EMBEDDED VIBRATION AND SHOCK SENSOR WITH AN INTEGRATED MOTOR DRIVE ASSEMBLY

The present disclosure is directed to an integrated drive module assembly with vibration-based anomaly detection. The integrated drive module assembly may include a motor coupled to a drive module. The drive module may provide electric power to the motor for operation. Moreover, the drive module may provide control signals to control operations of the motor. The drive module may include an accelerometer and a processing circuit. The processing circuit may determine baseline vibration profiles of the motor during operation using the accelerometer. Subsequently, the processing circuit may determine anomaly conditions of the motor based on comparing the vibrations of the motor with the baseline vibration profiles. Accordingly, the integrated drive module assembly may facilitate performing countermeasures with low latency based on detecting the anomaly conditions using the accelerometer when the drive module is coupled to the motor.

BACKGROUND

The present disclosure relates generally to drive modules, and more particularly, to drive modules for use in a motor-drive system, which may be part of an industrial automation system.

A wide range of systems in industry and other applications utilize automated control by actuating loads, such as electric motors. In motor-drives, for example, sophisticated control circuitry allows for implementation of control schemes that produce variable frequency output to drive motors at desired speeds. The motor-drives may be designed around individual packages, based on the power output of the motor or frame size, that can be programmed and wired to receive input power as well as to output conditioned power to the electric motor. Such packaged products typically include power condition circuitry that receives alternating current (AC) input voltage and converts the AC input voltage to a direct current (DC) voltage, before reconverting the DC voltage to controlled frequency AC voltage output. However, many products are designed to power specific sizes of motors (typically rated by the power output and/or frame size) and may only interface with a single size of motor. Accordingly, customers may have limited flexibility in using an existing motor-drive with different sized motors. Further, manufacturers and vendors of industrial automation systems may keep a larger inventory of motor-drives on hand to be compatible with a range of motor sizes. As such, motor-drives being designed to be compatible with specific motor sizes may result in increased cost, limited flexibility, and inventory-related inefficiencies.

BRIEF DESCRIPTION

In an embodiment, an integrated drive module assembly is described. The integrated drive module assembly may include a first housing and a second housing. The first housing may include a motor. Moreover, the first housing may be coupled to the second housing. The second housing may include a power circuit board that may provide one or more voltages to the motor. The second housing may also include a control circuit board and a potting material. The control circuit board may include at least one processor configured to control one or more operations of the power circuit board. The control circuit board may also include an accelerometer configured to detect a first set of vibrations. The potting material may surround the power circuit board and the control circuit board within the second housing. Accordingly, the first set of vibrations may be detected by the accelerometer matches the vibrations of the motor, based on the potting material bonding the control circuit to the second housing.

In another embodiment, a method is described. The method may include receiving a first set of vibration data of a motor of an integrated drive motor assembly by a processor of the integrated drive motor assembly. The first set of the vibration data of the motor is received by the processor from an accelerometer of the integrated drive motor assembly during a first period of time. The method may also include generating one or more baseline vibration profiles based on the first set of vibration data by the processor. The method further includes receiving a second set of vibration data of the motor from the accelerometer during a second period of time after the first period of time by the processor. The motor is operating during the second period of time. The method further includes comparing the second set of vibration data with the one or more baseline vibration profiles by the processor. The method may also include determining one or more anomalies (e.g., faults) based on the comparison by the processor.

In another embodiment, a method of manufacturing an integrated drive module assembly with vibration based anomaly detection is described. The method includes assembling a control circuit in a first housing of the integrated drive module assembly. The control circuit may include a processor and an accelerometer to detect vibrations. The method also includes potting, using potting material, the first housing to bond the control circuit with an interior of the first housing. The method may also include coupling the first housing to the second housing via an adapter. The second housing includes a motor that may operate to move a load. As such, the accelerometer may detect vibrations of the motor via the second housing and the potting material. The potting material may reduce vibrations of the accelerometer relative to the second housing.

