Csi Technology, Inc.

Eugene F Pardue

Ronald G Canada

James C Robinson

Paul Z Wolfensberger

William E Childress

David M Smith

A monitor attaches to a machine or proximate a machine to determine the health and operating status of the machine. The monitor is preferably self-contained, having its own internal power source, electronics, and sensor suite. One or more sensors are provided to sense machine operating characteristics such as temperature, flux, and vibration. Sensor outputs are processed and analyzed by monitor electronics to determine various operating parameters, including machine speed and load, and to determine when an anomalous machine operating condition is present. Monitor electronics are operable to transform time domain data generated by the sensors to frequency domain data for storage and/or analysis. A communications port enables a peripheral device, such as a notebook computer or portable data collector, to communicate with the monitor and download stored data. Downloaded data can be further analyzed and statistically compared to trend data at a base computer to further ascertain the health and condition of the machine.

Machine monitor with status indicator

A monitor attaches to a mount proximate a machine to determine the health operating history and operating status of the machine. The monitor is preferably self-contained, having its own internal power source, electronics, and sensor suite. If desired, the monitor may be powered by an external power source. One or more internal sensors disposed in the monitor are provided to sense machine operating parameters such as temperature, flux, and vibration. External sensors tethered to the monitor may be positioned at varying points on and/or in the machine. Monitor electronics process sensor outputs to determine machine operating parameters such as machine speed and load. Monitor electronics are also operable to transform time domain data generated by the sensors to frequency domain data. A communications port enables a peripheral device, such as a notebook computer or a computer network, to communicate with the monitor and download stored data. Downloaded data can be further analyzed and statistically compared with trend data at a base computer to further ascertain the health and condition of the machine.

Machine monitor with tethered sensors

Power saving features are employed in a machine monitor to reduce electrical power consumption and increase the life of an electrical power source (such as a battery) which is used to power the monitor. The monitor includes a microcomputer having a high operating speed and a low operating speed. Power consumption is reduced by placing the microprocessor in a low-power sleep mode when full power capabilities of the microprocessor are not needed. Power consumption is further reduced by operating the microprocessor at the low operating speed when a high operating speed is not needed. The monitor also includes a communications port in electrical communication with the microcomputer for communicating with a peripheral device, and sensors for sensing machine characteristics such as speed, temperature, flux, or vibration. Power switches are employed to remove electrical power from portions of the monitor electronics that are not being used or are not needed, and a DC/DC converter maximizes the amount of electrical power available for use by the monitor electronics. Power consumption is further reduced by the manner in which the monitor processes vibration signals to compute machine speed.

Method and apparatus for reducing electrical power consumption in a

A programmable apparatus is used to determine the running speed of an ac induction motor based on vibration and flux measurements. A first analysis is performed on at least one of the vibration and flux signals according to a first criterion to determine candidate speeds and whether speed will be determined based on the first analysis or whether a second analysis is required. A second analysis is selectively performed if required by the first analysis. In the first analysis, vibration signals (for example) are transformed to the frequency domain, such as by Fast Fourier Transform, and vibration amplitude peaks contained in the resulting spectrum are analyzed to identify candidate peaks. If only one candidate peak is identified, the frequency at which the candidate peak occurs is used to determine motor running speed. If two or more candidate peaks are identified and the motor is a two-pole motor, the candidate peak having the maximum amplitude is used to determine running speed. If two or more candidate peaks are identified and the motor has more than two poles, a second analysis is performed by producing a flux spectrum. Peaks at various frequencies within the flux spectrum are compared to the candidate peaks and each candidate peak is scored based on the comparison. The scores are compared to a predetermined score threshold to determine which candidate peak will be used to determine motor running speed. Preferably, each candidate peak is also subjected to testing to determine whether the candidate peak accurately represents the frequency at which the true peak occurs.

Method and apparatus for determining electric motor speed using

A machine monitor provides information for ascertaining the health and condition of a machine. The monitor is self-contained, having its own internal power source, electronics, and sensor suite, and attaches directly to the outer frame of the machine. Sensors disposed within the monitor include a machine frame temperature sensor, flux sensor, vibration sensor, and clock. Electronics are also disposed within the monitor for receiving and processing sensor outputs, producing machine status data which is stored over time. Sensors and electronics are housed in a protective bucket which includes an upper housing element joined with a lower housing element. The monitor is attached to the machine in such a way that an engagement surface formed in the monitor establishes sensory contact with the machine, enabling machine sensors disposed in the monitor to sense the machine characteristics. A communications port enables a peripheral device, such as a notebook computer or portable data collector, to communicate with the monitor and download data stored in memory. Downloaded data can be further analyzed and statistically compared to trend data at a base computer to ascertain the health and condition of the machine. The monitor electronics are configured to consume very little power so that the internal power source will continue to power the monitor for extended periods of time.

Structural enclosure for machine sensors

A monitor attaches to a mount proximate a machine to determine the health and operating status of the machine. The monitor is preferably self-contained, having its own internal power source, electronics, and sensor suite. One or more sensors are provided to sense machine operating characteristics such as temperature, flux, and vibration. Sensor outputs are processed and analyzed by monitor electronics to determine various operating parameters, including machine speed and load, which are stored in memory. Other parameters which can be calculated and stored include cumulative time of machine operation for different categories of loads, cumulative time of machine operation over a predetermined maximum temperature, and total number of machine starts. Monitor electronics are also operable to transform time domain data generated by the sensors to frequency domain data. A communications port enables a peripheral device, such as a notebook computer or portable data collector, to communicate with the monitor and download stored data. Downloaded data can be further analyzed and statistically compared to trend data at a base computer to further ascertain the health and condition of the machine. For purposes of prolonging the life of the internal power source, the monitor electronics are configured to consume very little power.

Machine monitor

An ac machine monitor, particularly applicable to ac induction motors, provides information for ascertaining the health and condition of the motor. The monitor is self-contained, having its own internal power source, electronics, and sensor suite, and attaches directly to the outer frame of the motor. Sensors disposed within the monitor include a motor frame temperature sensor, flux sensor, vibration sensor, and clock. The flux sensor includes a substantially planar substrate onto which a conductive trace is attached as the flux sensing element. Sensor outputs are processed and analyzed by monitor electronics to determine various life history parameters, including motor speed and load, which are stored in electronic memory. A communications port enables a peripheral device, such as a notebook computer or portable data collector, to communicate with the monitor and download the life history parameters stored in memory. Downloaded data can be further analyzed and statistically compared to trend data at a base computer to ascertain the health and condition of the motor. The monitor electronics are configured to consume very little power so that the internal power source will continue to power the monitor for several years.

Flux detector system

An ac machine monitor, particularly applicable to ac induction motors, provides information for ascertaining the health and condition of the motor. The monitor is self-contained, having its own internal power source, electronics, and sensor suite, and attaches directly to the outer frame of the motor. Sensors disposed within the monitor include a motor frame temperature sensor, flux sensor, vibration sensor, and clock. An ambient temperature sensor enables determination of motor frame temperature relative to ambient. Sensor outputs are processed and analyzed by monitor electronics to determine various life history parameters, including motor speed and load, which are stored in electronic memory. A communications port enables a peripheral device, such as a notebook computer or portable data collector, to communicate with the monitor and download the life history parameters stored in memory. Downloaded data can be further analyzed and statistically compared to trend data at a base computer to ascertain the health and condition of the motor. The monitor electronics are configured to consume very little power so that the internal power source will continue to power the monitor for several years.

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Lenoir City, TN, United States of America

Eugene F Pardue