US6326758B1
Expired / Lapsed
US
⏱️ 0.0 years remaining
Integrated diagnostics and control systems
Assignee: Rockwell Automation Technologies Inc
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Filing: 1999-12-15
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Granted: 2001-12-04
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Expires: 2019-12-15
Abstract
Abstract An integrated control and diagnostics system for a controlled system (e.g., a motor) includes a diagnostics module and a controller coupled to the motor. To optimize operation, the diagnostics information signal is used to modify the control provided by the controller as required. Moreover, the output of the control module is coupled to the diagnostics module so that the health assessment made by the diagnostics module can be based at least in part on the output of the controller. The invention uses a model-based diagnostics approach that allows integration of control algorithms with diagnostics algorithms to intelligently trade off optimizing performance to avert or accommodate failures, and to meet performance requirements in a wide range of applications.
Inventors
- 👤 Frederick M. Discenzo
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-27 06:45
CPC Classifications
G; G05; G05B; G05B23/00; G05B23/02; G05B23/0205; G05B23/0218; G05B23/0243; G05B23/0259; G05B23/0283; G05B23/0286; G05B23/0294; Y; Y10; Y10S; Y10S388/00; Y10S388/90; Y10S388/906; Y10S388/907; Y10S388/909
Claims Analysis
Total Claims: 36
Claim 1
Independent Claim
118 words
A method of optimizing control and diagnostics operations performed on a controlled system, the method comprising: providing a diagnostics module and a control module, wherein each module is integrated with the controlled system; generating, with the control module, a control signal in response to feedback from the controlled system; generating, with the diagnostics module and based on the control signal, a health assessment signal indicative of the health of the controlled system; predicting (1) when a controlled system failure will occur, and (2) the cause of the controlled unit failure, wherein said predicting step is performed in response to said health assessment and control signals; and determining whether to alter the control signal based on said predicting step.
Claim 2
Independent Claim
118 words
A method of optimizing control and diagnostics operations performed on a controlled system, the method comprising: providing a diagnostics module and a control module, wherein each module is integrated with the controlled system; generating, with the control module, a control signal in response to feedback from the controlled system; generating, with the diagnostics module and based on the control signal, a health assessment signal indicative of the health of the controlled system; predicting (1) when a controlled system failure will occur, and (2) the cause of the controlled unit failure, wherein said predicting step is performed in response to said health assessment and control signals; and determining whether to alter the control signal based on said predicting step.
Claim 3
Dependent Claim
32 words
The method according to claim 1 , further comprising planning a change in the control signal in response to said determining step, and altering the control signal based on said planning step.
Claim 4
Dependent Claim
27 words
The method according to claim 2 , further comprising determining, prior to said altering step, the stability of the controlled system in response to said planning step.
Claim 5
Dependent Claim
17 words
The method according to claim 3 , further comprising activating the controller prior to said altering step.
Claim 6
Dependent Claim
22 words
The method according to claim 1 , wherein the control signal is based on a process constraint associated with the controlled system.
Claim 7
Dependent Claim
17 words
The method according to claim 5 , wherein the process constraint is an operational frequency to avoid.
Claim 8
Dependent Claim
27 words
The method according to claim 6 , wherein the operational frequency to avoid is determined by the diagnostics module in response to feedback from the controlled system.
Claim 9
Dependent Claim
19 words
The method according to claim 1 , wherein the feedback is generated by a sensor monitoring the controlled system.
Claim 10
Independent Claim
98 words
A method of optimizing control and diagnostics operations performed on a motor, the method comprising: providing a feedback control circuit and a diagnostics circuit, both of the circuits being integrated with the motor; generating a health assessment signal with the diagnostics circuit, the health assessment signal being based on an output of the control feedback circuit; generating a controller modification signal with the diagnostics circuit wherein the controller modification signal is based on the health assessment signal; and generating a driving output with the feedback control circuit based on feedback from the motor and the controller modification signal.
Claim 11
Independent Claim
98 words
A method of optimizing control and diagnostics operations performed on a motor, the method comprising: providing a feedback control circuit and a diagnostics circuit, both of the circuits being integrated with the motor; generating a health assessment signal with the diagnostics circuit, the health assessment signal being based on an output of the control feedback circuit; generating a controller modification signal with the diagnostics circuit wherein the controller modification signal is based on the health assessment signal; and generating a driving output with the feedback control circuit based on feedback from the motor and the controller modification signal.
