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GB2064818A - Monitoring the operation of an industrial installation - Google Patents

Monitoring the operation of an industrial installation Download PDF

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Publication number
GB2064818A
GB2064818A GB8038280A GB8038280A GB2064818A GB 2064818 A GB2064818 A GB 2064818A GB 8038280 A GB8038280 A GB 8038280A GB 8038280 A GB8038280 A GB 8038280A GB 2064818 A GB2064818 A GB 2064818A
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United Kingdom
Prior art keywords
installation
stored
elements
memory device
information
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB8038280A
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GB2064818B (en
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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Priority to GB8038280A priority Critical patent/GB2064818B/en
Publication of GB2064818A publication Critical patent/GB2064818A/en
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Publication of GB2064818B publication Critical patent/GB2064818B/en
Expired legal-status Critical Current

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Classifications

    • GPHYSICS
    • G08SIGNALLING
    • G08BSIGNALLING OR CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS
    • G08B23/00Alarms responsive to unspecified undesired or abnormal conditions
    • GPHYSICS
    • G07CHECKING-DEVICES
    • G07CTIME OR ATTENDANCE REGISTERS; REGISTERING OR INDICATING THE WORKING OF MACHINES; GENERATING RANDOM NUMBERS; VOTING OR LOTTERY APPARATUS; ARRANGEMENTS, SYSTEMS OR APPARATUS FOR CHECKING NOT PROVIDED FOR ELSEWHERE
    • G07C3/00Registering or indicating the condition or the working of machines or other apparatus, other than vehicles
    • GPHYSICS
    • G07CHECKING-DEVICES
    • G07CTIME OR ATTENDANCE REGISTERS; REGISTERING OR INDICATING THE WORKING OF MACHINES; GENERATING RANDOM NUMBERS; VOTING OR LOTTERY APPARATUS; ARRANGEMENTS, SYSTEMS OR APPARATUS FOR CHECKING NOT PROVIDED FOR ELSEWHERE
    • G07C3/00Registering or indicating the condition or the working of machines or other apparatus, other than vehicles
    • G07C3/14Quality control systems

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Automation & Control Theory (AREA)
  • Quality & Reliability (AREA)
  • Business, Economics & Management (AREA)
  • Emergency Management (AREA)
  • Forging (AREA)

Abstract

Operating parameters of at least some of the elements in the industrial installation, or the parameters of a product produced by the installation, are stored in a memory device. During operation of the installation, information is received by a computer from the installation and is compared with the corresponding stored data. If the comparison indicates that the received information is not within a predetermined relationship of the stored data, then the result of the comparison is displayed on a visual display device.

