SYSTEMS AND METHODS FOR DATA COLLECTION AND FREQUENCY EVALUATION FOR A MIXER OR AN AGITATOR
Systems and methods for data collection and frequency evaluation for a mixer or agitator are disclosed. An example monitoring system for data collection may include a mixer or agitator with at least one component and a data acquisition circuit to interpret a plurality of detection values corresponding to input sensors operationally coupled to at least one component of the mixer or agitator. The system may further include a data storage circuit to store one or more operating frequencies and a frequency evaluation circuit to detect an operating signal in response to the plurality of detection values, wherein the operating signal comprises a frequency higher than the operating frequencies. The system may further include a response circuit to perform at least one operation in response to the detected operating signal.
1 . A monitoring system for data collection in a mixer or an agitator, the monitoring system comprising:
a mixer or agitator comprising at least one component;
a data acquisition circuit structured to interpret a plurality of detection values, each of the plurality of detection values corresponding to at least one of a plurality of input sensors, each of the plurality of input sensors operationally coupled to at least one of the at least one component;
a data storage circuit structured to store one or more operating frequencies of the at least one component;
a frequency evaluation circuit structured to detect an operating signal in response to the plurality of detection values, wherein the operating signal comprises a frequency higher than the one or more operating frequencies; and
a response circuit structured to perform at least one operation in response to the detected operating signal.
2 . The monitoring system of claim 1 , wherein the at least one component comprises at least one component selected from among a bearing, a driveshaft, a propeller, a blade, or a vane.
3 . The monitoring system of claim 2 , wherein at least one of the plurality of input sensors comprises a vibration sensor.
4 . The monitoring system of claim 1 , wherein the at least one component comprises at least one component selected from among a tank housing, a baffle, a vane, a stator, an input line, or an output line.
5 . The monitoring system of claim 4 , wherein at least one of the plurality of input sensors comprises at least one of a vibration sensor or a rotational speed sensor.
6 . The monitoring system of claim 1 , wherein the at least one operation comprises performing at least one of: adjusting a sampling rate of at least one of the plurality of detection values; requesting a maintenance event; changing a utilized input sensor corresponding to at least one of the plurality of input sensors; storing event data related to the mixer or agitator and the operating signal; and providing one of an alert or a notification in response to the operating signal.
7 . The monitoring system of claim 3 , wherein the frequency evaluation circuit is further structured to detect a misalignment in response to the operating signal indicating a change in energy at frequencies at least twice a frequency of the one or more operating frequencies.
8 . The monitoring system of claim 1 , wherein the operating signal indicates an anomalous condition.
9 . The monitoring system of claim 8 , wherein the anomalous condition comprises a pre-failure mode condition for the mixer or the agitator.
10 . The monitoring system of claim 1 , further comprising a data analysis circuit structured to analyze at least two of the plurality of detection values, to determine a relative phase value between the at least two of the plurality of detection values, and to detect an anomalous condition in response to the relative phase value.
11 . The monitoring system of claim 10 , wherein the at least one component comprises one or more rotating components, and wherein the data analysis circuit is further structured to perform band-pass tracking associated with the one or more rotating components to detect the anomalous condition.
12 . The monitoring system of claim 1 , wherein at least one of the plurality of input sensors comprises a vibration sensor, and wherein the frequency evaluation circuit is further structured to detect a noise pattern from the mixer or agitator in response to detection values from the vibration sensor.
13 . The monitoring system of claim 12 , wherein the frequency evaluation circuit is further structured to detect the noise pattern at frequencies higher than a frequency at which one or more rotating components of the mixer or the agitator rotates.
14 . The monitoring system of claim 11 , wherein detecting the anomalous condition comprises performing a frequency analysis at a selected multiple of a rotational speed of the one or more rotating components.
15 . The monitoring system of claim 1 , wherein the frequency evaluation circuit is further structured to perform a frequency analysis at a selected multiple of at least one of the one or more operating frequencies.
16 . The monitoring system of claim 1 , wherein the operating signal indicates a torsion on a driveshaft of an agitating impeller.
17 . The monitoring system of claim 1 , wherein the operating signal indicates an unexpected vibration or a resonant vibration, and wherein the at least one operation comprises an operation to avoid the unexpected vibration or the resonant vibration.
18 . The monitoring system of claim 1 , wherein the operating signal indicates at least one of an unexpected flow rate, an unexpected particulate content, a change in a fluid composition, a change in fluid density that amplifies a vibration at certain frequencies, or a change in fluid density that dampens a vibration at certain frequencies.
19 . A method for collecting data in a mixer or an agitator, the method comprising:
collecting data from a plurality of input channels, wherein a subset of the plurality of input channels are communicatively coupled to sensors measuring operational parameters of at least one component of the mixer or the agitator;
storing one or more operating frequencies related to an operation of the at least one component;
interpreting a plurality of detection values from the collected data, each of the plurality of detection values corresponding to at least one of the plurality of input channels; and
detecting an operating signal on the at least one of the plurality of input channels at a frequency higher than at least one of the one or more operating frequencies; and
performing at least one operation in response to the detected operating signal.
20 . The method of claim 19 , wherein the at least one component comprises at least one of a bearing, a tank housing, a driveshaft, a propeller, a blade, a baffle, a vane, a stator, an input line, or an output line.
21 . The method of claim 19 , further comprising analyzing at least two of the plurality of input channels, and wherein detecting the operating signal comprises detecting an anomalous condition in response to a relative phase difference between the at least two of the plurality of input channels.
22 . The method of claim 21 , wherein performing the at least one operation comprises performing at least one of: adjusting a sampling rate of at least one of the plurality of input channels; requesting a maintenance event; changing a utilized sensor corresponding to at least one of the plurality of input channels; storing event data related to the mixer or agitator and the anomalous condition; and providing one of an alert or a notification in response to the anomalous condition.
23 . The method of claim 19 , further comprising detecting a misalignment in response to the operating signal indicating a change in energy at frequencies at least twice a frequency of at least one of the one or more operating frequencies.
24 . The method of claim 19 , wherein the operating signal indicates an anomalous condition.
25 . The method of claim 24 , wherein the anomalous condition is a pre-failure mode condition for the mixer or the agitator.
26 . The method of claim 24 , further comprising performing band-pass tracking associated with one or more rotating components of the mixer or the agitator to detect the anomalous condition.
27 . The method of claim 19 , wherein at least one of the plurality of input channels is communicatively coupled to a vibration sensor, and wherein the method further comprises detecting a noise pattern from the mixer or agitator in response to detection values from the vibration sensor.
28 . The method of claim 24 , wherein detecting the anomalous condition comprises performing a frequency analysis at a selected multiple of a rotational speed of one or more rotating components of the mixer or the agitator.
29 . The method of claim 24 , wherein detecting the anomalous condition comprises performing a frequency analysis at a selected multiple of at least one of the one or more operating frequencies.