Abstract: An apparatus and method for machine data collection includes a hand-held personal computer (HPC) having route-based machine information data stored therein, and at least one hand-held sensor unit which includes a sensor for sensing an operating characteristic of the machine. The sensor unit includes a microcomputer for controlling the overall operation of the sensor unit, and a wireless communications port for wirelessly communicating with the HPC and/or other peripheral device. Wireless communications between the HPC and the sensor unit include uploading route-based machine information and instructions from the HPC to the sensor unit, and downloading collected sensor data from the sensor unit to the HPC. Data may also be manually input to the HPC, including reading from control panels and process gauges. All LCD visually displays information and instructions to the operator, and a set of headphones aurally informs and instructs the operator with regard to data collection.

Abstract: Solid particles combined with a water contaminated oil sample are counted by an optical particle counter. The contaminated oil sample is mixed at a substantially 1:1 ratio with a water masking solvent comprising about one part isopropanol and about three parts toluene. The oil and solvent mixture is passed through a transparent viewing volume between a light source and a light detector for detection and counting of oil suspended solid particles.

Abstract: A system and method for monitoring the operating condition of an electrode dresser for an automated spot welder includes a sensor for sensing an operating characteristic of the dresser. The output produced by the sensor is analyzed by a data acquisition system to determine the operating condition of the dresser. Various types of sensors may be employed including a current sensor which senses current flowing through the dresser motor, a flux sensor which senses leakage flux produced by the dresser motor, and a vibration sensor which senses vibration produced during operation of the dresser. Operating characteristics determined by the data acquisition system include whether the electrode dresser is operational, whether the dresser has been engaged by the electrodes of the welder, the amount of time that the welder electrodes were in dress, and the quality of the dress.

Abstract: Alignment data is analyzed to determine machine condition information that is not necessarily related to alignment. Alignment fixtures provide alignment data to an analyzer that finds a curve of a predetermined type, such as a sine curve, that best fits the data. A confidence factor is calculated indicating the probability that the alignment data corresponds to misalignment. The alignment data is further analyzed to determine a condition, other than misalignment, that contributed to the magnitudes of the alignment data. Preferably, the analyzer is used to check for machine conditions such as looseness in the machine, rubs, and spall defects in a bearing. Preferably, the condition analysis is based on both the confidence factors and curve parameters, such as phase, offset and amplitude of a sine curve. In the condition analysis mode, the analyzer provides both manual and automatic routine for removing selected segments of data to produce trial data sets that are analyzed to determine machine conditions.

Abstract: A portable data collector and analyzer having multiple paths for performing multiple processing functions on a single sensor signal in parallel. The portable data collector has a sensor which creates a sensor signal that represents a measured property of an operating machine. The sensor signal is simultaneously sent to at least two processor channels that are connected in parallel. Each processor is capable of performing different types of signal analysis with varying signal conditioning and sampling rate requirements on the sensor signal independent of the other processor(s). An operator of the parallel processing data collector and analyzer places the single sensor on the area desired to be tested and instructs the parallel processing data collector to begin taking measurements. The parallel processor channels work independently of each other to obtain results corresponding to a number of different tests in approximately the time normally required to perform a single test.

Abstract: 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.

Abstract: An efficient vibration data collection, analysis, and storage system automates the analysis of time waveform data and optimizes use of available memory and minimizes data collection time by parameterizing the time domain vibration waveform produced by a vibration transducer attached to a machine. Various parameters are calculated from the time domain waveform and compared to predetermined thresholds or other criteria representative of possible anomalous conditions within the monitored machine. When one or more anomaly criteria are met, an alarm is generated and the system automatically collects, or stores vibration data, which may include both the time waveform and frequency spectrum. Alternatively, the system may be programmed to conduct further analysis of the vibration data during an alarm condition prior to data storage. Preferably, time waveform data is stored only for machines that are in alarm, and the calculated parameters are stored for each machine regardless of the machine's condition.

Abstract: The disclosed invention senses a machine's vibration spectrum, converts the vibration signal into a frequency-domain vibration spectrum, and analyzes the vibration spectrum to generate a narrowband alarm limit envelope against which the vibration spectrum of a previously uncharacterized machine may be compared. The limit envelope is generated from the test vibration spectrum of the machine which is the subject of the test, thus providing a performance benchmark against which to compare the vibration level of the previously uncharacterized machine. A limit envelope is also generated from a test vibration spectrum which has been designated as a reference or baseline spectrum. Further, a limit envelope is generated based upon a mean spectrum which is generated by combining several test vibration spectra. A limit envelope is also generated based upon mean and standard deviation spectra when a statistically significant number of test spectra are available.

Abstract: A wireless machine monitoring and communication system includes one or more machine monitors which attach to one or more machines to sense a physical characteristic of the machine, such as vibration or temperature, and to produce wireless transmissions corresponding to the sensed characteristic. A command station executes machine status polling in accordance with a time-division communication protocol and processes machine status data obtained during polling to determine the status of the machine. The machine monitor incorporates a wireless transmitter for transmitting at least status information, and the command station incorporates a wireless receiver for receiving monitor transmissions. To conserve power, the machine monitors are turned on only at preprogrammed times in accordance with the time-division communication protocol. Each machine monitor includes a receiver and the command station includes a transmitter to enable the command station to send commands to each machine monitor.