Description

SPECIFICATION Monitoring the operation of an industrial installation This invention relates to a method of, and apparatus for, monitoring the operation of an industrial installation.
In many industrial instaliations, the operating parameters of some of the elements or groups of elements of the installation worsen over a period of time. The variation with time is usually small and very often a small worsening of the parameters is acceptable and has no significant effect on the operation of the installation. However, over a period of time, the worsening of the operating parameters may be such that the operating parameters fall below an acceptable level and there is a significant effect on the operation of the installation. Because the worsening of the parameters takes place slowly, it may be some time before the user of the installation realises that the parameters are below an acceptable level and the installation is operating below its optimum efficiency.
It is an object of the present invention to provide a method of, and apparatus for, monitoring the operation of an industrial installation to try and reduce the disadvantages referred to above.
According to a first aspect of the present invention, in a method of monitoring the operation of an industrial installation, the operating parameters of at least some of the elements or group of elements of the installation, and/or parameters of a product produced by the installation, are stored in a memory device and, during operation of the installation, information received by a computer from sensors associated with said elements or groups of elements, and/or said product, is automatically compared with corresponding information stored in the memory device and the result of the comparison is displayed on a visual display device at least when the comparison indicates that the information received from one or more of the sensors is not within a predetermined relationship range with the corresponding stored parameter.
In the industrial installation, the operating pressure or temperature, for example, of one of the elements forming part of the installation is known and it is stored in the memory device and, during operation of the installation, a sensor associated with that element periodically feds back information concerning the operating pressure or temperature and the computer compares this information fed back by the sensor with the corresponding parameter stored in the memory device and produces a comparison signal. The comparison may be displayed on a visual display device.Alternatively, so long as the result of the comparison is within a predetermined relationship, for example within + 20% of the stored parameter, then no action is taken but, as soon as the comparison indicates that the operating parameter is outside the acceptable range, then the results of the comparison are displayed on the visual display device. An operator can immediately see when this operating parameter is outside of, or moving away from, the acceptable value and can take steps to bring about a suitable correction.
A particular, but not sole, application of the invention is to a forging installation in which a metal ingot is supported by one or more manipulators and is forged in a forging press. The forging manipulators move towards and away from the forging press to manipulate the ingot and, over a period of time, the drive for the manipulator(s) may become less efficient due to say increasing friction and therefore the operational speed of the manipulator slowly reduces. As another example, the speed of operation of the hydraulic cylinders, which are used to raise and lower the forging tool, may slow down due to, say, leakage of hydraulic fluid, so that the time taken to produce one complete forging operation gradually increases thereby reducing the efficiency of the installation.
One of the dimensions of a workpiece produced in the forging installation may vary over a period of time and, since the variation is small, it may be some time before the variation is noticed, by which time some of the workpieces produced in the installation may be unsaleable, or may require a degree of rectification work, since they have one or more parameters which are outside the acceptable tolerances for that dimension.
A second application of the invention is to an extrusion press. In this instance, a metal billet is extruded through a die by the action of a pressing stem. At the end of the extruding operation, it is necessary to retract the pressing stem and carry out an automatic sequence of operations associated with the removal of the discard portion of the old billet and the introduction of a new billet into the container. The time taken by these non-productive operations is known as the Dead-Cycle Time. If the Dead-Cycle Time gradually increases over a long period, due to degradation of the performance of some of the system elements, the productivity of the press will be correspondingly reduced.By monitoring Dead-Cycle Time and comparing it with a standard established during commissioning (or otherwise), such a loss of productivity, which could otherwise go undetected, will be immediately identified.
In addition, or as an alternative, to this method of continuously monitoring the operation of the installation, one or more parameters of an article produced by the installation can be readily monitored.
For example, in a forging installation, after each forging stroke, a workpiece is programmed to have a particular dimension. This information is stored in the memory device and the parameter can be measured in some way after each operating stroke of the forge. The measured value and the corresponding stored value are compared by the computer and, if the comparison indicates that the required dimension is not within an acceptable tolerance, then this is indicated on the visual display device.
According to a second aspect of the invention, apparatus for carrying out the method described above comprises a plurality of sensors arranged to supply information concerning the operating parameters of elements or groups of elements of an industrial installation and/or parameters of a product produced by the installation, a memory device for receiving and storing preset information concerning said parameters, computer means for comparing the information received from said sensors with corresponding information stored in the memory device and for producing a comparison signal and a visual display device for displaying said comparison signal at least when the information received from one or more of the sensors is not within a predetermined relationship range with the corresponding stored information.
The sensors on a particular element of the installation may be connected to a micro-compressor which in turn has access to the computer.
A further application of the invention is in certain components in an industrial installation. The wear characteristics of certain elements, such as hydraulic pumps, is directly related to the work done by the element as opposed to the time for which the element is in use. In the case of a hydraulic pump Work done =
f(pump pressure) dt where f is some function to be established empirically or analytically.
By continuously monitoring the pump pressure for the time that the pump is in use and supplying this information to the computer, the computer can calculate the work done by the pump.
Avalue of the work done by the pump before maintenance is obtained from eitherthe pump manufacturer or from experience and is stored in the memory device. The computer periodically compares the calculated value of the work done with the stored value and, when the comparison indicates that maintenance is due, an indication is made so that the maintenance staff can be alerted.
As an alternative way of determining the degree of wear in a pump, the pump can be caused to deliver at rated power into a closed pipe. The pressure in the pipe will increase at a rate which depends upon the leakage in the pump and hence the wear of the pump. The pump is tested in this manner during of the pump. The pump is tested in this manner during commissioning of the installation and a pressure /time plot is stored in the memory. Subsequently, after periods of use, the pump is retested under the same operating conditions and the results compared with the parameters stored in the memory. If the comparison indicates that the wear in the pump has increased above an acceptable level, then this is indicated on the display device.If a plurality of pumps are delivering fluid into a common system, then the overall pressureltime plot of the installation is stored along with a pressure/time plot for each of the pumps. When the examination of the overall system indicates that excess wear has taken place, then the pressure/time plot of each of the pumps is monitored in turn to see which pump or pumps has worn excessively.
In the application of the invention to an extrusion press, the Dead-Cycle Time of the press as a whole is monitored along with the time for operating each of the motions which make up the Dead-Cycle Time. If the overall system indicates that the Dead-Cycle Time has increased beyond an acceptable level, then each of the motions is monitored in turn to indicate where the unacceptable increase in time has occurred.
When the invention is applied to a forging press, standard parameters for stroke, thickness and the like are stored in the memory device. The striking rate is monitored without metal in the press and this gives a measure of press performance which is repeated at regular intervals. The integrated stroking rate of the press and the ingot manipulator can also be tested in a similar manner with the manipulator gripping a cold ingot.

