AU2015201481B2

AU2015201481B2 - Interactive control and monitoring of machinery including a flame proof alternator

Info

Publication number: AU2015201481B2
Application number: AU2015201481A
Authority: AU
Inventors: Giuliano Res
Original assignee: Individual
Current assignee: Individual
Priority date: 2014-03-20
Filing date: 2015-03-20
Publication date: 2021-03-18
Anticipated expiration: 2035-03-20
Also published as: AU2015201481A1; ZA201501924B

Abstract

An interactive control system which enables an operator to monitor and control performance parameters of a machine which includes an alternator, the control system comprising a machine controller, a software module, associated firmware and a microcontroller; a communications interface which connects the microcontroller to the machine controller which includes an operator console; wherein the software module communicates with the machine controller and provides a visual output at the operator console reporting on the status and history of the machine's power system as detected by the alternator and also allows command data input from an operator. 1 1 Machine 20 Operator's Alternatorcosl 14 Microcontroller - Firmware , 12 Software Machine Module Control System 10 16 18 19 Figure 1 1

Description

1 Machine

20 Operator's

Alternatorcosl

14 Microcontroller

- Firmware

, 12 Software Machine Module Control System

16 18

19

Figure 1

INTERACTIVE CONTROL AND MONITORING OF MACHINERY INCLUDING A FLAME PROOF ALTERNATOR BACKGROUND OF THE INVENTION

[0001] The present invention relates to electrical machinery including flame proof alternators and more particularly relates to improvements in the control and monitoring of alternators used in such machinery and to functional software and data communications which provide real-time information for an operator and for control of the alternator by the operator. The present invention also relates to a communications system which is interfaced to a machine control system which provides visual output to and allows command input from a machine operator. More particularly, the present invention relates to a control system which is used with a flame proof alternator for detecting alternator faults such as, but not limited to earth leakage and for communicating such faults to an operator.

[0002] The invention further relates to a machine control system including a communications interface which allows real time monitoring of alternator parameters and also allows command input by an operator. The present invention further relates to such integrated communications and control systems for alternators including flame proof alternators which are used in particular though not exclusively, in dangerous environments such as occurs in underground mining. The present invention is capable of use by maintenance personnel when maintaining machinery which incorporates the communications system.

PRIOR ART

[0003] Alternators are widely used in industry and mining environments. An alternator is used in conjunction with other machinery and in use, converts the mechanical power from a rotating shaft into electrical power and heat. The electric power generated is typically used to drive electrical equipment. Efficiency of alternators is limited by various operational factors including fan cooling loss, bearing loss, iron loss, copper loss, and the voltage drop in the diode bridges. Efficiency is also reduced by overheating. Efficiencies can range from 60% 90% depending upon the environment in which the alternator is operating, its application, the type of alternator and the type of construction. Large AC generators used in power stations run at carefully controlled speeds and have no constraints on size or weight. They have very high efficiencies as high as 98%.

[0004] Flame proof alternators, as used, for example, in the mining and petrochemical industries, are generally required to detect faults and to shut down if a fault occurs. Some alternators provide diagnostic reporting to a piece of diagnostic equipment, typically using infrared communications in close proximity to the alternator itself. Flame proof alternators are used on pieces of machinery such as earth moving equipment, drilling equipment, etc. Common automotive alternators are very basic pieces of equipment without any integrated intelligence. Commonly a warning indicator lights up simply to indicate when the battery is not being charged which may be, for example, a fault with the alternator, a blown fuse or faulty wiring. Earth leakages is a common problem which may occur in electrical equipment which can lead to electrocution if not detected or if there are no means to interrupt the circuit to prevent that occurrence. One known electric earth leakage protection device comprises a detection circuit, a control circuit, a switching power supply and a control switch. The detection circuit is used for detecting abnormalities of a live wire, a neutral wire and a ground wire in a system circuit and outputting a detection result to the control circuit. At present, other than detecting the abnormality, there is no facility to enable interactive monitoring of the performance parameters of a machine with an alternator beyond fault identification.

[0005] In view of the demands placed on alternators and the need to know their operating parameters, it is of significant value to operators of such devices to be able to monitor performance in real time and during operation so that with knowledge of performance parameters, an operator can monitor alternator and associated machine performance. There currently no satisfactory interactive monitoring and communications systems for use with an alternator to enable real time management of machine performance and alternator during use and for maintenance purposes.

