Patent Publication Number: US-11662384-B2

Title: Motor malfunction monitoring device, drive motor system and motor malfunction monitoring method

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority to Chinese patent application No. 202022639085.1 filed on Nov. 13, 2020 and Chinese patent application No. 202011273318.9 filed on Nov. 13, 2020. The content of all of the above applications is incorporated herein by reference in their entirety as a part of the present application. 
     FIELD 
     The present disclosure generally relates to an apparatus utilized in the field of oilfield operations, and more specifically, to a motor malfunction monitoring device, a drive motor system and a motor malfunction monitoring method. 
     BACKGROUND 
     At present, the electrically-driven apparatus is widely used in the field of oilfield operations. For example, the electrically-driven apparatus may be employed for electrically-driven fracturing, electrically-driven mixing, electrically-driven sand mixing, electrically-driven sand transportation, and other engineering operations. An electrically-driven apparatus typically includes a motor for supplying power, equipped with a variable frequency drive (VFD) (also referred to as a drive unit of the motor) regulating the power source for the motor in frequency and voltage. The VFD includes a rectifier, an inverter and a control circuit, where the control circuit detects operation status of the inverter and the rectifier and controls an input from the inverter to the motor to protect electrical components (e.g., the motor and the like) of the circuit. The control circuit of the VFD can monitor parameters on a current, voltage, and the like, of the motor, triggers an alarm when those parameters exceed predetermined normal threshold ranges, and then cuts off the power supply circuit. 
     SUMMARY 
     The objective of the present disclosure is to provide an electrically-driven apparatus used in a well site with a motor malfunction monitoring device and a motor control system. For an electrically-driven apparatus used in a well site, due to complicated material and vibration conditions in the environment, some components of the apparatus are vulnerable after a period of time, causing shutdown of the electrically-driven apparatus and further incurring huge time and labor costs. Therefore, there is a necessity to monitor and determine a malfunction for an electrically-drive apparatus used in a well site, and send a prompt to the same, so as to give engineers a necessary reminder to examine and repair the electrically-driven apparatus. 
     The motor malfunction monitoring device according to the present disclosure cannot only monitor the electrical status of a motor (e.g., whether a voltage or current is normal, or the like) but also can monitor status of mechanical components (e.g., bearings, bases, and the like) of the motor. In the meantime, the motor control system can further control the motor based on the above status. 
     In a first aspect of the present disclosure, there is provided a motor malfunction monitoring device for monitoring a malfunction of a drive motor in oilfield operations, comprising: 
     a signal acquisition module configured to acquire operation data of the drive motor, wherein the signal acquisition motor comprises a vibration signal acquisition unit and/or an electrical signal acquisition unit, the vibration signal acquisition unit comprises one or more vibration sensors for detecting transverse vibration and/or longitudinal vibration of a component to be detected of the drive motor, and/or the electrical signal acquisition unit comprises a voltage sensor and a current sensor for detecting a voltage and a current of the drive motor, respectively; 
     a data storage module storing therein a normal operation data spectrum library created when the drive motor runs normally; and 
     a signal analysis module, wherein the signal analysis module is configured to extract an acquired operation data spectrum of the operation data acquired, compare the acquired operation data spectrum with a respective normal operation data spectrum in the normal operation data spectrum library to obtain a similarity, determine whether the similarity is less than a predetermined threshold, and determine that the drive motor fails when the similarity is less than the predetermined threshold. 
     Alternatively, the data storage module stores therein a database for malfunction spectrums created when the drive motor runs at different types of malfunctions, and the motor malfunction monitoring device further comprises a malfunction diagnosis module, and wherein, after the signal analysis module determines that the drive motor fails, the malfunction diagnosis module compares the acquired operation data spectrum with malfunction spectrums in the database for malfunction spectrums and diagnoses a malfunction type of the drive motor. 
     Alternatively, the data storage module is updated using operation data and/or the acquired operation data spectrums of the drive motor. 
     Alternatively, the data storage module expands the normal operation data spectrum library using the acquired operation data spectrum when the drive motor does not fail, and expands the database for malfunction spectrums using the acquired operation data spectrum when the drive motor fails. 
     Alternatively, the motor malfunction monitoring device comprises an alarming unit, wherein the alarming unit sends a malfunction alarm when the motor malfunction monitoring device determines that the drive motor fails. 