Claims (8)

1. A method of monitoring the operation of an industrial installation in which the operating parameters of at least some of the elements or group of elements of the installation, and/or parameters of a product produced by the installation, are stored in a memory device and, during operation of the installation, information received by a computer from sensors associated with said elements or group of elements, and/or said product, is automatically compared with corresponding information stored in the memory device and the result of the comparison is displayed on a visual display device at least when the comparison indicates that the information received from one or more of the sensors is not within a predetermined relationship range with the corresponding stored parameter.
2. A method as claimed in claim 1, in which the operating parameters are obtained and stored in the memory device when the installation is commissioned.
3. A method as claimed in claim 1 or 2, in which operating parameters representing the overall operation of a group of elements of the installation and operating parameters representing the operation of each element are stored in the memory device and, during operation of the installation, information received by the computer from sensors associated with the group of elements is automatically compared with the corresponding information stored in the memory device and, if the result of the comparison indicates that the information is not within the predetermined relationship range with the stored parameter, then the computer compares in turn the information received from the sensors associated with each of the elements with the corresponding information stored in the memory device.
4. A method as claimed in claim 1,2 or 3, in which the installation is an extrusion press and the Dead-Cycle Time of the press is monitored.
5. A method as claimed in claim 3, in which the installation includes a plurality of pumps feeding into a common system.
6. A method as claimed in claim 1, in which information concerning the operating parameters of an element are continuously monitored and from this information the computer calculates the wear of the element, said calculated wear being compared with a value of wear stored in the memory device.
7. Apparatus for carrying out the method claimed in claim 1 and comprising a plurality of sensors arranged to supply information concerning the operating parameters of elements or groups of elements of an industrial installation and/or parameters of a product produced by the installation, a memory device for receiving and storing preset information concerning said parameters, computer means for automatically comparing the information received from said sensors with corresponding information stored in the memory device and for producing a comparison signal and a visual display device for displaying said comparison at least when the information received from one or more of the sensors is not within a predetermined relationship range with the corresponding stored information.
8. Apparatus as claimed in claim 7, in which said sensors serve to monitor the operating pressure of pumps in an installation.
GB8038280A 1979-11-30 1980-11-28 Monitoring the operation of an industrial installation Expired GB2064818B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB8038280A GB2064818B (en) 1979-11-30 1980-11-28 Monitoring the operation of an industrial installation

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB7941407 1979-11-30
GB8038280A GB2064818B (en) 1979-11-30 1980-11-28 Monitoring the operation of an industrial installation

Publications (2)

