CONTINUOUS MONITORING SYSTEM OF DYNAMIC EQUIPMENT CONDITION

Abstract

The present invention proposes a system for continuous monitoring of dynamic equipment condition through the use of vibration, temperature and/or acoustic noise sensor modules associated with wireless technology (wireless) or LTE (Long Term Evolution). The system is characterized by having vibration, temperature and/or acoustic noise sensor modules. The sensor modules of the system also have the functionality to measure the sound signature of the machines.

Claims

1- A CONTINUOUS MONITORING SYSTEM OF DYNAMIC EQUIPMENT CONDITION, characterized in that it comprises: software (1), server (2), HUBs (3), sensor modules (4); and wireless or LTE connection.

2- THE SYSTEM according to claim 1, characterized in that the software performs the analyses of the acquired signals and Setup of the HUBs (3) and sensor modules (4).

3- THE SYSTEM according to claim 1, characterized in that the software analyzes the signals acquired by the sensor modules (4).

4- THE SYSTEM according to claims 1 and 3, characterized in that the signals acquired by the sensor modules (4) installed in the dynamic equipment are: vibration, temperature, and sound signature (acoustic rumorosity).

5- THE SYSTEM according to claim 1, characterized in that the sensor modules (4) of the system self-produce at least one third of the energy required for its operation.

6- THE SYSTEM according to claim 1, characterized in that the sensor modules (4) have an autonomy for operation of at least 7 years, without the need of changing the battery.

7- THE SYSTEM according to claim 1, characterized in that the HUBS (3) communicate with the sensor modules (4) and manage the acquisitions.

8- THE SYSTEM according to claim 1, characterized in that the server (2) communicates with the HUBs (3) through three different ways: wireless network (wireless), LTE network, or ethernet cable.

9- THE SYSTEM according to claim 1, characterized in that the HUBs (3) are responsible for managing the acquisition of signals of vibration, temperature and sound signature (acoustic rumorosity) requested by the software (1) through the server (2).

10- THE SYSTEM according to claim 1, characterized in that the sensor modules (4) communicate only with the HUBs (3) through a Zigbee wireless network.

11- THE SYSTEM according to claim 1, characterized in that the sensor modules (4) carry out the measurement and digitization of the acquired signals from a request made by the HUBs (3).

12- THE SYSTEM according to claim 11, characterized in that the information from the sensor modules (4) is transferred to the HUBs (3), which send the signals to the server (2).

13- THE SYSTEM according to claim 12, characterized in that the analyst accesses the measurements performed directly in the software (1).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The present invention will be described in more detail below, with reference to the attached figures which, in a schematic way and not limiting the inventive scope, represent examples of its embodiment. In the drawings, there are:

[0033] FIG. 1 illustrates a continuous condition monitoring system for dynamic equipment and its elements, represented by: software (1), server (2), HUBs (3), sensor modules (4);

[0034] FIG. 2 shows the main parts of the sensor modules, represented by: board A2 (5), board A1 (6), 17,500 lithium battery (SAFT) (7), electromagnetic energy converter (8), board B (9), metal base (10), fixing base (11). Boards A1, A2, and B are electronic boards on which the management/processing central functions, power management and all measurement chains associated with each of the physical quantities that can be monitored with the sensor module (vibration in the three axes X, Y, Z, temperature and sound signature (acoustic rumorosity). The electromagnetic energy converter (8) consists of a mobile block of permanent magnets supported by an elastic suspension and synthetic diamond bearings, which excites a matrix of electromagnetic coils fixed on the main body of the sensor module. The energy produced in the electromagnetic energy converter (8) is managed by board B (9);

[0035] FIG. 3 illustrates the constructive details of the electromagnetic energy converter of the sensor modules and its elements, being represented by: electromagnetic energy converter (8), fixed part (12), wire holder fixing (coils) (13), magnet fixing (14), mobile part (15), coupling of parts (16), components (17), helical spring (18), bearing-1 (19), shaft-1 (20), shaft-2 (21), bearing-2 (22), direction of movement (23). The movement is carried out with the aid of helical springs (18). There are 20 neodymium magnets (14) present (5-mm side cube), 20 coil holders (13), two shafts (shaft-1 responsible for axial movement and shaft-2 responsible for preventing rotation);

[0036] FIG. 4 illustrates the three-dimensional details of the upper electronic boards of the sensors, in which the sensor microphones and their elements are installed, being represented by: microphone access hole (24).

