SYSTEMS AND METHODS FOR MONITORING AND REMOTELY BALANCING MOTORS

Abstract

Systems and methods for monitoring and remote balancing a motor are disclosed. An exemplary system may include a plurality analog sensors operationally coupled to a motor, an analog switch communicatively coupled to at least one of analog sensors, wherein a first analog sensor input is a trigger channel and a second is an input channel. The analog switch may digitally derive a relative phase between the trigger channel and the input channel using a phase-lock loop (PLL) band-pass tracking filter on at least one of the analog sensor channels to obtain one of slow-speed rotations per minute (RPMs) or phase information for the motor. A response circuit may recommend a change in a process or an operating parameter of the motor to remotely balance the motor based on one or more of the slow-speed RPMs or the phase information.

Claims

1. A remote balancing system, comprising: a plurality of variable groups of analog sensor inputs, each of the plurality of variable groups of analog sensor inputs operationally coupled to a motor, an analog switch comprising a plurality of analog sensor channels, wherein each of the plurality of analog sensor channels is communicatively coupled to at least one of the plurality of variable groups of analog sensor inputs, wherein a first one of the plurality of analog sensor channels comprises a trigger channel and wherein a second one of the plurality of analog sensor channels comprises an input channel; wherein the analog switch comprises an on-board timer, and wherein the analog switch is configured to digitally derive a relative phase between the trigger channel and the input channel in response to the on-board timer, and wherein the analog switch is further configured to use a phase-lock loop (PLL) band-pass tracking filter on at least one of the plurality of analog sensor channels to obtain one of slow-speed rotations per minute (RPMs) or phase information for the motor operatively coupled to at least one of the variable groups of analog sensor inputs; and a response circuit that recommends a change in a process or an operating parameter of the motor to remotely balance the motor based on one or more of the slow-speed RPMs or the phase information.

2. The remote balancing system of claim 1, wherein at least one of the plurality of analog sensor channels is operationally coupled to an analog-to-digital (A/D) converter, and wherein the analog switch is further configured to auto-scale the A/D converter for peak detection on the at least one of the plurality of analog sensor channels.

3. The remote balancing system of claim 1, wherein at least one of the plurality of analog sensor channels is operationally coupled to a delta-sigma analog-to-digital (A/D) converter, and wherein the analog switch is further configured to use higher input oversampling to reduce anti-aliasing filter requirements for the delta-sigma A/D converter.

4. The remote balancing system of claim 1, wherein at least one of the plurality of analog sensor channels is operationally coupled to a delta-sigma analog-to-digital (A/D) converter, and wherein the analog switch is further configured to use a complex programmable logic device (CPLD) as a clock-divider for the delta-sigma A/D converter to achieve a lower sampling rate without digital resampling.

5. The remote balancing system of claim 1, wherein the response circuit is further structured to perform the at least one operation in response to a change in a frequency or a relative phase difference of at least one of the plurality of analog sensor channels.

6. The remote balancing system of claim 5, wherein the response circuit is further structured to provide an alert in response to the relative phase difference.

7. A remote balancing system, comprising: a plurality of variable groups of industrial sensor inputs, each of the plurality of variable groups of industrial sensor inputs operationally coupled to a motor, a multiplexer comprising a plurality of sensor channels, wherein each of the plurality of sensor channels is communicatively coupled to at least one of the plurality of variable groups of industrial sensor inputs, wherein a first one of the plurality of sensor channels comprises a trigger channel and wherein a second one of the plurality of sensor channels comprises an input channel, wherein the multiplexer comprises an on-board timer, and wherein the multiplexer is configured to digitally derive a relative phase between the trigger channel and the input channel in response to the on-board timer, and wherein the multiplexer is further configured to use a phase-lock loop (PLL) band-pass tracking filter on at least one of the plurality of sensor channels to obtain one of slow-speed rotations per minute (RPMs) or phase information for the motor operatively coupled to at least one of the variable groups of industrial sensor inputs; and a response circuit that recommends a change in a process or an operating parameter of the motor to remotely balance the motor based on one or more of the slow-speed RPMs or the phase information.

8. The remote balancing system of claim 7, wherein at least one of the plurality of sensor channels is operationally coupled to an analog-to-digital (A/D) converter, and wherein the multiplexer is further configured to auto-scale the A/D converter for peak detection on the at least one of the plurality of sensor channels.

9. The remote balancing system of claim 7, wherein at least one of the plurality of sensor channels is operationally coupled to a delta-sigma analog-to-digital (A/D) converter, and wherein the multiplexer is further configured to use higher input oversampling to reduce anti-aliasing filter requirements for the delta-sigma A/D converter.

10. The remote balancing system of claim 7, wherein at least one of the plurality of sensor channels is operationally coupled to a delta-sigma analog-to-digital (A/D) converter, and wherein the multiplexer is further configured to use a complex programmable logic device (CPLD) as a clock-divider for the delta-sigma A/D converter to achieve a lower sampling rate without digital resampling.

11. A method for monitoring a motor, the method comprising: interpreting a plurality of detection values, each of the plurality of detection values corresponding to at least one of a plurality of input sensors operationally coupled to the motor, generating at least one timing signal; determining a relative phase difference between at least one of the plurality of detection values and at least one of the timing signals; and performing at least one operation in response to the relative phase difference.

12. The method of claim 11, further comprising providing an alert in response to the relative phase difference.

13. The method of claim 11, further comprising enabling or disabling processing of at least one of the detection values.

14. A monitoring system for a motor, the system comprising: an industrial system comprising a motor, a data acquisition circuit structured to interpret a plurality of detection values, each of the plurality of detection values corresponding to at least one of a plurality of input sensors operationally coupled to the motor and communicatively coupled to the data acquisition circuit; a signal evaluation circuit comprising: a timer circuit structured to generate at least one timing signal; a phase detection circuit structured to determine a relative phase difference between at least one of the plurality of detection values and at least one of the timing signals from the timer circuit; and a response circuit structured to perform at least one operation in response to the relative phase difference.

15. The system of claim 14, wherein the response circuit is further structured to perform the at least one operation in response to a change in frequency or a relative phase of at least one of the plurality of detection values.

16. The system of claim 15, wherein the signal evaluation circuit is further structured to utilize a phase lock loop (PLL) to determine the change in the frequency or the relative phase of the at least one of the plurality of detection values.

17. The system of claim 16, wherein the signal evaluation circuit is further structured to utilize a band pass filter to determine the change in the frequency or the relative phase of the at least one of the plurality of detection values.

18. The system of claim 16, further comprising a multiplexor comprising a plurality of sensor channels, wherein each of the plurality of sensor channels is communicatively coupled to at least one of the plurality of input sensors, wherein a first one of the plurality of sensor channels comprises a trigger channel and wherein a second one of the plurality of sensor channels comprises an input channel.

19. The system of claim 18, wherein at least one of the plurality of sensor channels is operationally coupled to an analog-to-digital (A/D) converter, and wherein the multiplexor is further configured to auto-scale the A/D converter for peak detection on the at least one of the plurality of sensor channels.

20. The system of claim 18, wherein at least one of the plurality of sensor channels is operationally coupled to a delta-sigma analog-to-digital (A/D) converter, and wherein the multiplexor is further configured to use higher input oversampling to reduce anti-aliasing filter requirements for the delta-sigma A/D converter.

21. The system of claim 18, wherein at least one of the plurality of sensor channels is operationally coupled to a delta-sigma analog-to-digital (A/D) converter, and wherein the multiplexor is further configured to use a complex programmable logic device (CPLD) as a clock-divider for the delta-sigma A/D converter to achieve a lower sampling rate without digital resampling.