     Alternatively, the component to be detected comprises a bearing and a base of the drive motor. 
     In a second aspect of the present disclosure, there is further provided a drive motor system, comprising: a drive motor, a variable frequency drive for regulating an input current to the drive motor and a controller, characterized by further comprising the motor malfunction monitoring device according to any of embodiments of the present disclosure, wherein the controller controls, based on a diagnosis result of the motor malfunction monitoring device, the variable frequency drive to regulate the input current to the drive motor. 
     Alternatively, for an electrical signal of the drive motor, the controller controls the variable frequency drive to switch off the input current to the drive motor when either of the variable frequency drive and the motor malfunction monitoring device monitors that the drive motor fails. 
     In a third aspect of the present disclosure, there is also provided a motor malfunction monitoring method for monitoring a malfunction of a drive motor for oilfield operations, characterized by comprising steps of: 
     acquiring operation data of the drive motor, wherein the operation data comprise a transverse and/or a longitudinal vibration signal of a component to be detected of the drive motor, and/or a voltage and a current signal of the drive motor; 
     extracting an acquired operation data spectrum of the operation data acquired; and 
     comparing the acquired operation data spectrum with a pre-stored, respective normal operation data spectrum in a normal operation data spectrum library of the drive motor to obtain a similarity, and determining that the drive motor fails when the similarity is less than a predetermined threshold. 
     Alternatively, the motor malfunction monitoring method further comprises: 
     when determining that the drive motor fails, comparing the acquired operation data spectrum with malfunction spectrums in a database for malfunction spectrums pre-stored created when the drive motor runs at different types of malfunctions, and diagnosing a malfunction type of the drive motor. 
     Alternatively, the motor malfunction monitoring method further comprises: 
     storing the operation data and/or the acquired operation data spectrum of the drive motor. 
     Alternatively, the motor malfunction monitoring method further comprises: 
     expanding the normal operation data spectrum library using the acquired operation data spectrum when the drive motor does not fail, and expanding the database for malfunction spectrums using the acquired operation data spectrum when the drive motor fails. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For the sake of better understanding on the above and other objectives, features, advantages, and functions of the present disclosure, the preferred embodiments are provided with reference to the drawings. The same reference symbols refer to the same components throughout the drawings. It would be appreciated by those skilled in the art that the drawings are merely provided to illustrate preferred embodiments of the present disclosure, without suggesting any limitation to the protection scope of the present application, in which 
         FIG.  1    schematically illustrates a motor malfunction monitoring device according to an embodiment of the present disclosure; 
         FIG.  2    schematically illustrates a motor malfunction monitoring device according to another embodiment of the present disclosure; 
         FIG.  3    schematically illustrates a motor malfunction monitoring method according to an embodiment of the present disclosure; and 
         FIG.  4    schematically illustrates a motor malfunction monitoring method according to another embodiment of the present disclosure. 
     
    
    
     A LIST OF REFERENCE SIGNS 
     
         
         
           
               10 ,  10 ′ motor malfunction monitoring device 
               1 ,  1 ′ signal acquisition module 
               11 ,  11 ′ vibration signal acquisition unit 
               12 ,  12 ′ electrical signal acquisition unit 
               2 ,  2 ′ data storage module 
               21 ,  21 ′ database of normal operation spectrums 
               22 ′ database for malfunction spectrums 
               3 ,  3 ′ signal analysis module 
               4 ,  4 ′ malfunction diagnosis module 
           
         
       
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     Reference now will be made to the drawings to describe in detail the embodiments of the present disclosure. What will be described herein will only involve preferred embodiments of the present disclosure, as well as other manners conceivable for those skilled in the art on the basis of the preferred embodiments of the present disclosure, which also fall into the scope claimed by the present disclosure. 
