AU2015201505B2 - An alternator having integrated therewith a facility for performance parameter history logging - Google Patents
An alternator having integrated therewith a facility for performance parameter history logging Download PDFInfo
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- AU2015201505B2 AU2015201505B2 AU2015201505A AU2015201505A AU2015201505B2 AU 2015201505 B2 AU2015201505 B2 AU 2015201505B2 AU 2015201505 A AU2015201505 A AU 2015201505A AU 2015201505 A AU2015201505 A AU 2015201505A AU 2015201505 B2 AU2015201505 B2 AU 2015201505B2
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Abstract
An alternator capable of recording and saving alternator performance data;
the alternator having; a micro controller, a software module integrated into control firmware of
the microcontroller, and non volatile memory; wherein during operation of the alternator,
performance data information is available to the software module, with the non volatile memory
storing said data.
1
121
Machine
F, 1720 Operator's
console
Alternator
14 Microcontroller
F irmw i a re 7
12
4 Softwari- e Machine Control
Module System
10 Non-volatile
E Memory : ,2418
------ 19
Figure
Alternator
14 .---- Microcontroller
12
50~ftw,,,a re
Module. Diagnostic Unit
10 16
Memory 22
-24
=============419
Figure 2
1
Description
Machine
F, 1720 Operator's console 121 Alternator
14 Microcontroller
F irmw i a re 7 4 Softwari- e Machine Control Module System
Non-volatile
E Memory : ,2418
------ 19 12 Figure
Alternator
14 .---- Microcontroller
12 50~ftw,,,a re Module. Diagnostic Unit
10 16
Memory 22 -24
=============419
Figure 2
[0001] The present invention relates to electrical machinery including flame proof alternators and more particularly relates to improvements in the intelligence of and capacity to log performance parameters of such alternators. The present invention also relates to an alternator which has integrated intelligence which enables an operator of machinery to log the performance parameters of the alternator. More particularly, the present invention relates to a monitoring system which is used with a flame proof alternator for detecting and logging alternator faults such as, but not limited to earth leakage and for communicating such faults to an operator.
[0002] The invention further relates to an alternator including a communications interface which allows real time data logging during operation of machinery to which the alternator is connected. The present invention further relates to integrated data logging 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 data logging.
[0003] 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.
[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 and drilling equipment. Common automotive alternators are very basic pieces of equipment without any integrated intelligence. In known alternators, a warning indicator lights up simply to indicate when a battery is not being charged which may be, for example, a fault with the alternator, a blown fuse or faulty wiring.
[0005] Earth leakages are 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 log the faults and the performance of the alternator.
[0006] In view of the demands placed on alternators and their importance for electrical safety, there is a need to know their operating parameters and 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 are currently no satisfactory data logging systems for use with an alternator to enable real time management of machine performance and alternator performance during use.
[0007] Operating performance such as temperature of operation and therefore heat dissipation is a major consideration 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. There are therefore many operating parameters which require logging during use of an alternator for safety, and potentially control, and adjustment. However, there is currently no satisfactory system for enabling efficient real time data logging of performance history of an alternator.
[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 data logging capacity providing real-time information on the performance of the alternator.
[0009] The present invention provides improvements in the intelligence of alternators using functional software to enable data logging of alternator performance to provide real-time information. More particularly the present invention provides a software module and communications interface integrated into a flame proof alternator that logs operating readings and parameters and provides the logged information over a communications interface. More particularly the present invention provides a data logging system including functional software and an associated communications system that periodically logs operating parameters of an alternator and performance events detected by the alternator.
[0010] The present invention also provides a data logging system which is interfaced to a machine control system which provides data to operators relating to performance of an alternator used in conjunction with other machinery. The present invention further provides a flame proof alternator control system which is capable of detecting and logging alternator faults such as, but not limited to earth leakage.
[0011] The data logging system includes a communications interface which allows real time monitoring of alternator parameters and command input by an operator to receive or interrogate a software module for performance data. The present invention further provides functional software and an associated communications system providing real-time information on the performance of an alternator for an 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 to quickly identify faults and required repairs.
[0012] In its broadest form the present invention comprises;
a software module and communications interface integrated into a flame proof alternator; the alternator capable of recording a performance history log that includes operating readings and parameters and provides the logged information to an operator over a communications interface.
