Caterpillar Inc.

Yong Sun

Yanchai Zhang

Xuefei Hu

Zhijun Cai

Zhaoxu Dong

Wenming Zhao

Perry Dwain Converse

Suresh Baddam Reddy

Nathan Stephen Pauli

Maurice J Dust

Eric W Ohlson

Chunhui Pan

Mingang Wang

A detection system for detecting winding faults, such as inter-turn winding faults in the stator and/or rotor of an electrical generator utilizes one or more vibration sensors that can be located on a generator housing. The vibration sensors make mechanical vibration measurements and transmit them to a fault analyzer. The fault analyzer can compare the measured vibrations with a threshold to determine if a winding is occurring. In an embodiment, the fault analyzer can convert the mechanical vibration measurements from the time domain to a frequency domain to facilitate analysis.

System and method for detecting winding faults in a generator

A hydraulic fracturing machine includes a pump failure detection system. The hydraulic fracturing machine includes a hydraulic fracturing pump with a power end and a fluid end. The power end includes a plurality of roller bearings, and the fluid end includes a flow of fluid. A particle sensor coupled to the power end is configured to transmit particle information regarding a quantity of particles in the fluid. A temperature sensor, also coupled to the power end, is configured to transmit temperature information regarding a temperature of the fluid. A vibration sensor coupled to the power end is configured to transmit vibration information regarding a vibration of each of the plurality of roller bearings. An electronic control module analyzes the particle information, the temperature information and the vibration information, and calculates a failure warning level based on the analysis.

Hydraulic fracturing pump health monitor

A system and method for protecting a genset from pole slip is disclosed. The system may comprise a generator, a prime mover and a controller. The generator includes a stator and a rotor. The prime mover is configured to drive rotation of the rotor. The controller may be configured to: determine mechanical status of the generator based on data associated with a translational displacement of the rotor; determine electrical status of the generator based on (a) a load angle or (b) the load angle and a rate of change of the load angle associated with rotation of the rotor in the stator; determine an operating condition of the generator based on fusion of the mechanical status and the electrical status; if the operating condition is a pole-slip-warning, activate an output member to display or emit a warning; and, if the operating condition is a pole-slip, activate a protective action.

Generator pole slip detection

A rig management system is disclosed. The rig management system may be configured to receive vibration data from a set of sensors installed on one or more elements of a hydraulic fracturing rig. The rig management system may be configured to perform a first processing of the vibration data utilizing a moving window technique to identify a possible failure of a set of bearings. The rig management system may be configured to perform a second processing utilizing a set of processing techniques after identifying the possible failure of the set of bearings. The rig management system may be configured to determine that the possible failure is an actual failure based on a result of performing the second processing. The rig management system may be configured to perform an action after determining that the possible failure is the actual failure.

Bearing failure detection in a hydraulic fracturing rig

A system for detecting wear or failure of a genset coupling of a genset power system is provided. The system includes a vibration sensor for measuring vibrations, and an additional sensor for measuring an operating condition. A controller is configured to process operating condition data from the additional sensor using a modeling software to generate simulated data. The controller applies time domain information of at least one of the simulated data and vibration sensor data to the modeling software using a machine learning algorithm, and perform a comparison to identify wear or failure of the coupling, wherein, when performing the comparison, the controller compares at least one of: time domain information of the vibration sensor data to time domain information of the simulated data or frequency domain information of the vibration sensor data to frequency domain information of the simulated data, to identify wear or failure of the coupling.

Growing community of inventors

Dunlap, IL, United States of America

Yong Sun