DETAILED DESCRIPTION

When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. As used herein, “in-line” refers to a longitudinal axis of a drive module or a component of a drive module arranged parallel with a rotational axis of a rotor of a motor. As used herein, “potting” refers to covering electronic components (e.g., circuitry) and/or filling an assembly containing electronic components with a solid or gelatinous material to prevent adverse environmental factors (e.g., water, moisture, corrosion, and so forth) and/or adverse effects from physical forces (e.g., impacts, shocks, vibrations, and so forth). As used herein, “power conversion” refers to converting alternating current into direct current, converting direct current into alternating current, altering a voltage of a current, or altering a frequency of a current, or any combination thereof.

By way of introduction,FIG.1is a perspective view of an industrial automation system10. The industrial automation system10may include a power source12, a drive module14, which includes control circuitry16(e.g., a controller board) and power circuitry18(e.g., a power board), a motor20, and a load22. The control circuitry16, which may be used to control operations of the drive module14, may include various subcomponents, such as a non-transitory memory26, a processor28, an accelerometer30, a user interface, and the like. The drive module14may also include various subcomponents, such as a rectifier, an inverter, driver circuitry, one or more switches, etc., that may be used to control the operation of the motor20. In the instant embodiment, the industrial automation system10may include one or more drive modules14coupled to respective motors20, which are then coupled to one or more loads22via a connection24.

In some cases, the motor20(or some component associated with the motor) may be provided with an encoder or a similar device to provide feedback data to the drive module14. For example, the encoder measures the angular position of the motor shaft, from which velocity and acceleration data may be derived, to provide the feedback data to the drive module14. In certain motors and associated control circuitry, this information may be estimated for “sensorless” control. Where such information is measured or estimated, the system may be controlled to implement a closed-loop velocity control regime, a torque-control regime, or other known techniques to track the desired motion and/or load profile of the application. For example, the drive module14may adjust the power output to the motor20(e.g., the frequency of the drive signals), thereby controlling its speed, based on the signal from the encoder20.

The power circuitry18may be designed for any suitable power rating. The power circuitry18may receive three-phase power and output three-phase power for operation of the motor20. For example, the power circuitry18may include any number of components, such as rectifiers, inverters, converters, switches, and so forth that may receive three-phase AC power, may rectify the three-phase AC power to DC power (e.g., a DC voltage waveform), and may invert and may generate a three-phase output AC power waveform at a desired frequency for actuating the motor20connected to the drive module14. Moreover, the power circuitry18may be configured to condition the power signal output. For example, the power circuitry18converts a signal from alternating current (AC) to direct current (DC), convert a signal from DC to AC, step a signal up, step a signal down, and the like. In some cases, the processor28of the control circuitry16may control switching frequency or firing angles of one or more switching devices (e.g., IGBTs, transistors) that are disposed on the power circuitry18. The changes to switching frequency may adjust or modify the AC voltage waveforms, phase shifts between the AC voltage waveforms, and other properties associated with the AC voltage waveforms provided to the motor20within a motor housing.

The power source12may supply a regular voltage or high voltage AC signal provided by a utility power grid (e.g., a standard electrical outlet), a battery, a capacitor, a generator, or some other source of AC or DC electrical power. However, it should be understood that many possible embodiments are envisaged. For example, the control circuitry16may include various components that may output one or more control signals (directly or indirectly) to the motor20or actuator to cause the motor to operate. For example, the motor may operate to move (e.g., spin, rotate, etc.) a shaft. The processor28of the control circuitry16may provide the control signals based on data acquired from the accelerometer30, the non-transitory memory26, or both.

