Abstract:
A load monitor for monitoring the load of a motor comprises a Central Processing Unit (CPU) and a memory. During normal operation of the motor, the load monitor is arranged to repeatedly measure the torque and registering the speed of the motor. In connection with each measurement of the torque and registering of the speed, the load monitor determines a load limit value valid for the registered speed, which load limit value is a function of a plurality of torques and speeds and a predetermined deviation value stored in the memory. The measured torque is then compared with the determined load limit value and if the measured torque is not within an acceptable range limited by the determined load limit value then an appropriate action is taken.

Description:
TECHNICAL FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to a load monitor or load indicator for a motor. More specifically, the invention also relates to methods for initiating monitoring and for monitoring the load of a motor and to a frequency converter for driving a motor and including a load monitor. 
       BACKGROUND OF THE INVENTION 
       [0002]    Load monitors are often used for protecting electrical motor systems from underload and overload. Load monitors in fixed frequency applications, such as mains connected or soft starter driven motors, are fully described by a normal load parameter and margins to define under-/overload conditions from this normal load. Basically this is how stand alone load monitors or load monitors included in motor drive systems works. 
         [0003]    In WO 99/25049 A1, a load monitor for an electric motor is disclosed. This load monitor calculates, by a command from a user when the motor is running normally, the limits for under-/overload from the actual load. Then, during normal operation, the current motor load is repeatedly determined and compared with the calculated load limits. This load monitor is advantageous in relation to earlier load monitors in that the presetting of the load limit is relatively shift and easy. 
         [0004]    U.S. Pat. No. 5,720,231 discloses a method for monitoring the operating conditions of an induced draft fan electric motor of a gas furnace system. The system has a microprocessor to control the speed of the electric motor to ensure that adequate back pressure and flow rate for safe and efficient furnace operation exist. Readings of parameters proportional to speed and torque are taken over a selected range of back pressures and stored, and one minimum and one maximum value of acceptable back pressures are selected. Then, on a continuous basis during normal operation of the induced draft fan electric motor, readings of actual operating values proportional to speed and torque are taken and compared with the stored parameters at the minimum and maximum values of acceptable back pressures. If the actual operating values are outside the range limited by the minimum value and maximum value, the system is deenergized. 
         [0005]    Even though the above mentioned methods of load monitoring works perfectly well in applications such as the one exemplified above, there are other applications in which the above methods of load monitoring are not satisfying, e.g. in varying speed applications. The problem is that operational disturbances are not always detected by the load monitor even though maximum and minimum load limits are set based on the actual load. As an example, in a pump application an operational disturbance may be caused by a damaged pipe, e.g. a hole in a pipe or a broken pipe, resulting in decreasing pressure in the pipes and thus the load on the motor is decreased. Another cause of operational disturbance may be the presence of none desired objects in the pipe, these may result in increased pressure and thus the load on the motor is increased. 
       SUMMARY OF THE INVENTION 
       [0006]    An object of the present invention is to provide an improved load monitor and method for initiating monitoring and for monitoring the load of a motor. 
         [0007]    A particular object of the invention is to provide a load monitor and corresponding methods which solve the above mentioned problem with failing detection of operational disturbances. 
         [0008]    This and other objects are achieved by the provision of a method for monitoring the load of a motor according to claim  1 , a method for initiating monitoring and for monitoring the load of a motor according to claim  13 , a load monitor for monitoring the load of a motor according to claim  15 , and a frequency converter including a load monitor according to claim  19 . Preferred embodiments of the present invention are defined in the dependent claims. 
         [0009]    More specifically, a method according to the present invention for monitoring the load of a motor comprises the acts of repeatedly measuring the torque and registering the speed during normal operation, determining, in connection with each measurement of the torque during normal operation, a load limit value valid for the registered speed, the load limit value being a function of a plurality of stored torques and speeds and a predetermined deviation value, and comparing, in connection with each measurement of the torque during normal operation, the measured torque with the determined load limit value. If the measured torque is not within an acceptable range limited by the determined load limit value, then an appropriate action is taken, such as the generation of an action signal. 
