of the machine, and in addition, to make such evaluations at the location at which the machine is being operated.
An attempt to provide a portable data acquisition system is described in U.S. Patent Application Publication No. US 2005/0262221 A1 to Daniels et al. (“the '221 publication”), published Nov. 24, 2005. Specifically, the '221 publication describes a compact data acquisition unit modularly assembled from commercial-off-the-shelf components. According to the '221 publication, inside a casing, a DC-to-DC converter increases battery-generated DC voltage for a computer processor that communicates with storage/memory and collects sensory information via an analogue-to-digital converter. The data acquisition unit can be implemented with sensory instrumentation. A device, remotely placed, that includes a data acquisition unit, one or more sensors, and a pod containing the unit and the one or more sensors, may be communicated with wirelessly.
Although the '221 publication purports to describe a data acquisition system including one or more sensors, the '221 publication does not describe a system and method for identifying potential or actual problems associated with rotary machines or a portable system and method for acquiring vibration-related information associated with operation of a rotary machine. The systems and methods disclosed herein may be directed to addressing one or more of the possible concerns set forth above.
According to a first aspect, a system for acquiring vibration-related information associated with operation of a rotary machine may include a portable case configured to contain therein, and facilitate access to, components of the system. The system may include a first sensor configured to be detachably coupled to a rotary machine and generate a first signal indicative of vibrations related to operation of the rotary machine. The system may further include a supervisor module in communication with the first sensor and configured to receive the first signal indicative of vibrations related to operation of the rotary machine, and generate a first acceleration signal based at least in part on the first signal indicative of vibrations related to operation of the rotary machine. The system may also include a second sensor configured to be detachably coupled to the rotary machine and generate a second signal indicative of vibrations related to operation of the rotary machine. The system may also include a first subordinate module in communication with the supervisor module and the second sensor. The first subordinate module may also be configured to receive the second signal indicative of vibrations related to operation of the rotary machine and generate a second acceleration signal based at least in part on the second signal indicative of vibrations related to operation of the rotary machine. The system may further include a third sensor configured to be detachably coupled to the rotary machine and generate a third signal indicative of vibrations related to operation of the rotary machine. The system may further include a second subordinate module in communication with the supervisor module and the third sensor and configured to receive the third signal indicative of vibrations related to operation of the rotary machine. The second subordinate module may also be configured to generate a third acceleration signal based at least in part on the third signal indicative of vibrations related to operation of the rotary machine. The system may also include an output device in communication with the supervisor module. The supervisor module may be configured to provide operation instructions to the first subordinate module and to the second subordinate module. The supervisor module may also be configured to receive the second acceleration signal from the first subordinate module and the third acceleration signal from the second subordinate module, and communicate image data indicative of the first acceleration signal, the second acceleration signal, and the third acceleration signal to the output device.
According to a further aspect, a system for acquiring vibration-related information associated with operation of a rotary machine may include a case configured to contain therein, and facilitate access to, components of the system. The system may also include a sensor configured to be detachably coupled to a rotary machine and generate a signal indicative of vibrations related to operation of the rotary machine. The system may also include a supervisor module in communication with the sensor and configured to receive the signal indicative of vibrations related to operation of the rotary machine. The supervisor module may also be configured to generate a first acceleration signal based at least in part on the signal indicative of vibrations related to operation of the rotary machine. The system may also include a subordinate module in communication with the supervisor module and the sensor and configured to receive the signal indicative of vibrations related to operation of the rotary machine. The subordinate module may also be configured to generate a second acceleration signal based at least in part on the signal indicative of vibrations related to operation of the rotary machine. The system may also include an output device in communication with the supervisor module. The supervisor module may be configured to provide operation instructions to the subordinate module. The supervisor module may also be configured to receive the second acceleration signal from the subordinate module and communicate image data indicative of the first acceleration signal and the second acceleration signal to the output device.