[0013] In another broad form the present invention comprises:
an alternator capable of electronic detection and communication of its performance parameters; 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 alternator.
[0014] In another broad form the present invention comprises;
an alternator capable of recording and saving alternator performance data; the alternator having; a self -contained micro controller and, a software module integrated into control firmware of the self -contained microcontroller, and non -volatile memory; wherein during operation of the alternator, performance data information is available to the software module, the non volatile memory storing said performance data; wherein, the software module obtains or receives the alternator performance data information for data logging; and wherein the micro controller and the software module are in communication via a communications pathway.
[0015] In another broad form the present invention comprises;
an interactive data logging system which enables an operator to monitor and control performance parameters of an alternator during use, the alternator having associated therewith a machine controller, a software module, associated firmware and a self -contained microcontroller; a communications interface which connects the self -contained microcontroller to the machine controller which includes an operator console; wherein the software module communicates with the micro controller via a communications path and stores and provides data to the operator console reporting on the status and performance history of the alternator and performance data detected by said alternator; wherein, the software module obtains or receives the alternator performance data information for data logging. According to a preferred embodiment the interactive data logging system allows command data input from an operator.
[0016] In a broad form of a method aspect the present invention comprises;
a method enabling the establishment of a data log for monitoring performance history of 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 a machine controller; d) allowing data related to performance characteristics of the alternator to be obtained from a memory associated with the alternator by receipt of data or in response to an input command; e) creating a performance data history log that includes operating readings and parameters; f) assessing the performance data history of the alternator to determine if its performance lies within normal operating parameters.
[0017] According to a preferred embodiment, the method comprises the further steps of sending a request for logged data information to the software module via the communications link. The request involves the options of sending the request for logged data from a machine controller or sending the request for logged data from a diagnostic unit.
[0018] According to a preferred embodiment the alternator is a flame proof alternator. In a case where time -stamps are to be logged, run hours can be used as a time-stamp. Alternatively, a battery backed-up time-keeping clock can be used to keep time while the alternator is off.
[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.
[0020] The present invention will now be described in broad detail according to preferred but non limiting embodiments wherein;
Figure 1 shows a schematic arrangement of a data logging and 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; and
Figure 2 shows according to one embodiment the use of a diagnostic unit for accessing an alternator.
[0021] 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.
[0022] The present invention provides improvements to enable an operator to receive a historical data log of alternator performance. This ultimately improves equipment safety and provides a valuable tool for both operators and maintenance personnel.
[0023] 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.
[0024] 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 interface 19 via 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 is capable of acting in response to commands from the operator to provide alternator performance data. According to the present invention, the software module 10 either obtains the information to be logged from the control firmware 12 or receives information to be logged, such as an alternator activity, event, by the control firmware 12. The software module 10 saves the information to non-volatile memory 24.
10025] Figure 2 shows according to one embodiment the use of a diagnostic unit for accessing an alternator. When information is to be retrieved this may be achieved in one of two ways once a request command is sent to the software module 10 over the communications line 16. In the first method, a request is delivered by machine controller 18. In the second method a request is delivered by diagnostic unit 22. The software module 10 upon receipt of the request retrieves requested data/information from the non-volatile memory 24 and sends the data over the communications line 16 to the machine control system 18 or the diagnostic unit 22. The communications line 16 may be selected from any one of a number of industry standard communications systems such as but not limited to RS-232,1 2C, SPI, CAN, Bluetooth, infrared.
[0026] The type of information includes the alternator readings, faults and maintenance information that are either values with an associated time-stamp or are values that are aggregated over time such as but not limited to hours in use. Alternator readings include output voltage, output current, rotational speed, 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 (a count of the number of bits in a transmission unit that is included with the unit so that the receiver can check to see whether the same number of bits arrived), power on self-test results. Maintenance information includes manufacturing data such as serial number, batch number, date, firmware version, PCB revision, product compliance information and performance test results. The operational readings and parameters at the time of a fault are typically recorded with the fault as these values can be helpful in diagnosing an issue.
[0027] In one embodiment, a scratch-pad of non-volatile memory (a software controlled on-chip memory) may also be provided so the customer could include any type of company specific data or maintenance data. Depending on the operational needs of the machine the machine operator and/or the maintenance personnel could write to and/or read from the non volatile memory 24.
