Abstract: The present invention is directed to a system and method for proactively determining motor wellness arising from potential mechanical faults of the motor. A controller is configured to detect indicia of impending mechanical motor faults. The controller includes a processor configured to determine motor parameters of a given motor including a load and generate a set of baseline data for the given motor. The processor is also configured to acquire current spectrum data from the given motor during operation, map at least one from a plurality of load bins based on the load, and generate a mechanical fault signature from the current spectrum. The processor is caused to compare the mechanical fault signature to baseline data from the set of baseline data corresponding to the mapped bin and determine amplitude variances within the mechanical fault signature indicative of an impending mechanical fault prior to an actual mechanical fault occurrence.

Abstract: An induction motor having a rotor and a stator is protected during running overloads by connecting the motor to an overload protection relay that can be tripped to interrupt power to the motor in the event of an overload, tracking the stator winding temperature of the motor during running overloads with a hybrid thermal model by online adjustment in the hybrid thermal model, and tripping the overload protection relay in response to a predetermined running overload condition represented by the tracked stator winding temperature. In one embodiment of the invention, the stator winding temperature is tracked by use of an online hybrid thermal model that uses the resistance of the rotor as an indicator of rotor temperature and thus of the thermal operating conditions of the motor. The hybrid thermal model incorporates rotor losses and heat transfer between the rotor and the stator, and approximates the thermal characteristics of the rotor and stator.

Abstract: The present invention is directed to a power meter or overload relay including a housing and a plurality of sensors configured to monitor operation of a motor. A processor disposed within the housing and configured to receive operational feedback from the plurality of sensor and proactively determine an operational wellness of the motor from the operational feedback.

Abstract: The present invention is directed to a system and method for proactively determining motor wellness arising from potential mechanical faults of the motor. A controller is configured to detect indicia of impending mechanical motor faults. The controller includes a processor configured to determine motor parameters of a given motor including a load and generate a set of baseline data for the given motor. The processor is also configured to acquire current spectrum data from the given motor during operation, map at least one from a plurality of load bins based on the load, and generate a mechanical fault signature from the current spectrum. The processor is caused to compare the mechanical fault signature to baseline data from the set of baseline data corresponding to the mapped bin and determine amplitude variances within the mechanical fault signature indicative of an impending mechanical fault prior to an actual mechanical fault occurrence.

Abstract: The present invention is directed to a power meter or overload relay including a housing and a plurality of sensors configured to monitor operation of a motor. A processor disposed within the housing and configured to receive operational feedback from the plurality of sensor and proactively determine an operational wellness of the motor from the operational feedback.