         [0010]    A load limit value as mentioned herein may be regarded as a torque limit value, since the speed for each such value is given. As defined herein, “normal operation” means the operation of the motor when the motor is running during a process of application. During normal operation, operational disturbances may occur, and hence the load of the motor may vary due to the disturbances. 
         [0011]    As mentioned above, a particular object of the invention is to provide a load monitor and corresponding methods which solve the problem with failing detection of operational disturbances. This problem often arises in variable speed applications. However, both of the examples from prior art above works perfectly well in many applications in which the speed of the motor varies. As seen above, the application disclosed in U.S. Pat. No. 5,720,231, with an induced draft fan electric motor of a gas furnace system, is a typical variable speed application, where the speed and torque of the motor vary depending on the present back pressure of the gas furnace system. The main difference between applications in which the above prior art solutions of load monitoring works well and applications in which they do not lies in to what extent the load, i.e. torque, of the motor is depending on the motor speed. If “normal load” at one speed differs more than marginally from “normal load” at another speed and this difference is due to the speed itself and not some other external parameter, the above mentioned prior art methods of load monitoring can then only protect the system at the end points of operation, i.e. overload at high speed and underload at low speed. Some operational disturbances which occur when the motor is running at an intermediate speed will then remain undetected. For example, it is possible that operational disturbances are not detected when, for instance, the pump is driven at relative low speed, because the load resulting from the disturbance may be less than an acceptable high load at a higher speed or it may be higher than an acceptable low load at a lower speed. The present invention solves this problem by providing a load limit value which is valid for a present registered speed and which is a function of a plurality of stored torques and speeds and a predetermined deviation value. Hence, at any speed, at least within a normal speed range of operation, there will be a specific load limit value which is determined from a function of a plurality of stored torques and speeds and a predetermined deviation value. If the stored torques varies with the speed, then the resulting load limit value will also vary with the speed. Hence, the load limit value will at each speed be set in relation to a true normal torque, and therefore operational disturbances occurring at intermediate speeds will be detected. 
         [0012]    According to one embodiment of the present invention, the method further comprises the act of automatically collecting said plurality of stored torques and speeds during an initiating sequence. Thereby, the collection of the plurality of torques and speeds becomes swift, easy and flexible, as compared to for example collection of the torque and speed parameters by manually stepping up the motor speed, measuring the torque and registering the speed. 
         [0013]    According to another embodiment of the invention, the act of automatically collecting comprises the acts of setting a first speed for the motor, measuring, after the act of setting a first speed, a torque of the motor, storing the measured torque and the value of the corresponding speed in a memory, setting a second speed for the motor after storing the previously measured torque and the value of the corresponding speed, and repeating the acts of measuring and storing for the new speed. 
         [0014]    Preferably, the method further comprises, between said act of setting during the initiating sequence a first speed for the motor and said act of measuring a torque of the motor, the act of waiting until an equilibrium state of the motor torque at said first speed is reached. 
         [0015]    In another embodiment of the invention, said act of determining comprises the act of computing, in connection with each measurement of the torque during normal operation, the load limit value as the function of a plurality of stored torques and speeds and a predetermined deviation value. Hence, each time a measurement of the torque is made during normal operation, the load limit value valid for the registered speed is computed. Thereby, memory space and time for memory reading is saved, since no plurality of predetermined load limit values have to be stored, but only the plurality of stored torques and speeds and the predetermined deviation value. 
         [0016]    In another embodiment, said act of computing further includes the act of interpolating between said stored torques and speeds in order to provide the load limit value at the registered speed if the registered speed does not correspond to any one of the stored speeds. 
