Failure prediction in a rotating device

Some of the embodiments provide a method comprising: during an operation phase, operating a rotating device at a first speed; during the operation phase, monitoring a first current consumed by the rotating device to operate at the first speed; comparing the first current to a second current measured during a calibration phase while rotating the device at a second speed, wherein the first speed is substantially equal to the second speed; and based on comparing the first current and the second current, predicting a possible failure of the rotating device.

TECHNICAL FIELD

Embodiments of the present disclosure relate to rotating devices, and more particularly, to failure in rotating devices.

BACKGROUND

Unless otherwise indicated herein, the approaches described in this section are not prior art to the claims in the present disclosure and are not admitted to be prior art by inclusion in this section.

Fans are often used in a variety of systems and for a variety of purposes (e.g., for cooling an electronic system, for cooling a computer, etc.). A fan may fail for many reasons, e.g., due to a failure in a bearing that is used to mount the fan, dust or debris accumulating in an airflow path of the fan, etc. A failure of the fan (e.g., when the fan stops rotating) can be detected using, for example, a speed sensor that monitors a speed of rotation of the fan.

SUMMARY

In various embodiments, the present disclosure provides a method comprising: during an operation phase, operating a rotating device at a first speed; during the operation phase, monitoring a first current consumed by the rotating device to operate at the first speed; comparing the first current to a second current measured during a calibration phase while rotating the device at a second speed, wherein the first speed is substantially equal to the second speed; and based on comparing the first current and the second current, predicting a possible failure of the rotating device. In an embodiment, predicting the possible failure of the rotating device further comprises: in response to the first current being higher than the second current by a threshold percentage, predicting the possible failure of the rotating device. In an embodiment, predicting the possible failure of the rotating device further comprises: in response to the first current being higher than the second current by the threshold percentage for at least a threshold period of time, predicting the possible failure of the rotating device. The rotating device operates in the calibration phase during manufacturing or servicing the rotating device. Monitoring the first current consumed by the rotating device to operate at the first speed further comprises: during the operation phase, monitoring the first current at periodic intervals. Monitoring the first current consumed by the rotating device to operate at the first speed further comprises: during the operation phase, monitoring the first current during a start up of the rotating device. In an embodiment, the method further comprises: during the calibration phase, operating the rotating device at the second speed; and during the calibration phase, measuring the second current consumed by the rotating device to operate at the second speed. In an embodiment, the method further comprises subsequent to measuring the second current, storing a value of the first current in a memory.

In various embodiments, the present disclosure provides a system comprising: a rotating device; a speed control module configured to, during an operation phase, control the rotating device such that the rotating device operates at a first speed; and a failure prediction module configured to: during the operation phase, monitor a first current consumed by the rotating device to operate at the first speed, compare the first current and a second current measured during a calibration phase while rotating the device at a second speed, wherein the first speed is substantially equal to the second speed, and based on comparing the first current and the second current, predict a possible failure of the rotating device. The failure prediction module is further configured to: in response to the first current being higher than the second current by a threshold percentage, predict the possible failure of the rotating device. The rotating device operates in the calibration phase during manufacturing or servicing the rotating device. The failure prediction module is further configured to: during the operation phase, monitor the first current at periodic intervals. The failure prediction module is further configured to: during the operation phase, monitor the first current during a start up of the rotating device. The speed control module is further configured to, during the calibration operation phase, control the rotating device such that the rotating device operates at the second speed; and the failure prediction module is further configured to, during the calibration phase, monitor the second current consumed by the rotating device to operate at the second speed. The system further comprises: a memory configured to store a value of the second current. In an embodiment, the rotating device is a fan.

DETAILED DESCRIPTION

FIG. 1schematically illustrates a system100for operating a fan104, and selectively predicting a possible failure of the fan104. The system100comprises a motor106coupled to the fan104through a shaft108. The motor106is configured to drive the fan104through the shaft108. Although not illustrated inFIG. 1, the fan104comprises a plurality of blades, which rotates with the rotation of the motor106, thereby generating an air flow in the vicinity of the fan104. In an embodiment, the motor106, the shaft108and the fan104are housed in a single housing, and/or are combined to form a single component of the system100. InFIG. 1, the motor106, the shaft108, the fan104and any other associated mechanical arrangements (e.g., which are used to drive the fan104and the motor106) are referred to as a fan assembly122.