The motor20may have mechanical and/or electrical components and may include a linear motor, a servo, a rotational electric motor, a combustion engine, a trolley, a mover, or any other component configured to move in response to a control signal. The motor20may be disposed within a separate housing (e.g., the motor housing) as compared to the drive module14, such that the two housings may be coupled directly to each other or via an adapter module or housing element. The load22may be any load that is moved by the motor20. In some embodiments, the industrial automation system10may include sensors32disposed on the motor, on the load22, or both. The sensors32may be in communication with the control circuitry16(e.g., the processor28) of the drive module14. For example, the control circuitry16may generate the control signals based on receiving the measurements from the sensors32.

The drive module14may include circuitry designed for starting, driving, braking, actuating, and performing any other suitable control operations for the motor20. The circuitry may be designed for any suitable power rating, often referred to by the frame size, of the motor. For example, the processor28of the control circuitry16may monitor functions and coordinate operations of the motor20. The drive module14and the motor20may communicate using a network connection according to any suitable connection protocol, such as standard industrial protocols, Ethernet protocols, Internet protocols, wireless protocols, and so forth.

The processor28typically carries out predefined control routines, or those defined by an operator, based upon parameters set during commissioning of the equipment and/or parameters sensed and fed back to the control circuitry16during operation of the motor20. The control circuitry16may include an interface to transfer control, feedback, and other signals to the motor20and/or external devices. Many different control schemes and functions may be implemented by the control circuitry16. Programs for some of the operations may be stored on a non-transitory computer-readable medium (e.g., the non-transitory memory26).

With the foregoing in mind, the drive module14and the motor20may be assembled (e.g., coupled) in one piece as an integrated drive motor assembly34. The integrated drive motor assembly34may include the drive module14and the motor20coupled via an adapter. In some cases, the integrated drive motor assembly34may be assembled in one enclosure or housing during manufacturing to include the drive module14and the motor20. In addition, the integrated drive motor assembly34may be assembled after manufacturing to include the drive module14and the motor20in one enclosure or housing. In such cases, the drive module14of the integrated drive motor assembly34may move (e.g., vibrate) consistently with the movements of the motor20based on the drive module14and the motor20being coupled together.

The integrated drive motor assembly34may operate under the control of the control circuitry16. As such, the control circuitry16may monitor the operations of the power circuitry18and the motor20based on receiving collected data (e.g., vibrations, voltages, speeds, temperatures, pressures, and so forth) from any number of sensors. For example, the accelerometer30may provide vibration and/or shock data of the motor20to the processor28.

Moreover, the control circuitry16may control operations of the power circuitry18and the motor20based on the vibration data. In some cases, the control circuitry16may send the control signals to the power circuitry18and/or the motor20based on processing the vibration data. For example, the control signals may cause switches of the power circuitry18to open when detecting an anomaly (e.g., a high vibration of the motor20), thereby removing power to the motor20to prevent damage.

Moreover, in specific cases, the processor28of the control circuitry16may determine movements or vibrations of the motor20using the accelerometer30. For example, the processor28may determine various vibration and/or shock profiles of the motor20based on operational data related to the motor20and the corresponding vibration patterns measured by the accelerometer30. The processor28may store the vibration profiles on the non-transitory memory26or transmit the vibration profiles to other components of the industrial automation system10for storage and/or processing.

FIG.2illustrates an example integrated drive motor assembly34. The depicted integrated drive motor assembly34includes the drive module14and the motor20discussed above. As mentioned above, in some cases, the drive module14and the motor20of the integrated drive motor assembly34may be coupled to each other using an adapter52. The drive module14may actuate the motor20at controlled speeds. The drive module14may regulate output of the motor20in terms of speed, torque, power, or a combination of such parameters.

In a practical application, the motor20would be coupled to a load, such as the load22discussed above, to be driven to carry out industrial automation tasks (e.g., a pump, a conveyor, transmission equipment, and so forth). As will be appreciated by those skilled in the art, in many applications, the integrated drive motor assembly34may inter-operate with other machines, robots, conveyers, control equipment, and so forth (not separately shown) in an overall automation, packaging, material handling or other application.