Claim 12
Dependent Claim
54 words
The method according to claim 9 , wherein the controller includes a velocity feedback loop and a torque feedback loop, wherein said velocity feedback loop generates a current command signal in response to the feedback from the motor, and said torque feedback loop generates the driving output in response to the current command signal.
Claim 13
Dependent Claim
27 words
The method according to claim 10 , wherein the velocity feedback loop includes a sensor that is coupled to the motor, the sensor generating the feedback signal.
Claim 14
Dependent Claim
18 words
The method according to claim 11 , wherein the feedback is indicative of a velocity of the motor.
Claim 15
Dependent Claim
34 words
The method according to claim 12 , wherein said generating a health assessment signal step is performed by using a model associated with the motor, the model embedded in a memory of diagnostics circuit.
Claim 16
Independent Claim
119 words
A method of optimizing the useful life of a motor according to a preventive maintenance schedule that includes a plurality of preventive maintenance checkpoints, the method comprising: sensing a motor parameter during operation of the motor and generating a corresponding motor parameter signal; generating, with a controller, a driving output based on the motor parameter signal; diagnosing a health condition of the motor based on at least one of a group comprising (1) an operating objective, (2) the driving output, and (3) a process constraint; predicting, based on the health condition, whether a motor fault condition will occur prior to the next preventive maintenance checkpoint; and determining whether to alter the control signal in response to said predicting step.
Claim 17
Independent Claim
119 words
A method of optimizing the useful life of a motor according to a preventive maintenance schedule that includes a plurality of preventive maintenance checkpoints, the method comprising: sensing a motor parameter during operation of the motor and generating a corresponding motor parameter signal; generating, with a controller, a driving output based on the motor parameter signal; diagnosing a health condition of the motor based on at least one of a group comprising (1) an operating objective, (2) the driving output, and (3) a process constraint; predicting, based on the health condition, whether a motor fault condition will occur prior to the next preventive maintenance checkpoint; and determining whether to alter the control signal in response to said predicting step.
Claim 18
Dependent Claim
20 words
The method according to claim 14 , wherein the controller includes a velocity feedback circuit and a torque feedback circuit.
Claim 19
Dependent Claim
19 words
The method according to claim 15 , wherein said torque feedback circuit includes a P-I controller and an inverter.
Claim 20
Dependent Claim
21 words
The method according to claim 16 , wherein said diagnosing step is performed with a diagnostics module integrated with the motor.
Claim 21
Dependent Claim
15 words
The method according to claim 17 , wherein said controller is integrated with the motor.
Claim 22
Dependent Claim
21 words
The method according to claim 14 , wherein said diagnosing step is performed by using a model associated with the motor.
Claim 23
Independent Claim
135 words
A method of optimizing the useful life of a motor according to a preventive maintenance schedule that includes a plurality of preventive maintenance checkpoints, the method comprising: sensing a motor parameter during operation of the motor and generating a corresponding motor parameter signal; generating, with a controller, a driving output based on the motor parameter signal; diagnosing a health condition of the motor based on at least one of a group comprising (1) an operating objective, (2) the driving output, and (3) a process constraint; predicting, based on the health condition, whether a motor fault condition will occur prior to the next preventive maintenance checkpoint; and determining whether to alter the control signal in response to said predicting; wherein the operating objective is operating the motor at 200% duty for a predetermined amount of time.
Claim 24
Independent Claim
135 words
A method of optimizing the useful life of a motor according to a preventive maintenance schedule that includes a plurality of preventive maintenance checkpoints, the method comprising: sensing a motor parameter during operation of the motor and generating a corresponding motor parameter signal; generating, with a controller, a driving output based on the motor parameter signal; diagnosing a health condition of the motor based on at least one of a group comprising (1) an operating objective, (2) the driving output, and (3) a process constraint; predicting, based on the health condition, whether a motor fault condition will occur prior to the next preventive maintenance checkpoint; and determining whether to alter the control signal in response to said predicting; wherein the operating objective is operating the motor at 200% duty for a predetermined amount of time.
Claim 25
Independent Claim
129 words
A method of optimizing the useful life of a motor according to a preventive maintenance schedule that includes a plurality of preventive maintenance checkpoints, the method comprising: sensing a motor parameter during operation of the motor and generating a corresponding motor parameter signal; generating, with a controller, a driving output based on the motor parameter signal; diagnosing a health condition of the motor based on at least one of a group comprising (1) an operating objective, (2) the driving output, and (3) a process constraint; predicting, based on the health condition, whether a motor fault condition will occur prior to the next preventive maintenance checkpoint; and determining whether to alter the control signal in response to said predicting; wherein the process constraint is a motor operational frequency to avoid.