According to another aspect, a method for acquiring vibration-related information associated with operation of a rotary machine may include opening a portable case containing a supervisor module, a first subordinate module, a second subordinate module, a first sensor, a second sensor, and a third sensor. The method may also include withdrawing the first sensor, the second sensor, and the third sensor from the case, and coupling the first sensor, the second sensor, and the third sensor to a rotary machine. The method may further include receiving by the supervisor module, from the first sensor, a first signal indicative of vibrations related to operation of the rotary machine, receiving by the first subordinate module, from the second sensor, a second signal indicative of vibrations related to operation of the rotary machine, and receiving by the second subordinate module, from the third sensor, a third signal indicative of vibrations related to operation of the rotary machine. The method may also include generating a first acceleration signal, a second acceleration signal, and a third acceleration signal, respectively, via the supervisor module, the first subordinate module, and the second subordinate module. The method may further include displaying, based at least in part on the first acceleration signal, the second acceleration signal, and the third acceleration signal, an image providing at least one of a graphical representation of vibration associated with operation of the rotary machine or a tabular representation of vibration associated with operation of the rotary machine.
The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit of a reference number identifies the figure in which the reference number first appears. The same reference numbers in different figures indicate similar or identical items.
In the example shown in
Although the example system 100 described herein includes one or more sensors configured to generate signals indicative of vibrations related to operation of a rotary machine, it is contemplated that system 100 may include additionally, or alternatively, one or more sensors configured to generate signals indicative of other parameters related to a rotary machine. For example, other types of sensors may be used to identify the one or more components of the rotary machine that are experiencing an approaching and/or existing fault and/or failure. For example, one or more of the sensors may include a sensor configured to generate one or more signals indicative of a sound related to operation of the rotary machine, and the signals indicative of sound may be used to at least assist with identification of components of the rotary machine experiencing an approaching and/or existing fault and/or failure. For example, a sensor configured to generate signals indicative of sound may be used to assist with identifying that a valve of an internal combustion engine is contacting a piston of the internal combustion engine during operation, which may be an indication of a fault with a corresponding valve spring, the valve, and/or the corresponding piston.
In the example shown in
Different numbers of sensors 106 and/or modules 108 are contemplated. For example, some examples of system 100 are scalable to include more sensors 106 and/or modules 108. For example, system 100 may include additional subordinate modules and additional sensors 106 coupled to the additional subordinate modules. In some such examples, the additional subordinate modules may be in communication with supervisor module 118, which may at least partially control operation of one or more of the additional subordinate modules, for example, as described herein. This may permit data acquisition by additional sensors.
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As noted above, supervisor module 118 may be in communication with first subordinate module 122 and/or second subordinate module 128, either directly or indirectly, and supervisor module 118 may be configured to provide operation instructions to first subordinate module 122 and/or second subordinate module 128. For example, as shown in
In some examples, supervisor module 118 may create a data file in a specified folder with the timestamp of the test start to distinguish between tests. In some examples, supervisor module 118 may communicate a version of the program it is executing to first subordinate module 122 and/or second subordinate module 128, which may thereafter execute with parameters according to the standard operation mode and/or as defined by the user in the user-defined operation mode. In some such examples, each of supervisor module 118, first subordinate module 122, and/or second subordinate module 128 may determine vibration-related information (e.g., vibration measured by the one or more sensors), for example, by storing output voltages of the respective sensors and converting the output voltages into acceleration signals (e.g., in the form a fractions and/or multiples of the force due to gravitational pull (“Gs”). In some such examples, data from one or more of (e.g., each of) supervisor module 118, first subordinate module 122, or second subordinate module 128 may be input into an array, and the resulting arrays may thereafter be combined into a single array. Such example arrays may be used and/or manipulated to, for example, calculate and/or display via output device 134 values of interest derived from the original data generated by the one or more sensors. For example, output device 134 may display and/or communicate a single graph including one, two, or three results derived from the sensor signals generated by the one or more sensors as separate plot lines, a table providing, for example, mean, median, and a square-root average of the data, a graph including a single plot line in greater detail, and/or additional information of interest derivable from the sensor data.
In some examples, one or more of supervisor module 118, first subordinate module 122, or second subordinate module 128 may be, or include, any type of microcomputer suitable for performing the operations described herein. For example, supervisor module 118, first subordinate module 122, and/or second subordinate module 128 may be, or include, a small single-board computer, such as, for example, those marketed under the RASPBERRY PI® trademark. Other types of computing devices are contemplated.