[0006] Mining industry standards require that machines and machine components used in the mining and petrochemical industries are flameproof and/or intrinsically safe. Heat reduction is important to reduce the risk of combustion particularly in environments where sparks can cause fire and explosion.

[0007] A flameproof device must be able to withstand an internal explosion and any air passages between the internal space and the outside must meet specific flame-path requirements such as a maximum 0.3 mm gap over a minimum 12.5 mm distance. Intrinsically safe devices ensure internal temperatures remain low, even in fault conditions, and so do not pose an ignition hazard. Flameproof alternators need to meet additional requirements of the mining and petrochemical environments to avoid sparks. Heat dissipation is a major concern in the design of flameproof alternators and is, for a given size alternator, a major limiting factor in the output power capacity of the alternator. Current flameproof alternators typically have a fan that blows cooling air over the smooth outside surface of a bronze cylindrical housing. There are therefore many operating parameters which require monitoring during use of an alternator for safety, control, adjustment and eventually, maintenance. However, there is currently no satisfactory system for enabling the required monitoring and interactive data communications between an alternator and an operator.

[0008] Alternators heretofore devised and utilized are known to consist basically of familiar, expected and obvious structural configurations, notwithstanding the plurality of designs encompassed by the prior art which have been developed for the fulfilment of the objectives and requirements of alternator power generation. Flameproof alternators are used in hazardous explosive environments often found in the mining and petrochemical industries. While these devices fulfil their respective functions, particular objectives and requirements, the aforementioned prior art does not disclose an alternator which includes functional software and an associated communications system providing real-time information on the performance and control of the alternator for the machine operator.

[0010] The present invention provides improvements to enable an operator to receive indication of the real time performance of machinery and in particular an alternator via a communications link to a monitoring station. This ultimately improves equipment safety and enables the operator to adjust, control the performance of the alternator.

SUMMARY OF THE INVENTION

[0011] The present invention provides improvements in the control and monitoring of alternators using functional software and data communications which provide real-time information for interactive control by a machine operator of the alternator or machinery which employs the alternator. The present invention also provides a communications system which is interfaced to a machine control system which provides visual output to and allows command input from a machine operator relating to performance of machinery such as but not limited to an alternator. The present invention further provides a flame proof alternator control system which is capable of detecting alternator faults such as, but not limited to earth leakage and which allows an operator to receive and transmit data to improve the performance of the .

[0012] The machine control system including a communications interface which allows real time monitoring of alternator parameters and command input by an operator includes integrated communications and control systems for flame proof alternators which are used in particular though not exclusively, in dangerous environments such as occurs in underground mining. The present invention further provides functional software and an associated communications system providing real-time information and control of the alternator for the machine operator. The flame proof alternator's control system is capable of detecting many faults, such as but not limited to earth leakage and can also be used by maintenance personnel when maintaining the machine.

[0013] In its broadest form the present invention comprises:

an alternator capable of electronic detection and communication of the performance of an electrical power system of a machine to which the alternator is attached; the alternator including a micro controller having a software module integrated into control firmware of the alternator's microcontroller, wherein data available in the microcontroller is obtained by the software module and sent via a communications path to a control system associated with the machine; wherein the machine control system receives performance data detected by the alternator related to the status and history of the of the power system of the machine; and wherein an operator is able to receive data sent via the software module concerning the electrical performance of the machine

[0014] In another broad form the present invention comprises:

a control system for monitoring performance of a machine which includes an alternator; the alternator including a micro controller having a software module integrated into control firmware of the alternator's microcontroller, the control system enabling a machine operator to monitor, detect and communicate with the alternator wherein data available in the microcontroller is obtained by the software module and sent via a communications path to the control system associated with the machine.

[0015] In a broad form of a method aspect the present invention comprises;

a method for monitoring performance of a machine in a control system and which includes an alternator, the method comprising the steps of:

a) providing an alternator associated with a machine;

b) providing with the alternator a software module, firmware and a micro controller;

c) providing a two way communications link between the micro controller and an operator;

d) allowing the operator to receive and transmit data to and from the microprocessor;

e) assessing the performance of the alternator to determine if its performance lies within normal operating parameters.

f). adjusting the microprocessor data to alter the performance of the alternator to within normal operating parameters.