It is to be noted that although, as an example, some of the embodiments of this disclosure are directed towards predicting failure in the fan assembly122, the principles of this disclosure can be applied to predicting failure in any appropriate rotating device (e.g., any rotating device that rotates using electric power). For example, the principles of this disclosure can be applied to predicting failure in a disc drive system (e.g., in which a magnetic disc is rotated), a system that has one or more wheels being rotated by an electric motor, and/or the like.

In an embodiment, the fan assembly122is used for any appropriate purpose. For example, the fan assembly122can be used for cooling an electrical, electronic and/or mechanical system (e.g., for cooling a computing device, base station equipments mounted a cell phone tower, and/or the like), cooling a room, etc.

The system100further comprises one or more speed sensors112to measure a speed at which the fan104rotates. In an example, the speed sensor112comprises one or more hall effect sensors to measure the speed at which the fan104rotates, although any other appropriate speed measurement sensor can also be used.

The system100further comprises one or more thermal sensors114to measure a temperature of one or more locations within the system100, or external to the system100. In an example, the thermal sensor114measures a temperature of an electronic device that is cooled by the system100, e.g., cooled by the fan104(e.g., in such an example, the thermal sensor114may be located outside the system100). Additionally or alternatively, the thermal sensor114measures a temperature of one or more components within the system100, e.g., the temperature of the motor106and/or the fan104(e.g., in order to prevent over-heating of the motor106and/or the fan104).

The system100further comprises a speed control module116configured to control or regulate a speed of the fan104. Based on output of the speed sensor112, the thermal sensor114and/or other input received from a user of the system100, the speed control module116controls the speed of the fan104(e.g., by controlling the motor106). In an example, the speed control module116can dynamically vary the speed of the fan104, in order to regulate a temperature of an electronic system that is cooled by the fan104(e.g. maintain the temperature at substantially a constant level). In another example, the speed control module116is configured to run the fan104at a constant speed.

The system100further comprises a failure detection module118configured to detect a fault or a failure of the fan assembly122and/or of any other component of the system100. As an example, the failure detection module118receives an output from the speed sensor112. If the fan104and/or the motor106fails to start, stops for some reason, and/or runs at a speed that is different from a speed at which the fan104and/or the motor106is configured to be run by the speed control module116, the failure detection module118detects such an event using the output of the speed sensor112. Based on detecting such an event, the failure detection module118detects a fault or a failure of the fan assembly122. In another example, the failure detection module118can also detect a fault in the system100by any other appropriate manner (e.g., by detecting overheating of one or more components of the system100, using an output of the thermal sensor114). In an embodiment, the failure detection module118detects a fault in the system100only after the fault has occurred in the system100, and has limited capability in predicting a possible failure in the system100.

The system100further comprises a memory120, which may be configured to store instructions that, if executed, result in operations of one or more components (e.g., the failure prediction module110, the speed control module116, the failure detection module118, and/or the like) of the system100. The memory120stores various information for use by one or more modules of the system100, as will be discussed in more detail herein.

In an embodiment, the fan104, the shaft108and the motor106are coupled to each other via a mechanical arrangement (not illustrated inFIG. 1) comprising, for example, bearings, gears, and/or the like. Such a mechanical arrangement is used to mount and rotate various components of the fan assembly122. Usually, the mechanical arrangement undergoes wear and tear, as the fan assembly122is used over an extended period of time, leading to potential eventual failure of one or more components of the mechanical arrangement. For example, the bearings of the mechanical arrangement can develop cracks, and eventually fail over time. Generally, the failure of the mechanical arrangement is not a sudden event, and happens gradually with time (although in some situations, such a failure may occur suddenly, without any initial wear and tear of the mechanical arrangement).

The wear and tear of the mechanical arrangement increases a friction that the motor106and/or the fan104have to encounter to rotate. When the mechanical arrangement eventually fails, the motor106and/or the fan104may stop running. In an embodiment, with the wear and tear of the mechanical arrangement in the fan assembly122, a current required to operate the motor106at a given speed increases (e.g., because of the increase in the friction with the wear and tear of the mechanical arrangement).

For example, when the bearings in the mechanical arrangement work as intended (e.g., immediately after installing and/or replacing the bearings), a nominal current In is required to operate the motor106and/or the fan104at a given speed. If the bearings start to develop a fault (i.e., wears and tears by, for example, developing a crack in the bearings), the current required to operate the motor106and/or the fan104at the given speed increases (e.g., because of the increased friction caused by the faulty bearing), and is higher than the nominal current In. If the bearing eventually fails, the motor106and/or the fan104fail to operate at the given speed.