In some examples, one or more of supervisor module 118, first subordinate module 122, or second subordinate module 128 may include, and/or be in communication with, a real-time clock configured to maintain an accurate time stamp for the respective supervisor module 118, first subordinate module 122, and/or second subordinate module 128, for example, even when supervisor module 118, first subordinate module 122, and/or second subordinate module 128 is/are not in communication with a network, such as, for example, the internet. In some such examples, the one or more real-time clocks may be included in case 104 and, in some examples, each of the one or more real-time clocks may be electrically coupled to a power source, for example, a battery (e.g., a button battery) for each of the one or more real-time clocks. In some examples, the one or more real-time clocks may be electrically coupled to the one or more power sources, either directly or via, for example, respective data acquisition modules, such as, for example, the data acquisition modules described herein.
One or more of supervisor module 118, first subordinate module 122, or second subordinate module 128 may include one or more processors, which may execute any modules associated with supervisor module 118, first subordinate module 122, and/or second subordinate module 128 to cause supervisor module 118, first subordinate module 122, and/or second subordinate module 128 to perform a variety of functions, as set forth above and explained in further detail herein. In some examples, the processor(s) may include a central processing unit (CPU), a graphics processing unit (GPU), both CPU and GPU, or other processing units or components known in the art. Additionally, each of the processors may possess its own local memory, which also may store program modules, program data, and/or one or more operating systems.
Computer-readable media associated with supervisor module 118, first subordinate module 122, and/or second subordinate module 128 may include volatile memory (e.g., RAM), non-volatile memory (e.g., ROM, flash memory, miniature hard drive, memory card, or the like), or some combination thereof. The computer-readable media may be non-transitory computer-readable media. The computer-readable media may include or be associated with the one or more of the above-noted modules, which perform various operations associated with supervisor module 118, first subordinate module 122, and/or second subordinate module 128. In some examples, one or more of the above-noted modules may include or be associated with computer-executable instructions that are stored by the computer-readable media and that are executable by one or more processors to perform such operations. Supervisor module 118, first subordinate module 122, and/or second subordinate module 128 may also include additional components not listed above that may perform any function associated with supervisor module 118, first subordinate module 122, and/or second subordinate module 128. Supervisor module 118, first subordinate module 122, and/or second subordinate module 128 may communicate with one another using any known wired and/or wireless communication protocols and/or networks.
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In some examples of system 100, system 100 may be configured to facilitate identification of differences between vibration-related data associated with prior-in-time operation of rotary machine 102 and the one or more first acceleration signals, the one or more second acceleration signals, and/or the one or more third acceleration signals. For example, system 100 may be configured to access memory, integrated into system 100 (e.g., contained within case 104) and/or remote from system 100, configured to store vibration-related data associated with prior-in-time operation of rotary machine 102. In some examples, such differences may be an indication of a potential fault, a worsening fault, and/or a failure of one or more components of rotary machine 102. For example, a difference in vibration-related data during operation of rotary machine 102 may be an indication of an impending failure of a bearing, an insufficiency of lubrication and/or cooling in rotary machine 102, a rotating imbalance due, for example, to component wear and/or fracture, and/or a crack in one or more components of rotary machine 102. In examples configured to access memory, the memory may contain data recorded during fault-free operation of rotary machine 102 (e.g., operation according to specification), and thus, differences may be an indication of a potential, impending, and/or actual fault with one or more components of rotary machine 102.
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Other configurations of recesses and/or storage arrangements for components of system 100 are contemplated. In some examples, one or more of the communications cables may be supplemented or replaced with wireless communications, for example, according to known wireless communications protocols.
The example process 800, at 802, may include opening a portable case containing a supervisor module, a first subordinate module, a second subordinate module, a first sensor, a second sensor, and a third sensor. For example, the portable case may be transported via a user to a remote worksite, such as, for example, a construction site or a mining site, at which a rotary machine is present. As explained herein, the case and components may be light enough for a person to carry the case and components, for example, without the assistance of a vehicle. In some examples, one or more batteries may be included in the case. Thus, in some examples, the process 800 may be carried out at a location remote from an external electrical power supply.
