Patent Grant
11156666
The present disclosure relates to fault detection, and more specifically, to systems and methods for fault detection using energy monitoring.
Commercial buildings are typically filled with critical devices driven by electric motors, such as heating and air conditioning ventilation systems, elevators, pumping systems, etc. Electric motors are susceptible to various types of malfunctions that disrupt building occupants and operations. For example, electric motors include rotor bars with a rotating magnetic field which induces a voltage in the rotor bars as it passes over them. Motors are the key component to many types of machines. For example, building power systems may support three-phase induction motors that run compressors, fans, blowers, elevators, pumps, conveyor belts, turbines, etc.
Related art studies have shown that the average failure rate for time to first failure is about 3.13% for common three-phase induction motors. Different components of a motor have different likelihoods of failure. Given a faulty motor, this is the likelihood of failure for the primary components.
A motor fault does not necessarily mean the motor ceases to work. Motor faults may include inefficient performance or performance that indicate a component of the motor is close to complete failure.
In example implementations, the energy monitors as described herein can automatically detect faults and abnormal performance of electric motors when connected to a power line or power system, thereby eliminating the need for independent monitoring of motors.
The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
The following detailed description provides further details of the figures and example implementations of the present application. Reference numerals and descriptions of redundant elements between figures are omitted for clarity. Terms used throughout the description are provided as examples and are not intended to be limiting. For example, the use of the term “automatic” may involve fully automatic or semi-automatic implementations involving user or administrator control over certain aspects of the implementation, depending on the desired implementation of one of ordinary skill in the art practicing implementations of the present application. Selection can be conducted by a user through a user interface or other input means, or can be implemented through a desired algorithm. Example implementations as described herein can be utilized either singularly or in combination, and the functionality of the example implementations can be implemented through any means according to the desired implementations.
The monitoring of motor faults requires a high resolution spectrum to separate different frequency components. At light load condition, it is quite difficult to distinguish between healthy and faulty rotors because the characteristics of broken rotor bar fault frequencies are very close to fundamental component and their amplitudes are small in comparison. Related art systems are unable to detect a fault and classification of the fault severity under light loads.
A stator winding fault occurs when insulation fails that can create shorts within the stator winding. A rotor bar fault occurs due to fissions or cracking in the rotor bars that can cause the motor to overheat and completely break the rotor bar. In another example, bearing faults occur in electric motors when the bearings become pitted, causing micro shifts inside the internals of the motors. Traditionally, electric motor faults are diagnosed after the motor fails. In the related art, pre-emptive motor fault detection involves sophisticated sensitive sensors attached directly to each motor that gather large amounts of motor specific metrics.
Devices without internal diagnostics system typically require a specialized technician to physically inspect the device to verify a fault and troubleshoot to identify the type of fault or root cause. The information gathered by the sensors and analyzed by the maintenance diagnostic service can reduce the frequency and costs of service trips.
Methods and systems described herein include detection of eccentric loads that indicate a potential motor fault prior to motor failure, for example due to a cracked rotor or pitted ball bearing.
The specific frequencies are functions of the current state of the motor and motor parameters. The system includes a Motor Current Signature Analysis (MCSA) module for detecting and diagnosing device health. The MCSA may be implemented by a computing device, such as computing device 605 illustrated in
In an example implementation, load detection occurs at a central location of a local power system without motor-specific sensors. In an example implementation, sensors are attached to circuits at a breaker panel and power draw data is analyzed to identify separate device signatures from each motor attached to the circuit. In an example implementation, rotor bar faults are detected based on the power draw of a motor.
A data collector system can be coupled to the local power system to monitor aggregate power used at a location (e.g., commercial, industrial, or residential building). In an example implementation, circuit based sensors can collect power usage data at a central location, for example, a distribution board (e.g., panelboard, breaker panel, electric panel, etc.). For example, circuit based sensors can be used at an electric panel, where a single sensor is clamped onto each circuit, and the sensors are daisy-chained together, with a data transmitter to connect to a cloud analyzer system. Circuit based sensors can be used for super-high-frequency disaggregation (e.g., 8 kilohertz). In an example implementation, sensors are clipped onto circuit breakers, networked together and wired into an independent communication interface. Data from the sensors is streamed to cloud-based software for analysis that is coupled with weather and electricity pricing data from utilities or alternative energy resources (e.g., solar cells, on-site batteries, etc.). The system can alert building managers (e.g., users) when the facilities are using large amounts of electricity during high demand and identify devices to mitigate the demand, for example, adjusting heating and cooling systems based on current weather data, utility power pricing, building performance forecasts, etc.