Abstract: A signal processing device for processing a machine vibration signal includes a peak value detector for determining the peak vibration amplitude values during predetermined sample time periods. In one embodiment, the vibration signal is digitally processed prior to receipt by a digital peak value detector. In another embodiment, analog processing and peak value detection of the vibration signal is employed. The peak values are then made available for further processing. In many situations, the peak values will be associated with mechanical faults which will be detected at periodic rates corresponding to the mechanical component defect frequencies without additional signal enhancement. Further enhancement can be acquired by synchronous averaging the peak values with the speed of a rotating element.

Abstract: The operational condition of a machine is evaluated when the machine's vibration spectrum deviates from an acceptable state, where an acceptable state is defined by an alarm limit envelope. The amplitude of individual peaks within the machine's vibration spectrum is compared to the alarm limit envelope, and a deviation severity value characterizing the severity of the machine's deviation from an acceptable state is determined for each deviating peak. The deviation severity value represents the severity of deviation when at least one individual peak within the machine's vibration spectrum exceeds the alarm limit envelope. The deviation severity value is obtained by determining the peak excess magnitude for each vibration peak, where the peak excess magnitude is the amount by which the amplitude of each deviating vibration peak exceeds the alarm limit envelope level. The peak excess magnitude is then normalized by a frequency-dependent normalization factor.

Abstract: A hand held data collector and analyzer achieves superior stability, accuracy and reliability through the use of a fixed frequency anti-aliasing filter and two analog to digital converters, one for high frequency signals and one for low frequency signals. Efficient digital filtering and decimation is achieved by providing specialized hardware filters and decimators and implementing software filters and decimators in a data processor. A true zoom method is employed to take advantage of the filtering and decimation capabilities, and independent digital signal processors operate serially on incoming signals to further reduce demands on the central processing unit. In addition, the RAM system memory is formatted as a pseudo-card to facilitate use of a PCMCIA memory card or the RAM system memory.

Abstract: A plurality of monitoring devices are connected to respective pieces of switchyard equipment and associated with a common communications network. A remote host computer is connected to the network to bidirectionally communicate with each monitoring device. The communications network is the existing power line used for delivering power and control signals to the switchyard equipment. Each monitoring device includes testing and/or monitoring circuitry for testing and/or monitoring one or more conditions of the piece of switchyard equipment and generating condition data therefrom, a storage device for storing the generated data, and a transmitter adapted to transmit the data to the remote location via the power line. The remote host computer receives the data transmitted to the remote location and stores the received data therein in a database format. The monitoring device can request previously sent data from the remote host computer.

Abstract: An apparatus is disclosed consisting of one or more machine monitors which attach to one or more machines to sense a physical characteristic of the machine, such as vibration or temperature, and produce wireless transmissions corresponding to the sensed characteristic, and a command station which receives the transmissions from the machine monitors and processes the information to give an indication of the condition of the machine. The machine monitor incorporates a wireless transmitter to transmit the sensor data, and the command station incorporates a wireless receiver to receive the sensor data. In the preferred embodiment of the invention, the machine monitors are not continuously on, but turn on only at preprogrammed times according to turn-on commands generated by a timer circuit within each machine monitor. In another preferred embodiment, each machine monitor includes a receiver and the command station includes a transmitter to enable the command station to send commands to each machine monitor.

Abstract: 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.

Abstract: 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.

Abstract: A method is provided for evaluating a multiplicity of lubrication quality parameters. For a particular lubrication system, a parameter profile is designated to define all the measurable parameters to be monitored. Each parameter in the profile is assigned to single category respective to WEAR, CHEMISTRY and CONTAMINATION. Parameter values are proportionalized in a finite number of increments between acceptable and unacceptable limits. The worst case parameter of a category is selected to represent that category on a 3-axis, Cartesian graph for placing a data point along the respective category axis. Three data points respective to the three axes are linked with a triangular plane, the area of which is representative of the system quality state.

Abstract: A method for detecting the presence of and removing jams in a chute used for transporting a flowable material includes a jam breaking device which travels within the chute. An acoustic detector detects acoustic signals associated with movement of the material through the chute and compares the acoustic signal to a stored acoustic signature representative of an unjammed chute. If a jam is detected, the jam breaking device is operated for a fixed period of time to attempt to break up the jam. After another fixed period of time, a new acoustic signal is detected and processed to determine whether the jam is still present. If so, the jam breaking device is moved a predetermined distance along the chute and operated again. These steps are repeated as long as each new acoustic signal indicates that the jam is still present.

Abstract: A method of determining the rotational speed of a rotating shaft from machine vibration data. The vibration produced by the shaft is sensed to produce a test vibration signal at an unknown rotational speed of the shaft, which test vibrational signal is converted to a test frequency spectrum. A reference frequency spectrum, corresponding to a known rotational speed of the shaft, is provided, and a stretch factor is determined. The stretch factor provides optimum correlation between the test frequency spectrum and the reference frequency spectrum. The unknown speed of the rotating shaft is calculated using the known speed of the reference frequency spectrum and the stretch factor.

Abstract: A method for nonintrusive detection of anomalies in electric machines. A flux coil is positioned external to the motor to obtain magnetic leakage flux measurements, which are transformed to the frequency domain to obtain a flux spectrum. Asymmetry-producing faults, such as turn-to-turn stator winding shorts, produce changes in the amplitudes of individual frequencies and groups of frequencies within a defined slot pass family of frequencies of the flux spectrum. The measured amplitudes of the slot pass family of frequencies are compared to reference and trend data. Significant changes in the slot pass frequency amplitudes indicate the presence of a machine fault or other anomalous condition. Significant changes are determined by comparing individual amplitudes and groups of amplitudes of the slot pass family of frequencies to an absolute or delta threshold value.