The integrated drive motor assembly34may be part of an industrial automation system, such as the industrial automation system10, to automate groups of tasks. For example, the integrated drive motor assembly34may automate manufacturing, material handling, mining, food processing, oil and gas extraction, refining, chemical processing, or any other useful application. Further, the industrial automation system may be physically and/or communicatively coupled with other systems by networks, both wired and wireless, at a single location or at dispersed locations in an organization.

The integrated drive motor assembly34may receive three-phase power and/or direct current power from a power source (e.g., the power source12), such as an electrical grid, a battery, a generator, etc. The integrated drive motor assembly34may also convert fixed frequency input power from the power source to controlled frequency output power. As such, the integrated drive motor assembly34may manage application of electrical power to the loads (e.g., the load22). The loads may include various machines or motors.

In the depicted embodiment, the drive module14may collect vibration data of the motor20based on being coupled to the motor20via the adapter52. The drive module14may use the accelerometer30to collect the vibration and/or shock data. The drive module14may use the vibration data for monitoring and controlling functions of the motor20. For example, the drive module14may determine anomalies of the integrated drive motor assembly34based on detecting outlier vibration data of the motor20. Moreover, the drive module14may provide the control signals to adjust operations of the motor20based on the vibration data (e.g., detecting the anomalies). Additionally, the drive module14may also collect other data such as current, voltage, speed, rotational velocity, temperatures, pressures, and so forth. This other collected data may be correlated or matched with the collected vibration data to track operational characteristics of the drive module14with respect to the detected vibration data. That is, changes in the vibration data may correspond to direct correlations with other data changes. In this way, the vibration data may be used to determine or predict whether other aspects or operational characteristics are changing.

The integrated drive motor assembly34may include a housing54. The housing54may include any number of portions, such as body portion54A and end cap portion54B. The body portion54A may have an interior cavity that houses drive circuitry. In particular, the body portion54A may include the control circuitry16and the power circuitry18for starting, driving, braking, actuating, sensing (e.g., collecting vibration data), and any suitable control of the motor20. In particular, the control circuitry16may be assembled in the body portion54A using any viable connector (e.g., bearings). The end cap portion54B may be located at a first end of the body portion54A and may be coupled to the body portion54A (e.g., via fasteners, snaps, adhesives, etc.).

In some embodiments, the end cap portion54B may be formed of a metal material, molded plastic, etc. For example, the end cap portion54B may include a user interface56. The user interface56may include one or more illuminating indicators, actuatable buttons or knobs, a display, a human-machine interface (HMI), and so forth, that may provide an indication of an operational state (e.g., on, off, starting, braking, fault, and so forth) of the drive module14and the motor20. In certain embodiments, the user interface56may include any suitable type of display, such as any number of light emitting diodes (LEDs), a liquid crystal display (LCD), plasma display, and so forth. For example, the LEDs may illuminate in particular colors to provide an indication to a user of the operational state of the drive module14and the motor20. Additionally, the user interface56may include a touch-sensitive mechanism (e.g., a touch screen) that may serve as part of a control interface for the integrated drive motor assembly34.

The integrated drive motor assembly34may also include any number of data and/or power interfaces, such as hybrid connectors58, coupled (e.g., mounted, fastened, and so forth) to the housing54of the drive module14. The hybrid connectors58may enable data communication between the integrated drive motor assembly34and external devices (e.g., another drive module, a power interface module, and so forth). The hybrid connectors58may also transfer power between the integrated drive motor assembly34and the external devices (e.g., another drive module, a power interface module, and so forth).

For example, the hybrid connectors58may include an Ethernet interface to communicate via various industrial data exchange protocols. The Ethernet capability allows the integrated drive motor assembly34to be integrated into an Ethernet/IP infrastructure of an industrial automation system. The communication may follow any desired protocol, such as Ethernet/IP, DeviceNet, high speed drive serial interface (HSDSI), Modbus, and so forth. The hybrid connectors may also provide DC and/or AC power transfer.

