Motor drive and method for monitoring operational measurement data of a electric motor having at least one operating point
The invention relates to a motor drive for monitoring operational measurement data ( 34 ) of an electric motor ( 12 ) having at least one operating point ( 78, 80, 82, 84 ), wherein the electric motor ( 12 ) is configured to drive a load ( 21 ), the motor drive ( 10 ) comprising a measurement unit ( 14 ) for acquiring initial measurement data ( 118 ) for at least one of the operating points ( 78, 80, 82, 84 ) of the electric motor ( 12 ), wherein the initial measurement data comprises sensor data and/or estimated data; a processing unit ( 26 ) for determining a baseline ( 58, 60, 62, 64 ) from the initial measurement data ( 118 ) for the at least one operating point ( 78, 80, 82, 84 ); an output unit ( 28 ); characterized in that the processing unit ( 26 ) is configured to generate at least one threshold level ( 36, 38, 40 ) for the at least one determined baseline ( 58, 60, 62, 64 ), while the electric motor ( 12 ) is on an on state or an off state; wherein the at least one threshold level ( 36, 38, 40 ) defines a level of deviation from the determined baseline ( 58, 60, 62, 64 ), wherein the output unit ( 28 ) is configured to provide the at least one threshold level ( 36, 38, 40 ) resulting in conditions for monitoring the operational measurement data ( 34 ) of the electric motor ( 12 ). The invention provides an improved motor drive ( 10 ) for monitoring operational measurement data ( 34 ) of a electric motor ( 12 ) that are more accurate than in the prior art.
1 . A motor drive for monitoring operational measurement data of an electric motor having at least one operating point, wherein the electric motor is configured to drive a load, the motor drive comprising:
a measurement unit for acquiring initial measurement data for the at least one operating point of the electric motor, wherein the initial measurement data comprises sensor data and/or estimated data;
a processing unit for determining a baseline from the initial measurement data for the at least one operating point;
an output unit;
wherein the processing unit is configured to generate at least one threshold level for the at least one determined baseline, while the electric motor is in an on state or an off state;
wherein the at least one threshold level defines a level of deviation from the determined baseline,
wherein the output unit is configured to provide the at least one threshold level resulting in conditions for monitoring the operational measurement data of the electric motor,
wherein the motor drive is configured to receive an incoming frequency from an input line and provide an output frequency to the electric motor via an output line, and
wherein the motor drive is configured to drive the electric motor through the output frequency provided to the electric motor.
2 . The motor drive according to claim 1 , wherein the measurement unit is configured to receive operational measurement data for an operating point of the at least one operating point of the electric motor, wherein the processing unit is further configured to determine the threshold levels that are exceeded by the operational measurement data corresponding to the operating point.
3 . The motor drive according to claim 2 , wherein the processing unit is further configured to provide a monitoring signal indicating the number of threshold levels being exceeded by the operational measurement data.
4 . The motor drive according to claim 3 , wherein the at least one threshold level comprises at least two threshold levels, wherein the monitoring signal is a warning signal if the operational measurement data exceeds one threshold level of the at least one threshold level, and wherein the monitoring signal is an alarm signal if the operational measurement data exceeds all threshold levels of the at least one threshold level.
5 . The motor drive according to claim 3 , wherein the operational measurement data comprises more than one measured signal and/or more than one estimated signals.
6 . The motor drive according to claim 2 , wherein the processing unit is further configured to provide at least one automatically or manually provided value as the at least one generated threshold level, and wherein the at least one automatically or manually provided value is a factory default value for the electric motor.
7 . The motor drive according to claim 1 , wherein the processing unit is further configured to provide at least one automatically or manually provided value as the at least one generated threshold level.
8 . The motor drive according to claim 7 , wherein the at least one automatically or manually provided value is a factory default value for the electric motor.
9 . The motor drive according to claim 1 , wherein the at least one operating point comprises a plurality of operating points, wherein the measurement unit is configured to acquire at least a portion of the initial measurement data during a transition of the electric motor between two of the plurality of operating points.
10 . The motor drive according to claim 1 , wherein the at least one operating point comprises a speed profile of the electric motor.
11 . The motor drive according to claim 1 , wherein the initial measurement data and the operational measurement data comprises one or more of vibration data, load data, flux data, torque data, current data, data from stator windings, temperature data, humidity data, lifetime data, and operating hours data.