At 804, the example process 800 may include withdrawing the first sensor, the second sensor, and the third sensor from the case. For example, the case may be opened to access one or more of the sensors, which may be withdrawn from the case so that they may be used to acquire vibration-related information associated with operation of the rotary machine to which the case has been transported.
The example process 800 may also include, at 806, coupling the first sensor, the second sensor, and the third sensor to a rotary machine. For example, one or more of the first, second, or third sensors may include a housing, and the housing may include a coupling device configured to detachably couple the one or more sensors to the rotary machine (e.g., directly to the rotary machine). For example, the housing(s) of the one or more sensors may include a magnetic coupling device, for example, as described herein, and the one or more sensors may be coupled to the rotary machine via the magnet(s). For example, if the rotary machine is an internal combustion engine, access may be gained to the exterior surface of the internal combustion engine, and one or more of the first, second, or third sensors may be coupled to the exterior surface of the internal combustion engine. In some examples of the process 800, the first, second, and third sensors may be single-axis accelerometers and may be coupled to the rotary machine, such that respective measurement axes of each of the first, second, and third sensors are substantially mutually orthogonal with respect to one another. In some examples, the sensors and/or respective housings may include an arrow identifying the measurement axis of each of the sensors (see, e.g.,
At 808, the example process 800 may include receiving by the supervisor module, from the first sensor, a first signal indicative of vibrations related to operation of the rotary machine. For example, the first sensor may be communicatively coupled to the supervisor module. The first sensor may generate one or more voltage signals corresponding to vibrations of the rotary machine during operation, and the supervisor module may be configured to convert the one or more voltage signals into one or more signals indictive of accelerations corresponding to the vibrations, for example, in an axis substantially aligned with the measurement axis of the first sensor.
The example process 800, at 810, may also include receiving by the first subordinate module, from the second sensor, a second signal indicative of vibrations related to operation of the rotary machine. For example, the second sensor may be communicatively coupled to the first subordinate module. The second sensor may generate one or more voltage signals corresponding to vibrations of the rotary machine during operation, and the first subordinate module may be configured to convert the one or more voltage signals into one or more signals indictive of accelerations corresponding to the vibrations, for example, in an axis substantially aligned with the measurement axis of the second sensor, which may be, in some examples, substantially orthogonal with respect to the measurement axis of the first sensor.
At 812, the example process 800 may further include receiving by the second subordinate module, from the third sensor, a third signal indicative of vibrations related to operation of the rotary machine. For example, the third sensor may be communicatively coupled to the second subordinate module. The third sensor may generate one or more voltage signals corresponding to vibrations of the rotary machine during operation, and the second subordinate module may be configured to convert the one or more voltage signals into one or more signals indictive of accelerations corresponding to the vibrations, for example, in an axis substantially aligned with the measurement axis of the third sensor, which may be, in some examples, substantially orthogonal with respect to the measurement axis/axes of the first sensor and/or the second sensor.
The example process 800, at 814, may also include generating a first acceleration signal, a second acceleration signal, and a third acceleration signal respectively via the supervisor module, the first subordinate module, and the second subordinate module, for example, as described above.
At 816, the example process 800 may also include displaying, based at least in part on the first acceleration signal, the second acceleration signal, and the third acceleration signal, an image providing at least one of a graphical representation of vibration associated with operation of the rotary machine or a tabular representation of vibration associated with operation of the rotary machine. For example, the second acceleration signal and/or the third acceleration signal may be communicated to the supervisor module, and the supervisor module may generate image data for communication to an output device, such as, for example, a display device. The image data may be configured to result in display of a graphical representation of the first, second, and/or third acceleration signals, for example, in a single graph, two graphs, and/or three graphs. In some examples, the image data may be configured to result in display of a tabular representation of the first, second, and/or third acceleration signals, for example, in a single table, two tables, and/or three tables. In some examples, the graphical and/or tabular representations may show magnitude of vibration versus corresponding frequencies of vibration associated with operation of the rotary machine.