[0028] The present invention provides data logging of alternator performance that machine manufacturers or their component suppliers can adopt for designing in new features based on the logged alternator information. The overall efficiency and safety of the alternator is improved as the performance parameters can be closely monitored and faults diagnosed in use and during down time.
[0029] 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.
[0030] The data logging system allows an operator to address an alternator fault condition, send commands to enable the machinery and alternator to re-activate itself. The logging system may include a self-test occurrence so an operator would know that a particular fault was not a true equipment fault. Integrity test logs can be used to demonstrate operational and maintenance conformance with any specified or required routine safety checks.
[0031] The general purpose of the present invention, which is described herein in detail, is to provide a data logging and associated 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 logging alternator performance which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art devices, either alone or in any combination thereof.
[0032] 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 (29)
1. An alternator capable of recording and saving alternator performance data; the alternator having; a self -contained micro controller; and a software module integrated into control firmware of the self -contained microcontroller, and a non -volatile memory; wherein during operation of the alternator, performance data information is available to the software module, the non -volatile memory storing said performance data; wherein, the software module obtains or receives the alternator performance data information for data logging; and wherein the micro controller and the software module are in communication via a communications path.
2 An alternator according to claim 1 wherein, the software module is capable of obtaining the information from the control firmware.
3. An alternator according to claim 2 wherein the software module is capable of receiving the information from the control firmware.
4. An alternator according to claim 3 wherein the information relates to an alternator performance event.
5. An alternator according to claim 4 wherein the alternator is in communication with a machine controller during operation.
6. An alternator according to claim 5 wherein data stored in the non -volatile memory is retrievable by a request command sent to the software module.
7. An alternator according to claim 6 wherein the request command to retrieve stored information is sent to the software module from the machine controller.
8. An alternator according to claim 6 wherein the alternator has associated with it a diagnostic unit.
9. An alternator according to claim 8, wherein the request command to retrieve stored information is sent to the software module from the diagnostic unit.
10. An alternator according to claim 9, further comprising means to allow an operator is able to send a command and retrieve data sent from the software module via the communications line concerning the electrical performance of the alternator.
11. An alternator according to claim 10 wherein, an operator is able to read and display logged data stored and sent by the software module and received by the machine control system.
12. An alternator according to claim 11 wherein, the performance data relates to the status and history of the operation of the alternator.
13. An alternator according to claim 12 wherein the communications path is a communications line selected from one or more of industry standard communications systems RS-232, 12 C, SPI, CAN, Bluetooth, infrared.
14. An alternator according to claim 13 wherein the data information includes the alternator readings, faults and maintenance information.
15. An alternator according to claim 14 wherein alternator readings include output voltage, output current, rotor RPM, temperature and hours in use.
16. An alternator according to claim 15 wherein the data detected and transmitted from the software module include faults data.
17. An alternator according to claim 16 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.
18. An alternator according to claim 17 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.
19. An alternator according to claim 18 wherein the operational performance information and parameters at the time of a fault, are recorded with the fault, to enable future fault diagnosis using the data log.
20. An alternator according to claim 19 wherein the non -volatile memory includes any type of company specific data or maintenance data.
21. An alternator according to claim 20 wherein the communications between the software module and controller are interactive.
22. An interactive data logging system which enables an operator to monitor and control performance parameters of an alternator during use, the alternator having associated therewith a machine controller, a software module, associated firmware and a self -contained microcontroller; a communications interface which connects the self -contained microcontroller to the machine controller which includes an operator console; wherein, the software module communicates with the machine controller via a communications path and stores and provides data to the operator console reporting on the status and performance history of the alternator and performance data detected by said alternator; and wherein, the software module obtains or receives the alternator performance data information for data logging.
23. An interactive data logging system according to claim 22 further comprising means to enable command data input from an operator.
24 A software module and communications interface integrated into a flame proof alternator; the alternator including a micro controller having a software module integrated into control firmware of the alternator's microcontroller; the alternator capable of recording a performance history log that includes operating readings and parameters and provides the logged information to an operator over the communications interface.
A software module and communications interface according to claim 24 wherein data available in the microcontroller is obtained by the software module and sent via the communications interface to a control system associated with the alternator.