         [0017]    In an another embodiment, which is an alternative to the one of computing the load limit value in connection with each measurement of the torque during normal operation, the method further comprises the acts of computing a plurality of load limit values as functions of said plurality of stored torques and speeds and the predetermined deviation value during an initiating sequence before said normal operation, and storing the computed load limit values during said initiating sequence. Instead of saving memory space, computing power may be saved in this embodiment, which may be advantageous for some applications. 
         [0018]    In another embodiment, the act of computing further includes the act of interpolating between said stored torques and speeds in order to provide further load limit values in the case the registered speed will not correspond to any one of the stored speeds. 
         [0019]    According to another embodiment of the invention, said act of determining includes both the act of determining a maximum load limit value and the act of determining a minimum load limit value, wherein said act of comparing includes both the act of comparing the measured torque with the determined maximum load limit value and the act of comparing the measured torque with the determined minimum load limit value, and wherein said acceptable range is between and limited by the maximum load limit value and the minimum load limit value. Thereby, both overload and underload may be detected. 
         [0020]    According to yet another embodiment of the invention, said act of determining includes both the act of determining said load limit value and the act of determining a warning limit value being a function of said plurality of stored torques and speeds and a predetermined warning deviation value which is smaller than said deviation value for said load limit value, and wherein said act of comparing includes both the act of comparing the measured torque with the determined load limit value and the act of comparing the measured torque with the determined warning limit value. By providing a warning limit value, different actions may be taken depending on how critical the overload/underload is. 
         [0021]    In another embodiment, said predetermined deviation value is in the form that it yields said load limit value when multiplied by a function of said plurality of stored torques and speeds. In an alternative embodiment, said predetermined deviation value is in the form that it yields said load limit value when added to a function of said plurality of stored torques and speeds. The choice of form of the predetermined deviation value may depend on the application. 
         [0022]    According to another aspect of the present invention, a method for initiating monitoring and for monitoring the load of a motor comprises the acts of: entering initiating sequence, setting, during the initiating sequence, a first speed for the motor, measuring, after the act of setting a first speed, a torque of the motor, storing the measured torque and the value of the corresponding speed in a memory, setting a second speed for the motor after storing the previously measured torque and the value of the corresponding speed, repeating the acts of measuring and storing for the new speed, shifting to normal operation when initiating sequence is completed, and monitoring a present torque of the motor at a present speed during the normal operation and relating the present torque to the torques and corresponding speeds stored during the initiating sequence in order to decide whether or not the present torque at the present speed is within an acceptable torque range. 
         [0023]    According to yet another aspect of the present invention, a load monitor for monitoring the load of a motor comprises a Central Processing Unit (CPU), means for automatically and repeatedly generating a signal for changing the speed of the motor during an initiating sequence, an input for a signal representing the torque, an input for a signal representing the speed, and a memory for storing a plurality of measured torques and corresponding speeds during the initiating sequence. Further, the inventive load monitor comprises means for repeatedly, during normal operation, comparing an input signal representing the torque with a load limit value valid for a speed given by the input signal representing the speed, and means for providing a load limit value, the load limit value being a function of the plurality of torques and speeds stored in the memory and a predetermined deviation value. 
         [0024]    According to another embodiment, the load monitor further comprises means for generating an action signal when the load, given by said input signal representing the torque generated by the motor, is out of a range defined by at least said load limit value. 
         [0025]    In another embodiment of the invention, said load monitor is included in a frequency converter, the frequency converter being arranged to drive a motor. This is advantageous in that the motor torque and speed parameters to be measured and registered, respectively, are easily accessible inside the frequency converter as the speed may be calculated from the present frequency of the frequency converter and the torque usually may be calculated from information provided by the frequency converter. For instance, the supply voltage and the supply current to the motor may be used to calculate the torque. The supply current to the motor is preferably measured. The supply voltage may be measured or may be calculated based on control signals in the frequency converter combined with a DC-voltage of a rectifier circuit of the frequency converter. 