12 . The motor drive according to claim 1 , wherein the measurement unit is a frequency converter for driving the electric motor.
13 . The motor drive according to claim 1 , wherein at least the processing unit is connected to a further Cloud based device, wherein the processing unit is configured to receive at least one threshold level for the at least one determined baseline by the Cloud based device as the at least one generated threshold level, wherein the Cloud based device is configured to determine a baseline from the initial measurement data for the at least one operating point.
14 . The motor drive according to claim 1 , wherein the at least one threshold level comprises a first threshold level and a second threshold level.
15 . The motor drive according to claim 14 , wherein the first threshold level indicates a first probability of failure of the motor drive and the second threshold level indicates a second probability of failure of the motor drive, and wherein the first probability of failure is different than the second probability of failure.
16 . A method for monitoring operational measurement data of an electric motor having at least one operating point, the method comprising the following steps:
acquiring initial measurement data for the at least one of the operating point of the electric motor using a motor drive;
receiving an operating point signal indicating the operating point of the electric motor;
determining a baseline from the initial measurement data for each operating point;
generating at least one threshold level for the determined baseline; wherein the at least one threshold level defines a level of deviation from the determined baseline; and
providing the at least one threshold level resulting in conditions for monitoring the operational measurement data of the electric motor;
wherein the motor drive comprises:
a measurement unit for acquiring initial measurement data for at least one of the operating points of the at least one operating point of the electric motor, wherein the initial measurement data comprises sensor data and/or estimated data;
a processing unit for determining a baseline from the initial measurement data for the at least one operating point;
an output unit;
wherein the processing unit is configured to generate at least one threshold level for the at least one determined baseline, while the electric motor is in an on state or an off state;
wherein the at least one threshold level defines a level of deviation from the determined baseline,
wherein the output unit is configured to provide the at least one threshold level resulting in conditions for monitoring the operational measurement data of the electric motor,
wherein the motor drive is configured to receive an incoming frequency from an input line and provide an output frequency to the electric motor via an output line, and
wherein the motor drive is configured to drive the electric motor through the output frequency provided to the electric motor.
17 . The method according to claim 16 , wherein the method further comprises the steps:
receiving operational measurement data for an operating point of the at least one operating point of the electric motor, and
determining the threshold levels that are exceeded by the operational measurement data corresponding to the operating point.
18 . The method according to claim 17 , wherein the method further comprises the step:
providing a monitoring signal indicating the number of threshold levels being exceeded by the operational measurement data.
19 . The method according to claim 18 , wherein the method further comprises the step:
initiating a maintenance process based on the monitoring signal if the monitoring signal indicates that the operational measurement value exceeds at least one of the threshold levels.
20 . The method according to claim 16 , wherein the generating the at least one threshold level for the determined baseline comprises generating a first threshold level and a second threshold level, wherein the first threshold level indicates a first probability of failure of the motor drive and the second threshold level indicates a second probability of failure of the motor drive, and wherein the first probability of failure is different than the second probability of failure.
21 . A motor drive for driving an electric motor and for monitoring operational measurement data of the electric motor, the motor drive comprising:
a measurement unit for acquiring initial measurement data for at least one operating point of the electric motor, wherein the initial measurement data comprises sensor data and/or estimated data;
a processing unit for determining a baseline from the initial measurement data for the at least one operating point;
an output unit; and
an enclosure;
wherein the processing unit is configured to generate at least one threshold level for the at least one determined baseline independent of the electric motor being in an on state or an off state;
wherein the at least one threshold level defines a level of deviation from the determined baseline;
wherein the output unit is configured to provide the at least one threshold level resulting in conditions for monitoring the operational measurement data of the electric motor;
wherein the motor drive is configured to receive an incoming frequency from an input line and provide an output frequency to the electric motor via an output line;
wherein the motor drive is configured to drive the electric motor through the output frequency provided to the electric motor; and
wherein the measurement unit, the processing unit, and the output unit are arranged within the enclosure, and the enclosure encloses motor drive elements that receive the incoming frequency from the input line and provide the output frequency to the electric motor via the output line in order to drive the electric motor.
22 . The motor drive according to claim 21 , wherein the processing unit is configured to transmit an alarm signal indicating a severe fault in the electric motor that may cause damage and a soon failure when the processing unit determines that the operational measurement data exceeds a highest threshold level of the at least one threshold level.