In the depicted embodiment, the drive module14may include any number of input/output (I/O) ports, such as I/O port60. The I/O port60may be a communication interface and may couple to other peripheral components such as input devices (e.g., keyboard, mouse, and so forth), sensors, I/O modules, and so forth. For example, a connected I/O module may permit the drive module14to communicate or interact with other devices in the industrial automation system. The drive module14may use the control circuitry16to communicate or interact with other devices in the industrial automation system.

The integrated drive motor assembly34may also include a housing extension (e.g., the adapter52). The adapter52may be coupled to the housing54at an opposite end from the end cap portion54B. The adapter52may couple the housing54to the motor20. The adapter52may be coupled to the housing54at a first end and may be coupled to the motor20at a second end, opposite of the first end, such that the adapter52is disposed between the housing54and the motor20.

For example, the adapter52may couple the body portion54A of the housing54to a rotational axis of the shaft of the motor20in parallel with the longitudinal axis of the housing54. Additionally, the rotational axis of the motor shaft may be aligned with the longitudinal axis of the housing54. In different embodiments, the adapter52may be shaped differently according to a particular frame size of the motor20. In any case, the adapter52provides an interface to couple the drive module to the motor20.

Moreover, the integrated drive motor assembly34may use the control circuitry16, positioned inside the housing54, to collect the vibration data of the motor20since the adapter52physically couples the drive module14with the motor20. As such, the accelerometer30of the drive module14may detect vibrations of the motor20based on the adapter52connecting the drive module14with the motor20. The drive module14may use the processor28and the accelerometer30to collect the vibration data and/or shock data of the motor20. The drive module14may use the received vibration data to determine the control signals that may be sent to the power circuitry18and/or the motor20.

Furthermore, in some embodiments, the housing54may be filled (e.g., partially filled, fully filled) with potting material (e.g., silicone-based potting compound, sealant, or any other viable potting materials) to bond the control circuitry16and the housing54together. In such embodiments, the accelerometer (e.g., the accelerometer30) of the drive module14may vibrate with the motor20based on the movement of the adapter52coupling the drive module14with the motor20. Moreover, the potting material that bonds the housing54to the control circuitry16may transfer the vibrations of the motor20and the adapter52to the accelerometer30. Accordingly, the processor28of the drive module14may monitor the vibrations of the motor20based on vibrations detected by the accelerometer30.

FIG.3Aillustrates an exploded view of the integrated drive motor assembly34. The housing54may include an interior cavity62. The cavity62may extend along a length of the body portion54A. For example, the cavity62may extend from a first end adjacent the end cap portion54B to an opposite end adjacent the adapter52. The end cap portion54B may couple to the body portion54A at the first end and may cover an opening of the body portion54A to enclose the cavity62. The cavity62may include any number of circuit boards including the control circuitry16and the power circuitry18. In the depicted embodiment, the non-transitory memory26, the processor28, and the accelerometer30may be positioned on the control circuitry16.

The control circuitry16and the power circuitry18may be coupled to the body portion54A and/or the end cap portion54B via any number of fasteners. As mentioned above, in some embodiments, the cavity62of the housing54, including the control circuitry16, may be potted. In different cases, the cavity62may be partially or fully filled with potting material to bond the control circuitry16with the body portion54A and/or the end cap portion54B. As such, potting the cavity62may reduce or prevent vibrations of the accelerometer30disposed on the control circuitry16relative to the housing of the motor20. Instead, the accelerometer30and the control circuitry16may move or vibrate at the same frequency or consistent with the vibrations of the motor20of the integrated drive motor assembly34during operation. That is, the potting material may limit the vibrations that may be created from sources other than the vibrations of the motor20.