         [0026]    A further scope of applicability of the present invention will become apparent from the detailed description given below. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0027]    Other features and advantages of the present invention will become apparent from the following detailed description of presently preferred embodiments, with reference to the accompanying drawings, in which 
           [0028]      FIG. 1  is a schematic block diagram of a first embodiment of a frequency converter including a load monitor according to the invention, the frequency converter being connected to a motor; 
           [0029]      FIG. 2  is a schematic block diagram of a second embodiment of a load monitor according to the invention, the load monitor being connected to a motor and possibly a frequency converter; 
           [0030]      FIG. 3  is a flow diagram of the initiating sequence in an embodiment of a load monitor; 
           [0031]      FIG. 4  is a flow diagram illustrating the function of an embodiment of a load monitor according to the invention during normal operation; and 
           [0032]      FIG. 5  is a graph of torque versus speed illustrating collected values of torque at different speeds and corresponding load limit value curves. 
       
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
       [0033]    In  FIG. 1  an electric motor  100  receiving its power supply  102  from a frequency converter  110  is shown. The frequency converter  110  is arranged to vary the speed of the electrical motor  100  by controlling the voltage and/or the current by means of power electronics  112  in the frequency converter  110 . The control of the power electronics is performed by means of a controller  114 . 
         [0034]    According to one embodiment of the invention a load monitor  116  is arranged in the frequency converter  110 . The information needed by the load monitor may then be provided directly by the frequency converter  110  or the controller  114  of the frequency converter  110 . The information may be represented by data transferred over a data bus or at least a signal carrying the information over a signal line. The information provided to the load monitor may be information representing the present torque T of the motor and information representing the present speed n of the motor. 
         [0035]    According to one embodiment the present torque and speed of the motor may be calculated from the present current and the present voltage, such implementations are known by the person skilled in the art. In a further embodiment the speed of the motor may alternatively be given by the desired value of the speed provided to the controller. 
         [0036]    The load monitor  116  may be connected to a memory  118  for storing data related to the function of the load monitor  116 , the data to be stored will be discussed below. 
         [0037]    Further, the load monitor  116  may be connected to the controller in order to send signals to the controller, these signals may be arranged to halt the motor or instruct the frequency converter  110  to perform other actions in response to a warning or alarm originating from the load monitor  116 . The load monitor may also be arrange to provide such alarm signals and/or other data relating to the operation of the load monitor to an external interface, e.g. a network connection, a data bus, separate signal lines, etc. 
         [0038]    According to one embodiment the controller  114  and the load monitor  116  are program modules executing in a processor  120 , e.g. a micro processor, a cpu, or any other processing device capable of executing program modules. In such embodiment the memory  118  may be the memory used by the processor and, thus, both the load monitor  116  and the controller  114  may use the same memory. 
         [0039]    In  FIG. 2 , another embodiment is shown. In this embodiment the load monitor  200  is arranged external to a frequency converter  210 . The frequency converter being arranged to provide the electrical motor  212  with power, via power supplies  214 , and to control the speed of the motor by controlling characteristics of the power to the electrical motor  212 . The frequency converter  210  may be a frequency converter similar to the frequency converter of  FIG. 1 . The general functionality of a frequency converter is known to the skilled person. 
         [0040]    The load monitor  200  includes a processor  202  and a memory  206  arranged to collect and analyze received information in order to monitor the load of the electrical motor  212 , the functionality will be described in more detail below. 
         [0041]    Input of information to the load monitor  200  may be arranged in a couple of ways. For instance the load monitor may include inputs  216  arranged to be connected to signal lines carrying signals from volt measuring means and or current measuring means arranged at the power supplies  214  between the motor and the frequency converter. In such an embodiment the line  218  between the load monitor may be arranged to provide the frequency converter with any one or any combination of alarm signals, halt instructions, instructions regarding performing some specified action, and other data. 
         [0042]    According to another embodiment the signals to the inputs  216  may originate from the frequency converter. In such case there is no need to install separate measuring equipment. 