26. A method enabling the establishment of a data log for monitoring performance history of 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 self -contained micro controller;
c) providing a two way communications interface between the micro controller and a machine controller; d) allowing data related to performance characteristics of the alternator to be obtained from a memory associated with the alternator by receipt of data or in response to an input command; e) creating a performance data history log that includes operating readings and parameters; f) assessing the performance data history of the alternator to determine if its performance lies within normal operating parameters.
27. A method according to claim 26 comprising the further step of sending a request for logged data information to said software module via the communications link.
28. A method according to claim 27 comprising the further step of sending the request for logged data from a machine controller.
29. A method according to claim 27 comprising the further step of sending the request for logged data from a diagnostic unit.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2015201505A AU2015201505B2 (en) | 2014-03-23 | 2015-03-23 | An alternator having integrated therewith a facility for performance parameter history logging |
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2014901020 | 2014-03-23 | ||
| AU2014901020A AU2014901020A0 (en) | 2014-03-23 | A software module and communications interface integrated into a flame proof alternator that logs operating readings and parameters and provides the logged information over a communications interface. | |
| AU2015201505A AU2015201505B2 (en) | 2014-03-23 | 2015-03-23 | An alternator having integrated therewith a facility for performance parameter history logging |
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| Publication Number | Publication Date |
|---|---|
| AU2015201505A1 AU2015201505A1 (en) | 2015-10-08 |
| AU2015201505B2 true AU2015201505B2 (en) | 2020-11-26 |
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| Application Number | Title | Priority Date | Filing Date |
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| AU2015201505A Active AU2015201505B2 (en) | 2014-03-23 | 2015-03-23 | An alternator having integrated therewith a facility for performance parameter history logging |
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| AU (1) | AU2015201505B2 (en) |
| ZA (1) | ZA201501966B (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| US20250079831A1 (en) * | 2023-09-06 | 2025-03-06 | Hamilton Sundstrand Corporation | Data-enabled aircraft generator |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2178601A (en) * | 1985-06-15 | 1987-02-11 | Becorit | Flame proof excitation and control of alternators |
| US5280223A (en) * | 1992-03-31 | 1994-01-18 | General Electric Company | Control system for an electrically propelled traction vehicle |
| US5602459A (en) * | 1988-07-13 | 1997-02-11 | Electronic Development Inc. | Fuel saving multi-battery charging system and method |
| US6731098B1 (en) * | 2000-10-24 | 2004-05-04 | Kohler Co. | Method and apparatus for sensing variable currents within the alternator of a genset that employs an amplifier and a switched feedback resistance |
| US7283899B1 (en) * | 2007-02-20 | 2007-10-16 | Remy International, Inc. | Vehicle alternator and methods for controlling torque loading of the vehicle alternator on an engine |
| US8102145B2 (en) * | 2008-06-26 | 2012-01-24 | Remy Technologies Llc | Internal packaged alternator with microprocessor controlled multi-input regulator |
-
2015
- 2015-03-23 AU AU2015201505A patent/AU2015201505B2/en active Active
- 2015-03-23 ZA ZA2015/01966A patent/ZA201501966B/en unknown
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2178601A (en) * | 1985-06-15 | 1987-02-11 | Becorit | Flame proof excitation and control of alternators |
| US5602459A (en) * | 1988-07-13 | 1997-02-11 | Electronic Development Inc. | Fuel saving multi-battery charging system and method |
| US5280223A (en) * | 1992-03-31 | 1994-01-18 | General Electric Company | Control system for an electrically propelled traction vehicle |
| US6731098B1 (en) * | 2000-10-24 | 2004-05-04 | Kohler Co. | Method and apparatus for sensing variable currents within the alternator of a genset that employs an amplifier and a switched feedback resistance |
| US7283899B1 (en) * | 2007-02-20 | 2007-10-16 | Remy International, Inc. | Vehicle alternator and methods for controlling torque loading of the vehicle alternator on an engine |
| US8102145B2 (en) * | 2008-06-26 | 2012-01-24 | Remy Technologies Llc | Internal packaged alternator with microprocessor controlled multi-input regulator |
Non-Patent Citations (1)
| Title |
|---|
| Designing a microcontroller-driven alternator voltage regulator; URL: https://www.embedded.com/designing-a-microcontroller-driven-alternator-voltage-regulator/; 20 September 2005 * |
Also Published As
| Publication number | Publication date |
|---|---|
| AU2015201505A1 (en) | 2015-10-08 |
| ZA201501966B (en) | 2016-11-30 |
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