     The motor malfunction monitoring device as described therein is generally provided for monitoring malfunctions of a drive motor used in oilfield operations.  FIG.  1    schematically illustrates a modular structure diagram of a motor malfunction monitoring device  10  according to an embodiment of the present disclosure. As shown in  FIG.  1   , the motor malfunction monitoring device  10  includes a signal acquisition module  1 , a data storage module  2  and a signal analysis module. Specifically, the signal acquisition module  1  is responsible for acquiring operation data during the operation of the drive motor, where these operation data include an electrical signal of the drive motor, namely a current or voltage signal, and/or vibration signal of components to be detected. To this end, the signal acquisition module  1  may include an electrical signal acquisition unit  12  and/or a vibration signal acquisition unit  11 , where the electrical signal acquisition unit  12 , for example, can include voltage sensor(s) and current sensor(s) and be mounted at appropriate positions of the drive motor, as disclosed in the prior art, to detect and acquire the voltage signal and current signal of the drive motor. In addition, the vibration signal acquisition unit  11  may include one or more vibration sensors, where, depending on components of the drive motor and vibration directions to be detected, the vibration sensors may be mounted at the components to be detected, particularly along specific directions of the vibration, such that the vibration sensors can detect and acquire the vibration signals of the components in the specific directions. Within the scope of the present disclosure, since components of the drive motor often vibrate in transverse and longitudinal directions in case of failure, the vibration signal acquisition unit  11  is used to mainly acquire vibration in the transverse and longitudinal directions. It is noted that, within the scope of the present disclosure, “a transverse direction” refers to a direction parallel to a mounting plane of the drive motor and perpendicular to a longitudinal direction of the drive motor, and “a longitudinal direction” refers to a direction perpendicular to both of the mounting plane and the longitudinal direction of the drive motor. For example, within the scope of the present disclosure, depending on the components concerned and need to be detected, the vibration sensors of the vibration signal acquisition unit  11  may be mounted at the bearings and the bases of the drive motor to detect and acquire vibration of the bearings and the bases, for detecting whether there is abnormality, loosening or damage of the bearings, loosening of bases, and the like. 
     Although the vibration signal acquisition unit, for example, includes vibration sensors mounted at the bearings of the drive motor and the bases of the drive motor, as described above, vibration sensors may be mounted at other components of the drive motor, depending on the different components need to be detected and concerned, which also fall into the scope of the present disclosure. 
     The data storage module  2  of the motor malfunction monitoring device  10  stores therein a database  21  of normal operation spectrums during the normal operation of the drive motor. Specifically, the database  21  of normal operation spectrums includes therein operation data spectrums when the drive motor runs normally in different operating conditions, for example, transverse vibration signal spectrums, longitudinal vibration signal spectrums, voltage or current signal spectrums, and the like, of the components to be detected. 
     The signal analysis module  3  of the motor malfunction monitoring device  10  can perform processing and analysis on the operation data acquired by the signal acquisition module  1 , extract acquired operation data spectrums of the acquired operation data, and then compare them with corresponding normal operation spectrums in the database to obtain a similarity therebetween. If the similarity is lower than a predetermined threshold, the signal analysis module determines that the drive motor fails. Specifically, for example, when the signal acquisition module  1  has acquired the current or voltage signals and the transverse and longitudinal vibration signals when the drive motor runs in a certain operating condition, the signal analysis module extracts spectrums of these signals and compares them with the current or voltage signal spectrums and the transverse and longitudinal vibration signal spectrums at the bearing when the drive motor runs normally in the corresponding operating condition to obtain a similarity therebetween. If the similarity is lower than a predetermined threshold, it is determined that the drive motor fails. The predetermined threshold as mentioned above may be predetermined based on factors, such as the operating status of the drive motor and the like. 
       FIG.  2    schematically illustrates a motor malfunction monitoring device  10 ′ according to another embodiment of the present disclosure. To avoid duplication, only differences between the embodiments as shown in  FIG.  2    and the one in  FIG.  1    will be described below. In order to differentiate the two embodiments, the reference symbols involved in  FIG.  2    are represented with an additional Superscript “′”, as compared with those in  FIG.  1   . As shown in  FIG.  2   , in addition to the modules in  FIG.  1   , the motor malfunction monitoring device  10 ′ further includes a malfunction diagnosis module  4 ′. To be specific, when the signal analysis module  3  determines that the drive motor fails, the malfunction diagnosis module  4 ′ further determines the malfunction type of the drive motor. With respect to the motor malfunction monitoring device  10 ′ in the embodiment, the data storage module  2 ′ further stores therein a database  22 ′ for malfunction spectrums when the drive motor runs at different types of malfunctions, and the malfunction diagnosis module  4 ′ compares the acquired operation data spectrums with the malfunction spectrums in the database and diagnoses the malfunction type of the drive motor. Specifically, the database  22 ′ of malfunction spectrums stored in the data storage module  2 ′ at least includes characteristic spectrums of operation data when the drive motor fails at different operating conditions, for example, characteristic spectrums of the drive motor when bearings, bases, or stator coils are loose, short circuit occurs between stator winding turns, and the like. The malfunction diagnosis module  4 ′ compares the acquired operation data with those malfunction spectrums to find out a malfunction spectrum mostly similar to the acquired operation data, and then determines the specific malfunction type of the drive motor. 