DETAILED DESCRIPTION OF THE INVENTION

[0037] There follows below a detailed description of a preferred embodiment of the present invention, by way of example and in no way limiting. Nevertheless, it will be clear to a technician skilled on the subject, from reading this description, possible additional embodiments of the present invention still comprised by the essential and optional features below.

[0038] The continuous condition monitoring system for dynamic equipment is characterized by comprising the following elements and their functions: [0039] 1—Software—the computer program that performs the analysis of the acquired signals and Setup of the hubs and sensors; [0040] 2—Server—performs communication with hubs and sensors and signal processing codes; [0041] 3—HUBs communicates with sensors and manages acquisitions; [0042] 4—Sensor Modules—perform the acquisition of vibration, temperature and acoustic noise signals.

[0043] FIG. 1 presents a diagram showing the relation between the components of the invention. The software, as in other equipment condition monitoring systems, is the component that automatically manages the data flow (vibration in the three axes X, Y, Z, temperature and sound signature (acoustic rumorosity), and/or other signal) after configuring the acquisition parameters, along the entire path, from the sensor modules, passing through the HUBs to their filing in the database acquired by the system. It is through the software that the equipment tree of the process plant is designed, a tree in which it is specified which equipment is being monitored and in which equipment each sensor module is mounted. It is used to analyze the signals acquired by the sensor modules (vibration, temperature and sound signature (acoustic rumorosity)) from different tools (trend, temporal analysis, spectral response, filtering, windowing, among others), in addition to having several functionalities for the setup of HUBs and sensor modules such as, for example, the registration of HUBs and sensor modules in the context of the industrial plant in application as described above, the inclusion of the sensitivity of the sensors involved and the time between data acquisitions of the physical quantities that can be monitored by the system (vibration in the three axes X, Y, Z, temperature and sound signature (acoustic rumorosity)).

[0044] The software is capable of communicating solely with the server; that is, the entire setup of the HUBs and sensor modules is done by the software through the server, which communicates with the HUBs. It is important to point out that the processing of the signals acquired by the sensors is done on the server. The software can be accessed from any computer (web-based interface), as long as the user has a registered login and password. Thus, when the analyst makes an analysis request, such as filtering a time signal acquired from his computer, a request is sent to the server that performs the process and returns the required information to the computer on which the request was made, such as, for example, a filtered signal. The server has a database with all the acquired signals, in addition to setup information for the HUBs and sensors in the context of the industrial plant being applied. The server can communicate with the HUBs (only) in three different ways: wireless network (wireless), LTE network or ethernet cable. The HUBs are responsible for managing the acquisition of signals of vibration, temperature and acoustic noise requested by the software through the server.

[0045] Finally, the sensors only communicate with the HUBs over a Zigbee wireless network. From a request made by the HUBs, the sensors measure and digitize the acquired signals. This information is then transferred to the HUBs, which then send the signals to the server. From there, the analyst can have access to the measurements performed directly in the software.

[0046] The invention can be used for continuous monitoring of vibration, temperature and acoustic noise of different machines and equipment in various industry segments (oil and gas, nuclear, naval, railway, automotive, food, etc.). It is important to emphasize that the HUBs and sensors of this invention have certification for operation in explosive environments in zone 0 (area where the formation of explosive mixture exists for long periods or is continuous and protection degree IP66 (protected against dust and strong jets of water).

[0047] The system sensors have the functionality of self-production of approximately one third of the energy required for its operation. This is achieved through a process of harvesting energy in which part of the vibrating mechanical energy of the machine on which the sensor is mounted is converted into electrical energy by an electromagnetic energy converter as indicated on the right in FIG. 2, and duly stored by an electrical charge management electronic sub-module (Board B indicated on the right in FIG. 2). The constructive details and main parts of the electromagnetic energy converter of the sensors are shown in FIG. 3.

[0048] The system sensors also have the functionality of measuring the sound signature (acoustic rumorosity) of the monitored machines through the incorporation of a microphone. This functionality enables a significant expansion of diagnostic techniques that can be used to predict the operating condition of the machines monitored by the system. FIG. 4 shows three-dimensional details of the upper electronic boards of the sensors, in which the sensor microphones are installed.

Examples

[0049] The continuous vibration monitoring system has already been applied in two process plants of a large oil industry and allowed the detection of incipient failures in the equipment in which the system was installed. This allowed preventive maintenance interventions whose costs are, on average, 80% lower in relation to the maintenance costs involved when failures evolve into a catastrophic failure.