In some embodiments, the accelerometer30may sample the vibrations and provide the vibration data to the processor28. For example, the accelerometer30may provide the vibration data to the processor28via a trace66or some other electrical connection. In some embodiments, the accelerometer30may provide one or more analog or digital signals indicative of the detected (e.g., sensed) vibrations to the processor28. For example, the accelerometer30may provide the one or more analog signals to the processor28via the trace66. In such cases, the processor28may sample the received analog signal to determine the vibration data. In any case, the processor28may receive the vibration data (e.g., determine the vibration data) with low latency (e.g., 1 nanosecond, 2 nanoseconds, 5 nanoseconds, 10 nanoseconds, and so on, 1 microsecond, 2 microseconds, 5 microseconds, 10 microseconds, and so on) based on the relatively close distance between the processor28and the accelerometer30, as opposed to the accelerometer30being positioned on the motor20or away from the processor28.

FIG.3Billustrates the integrated drive motor assembly34with a transparent side view of the body portion54A. In the depicted embodiment, a transparent side view of the adapter52is also illustrated. It should be appreciated that in different embodiments, a different adapter52may couple the drive module14to the motor20. In any case, in the depicted embodiment, the housing54may be filled (e.g., partially filled, fully filled) with potting material to bond the control circuitry16and the housing54. A potted area64is shown for bonding the control circuitry16and the housing54of the drive module14inside the cavity62.

In other embodiments, the potting material of the potted area64may partially or fully fill the cavity62to bond the control circuitry16with the body portion54A and/or the end cap portion54B. Accordingly, the potted area64may reduce (or prevent) vibrations of the control circuitry16and the accelerometer30that may be related to the coupling of the control circuitry16to the body portion54A and/or the end cap portion54B or other couplings. As such, the accelerometer30of the control circuitry16may detect (e.g., only detect) vibrations and/or shocks of the motor20of the integrated drive motor assembly34during operation.

FIG.4illustrates a flowchart of a process80for providing an indication of vibrations of the motor20that exceed a threshold or an expected vibration level to a supervisory controller. For example, the supervisory controller may include the processor28of the drive module14inFIG.1, an external controller positioned outside the integrated drive module assembly, or any other viable processing circuitry. With this in mind, although the following description of the process80is described as being performed by the processor28in a particular order, it should be noted that the process80may be performed by other suitable computing devices and in any suitable order.

At block82, the processor28may receive vibration data and/or shock data (e.g., first set of vibration data) from the accelerometer30. For example, the processor28may receive the vibration data and/or shock data during operation of the motor20or when the motor is not operating. The vibration data may include analog or digital data indicative of the detected vibrations. In some cases, the processor28may associate or track the vibration data to a time in which the vibration data was acquired. The time data may be correlated to the operation of the motor20. In additional, the processor28may transform the vibration data to the frequency domain and associate the determined frequency responses to times corresponding to the operations of the motor20. As such, the processor28may associate (e.g., synchronize) the vibration data (e.g., time-series and/or frequency domain vibration data) to one or more operation characteristics of the motor20. The operation characteristics of the motor20may include a spinning speed of a rotor/shaft of the motor20, a position of the rotor/shaft, a spinning direction of the rotor/shaft, and so on.

At block84, the processor28may generate one or more baseline vibration profiles based on the collected vibration data and/or shock data. Although embodiments herein are described with respect to vibration data and vibration profiles, it should be appreciated that the described embodiments may alternatively or additionally include shock data and shock profiles. For example, the accelerometer30may detect shocks and provides shock data as well as detecting the vibrations and providing the vibration data.

The processor28may generate the baseline vibration profiles by associating (e.g., synchronizing, correlating) the vibration data (e.g., time-series and/or frequency domain vibration data) with different times and/or modes of operations (e.g., operation characteristics) of the motor20. For example, the processor28may store the one or more baseline vibration profiles using the non-transitory memory26that correspond to one or more operation modes. In some embodiments, generating a baseline vibration profile may include a learning period. The learning period for generating a baseline vibration profile may correspond to receiving a threshold amount of vibration data over a period of time for characterizing different operations performed by the motor20over the same period of time.