     Alternatively, within the scope of the present disclosure, the data storage module  2 ,  2 ′ is configured to store operation data and/or acquired operation data spectrums of the drive motor. Those spectrums may be stored in a local or remote memory of the data storage module  2 ,  2 ′, which can be implemented by means of existing storage technique in the related fields. In this circumstance, alternatively, in some embodiments, the data storage module  2 ,  2 ′ can further update and expand the database stored therein (i.e., the database of normal operation spectrums and the database for malfunction spectrums) by using operation data and/or acquired operation data spectrums of the drive motor. Specifically, the data storage module  2 ,  2 ′ expands and updates the database of normal operation spectrums by using the acquired operation data spectrums when the drive motor does not fail, and expands and updates the database for malfunction spectrums by using the acquired operation data spectrums when the drive motor fails. More specifically, the acquired operation data spectrums are respectively categorized according to the malfunction categories into which they fall. 
     Alternatively, in some embodiments of the present disclosure, the motor malfunction monitoring device  10 ,  10 ′ may further include an alarming unit which can send out an alarm based on the malfunction determined by the motor malfunction monitoring device  10 ,  10 ′, more specifically, a respective malfunction alarm (e.g., warning light, alarm sound, alarm information, or the like) corresponding to the malfunction type. 
     In the present disclosure, there is further provided a drive motor system, including: a drive motor, a variable frequency drive (also referred to as drive unit) that can regulate the current or voltage of the drive motor, a motor malfunction monitoring device and a controller, where the motor malfunction monitoring device can be configured in the form of the motor malfunction monitoring device  10 ,  10 ′ according to any of the embodiments of the present disclosure. The controller controls the drive motor, based on the drive motor&#39;s malfunction information obtained by the motor malfunction monitoring device  10 ,  10 ′ (i.e. presence or absence of a malfunction in the drive motor and/or the malfunction type of the drive motor). For example, in some malfunctions, the controller stops the drive motor. It is noted that, under this circumstance, the variable frequency drive monitors the current and voltage of the drive motor as mentioned in the prior art, but since the motor malfunction monitoring device is included in the present disclosure, the variable frequency drive may be configured to only regulate the input current to the drive motor under the control of the controller, without the necessity to monitor the current and voltage of the drive motor. 
     In addition, within the scope of the present disclosure, the variable frequency drive is configured as a conventional variable frequency drive employed in the related technical fields of drive motors, which may include a rectifier, an inverter, a control circuit assembly for detecting the current or voltage of the drive motor and regulating an input current to the drive motor, and the like. Specifically, the controller controls, based on the malfunction of the drive motor determined by the motor malfunction monitoring device  10 ,  10 ′, the variable frequency drive to regulate an input current or voltage to the drive motor. 
     Alternatively, in some embodiments of the present disclosure, for the electrical signals (i.e., current or voltage) of the drive motor, when one of the variable frequency drive and the motor malfunction monitoring device  10 ,  10 ′ monitors an electrical signal malfunction (i.e., abnormality), the controller controls the variable frequency drive to cut off the input current to the drive motor. In other words, if the voltage or current malfunction cannot be detected due to failure of the variable frequency drive or one of the voltage sensor and the current sensor in the motor malfunction monitoring device, the controller can switch off the input current to the drive motor for the sake of security, rather than performing control based on the monitored result from one of the above. Such redundant determination avoids the deficiency of misjudging the malfunction of the drive motor due to circuit failure in the variable frequency drive. 