Abnormal or inefficient performance of an electric motor is detectable even if the abnormality does not cause a fault or catastrophic malfunction. For example, the system can detect abnormal performance of a motor that gradually over time or sporadically consumes more power than required for normal operation. In some cases, overconsumption of power can cause components or casings to heat up. Non-catastrophic overheating increases building cooling costs and creates potential secondary dangers, such as harming maintenance staff or starting fires.
A short cycling detector uses an algorithm to detect appliances (e.g., HVAC, air conditioning, refrigerator, etc.) that experience set-point problems (e.g., clogged valves, mis-configurations, etc.). Short cycling malfunctions waste energy, reduce the lifetime of the appliance, and can cause catastrophic failure or secondary damage to buildings (e.g., flooding).
As illustrated, a current is applied to the motor at 505 to cause the motor to rotate. As current is applied to the motor, the current draw spectrum of the motor is measured at 510. The current draw spectrum may be measured by a current sensor placed at a circuit breaker or control box connecting the motor to a power source. In other words, the current sensor may be remotely located from the motor. Additionally, the current sensor may be independent from the motor such that replacement of the sensor does not require access to the motor.
At 515, a determination is made whether the current spectrum measured by the current sensor shows any frequency peaks independent from the current frequency of the power source. If no frequency peaks independent from the current frequency of the power source are detected (NO at 515), the motor is determined to not have any faults currently at 520. The sensor may continue to measure a current draw spectrum of the motor over time at 530 and any new frequency peaks that may be detected over time are correlated as indicative of developing faults within the motor 535. If faults have developed, potential corrective action such as maintenance, repair or replacement may be taken at 540.
Conversely, returning to the determination of 515, if any frequency peaks independent from the current frequency of the power source are detected (YES at 515), the frequency peaks independent from the current frequency of the power source are correlated with motor faults at 525. If motor faults are detected, potential corrective action such as maintenance, repair or replacement may be taken at 540.
Thus, the system detects the electric motor performance based on the currents going through to the motor. In response to detecting a potential motor fault or abnormal performance, the system can alert a building operator to the location of the electric motor, provide detailed historical performance reports, forecast the likelihood of a catastrophic motor malfunction, a fault type, and a response strategy.
The response strategy can alert the building manager to take action, for example, place the device into a safe-mode, switch to a back-up device, and/or schedule a specialist to inspect and repair the device. To assist with diagnostic and repair of a device, the system provides the user (e.g., building manager) a detailed report with information including graphical depictions of the historical electric signal that can be forwarded to a repair vendor or specialist.
The detailed information collected by the system provides the repair vendor with diagnostic information that might not be otherwise available directly from the device or motor. Based on the history of how quickly the fault frequency develops, fault likelihood and lifetime performance hours can be used as a countdown to a fault or need for maintenance. In an example implementation, the report can include a severity rating relative to the other motors that are being monitored on that site or based on similarly tracked devices at other locations.
Further, when multiple devices of the same type are monitored, the performance of each common device can be analyzed relative to the other common devices to provide a health assessment and forecast or prioritize maintenance needs. The system can determine a predicted time to failure and include an estimated remaining life of the motor.
For example, the system monitoring a building with multiple elevator devices that each includes electric motors can track the performance of each motor that is compared to the other elevator devices and assess the likelihood of faults in the electric motors to improve pattern detection for faults and prioritize maintenance among the multiple elevator devices. In some example implementations, the system may build a statistical model using data from motors with similar characteristics, for example an induction motor with the same number of poles and slots, etc. For example, based on previously observed total faults, the system determines an estimate of the time until the developed fault becomes a total fault, for example, if part of a motor is slipping or beginning to crack. Accordingly, a building with a single elevator system can be compared to other similar elevator systems in order to provide comparative metrics.
The system collects detailed performance data to develop diagnostics (e.g., a phase of the motor that malfunctioned) that can be sent to an electrician, vendor, manufacturer, insurance company, etc. The system enables gathering performance metrics for electric motors in devices that are otherwise not connected with the need for independent real-time monitoring systems for each device. For example, the system providing the motor's RPM data and number of rotor bar slots can verify a fault occurred and reduce onsite diagnostic time by the repair vendor.
Additionally, device vendors can use the historical performance of the devices for future improvements or upgrades based on actual performance data without each device vendor having to support independent real-time monitoring systems. For example, fault frequencies can be tracked with the device performance data, rather than being tracked independently by a vendor's repair visit database.