In some cases, the processor28may generate the one or more baseline vibration profiles based on nominal or expected operations (e.g., full load, expected load) of the motor20. In such cases, the one or more baseline vibration profiles may correspond to an expected operating condition of the motor20. In some cases, the processor28may use the one or more baseline vibration profiles to determine whether faults or other issues are present with the motor20. That is, the processor28may compare received vibration data to the a respective baseline vibration profile and if the vibration data does not correlate to the baseline vibration profile within a threshold percentage, the processor28may determine that an anomaly (e.g., a fault condition) is present on the motor20. Alternatively or additionally, the processor28may compare received vibration data to one or more alignment thresholds (e.g., based on a threshold percentage) associated with one or more anomalies to determine that an anomaly is present on the motor20. In some embodiments, the processor28may identify the type of anomaly or issue that is present based on matching the vibration data to anomaly vibration profiles determined during previous anomalies of the motor20.

With the foregoing in mind, the processor28may generate the baseline vibration profiles by synchronizing the time-series and/or frequency domain vibration data with the speed of a rotor/shaft of the motor20, a position of the rotor/shaft, a rotational direction of the rotor/shaft, an axis of the motor20, and/or other operations of the motor20. For example, the processor28may associate the frequency response of baseline vibration profiles to the operation characteristic of the motor20based on receiving user inputs, using a machine learning process, among other things. In some cases, the processor28may store one or more baseline vibration profiles in the memory26based on associating a frequency response of the baseline vibration profiles to an operation characteristic of the motor20.

In one example, the processor28may generate a baseline vibration profile for one or more spinning speeds of the shaft of the motor20by correlating a frequency response of the acquired vibration data with the one or more spinning speeds of the shaft. In another example, the processor28may generate a baseline vibration profile for one or more positions of the rotor/shaft by correlating a frequency response of the acquired vibration data with the one or more positions of the rotor/shaft. It should be appreciated that different vibration profiles may be determined for different operations of the motor20. As such, the processor28may characterize different operations of the motor20based on a comparison between subsequently acquired vibration data and the corresponding vibration profiles. In some cases, matching the subsequently received vibration data with the baseline vibration profiles in frequency domain may facilitate efficient anomaly detection of the corresponding operation characteristic of the motor20.

Furthermore, in some cases, the processor28of the integrated drive motor assembly34may generate the one or more baseline vibration profiles. For example, the processor28may use machine learning to generate the one or more baseline vibration profiles of the vibration data based on receiving a threshold amount (e.g., days, weeks, years) of vibration data (e.g., time-series and/or frequency domain vibration data). For example, the machine learning may include supervised machine learning, semi-supervised machine-learning, and/or unsupervised machine learning. In any case, the processor28may use each of the baseline vibration profiles to detect anomalies (e.g., high vibrations) of the motor20.

In some cases, the processor28may detect the anomalies (e.g., faults) during operation of the motor20based on detecting deviations of the acquired vibration data from the baseline vibration profile of the motor20or based on detecting that the acquired vibration data is aligned (e.g., matches) with the anomaly vibration profile of the motor20. For example, the processor28may detect the anomalies based on matching the acquired vibration data with the anomaly vibration profile of the motor20according to an alignment threshold (e.g., within 1% of the anomaly vibration profile, within 2% of the anomaly vibration profile, within 5% of the anomaly vibration profile). Such anomalies may include mechanical failures associated with mechanical components attached to the motor. For example, the mechanical failures may be associated with coupling misalignments, gearbox wears, belt tensions, and/or motor roller bearings wear or misalignment.

At block86, the processor28may receive additional vibration data and/or shock data (e.g., second set of vibration data) from the accelerometer30during operation of the motor20. The processor28may receive the additional vibration data after generating the one or more baseline vibration profiles. Moreover, the processor28may associate the additional vibration data to one or more operations of the motor20based on the vibrations.