         [0043]    Now, with reference to  FIGS. 3 ,  4  and  5 , the function of an embodiment of a load monitor, e.g. load monitor  116  or  200 , according to the invention will be described. 
         [0044]      FIG. 3  shows the initiating sequence in an embodiment of a load monitor according to the invention. In the following, when different parts of the inventive load monitor or other parts of a motor system in which the load monitor is implemented are mentioned, references are made to the embodiment shown in  FIG. 1  as an illustrative example. 
         [0045]    The initiating sequence for the load monitor  116 , 200  preferably is started when the motor and the system has reached a state of “normal operation”, i.e. when the system and the motor has been checked and found to work properly. Such a state may be determined manually or by means of some automation. However, in order to facilitate installation of the load monitor in a plurality of diverse systems said state may advantageously be determined manually. 
         [0046]    During the initiating sequence, the motor  100 ,  212  is run at a range of different speeds and the present torque at each speed is measured and stored together with the corresponding registered speed. By automatically collecting a plurality of torques and corresponding speeds in this way, a substantially correct load limit value at each speed may be calculated based on a true normal torque/load of the motor  100 ,  212  even though the load varies with speed. 
         [0047]    Referring now to  FIG. 3  in more detail, the initiating sequence for the load monitor  116 ,  200  is entered in step  1 . In step  2 , the automatic collection of torques and speeds starts by the setting of a first speed for the motor  100 , 212 . When the first speed is set, the load monitor  116 ,  200  waits in step  3  until an equilibrium state of the motor torque at the first speed is reached. Then, in step  4 , the torque of the motor  100 ,  212  is measured at the first speed. The measured torque and the registered first speed are then in step  5  stored together in the memory  118 ,  206  of the load monitor  116 ,  200 . 
         [0048]    An operator of the motor system may choose at which speeds the torque should be measured by setting a range of speeds before or in connection with an initiating sequence, e.g. the one described in connection with  FIG. 3 , is started. The setting of the range may be performed by setting each speed value individually or by setting the speed range and the frequency of the speeds or the number of speeds within the range. For example, the operator may choose to store nine pairs of corresponding torques and speed evenly distributed in a range of speeds from 300 rpm to 1500 rpm as illustrated in  FIG. 5 . 
         [0049]    If the application is such that the motor  100 ,  212  shall only run at one single speed, in which case prior art solutions would work just as well as the present invention, the initiating sequence will be finished after that one pair of corresponding torque and speed is stored, and hence the initiating sequence will end without looping and shift directly from step  6  to step  7  in which normal operation of the motor system starts. 
         [0050]    If two or more pairs of corresponding torques and speeds shall be stored, the initiating sequence jumps back from step  6  to step  2  and repeats steps  2  to  6  until the torque and corresponding speed has been stored for each speed that the operator has selected. Then, the process is shifted to normal operation of the motor system, step  7 . 
         [0051]    Hence, after the initiating sequence, a range of torques and corresponding speeds are stored in the memory  118 ,  206  of the load monitor  116 ,  200 . If for some reason the operator would like to change any of the stored torque values at different speeds, the implementation could be such that the stored values of normal torque may be changed manually. 
         [0052]    Reference is now made to  FIG. 4 , in which the function of an embodiment of a load monitor according to the invention during normal operation is illustrated. Reference is still made to  FIG. 1  when different parts of the motor system are mentioned. 
         [0053]    During the normal operation, the present torque of the motor  100 ,  212 , i.e. the load the motor is exposed to, at the present speed is monitored. This present torque is related to the torques and corresponding speeds stored during the initiating sequence in order to decide whether or not the present torque at the present speed is within an acceptable torque range. 
         [0054]    In step  8  the present torque is measured. The present speed is registered in step  9 . In step  10 , it is decided whether the registered speed corresponds to any one of the speeds stored in the memory  118 ,  206  during the initiating sequence. 