Failure of the motor106and/or the fan104may also be caused due to various other reasons, e.g., due to accumulation of dust and/or other debris in an airflow path of the fan104. Failure due to accumulation of dust and/or other debris is also gradual in nature. That is, usually, dust and/or other debris accumulates gradually over time, and a current required to operate the motor106and/or the fan104at a given speed increases with such dust and/or other debris accumulation. When a level of the accumulated dust and/or other debris is very high (e.g., higher than a threshold level), the motor106and/or the fan104fail to operate at the given speed.

In an embodiment, the system100comprises a failure prediction module110configured to selectively predict a possible failure of the fan assembly122. In an embodiment, the failure prediction module110monitors a current level used by the motor106to operate the fan104at a given speed. Based on monitoring the current level, the failure prediction module110predicts a possible failure of the fan104.

In an embodiment, the system100operates in a calibration phase and an operation phase.FIG. 2illustrates a graph200including example variations of a current used to drive the motor106at a given speed during the calibration phase and the operation phase of the system100.

During the calibration phase, the system100(e.g., the fan assembly122, including the motor106, the shaft108and/or the fan104) is known to operate without any fault or failure in the fan assembly122. The calibration phase occurs, for example, during or immediately after manufacturing the fan assembly122, after servicing the fan assembly122(e.g., after checking and possibly replacing at least some of the bearings of the fan assembly122), and/or the like.

In an embodiment, during the calibration phase, current required to operate the fan104at various speed levels (e.g., those speed levels in which the fan would normally operate in the operation phase) are measured. As an example, during the calibration phase, current required to operate the fan104at 10,000 revolutions per minute (i.e., 10,000 RPM, which, for example, may be a nominal speed of the fan104) is measured, which is referred to herein as nominal current In. For example, referring toFIG. 2, a time period between time T1 and T2 denotes the calibration phase of the system100. During the calibration phase, the current required to operate the fan104at 10,000 RPM is illustrated as the nominal current In in the graph200. In an embodiment, a value of the nominal current In is stored in the memory120.

It is to be noted that the 10,000 RPM speed of the fan104is used merely as an example, and one or more other RPM values of the fan104may be used instead. For example, in an embodiment, during the calibration phase, currents required to operate the fan104at each of 5000 RPM, 6000 RPM, . . . , 12,000 RPM (or any other appropriate RPM values) may also be measured and stored in the memory120.

The operation phase of the system100refers to a regular or normal operation of the system100(e.g., when the fan104is used for cooling purposes). Assume, for example, that during at least a part of the operation phase of the system100, the fan104is rotated at 10,000 RPM. A current required by the motor106to drive the fan104at 10,000 RPM during the operation phase is denoted herein as actual current Ia. InFIG. 2, the operation phase starts from time T3.FIG. 2illustrates a variation of the actual current Ia during the operation phase of the system100. It is to be noted that the variation of the actual current Ia illustrated inFIG. 2is merely an example.

In an embodiment, if no fault has developed in the fan assembly122(e.g., if the bearings in the fan assembly122are working as intended, if dust and/or debris accumulation is below a permissible level, and/or the like), then the actual current Ia has a similar, or almost similar value compared to the value of the nominal current In. For example, if no fault has developed in the fan assembly122, then the actual current Ia is within a threshold percentage of the nominal current In (e.g., the actual current Ia is ±50% of the nominal current In). For example, between time T3 and time T4 inFIG. 2, when no fault has developed in the fan assembly122, the actual current Ia is illustrated to be very close to the nominal current In.

However, as and when a fault starts developing in the fan assembly122, the actual current Ia increases. For example, if a bearing of the fan assembly122develops a fault, the faulty bearing generates friction against the rotation of one or more components within the fan assembly122, and an increase in the actual current Ia is required to counter the friction while rotating the fan104at 10,000 RPM. In another embodiment, the fault is developed due to increase in dust and/or other debris accumulation in the fan assembly122, or in the airflow path of the fan104. For example, at or around time T4 inFIG. 2, a fault develops in the fan assembly122. Accordingly, the actual current Ia starts increasing from at or around time T4, as illustrated inFIG. 2.