Some portions of the detailed description are presented in terms of algorithms and symbolic representations of operations within a computer. These algorithmic descriptions and symbolic representations are the means used by those skilled in the data processing arts to convey the essence of their innovations to others skilled in the art. An algorithm is a series of defined steps leading to a desired end state or result. In example implementations, the steps carried out require physical manipulations of tangible quantities for achieving a tangible result.
Computing device 605 can be communicatively coupled to input/interface 635 and output device/interface 640. Either one or both of input/interface 635 and output device/interface 640 can be a wired or wireless interface and can be detachable. Input/interface 635 may include any device, component, sensor, or interface, physical or virtual, which can be used to provide input (e.g., buttons, touch-screen interface, keyboard, a pointing/cursor control, microphone, camera, braille, motion sensor, optical reader, and/or the like).
Output device/interface 640 may include a display, television, monitor, printer, speaker, braille, or the like. In some example implementations, input/interface 635 (e.g., user interface) and output device/interface 640 can be embedded with, or physically coupled to, the computing device 605. In other example implementations, other computing devices may function as, or provide the functions of, an input/interface 635 and output device/interface 640 for a computing device 605. These elements may include, but are not limited to, well-known AR hardware inputs so as to permit a user to interact with an AR environment.
Examples of computing device 605 may include, but are not limited to, highly mobile devices (e.g., smartphones, devices in vehicles and other machines, devices carried by humans and animals, and the like), mobile devices (e.g., tablets, notebooks, laptops, personal computers, portable televisions, radios, and the like), and devices not designed for mobility (e.g., desktop computers, server devices, other computers, information kiosks, televisions with one or more processors embedded therein and/or coupled thereto, radios, and the like).
Computing device 605 can be communicatively coupled (e.g., via I/O interface 625) to external storage 645 and network 650 for communicating with any number of networked components, devices, and systems, including one or more computing devices of the same or different configuration. Computing device 605 or any connected computing device can be functioning as, providing services of, or referred to as a server, client, thin server, general machine, special-purpose machine, or another label.
I/O interface 625 can include, but is not limited to, wired and/or wireless interfaces using any communication or I/O protocols or standards (e.g., Ethernet, 802.11xs, Universal System Bus, WiMAX, modem, a cellular network protocol, and the like) for communicating information to and/or from at least all the connected components, devices, and networks in computing environment 600. Network 650 can be any network or combination of networks (e.g., the Internet, local area network, wide area network, a telephonic network, a cellular network, satellite network, and the like).
Computing device 605 can use and/or communicate using computer-usable or computer-readable media, including transitory media and non-transitory media. Transitory media includes transmission media (e.g., metal cables, fiber optics), signals, carrier waves, and the like. Non-transitory media includes magnetic media (e.g., disks and tapes), optical media (e.g., CD ROM, digital video disks, Blu-ray disks), solid state media (e.g., RAM, ROM, flash memory, solid-state storage), and other non-volatile storage or memory.
Computing device 605 can be used to implement techniques, methods, applications, processes, or computer-executable instructions in some example computing environments. Computer-executable instructions can be retrieved from transitory media, and stored on and retrieved from non-transitory media. The executable instructions can originate from one or more of any programming, scripting, and machine languages (e.g., C, C++, C#, Java, Visual Basic, Python, Perl, JavaScript, and others).
Processor(s) 610 can execute under any operating system (OS) (not shown), in a native or virtual environment. One or more applications can be deployed that include logic unit 655, application programming interface (API) unit 660, input unit 665, output unit 670, current spectrum collector unit 675, current spectrum analyzer unit 680 and fault correlator unit 685, and inter-unit communication mechanism 695 for the different units to communicate with each other, with the OS, and with other applications (not shown).
For example, current spectrum collector unit 675, current spectrum analyzer unit 680 and fault correlator unit 685 may implement one or more processes shown in
In some example implementations, when information or an execution instruction is received by API unit 660, it may be communicated to one or more other units (e.g., current spectrum collector unit 675, current spectrum analyzer unit 680 and fault correlator unit 685). For example, the current spectrum collector unit 675 may collect current data associated with one or more motors from current sensors associated with the power supplied to the motor and provide the collected data to the current spectrum analyzer. Further, the current spectrum analyzer unit 680 may analyze the data from the current spectrum collector unit 675 to identify frequency peaks that are independent of the drive frequency of the power source and provide the identified peaks to the fault correlator unit 685. Further, the fault correlator unit 685 may identify motor faults based on the identified peaks and generate a UI identifying the fault and provide response options to a user via an output unit.