         [0055]    If the registered speed corresponds to a stored speed, the “normal” torque which is stored together with the stored speed is read from the memory  118 ,  206  in step  11 . 
         [0056]    If the registered speed does not correspond to a stored speed, the normal torque is in step  12  calculated from stored torque values at stored speeds which are higher and lower than the present speed. This is preferably made by means of some kind of interpolation method known to a person skilled in the art. A simpler alternative to using interpolation is to select from the memory a “normal” torque value corresponding to a torque value relating to a stored speed close to the registered speed. Other methods of approximating the “normal” torque is known by the person skilled in the art. 
         [0057]    In step  13 , maximum and minimum warning limit values are computed from the determined normal torque value. The warning limit values define load limits at which a warning to the operator or another part of the motor system is to be generated. These warning limits are used in addition to those limit values which herein are called load limit values and which define the load limits at which an alarm is to be generated and/or the motor system is halted. Hence, the warning limits are closer to the normal torque than the load limits, see  FIG. 5 . 
         [0058]    The warning limit values are calculated as a function of the normal torque value at a specific speed, which as seen above in turn is a function of the plurality of torques and speeds stored in the memory  118 ,  206 , and a predetermined warning deviation value. This warning deviation value is pre-set and may be manually changed by the operator. The warning limit value may either be calculated by adding the warning deviation value in the form of e.g. a preset torque value to the normal torque value or by multiplying the warning limit value with the warning deviation value in the form of a factor such as a percentage value. 
         [0059]    When the maximum and minimum warning limit values are determined in step  13 , the measured torque is compared with the warning limit values in step  14 . In step  15 , it is determined whether the measured torque is within the warning limit range defined by the maximum and minimum warning limit values. If the measured torque is within the range between the warning limits, the load monitor process proceed to the next step  17  and computes maximum and minimum load limit values. If the measured torque is not within the range between the warning limits, a warning e.g. to the operator is activated in step  16  and then the process proceed to step  17 . 
         [0060]    In step  17 , the maximum and minimum load limit values are calculated in a similar way as the warning limit values, i.e. by taking the determined normal torque at the registered speed and either adding a torque deviation value to it or multiplying it with a torque a torque deviation value. The torque deviation value is also pre-set and may be manually changed by the operator. 
         [0061]    Then, when the maximum and minimum load limit values are determined in step  17 , the measured torque is compared with the load limit values in step  18 . In step  19 , it is determined whether the measured torque is within the load limit range defined by the maximum and minimum load limit values. If the measured torque is not within the load limit range, an alarm is generated and/or the motor process is stopped in step  20 . If the measured torque is within the load limit range, the load monitor process goes to step  21  and waits a predetermined period of time before it jumps back to step  8  again for a new monitoring loop. 
         [0062]    In  FIG. 5 , torque/load versus speed is illustrated for nine collected values of normal torque at speeds in a range from 300 rpm to 1500 rpm. Further, the corresponding maximum and minimum warning limit values and maximum and minimum load limit values are shown. In this example, the warning limit values are calculated by adding the values of ±5 to the normal torque, and the load limit values are calculated by adding the values of ±10 to the normal torque. 
         [0063]    As in the above described embodiment of the invention, the warning and load limits may be calculated at each measurement loop of the load monitor during normal operation. This is advantageous since there is no need to store all the limit values for all possible speeds which the motor may adopt during normal operation. However, in an another embodiment in accordance with the invention all the possible limit values may be computed and stored during the initiating sequence before the normal operation. 
         [0064]    In the above exemplary embodiment, both maximum and minimum warning/load limit values are calculated. Alternatively, only a maximum torque/warning limit value could be calculated, wherein the acceptable torque range of operation is defined by the maximum load limit value and zero torque. 
         [0065]    In the above described embodiment, both load limit values and warning limit values are used. Alternatively, only load limit values could be used. 
         [0066]    It is to be understood that modifications of the above described systems and methods can be made by a person skilled in the art without departing from the spirit and scope of the invention.