Publication Number Publication Date
GB2064818A true GB2064818A (en) 1981-06-17
GB2064818B GB2064818B (en) 1983-11-23

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Cited By (24)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2127122A (en) * 1982-09-20 1984-04-04 Mac Lean Fogg Co Fastener assembly for clamped wheels
EP0088591A3 (en) * 1982-03-06 1985-10-09 Plessey Overseas Limited On board memory for multi component manufacturing products
WO1986003281A1 (en) * 1983-06-02 1986-06-05 Enstroem Henrik Sven Method primarily for performance control at heat pumps or refrigerating installations and arrangement for carrying out the method
EP0319762A1 (en) * 1987-12-10 1989-06-14 Richard Wolf GmbH Means for monitoring the operations of supply devices for endoscopes
EP0237288A3 (en) * 1986-03-07 1989-08-30 Celanese Corporation Diagnostic and control system for cigarette filter rod making machine
EP0453302A1 (en) * 1990-04-19 1991-10-23 Whitbread Plc Refrigeration circuit including diagnostic equipment
GB2364807A (en) * 2000-02-12 2002-02-06 Sennheiser Electronic Installation monitoring system
US8065886B2 (en) 2001-05-03 2011-11-29 Emerson Retail Services, Inc. Refrigeration system energy monitoring and diagnostics
US8473106B2 (en) 2009-05-29 2013-06-25 Emerson Climate Technologies Retail Solutions, Inc. System and method for monitoring and evaluating equipment operating parameter modifications
US8495886B2 (en) 2001-05-03 2013-07-30 Emerson Climate Technologies Retail Solutions, Inc. Model-based alarming
US8700444B2 (en) 2002-10-31 2014-04-15 Emerson Retail Services Inc. System for monitoring optimal equipment operating parameters
US8964338B2 (en) 2012-01-11 2015-02-24 Emerson Climate Technologies, Inc. System and method for compressor motor protection
US8974573B2 (en) 2004-08-11 2015-03-10 Emerson Climate Technologies, Inc. Method and apparatus for monitoring a refrigeration-cycle system
US9121407B2 (en) 2004-04-27 2015-09-01 Emerson Climate Technologies, Inc. Compressor diagnostic and protection system and method
US9140728B2 (en) 2007-11-02 2015-09-22 Emerson Climate Technologies, Inc. Compressor sensor module
US9285802B2 (en) 2011-02-28 2016-03-15 Emerson Electric Co. Residential solutions HVAC monitoring and diagnosis
US9310094B2 (en) 2007-07-30 2016-04-12 Emerson Climate Technologies, Inc. Portable method and apparatus for monitoring refrigerant-cycle systems
US9310439B2 (en) 2012-09-25 2016-04-12 Emerson Climate Technologies, Inc. Compressor having a control and diagnostic module
US9551504B2 (en) 2013-03-15 2017-01-24 Emerson Electric Co. HVAC system remote monitoring and diagnosis
US9638436B2 (en) 2013-03-15 2017-05-02 Emerson Electric Co. HVAC system remote monitoring and diagnosis
US9765979B2 (en) 2013-04-05 2017-09-19 Emerson Climate Technologies, Inc. Heat-pump system with refrigerant charge diagnostics
US9803902B2 (en) 2013-03-15 2017-10-31 Emerson Climate Technologies, Inc. System for refrigerant charge verification using two condenser coil temperatures
US9823632B2 (en) 2006-09-07 2017-11-21 Emerson Climate Technologies, Inc. Compressor data module
US9885507B2 (en) 2006-07-19 2018-02-06 Emerson Climate Technologies, Inc. Protection and diagnostic module for a refrigeration system