Claim 26
Independent Claim
129 words
A method of optimizing the useful life of a motor according to a preventive maintenance schedule that includes a plurality of preventive maintenance checkpoints, the method comprising: sensing a motor parameter during operation of the motor and generating a corresponding motor parameter signal; generating, with a controller, a driving output based on the motor parameter signal; diagnosing a health condition of the motor based on at least one of a group comprising (1) an operating objective, (2) the driving output, and (3) a process constraint; predicting, based on the health condition, whether a motor fault condition will occur prior to the next preventive maintenance checkpoint; and determining whether to alter the control signal in response to said predicting; wherein the process constraint is a motor operational frequency to avoid.
Claim 27
Dependent Claim
21 words
The method according to claim 21 , wherein the operational frequency to avoid is determined based on the motor parameter signal.
Claim 28
Independent Claim
132 words
A method of optimizing the useful life of a motor according to a preventive maintenance schedule that includes a plurality of preventive maintenance checkpoints, the method comprising: sensing a motor parameter during operation of the motor and generating a corresponding motor parameter signal; generating, with a controller, a driving output based on the motor parameter signal; diagnosing a health condition of the motor based on at least one of a group comprising (1) an operating objective, (2) the driving output, and (3) a process constraint; predicting, based on the health condition, whether a motor fault condition will occur prior to the next preventive maintenance checkpoint; and determining whether to alter the control signal in response to said predicting; wherein the process constraint is the criticality of a mission including an allowable risk.
Claim 29
Independent Claim
132 words
A method of optimizing the useful life of a motor according to a preventive maintenance schedule that includes a plurality of preventive maintenance checkpoints, the method comprising: sensing a motor parameter during operation of the motor and generating a corresponding motor parameter signal; generating, with a controller, a driving output based on the motor parameter signal; diagnosing a health condition of the motor based on at least one of a group comprising (1) an operating objective, (2) the driving output, and (3) a process constraint; predicting, based on the health condition, whether a motor fault condition will occur prior to the next preventive maintenance checkpoint; and determining whether to alter the control signal in response to said predicting; wherein the process constraint is the criticality of a mission including an allowable risk.
Claim 30
Independent Claim
103 words
A method of optimizing control and diagnostics operations performed on a controlled system, the method comprising: providing a diagnostics module and a control module, wherein each module is integrated with the controlled system; generating, with the control module, a driving output in response to feedback from the controlled system; generating, with the diagnostics module and based on the driving output, a diagnostics signal indicative of the health of the controlled system; determining an expected time to fail based on the diagnostics signal; and predicting whether the controlled system will operate according to a predetermined set of criteria in response to said determining step.
Claim 31
Independent Claim
103 words
A method of optimizing control and diagnostics operations performed on a controlled system, the method comprising: providing a diagnostics module and a control module, wherein each module is integrated with the controlled system; generating, with the control module, a driving output in response to feedback from the controlled system; generating, with the diagnostics module and based on the driving output, a diagnostics signal indicative of the health of the controlled system; determining an expected time to fail based on the diagnostics signal; and predicting whether the controlled system will operate according to a predetermined set of criteria in response to said determining step.
Claim 32
Dependent Claim
58 words
The method of claim 24 , further comprising: planning a change in control based on said predicting step; determining a new expected time to fail in response to said planning step; and predicting whether the controlled unit will operate according to the predetermined set of criteria in response to said determining a new expected time to fail step.
Claim 33
Dependent Claim
37 words
The method according to claim 25 , further comprising: prescribing a change in control based on an operating objective; and predicting whether the controlled unit will operate according to the operating objective based on said prescribing step.
Claim 34
Dependent Claim
23 words
The method of claim 26 , further comprising generating a controller modification signal in response to at least one of said predicting steps.
Claim 35
Dependent Claim
11 words
The method of claim 27 , further comprising activating the controller.
Claim 36
Dependent Claim
28 words
The method of claim 25 , wherein the predetermined set of criteria includes controlled system operation according to a normal operating characteristic for a predetermined amount of time.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2004-12-03 | 2005-06-04 | 2005-12-04 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2008-12-03 | 2009-06-04 | 2009-12-04 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2012-12-03 | 2013-06-04 | 2013-12-04 | $7700.00 | Window Closed / Lapsed |