[0016] In another broad form according to an alternative method aspect, the present invention comprises:

a) providing an alternator associated with a machine; the alternator including a micro controller having a software module integrated into control firmware of the alternator's microcontroller

b) providing a two way communications link between the micro controller and an operator;

c) allowing the operator to receive and transmit data to and from the microprocessor;

d). adjusting the microprocessor data to alter the performance of the alternator to within normal operating parameters;

wherein the machine control system receives performance data detected by the alternator related to the status and history of the of the power system of the machine; and wherein the operator is able to receive data sent via the software module concerning the electrical performance of the machine.

[0017] According to a preferred embodiment the alternator is a flame proof alternator. Preferably the command inputs allow the operator to invoke actions by the firmware of the alternator depending upon the performance parameters of the machine as indicated by the alternator.

[0018] In another broad form the present invention comprises:

a control system for monitoring the performance of a machine which includes an alternator; the alternator including a micro controller having a software module integrated into control firmware of the alternator's microcontroller, the control system enabling a machine operator to monitor, detect and communicate with the alternator wherein data available in the microcontroller is obtained by the software module and sent via a communications path to the control system associated with the machine.

[0019] The present invention provides an alternative to the known prior art and the shortcomings identified. The foregoing and other objects and advantages will appear from the description to follow. In the description reference is made to the accompanying representations, which forms a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. In the accompanying illustrations, like reference characters designate the same or similar parts throughout the several views. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is best defined by the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The present invention will now be described in broad detail according to preferred but non limiting embodiments wherein;

[0021] Figure 1 shows a schematic arrangement of a control system including a machine controller and a communications interface between the controller an alternator that is installed in a machine according to a preferred embodiment.

DETAILED DESCRIPTION

[0022] Although the invention will be described according to preferred embodiments it will be appreciated that other variants are contemplated. The design and construction may be variously modified, without departing from the spirit and scope of the invention, as defined herein. Referring to Figure 1 there is shown a schematic arrangement of a control system 1 including a machine controller 18, a communications interface 19 between the machine controller 18 and an alternator 11 that is installed in a machine according to a preferred embodiment.

[0023] In this preferred embodiment of the present invention, there is provided associated with the alternator 11 a software module 10 integrated into control firmware 12 of the alternator's control microcontroller 14. The relevant data and information available within the microcontroller 14 is obtained by the software module 10 and sent over communications line 16 to the control machine controller 18 that presents graphical output to and receives command input from machine operator's console 20. Input commands from the operator console 20 are sent to the software module 10 over the communications line 16. The software module 10 then initiates appropriate action or actions in response to commands from the operator.

[0024] According to preferred embodiments, the communications line 16 comprises any one of a number of industry standard communications systems such as, but not limited to RS 232,1 C, SPI, CAN, Bluetooth, infrared, etc.

[0025] The type of information/data received by the machine controller 18 includes performance data from alternator 11 and includes faults and maintenance information. Readings from alternator 11 include output voltage, output current, rotor RPM, temperature and hours in use. Faults include positive or negative earth leakage, over voltage, over current, short circuit, over temperature, over and under RPM, firmware checksum, power on self-test results. Maintenance information includes manufacturing data such as serial number, batch number, date, firmware version, PCB revision, unit compliance and performance test results etc. Maintenance information can also include logging of fault occurrences and possibly operational readings and parameters. It is generally important to know the operational readings and parameters at the time of the fault so these would typically be logged with the fault.

[0026] In a further embodiment, the control system 1 includes a scratch-pad of non volatile memory which enables a customer to include any company specific data or maintenance data appropriate to a particular piece of machinery. This will allow an operator to tailor maintenance or operation requirements to the requirements of a particular piece of machinery.

[0027] The monitoring system allows an operator to acknowledge and respond to an alternator fault condition and to reset a fault condition which had caused the alternator to shut down. The operator can send commands to enable the machinery and alternator to re-activate itself. The operator can also do integrity tests such as triggering a built-in test circuit to induce an earth leakage so as to check the integrity of the earth leakage detection circuitry as a corresponding earth fault condition should occur. Other such self-test circuits and corresponding control software may also be provided. The logging system would typically include the self-test occurrence so an operator would know that a particular fault was not a true equipment fault.

[0028] The present invention provides new functionality that machine manufacturers or their component suppliers can use to design in new features based on the real-time or logged alternator information. The overall safety of the machine is improved as the operation of a flame proof alternator is critical in the safe operation of the machine. Likewise, the integrity test logs can be used to demonstrate operational and maintenance conformance with any specified or required routine safety checks.