At block88, the processor28may compare the additional data to the one or more baseline vibration profiles. For example, the processor28may compare the additional vibration data to one or more baseline vibration profiles associated with the operations of the motor20causing the vibrations.

At block90, the processor28may determine one or more anomalies based on the comparison. As mentioned above, the processor28may determine the one or more anomalies based on deviations between the additional data and the respective baseline vibration profiles. The processor28may determine the deviations of the additional data from the respective baseline vibration profiles based on one or more thresholds as described above. The thresholds may be user configurable, pre-set, or determined by the processor28, user input, machine learning algorithms, or the like.

For example, the processor28may determine a table of motor shaft speed versus root mean square value (RMS) of vibration data to determine the one or more anomalies. The processor28may then use the table to generate a regression model baseline vibration profile. Accordingly, the processor28may use the regression model baseline vibration profile to determine the one or more anomalies based on detecting deviations from the regression model baseline vibration profile. Moreover, the processor28may also use the regression model baseline vibration profile to estimate performance metrics of the motor20based on receiving additional data associated with measured speed and vibration of the motor20.

In any case, the processor28may determine anomalies based on detecting deviations of the acquired vibration data from the baseline vibration profile of the motor20or based on detecting that the acquired vibration data is aligned (e.g., matches) with the anomaly vibration profile of the motor20. For example, anomalies may be caused by misalignment of the motor shaft, bearings of the integrated drive motor assembly34wearing off, among other things. In some embodiments, the integrated drive motor assembly34may provide all the vibration data to the processor28. In alternative or additional embodiments, the integrated drive motor assembly34may provide the indication of anomalies, the vibration data associated with a detected anomaly, or both to the processor28. Accordingly, the integrated drive motor assembly34and/or the processor28may use less storage based on storing relevant anomalies (e.g., the indication of anomalies, the vibration data of the detected anomalies).

At block92, the processor28may provide commands (e.g., one or more notifications) in response to determining the one or more anomalies. For example, the processor28may halt an operation of the motor20, may reduce the speed of operation of the motor20, or may cause performing any other viable countermeasure, in response to receiving an indication of the anomaly in the operation of the motor20. Moreover, based on the position of the accelerometer30on the control circuitry16(e.g., in close proximity of the motor20and the processor28), the processor28may determine the anomaly with low latency. As such, the processor28may cause performing the countermeasure with low latency (e.g., 1 millisecond, 2 millisecond, 5 milliseconds, 10 milliseconds, and so on) to reduce (e.g., minimize, eliminate) possible damages to the motor20caused by the anomaly.

As mentioned above, alternatively or additionally, the processor28may determine one or more anomalies associated with the motor20(e.g., mechanical components of the motor20) based on user provided vibration and shock thresholds. In some cases, the processor28may receive one or more thresholds provided by a user or pre-set during manufacturing to detect the anomalies (e.g., instantaneously detect the anomalies). For example, the processor28may detect deviations of the vibration data and/or shock data provided by the accelerometer30associated with the motor20higher than one or more user provided thresholds or one or more thresholds set during manufacturing.

The present disclosure includes drive modules for drive assemblies of an industrial automation system. The drive modules may provide power and control operations of the motor. The drive modules may include a housing containing the control circuitry and the power circuitry and the housing may be independent of the frame size and/or power of the motor. As such, the housing may be interchangeable for any motor frame size and/or motor power. The drive modules may also include an adapter that may be shaped and/or sized to connect the drive module to the motor. As such, the size and/or shape of the adapter may be based on the frame size and/or power of the motor. Technical effects of the disclosed techniques include providing interchangeable housings for drive modules of drive assemblies and reducing manufacturing cost by using uniform housings for multiple motor frame sizes and/or motor powers.

While only certain features of the disclosure have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the present disclosure. The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible, or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for [perform]ing [a function] . . . ” or “step for [perform]ing [a function] . . . ”, it is intended that such elements are to be interpreted under 35 U.S.C. 62(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 62(f).