In some examples, the process 800 may also include transmitting at least one of the image, the first acceleration signal, the second acceleration signal, or the third acceleration signal to a location remote from the case. For example, the system may include a transmitter configured to transmit the vibration-related related information, via communications cable and/or via wireless communication, to a remote facility such as an on-site maintenance location and/or to a maintenance location and/or service location remote from the worksite, such as a location associated with the manufacturer and/or distributor of the rotary machine.
In some examples, the process 800 may further include identifying differences between vibrational data associated with prior-in-time operation of the rotary machine and the first acceleration signals, the second acceleration signals, and/or the third acceleration signals, for example, as explained herein. In some examples, the process 800 may also include determining that the differences are an indication of a fault associated with the rotary machine, for example, as explained herein. In some examples, identifying the differences may include accessing memory configured to store vibrational data associated with prior-in-time operation of the rotary machine, and identifying differences between the vibrational data associated with prior-in-time operation of the rotary machine and at least one of the first acceleration signals, the second acceleration signals, or the third acceleration signals. This may be performed manually by a human and/or automatically via a system configured to identify such differences, such as one or more computer systems executing software configured to perform such operations.
The exemplary systems and related methods for acquiring vibration-related information associated with operation of a rotary machine may be applicable to a variety of rotary machines, for example, any machine having components that rotate and/or revolve during operation of the rotary machine. For example, the systems and methods may be applicable to internal combustion engines, such as, for example, reciprocating-piston engines and gas turbine engines, electric generators, electric motors, compressors, and pumps. The systems and methods, in some examples, may render is possible to identify one or more potential faults (e.g., rotational imbalance, component fracture, component wear, and/or excessive heat build-up) of one or more components of a rotary machine, for example, as explained herein. Thus, the systems and methods may be used to identify a problem with one or more components of the rotary machine prior to failure, which may reduce or prevent damage to additional components of the rotary machine, thereby potentially reducing down time and/or repair costs associated with repair of the rotary machine. For example, failure of some components of the rotary machine may result in damage to additional, and sometimes more-costly, components. However, identification of problems prior to failure of the component at issue may render it possible to replace and/or repair only the component at issue prior to damage occurring to additional components. In some examples, the systems and methods described herein may be used to acquire vibration-related data that may be used to identify problems before they result in damage to additional components of the rotary machine, for example, as described herein. This may reduce machine down time and costs associated with maintenance and/or repair of the rotary machine.
In addition, or alternatively, the systems and methods described herein, in some examples, may result in a portable system that may be used, for example, without an external electrical power source. For example, some examples of the system may include one or more batteries, for example, as described herein, rendering it possible to use the system in a remote location without the use of an external electrical power source. This may render it possible for use of the system at a remote worksite, such as, for example, a construction worksite or a mining worksite. In some examples, operation of the system may be performed by personnel that have not been trained to use the system, and thus, a customer using a rotary machine may use the system and/or method to identify potential, impending, and/or existing problems with the rotary machine, for example, prior to more costly damage to the rotary machine. This may result in increasing the likelihood that the operator of the rotary machine detects faults with the rotary machine prior to severe damage to the offending component and/or prior to additional components being damaged. In some examples, the systems and methods may render it possible to determine that the rotary machine is operating properly (e.g., according to specification) without unnecessarily expending the time and/or cost associated with transporting the rotary machine to a maintenance or service facility remote from the location at which the rotary machine is being used.
In some examples, the vibration-related information that may be acquired by the systems and methods described herein may be compared to similar data recorded while the rotary machine is operated in a fault-free manner (e.g., according to specification). For example, the similar vibration-related data for the rotary machine, or other rotary machines of the same or similar model, may be stored in a data base for comparison to vibration-related data obtained via some examples of the systems and methods described herein. Differences between the stored vibration-related data may be identified, for example, manually and/or automatically via a computer system, and the differences may be used to determine whether the rotary machine may have a potential or actual fault with one or more of its components.
While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed machines, systems, and methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.