As disclosed above, in the local power system 604, a data collection sensor 602 (e.g., one of the data collection sensors in a data collector) is coupled to a motor 601 via the local power system 604. A circuit breaker 603, where the data collection sensor 602 may be physically attached to perform the monitoring, may be electrically coupled with the motor 601 via the local power system 604.
In some instances, the logic unit 655 may be configured to control the information flow among the units and direct the services provided by API unit 660, input unit 665, current spectrum collector unit 675, current spectrum analyzer unit 680 and fault correlator unit 685 in some example implementations described above. For example, the flow of one or more processes or implementations may be controlled by logic unit 655 alone or in conjunction with API unit 660.
Although a few example implementations have been shown and described, these example implementations are provided to convey the subject matter described herein to people who are familiar with this field. It should be understood that the subject matter described herein may be implemented in various forms without being limited to the described example implementations. The subject matter described herein can be practiced without those specifically defined or described matters or with other or different elements or matters not described. It will be appreciated by those familiar with this field that changes may be made in these example implementations without departing from the subject matter described herein as defined in the appended claims and their equivalents.
Unless specifically stated otherwise, as apparent from the discussion, it is appreciated that throughout the description, discussions utilizing terms such as “processing,” “computing,” “calculating,” “determining,” “displaying,” or the like, can include the actions and processes of a computer system or other information processing device that manipulates and transforms data represented as physical (electronic) quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system's memories or registers or other information storage, transmission or display devices.
Example implementations may also relate to an apparatus for performing the operations herein. This apparatus may be specially constructed for the required purposes, or it may include one or more general-purpose computers selectively activated or reconfigured by one or more computer programs. Such computer programs may be stored in a computer readable medium, such as a computer-readable storage medium or a computer-readable signal medium. A computer-readable storage medium may involve tangible mediums such as, but not limited to, optical disks, magnetic disks, read-only memories, random access memories, solid state devices and drives, or any other types of tangible or non-transitory media suitable for storing electronic information. A computer readable signal medium may include mediums such as carrier waves. The algorithms and displays presented herein are not inherently related to any particular computer or other apparatus. Computer programs can involve pure software implementations that involve instructions that perform the operations of the desired implementation.
Various general-purpose systems may be used with programs and modules in accordance with the examples herein, or it may prove convenient to construct a more specialized apparatus to perform desired method steps. In addition, the example implementations are not described with reference to any particular programming language. It can be appreciated that a variety of programming languages may be used to implement the teachings of the example implementations as described herein. The instructions of the programming language(s) may be executed by one or more processing devices, e.g., central processing units (CPUs), processors, or controllers.
As is known in the art, the operations described above can be performed by hardware, software, or some combination of software and hardware. Various aspects of the example implementations may be implemented using circuits and logic devices (hardware), while other aspects may be implemented using instructions stored on a machine-readable medium (software), which if executed by a processor, would cause the processor to perform a method to carry out implementations of the present application. Further, some example implementations of the present application may be performed solely in hardware, whereas other example implementations may be performed solely in software. Moreover, the various functions described can be performed in a single unit, or can be spread across a number of components in any number of ways. When performed by software, the methods may be executed by a processor, such as a general purpose computer, based on instructions stored on a computer-readable medium. If desired, the instructions can be stored on the medium in a compressed and/or encrypted format.
Moreover, other implementations of the present application may be apparent to those skilled in the art, from consideration of the specification and practice of the teachings of the present application. Various aspects and/or components of the described example implementations may be used singly or in any combination. It is intended that the specification and example implementations be considered as examples only, with the true scope and spirit of the present application being indicated by the following claims.
This application claims benefit of priority from Provisional U.S. Patent application Ser. No. 62/543,165, filed Aug. 9, 2017, the contents of which are incorporated by reference.
| Number | Name | Date | Kind |
|---|---|---|---|
| 4965513 | Haynes | Oct 1990 | A |
| 5049815 | Kliman | Sep 1991 | A |
| 5345158 | Kliman | Sep 1994 | A |
| 6590362 | Parlos | Jul 2003 | B2 |
| 7539549 | Discenzo | May 2009 | B1 |
| 9453869 | Parkin | Sep 2016 | B1 |
| 20090109021 | Paoletti | Apr 2009 | A1 |
| 20100169030 | Parlos | Jul 2010 | A1 |
| 20100293397 | Pham | Nov 2010 | A1 |
| 20140266755 | Arensmeier | Sep 2014 | A1 |
| 20150260794 | Athikessavan | Sep 2015 | A1 |
| Number | Date | Country | |
|---|---|---|---|
| 20200348363 A1 | Nov 2020 | US |
| Number | Date | Country | |
|---|---|---|---|
| 62543165 | Aug 2017 | US |