[0029] The general purpose of the present invention, which is described herein in detail, is to provide a monitoring and control system for an alternator included in plant and machinery and while possessing some of the attributes of the known alternators such as conventional earth leakage detection has the additional advantages along with novel features that result in a new, advantageous and more efficient means for monitoring and controlling machinery which includes an alternator which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art devices, either alone or in any combination thereof.

[0030] It will be recognized by persons skilled in the art that numerous variations and modifications may be made to the invention as broadly described herein without departing from the overall spirit and scope of the invention.

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1 An alternator capable of electronic detection and communication of the performance of an electrical power system of a machine to which the alternator is attached; the alternator including a micro controller having a software module integrated into control firmware of the alternator's microcontroller, wherein data available in the microcontroller is obtained by the software module and sent via a communications path to a control system associated with the machine; wherein the machine control system receives performance data detected by the alternator related to the status and history of the of the power system of the machine; and wherein an operator is able to receive data sent via the software module concerning the electrical performance of the machine
2. An alternator according to claim 1 wherein an operator is able to input data for delivery to the microprocessor.
3. An alternator according to claim 2 wherein an operator is able to read and display data generated by the software module and received by the machine control system.
4. An alternator according to claim 3 wherein the data is received at a machine operator console in the form of graphics.
5. An alternator according to claim 4 wherein the operator console is capable of receiving operator input data for delivery to the software module.
6. An alternator according to claim 5 wherein the communications path is a communications line selected from one or more of industry standard communications systems RS-232, 12C, SPI, CAN, Bluetooth, infrared.
7. An alternator according to claim 6 wherein the data information includes the alternator readings, faults and maintenance information.
8. An alternator according to claim 7 wherein alternator readings include output voltage, output current, rotor RPM, temperature and hours in use.
9. An alternator according to claim 8 wherein the data detected and transmitted from the software module include faults data.
10. An alternator according to claim 9 wherein the fault data includes positive or negative earth leakage, over voltage, over current, short circuit, over temperature, over and under RPM, firmware checksum, power on self-test results.
11. An alternator according to claim 10 wherein the transmitted data comprises maintenance information including manufacturing data such as serial number, batch number, date, firmware version, PCB revision, unit compliance and performance test results.
12. An alternator according to claim 11 wherein maintenance information also includes logging of fault occurrences, operational readings and parameters.
13. An alternator according to claim 12 wherein fault log data includes operational data and parameters at the time of the fault.
14. An alternator according to claim 13 wherein the control system further comprises a scratch pad of non-volatile memory.
15. An alternator according to claim 14 wherein the machine control system is interactive.
16. An alternator according to claim 15 wherein the non volatile memory allows a user to input company specific data or maintenance data.
17. An alternator according to claim 16 wherein input commands can be sent from the operator to the software module via the communications line, enabling the software module to initiate actions.
18. An alternator according to claim 17 wherein the control system further comprises at least one self test circuit which allows fault condition simulation to enable an operator to check the integrity of the alternator.
19. An alternator according to claim 18 wherein the control system receives operator commands which acknowledge and reset a fault condition which causes the alternator to shut down.
20. An alternator according to claim 19 wherein the control system is capable of reactivating the alternator after a fault condition is detected.
21. An alternator according to claim 20 wherein there is provided a logging system which receives performance data for an operator to enable determination of whether a system fault is a legitimate fault.
22. An alternator according to claim 21 wherein the alternator is a flame proof alternator.
23. An interactive control system for monitoring the performance of a machine which includes an alternator; the alternator including a micro controller having a software module integrated into control firmware of the alternator's microcontroller, the control system enabling a machine operator to monitor, detect and communicate with the alternator wherein data available in the microcontroller is obtained by the software module and sent via a communications path to the control system associated with the machine; wherein the machine control system receives performance data detected by the alternator related to the status and history of the of the power system of the machine; and wherein the operator is able to receive data sent via the software module concerning the electrical performance of the machine.
24. A method for monitoring performance of a machine in a control system and which includes an alternator, the method comprising the steps of:

a) providing an alternator associated with a machine; the alternator including a micro controller having a software module integrated into control firmware of the alternator's microcontroller

b) providing a two way communications link between the micro controller and an operator;

c) allowing the operator to receive and transmit data to and from the microprocessor;

d). adjusting the microprocessor data to alter the performance of the alternator to within normal operating parameters;

wherein the machine control system receives performance data detected by the alternator related to the status and history of the of the power system of the machine; and wherein the operator is able to receive data sent via the software module concerning the electrical performance of the machine.