If no action is taken to rectify the developed fault, the fan assembly122will eventually fail at, for example, time T6, as illustrated inFIG. 2. For example, at time T6, the fan104will stop rotating, or will start rotating at a reduced speed (e.g., compared to a desired speed provided by the speed control module116to the fan assembly122). Such a failure can be detected by the failure detection module118(e.g., using the output of the speed sensor112). However, the failure detection module118can detect the failure at time T6, i.e., after the fan104has already failed.

In an embodiment, prior to the actual failure of the fan assembly122at time T6, the failure prediction module110predicts a possible failure of the fan assembly122at time T5. In an embodiment, the failure prediction module110continuously or periodically (e.g., at every few seconds, few minutes, few hours, after every start up of the fan104, etc.) monitors the actual current Ia, and compares the actual current Ia and the nominal current In. When the actual current Ia exceeds the nominal current In by a threshold percentage T, the failure prediction module110predicts a possible failure of the fan assembly122. For example, at time T5, the actual current Ia exceeds the nominal current In by the threshold percentage T, based on which at time T5 the failure prediction module110predicts a possible failure of the fan assembly122. In an embodiment, predicting a possible failure of the fan assembly122comprises predicting a high probability of imminent failure of the fan assembly122(e.g., high probability of failure of the fan assembly122in near future).

The threshold percentage T is, merely as an example, 150%. Accordingly, if the nominal current is 2 amperes, the failure prediction module110predicts the possible failure of the fan assembly122when the actual current Ia exceeds 3 amperes.

In an embodiment, the failure prediction module110predicts the possible failure of the fan assembly122if the actual current Ia exceeds the nominal current In by the threshold percentage T for at least a threshold period of time (which may be, for example, at least a few seconds). Using the threshold period of time avoids false prediction due to, for example, a momentary spike in the actual current Ia during, for example, start up of the motor106.

Once the failure prediction module110predicts the possible failure of the fan assembly122, various corrective measures may be taken. For example, the bearings of the fan assembly122may be checked and possibly replaced, dust and debris accumulation near the fan assembly122may be removed, and/or the like. Such corrective measures may prevent the eventual failure of the fan assembly122.

Without the failure prediction module110, the failure of the fan assembly122is detected (e.g., by the failure detection module118) only after the fan assembly122has actually failed. However, the failure prediction provided by the failure prediction module110results in timely corrective actions, thereby preventing actual failure of the fan assembly122.

FIG. 3illustrates an example method300for predicting a failure of a rotating device (e.g., the fan104ofFIG. 1) while operating the rotating device. At302, during a calibration phase of the rotating device, the rotating device is operated at a first speed (e.g., at a nominal speed of the rotating device, which is, for example, 10,000 RPM). At304, during the calibration phase, a first current (e.g., the nominal current In) consumed by the rotating device to operate at the first speed is measured. In an embodiment, a value of the first current is stored in a memory (e.g., memory120ofFIG. 1).

At306, during an operation phase, the rotating device is operated at a second speed that is substantially equal to the first speed. For example, a speed control module (e.g., the speed control module116ofFIG. 1) controls the speed of the rotating device such that the rotating device operates at the second speed that is substantially equal to the first speed. At308, during the operation phase, a second current (e.g., the actual current Ia) consumed by the rotating device to operate at the second speed is monitored (e.g., by the failure prediction module110). At310, the first current is compared (e.g., by the failure prediction module110) with the second current. At312, based on comparing the first current and the second current, a possible failure of the rotating device is predicted (e.g., by the failure prediction module110). For example, based on the second current being higher than the first current by a threshold percentage (and for at least a threshold period of time), the possible failure of the rotating device is predicted.

In accordance with various embodiments, an article of manufacture may be provided that includes a storage medium having instructions stored thereon that, if executed, result in the operations described herein with respect to the method300ofFIG. 3(and/or various other operations discussed in the present disclosure). In an embodiment, the storage medium comprises some type of non-transitory memory (e.g., memory120). In accordance with various embodiments, the article of manufacture may be a computer-readable medium such as, for example, software or firmware.

Although specific embodiments have been illustrated and described herein, it is noted that a wide variety of alternate and/or equivalent implementations may be substituted for the specific embodiment shown and described without departing from the scope of the present disclosure. The present disclosure covers all methods, apparatus, and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents. This application is intended to cover any adaptations or variations of the embodiment disclosed herein. Therefore, it is manifested and intended that the present disclosure be limited only by the claims and the equivalents thereof.