       FIG.  3    schematically illustrates a flowchart of a motor malfunction monitoring method according to the present disclosure. The motor malfunction monitoring method involved herein is particularly used to monitor a malfunction of a drive motor in oilfield operations, including steps of: 
     S 101 : acquiring operation data of the drive motor, where the operation data include a transverse and/or a longitudinal vibration signal of components to be detected of the drive motor, and/or an electrical signal, namely a voltage or current signal, of the drive motor; 
     As aforementioned, depending on different components need to be detected, the transverse and longitudinal vibration signals at the bearings and the bases of the drive motor may be acquired, to detect and acquire vibration of the bearings and bases of the drive motor for subsequent determination of a malfunction, such as abnormality, loosening or damage of the bearings, loosening of bases, and the like. 
     S 102 : extracting acquired operation data spectrums of the operation data acquired; 
     Specifically, the operation data acquired are processed and analyzed, and the acquired operation data spectrums of the operation data acquired are extracted. 
     S 103 : comparing the acquired operation data spectrums with normal operation data spectrums pre-stored in the database of normal operation spectrums of the drive motor to obtain a similarity, and determines that the drive motor fails when the similarity is less than a predetermined threshold. 
     Specifically, the database of normal operation spectrums during the normal operation of the drive motor is pre-stored. More specifically, the database of normal operation spectrums includes operation data spectrums (e.g., transverse vibration signal spectrums, longitudinal vibration signal spectrums, voltage or current signal spectrums, and the like, of components to be detected) when the drive motor runs normally under different operating conditions. 
     In other words, for example, after the current or voltage electrical signals and transverse and longitudinal vibration signals at the bearings under a certain operating condition of the drive motor are acquired, the spectrums of these signals are extracted and compared with the current or voltage signal spectrums and the transverse and longitudinal signal spectrums in the corresponding normal operating condition to obtain a similarity therebetween, and it is determined that the drive motor fails if the similarity is less than a predetermined threshold. The predetermined threshold as mentioned above may be predetermined based on factors, such as the use status of the drive motor and the like. 
       FIG.  4    schematically illustrates a flowchart of a motor malfunction monitoring method according to another embodiment of the present disclosure, where steps S 201  to S 203  are identical with those in  FIG.  3   , which are omitted herein. 
     In addition, the motor malfunction monitoring method as shown in  FIG.  4    further includes steps of: 
     S 204 : when determining that the drive motor fails, comparing the acquired operation data spectrums with the malfunction spectrums pre-stored in the database for malfunction spectrums under different malfunction types of the drive motor, and diagnosing a malfunction type of the drive motor. 
     Specifically, determining that the drive motor fails further includes determining a malfunction type of the drive motor. The database for malfunction spectrums created when the drive motor fails at different types of malfunctions is pre-stored, including at least characteristic spectrums of operation data when the drive motor fails at different operating conditions, for example, characteristic spectrums of the drive motor when bearings, bases, or stator coils are loose, short circuit occurs between stator winding turns, and the like. Then, the acquired operation data spectrums are compared with those malfunction spectrums, to determine malfunction spectrums mostly corresponding to the acquired operation data spectrums and thus determine a specific malfunction type of the drive motor. 
     Alternatively, in some embodiments of the present disclosure, the motor malfunction monitoring method further includes a step of: 
     storing operation data and/or the acquired operation data spectrums of the drive motor. 
     In other words, the database of normal operation spectrums and the database for malfunction spectrums can be updated and expanded by using the operation data and/or the spectrums of the acquired operation data of the drive motor. The database of normal operation spectrums is expanded and updated by using the acquired operation data spectrums when the drive motor does not fail, while the database for malfunction spectrums is expanded and updated by using the acquired operation data spectrums when the drive motor fails. More specifically, the acquired operation data spectrums are categorized according to the malfunction categories into which they fall. 
     The above description on multiple embodiments of the present disclosure is provided to the ordinary skilled in the related field for illustration, without any intention to be exclusive or limited to a single embodiment of the present disclosure. Given the teaching, the ordinary skilled in the art would envision multiple types of substitution and variation of the present disclosure. Therefore, although some alternative embodiments are described herein, the ordinary skilled in the art would understand or easily devise other embodiments. The present disclosure intends to cover all substitution, modification and variation of the embodiments described herein, as well as other embodiments falling within the spirits and scope described above.