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2005022049A2 (en) 2003-08-25 2005-03-10 Computer Process Controls, Inc. Refrigeration control system
WO2006091521A2 (en) 2005-02-21 2006-08-31 Computer Process Controls, Inc. Enterprise control and monitoring system
US7752853B2 (en) 2005-10-21 2010-07-13 Emerson Retail Services, Inc. Monitoring refrigerant in a refrigeration system
US7665315B2 (en) 2005-10-21 2010-02-23 Emerson Retail Services, Inc. Proofing a refrigeration system operating state
US7596959B2 (en) 2005-10-21 2009-10-06 Emerson Retail Services, Inc. Monitoring compressor performance in a refrigeration system
US7752854B2 (en) 2005-10-21 2010-07-13 Emerson Retail Services, Inc. Monitoring a condenser in a refrigeration system
US7594407B2 (en) 2005-10-21 2009-09-29 Emerson Climate Technologies, Inc. Monitoring refrigerant in a refrigeration system

Cited By (54)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0088591A3 (en) * 1982-03-06 1985-10-09 Plessey Overseas Limited On board memory for multi component manufacturing products
GB2127122A (en) * 1982-09-20 1984-04-04 Mac Lean Fogg Co Fastener assembly for clamped wheels
WO1986003281A1 (en) * 1983-06-02 1986-06-05 Enstroem Henrik Sven Method primarily for performance control at heat pumps or refrigerating installations and arrangement for carrying out the method
US4611470A (en) * 1983-06-02 1986-09-16 Enstroem Henrik S Method primarily for performance control at heat pumps or refrigerating installations and arrangement for carrying out the method
EP0237288A3 (en) * 1986-03-07 1989-08-30 Celanese Corporation Diagnostic and control system for cigarette filter rod making machine
EP0319762A1 (en) * 1987-12-10 1989-06-14 Richard Wolf GmbH Means for monitoring the operations of supply devices for endoscopes
EP0453302A1 (en) * 1990-04-19 1991-10-23 Whitbread Plc Refrigeration circuit including diagnostic equipment
GB2364807B (en) * 2000-02-12 2003-11-05 Sennheiser Electronic Installation monitoring system
GB2364807A (en) * 2000-02-12 2002-02-06 Sennheiser Electronic Installation monitoring system
US8065886B2 (en) 2001-05-03 2011-11-29 Emerson Retail Services, Inc. Refrigeration system energy monitoring and diagnostics
US8316658B2 (en) 2001-05-03 2012-11-27 Emerson Climate Technologies Retail Solutions, Inc. Refrigeration system energy monitoring and diagnostics
US8495886B2 (en) 2001-05-03 2013-07-30 Emerson Climate Technologies Retail Solutions, Inc. Model-based alarming
US8700444B2 (en) 2002-10-31 2014-04-15 Emerson Retail Services Inc. System for monitoring optimal equipment operating parameters
US9669498B2 (en) 2004-04-27 2017-06-06 Emerson Climate Technologies, Inc. Compressor diagnostic and protection system and method
US9121407B2 (en) 2004-04-27 2015-09-01 Emerson Climate Technologies, Inc. Compressor diagnostic and protection system and method
US10335906B2 (en) 2004-04-27 2019-07-02 Emerson Climate Technologies, Inc. Compressor diagnostic and protection system and method
US9081394B2 (en) 2004-08-11 2015-07-14 Emerson Climate Technologies, Inc. Method and apparatus for monitoring a refrigeration-cycle system
US9304521B2 (en) 2004-08-11 2016-04-05 Emerson Climate Technologies, Inc. Air filter monitoring system
US9021819B2 (en) 2004-08-11 2015-05-05 Emerson Climate Technologies, Inc. Method and apparatus for monitoring a refrigeration-cycle system
US9023136B2 (en) 2004-08-11 2015-05-05 Emerson Climate Technologies, Inc. Method and apparatus for monitoring a refrigeration-cycle system
US9046900B2 (en) 2004-08-11 2015-06-02 Emerson Climate Technologies, Inc. Method and apparatus for monitoring refrigeration-cycle systems
US8974573B2 (en) 2004-08-11 2015-03-10 Emerson Climate Technologies, Inc. Method and apparatus for monitoring a refrigeration-cycle system
US9086704B2 (en) 2004-08-11 2015-07-21 Emerson Climate Technologies, Inc. Method and apparatus for monitoring a refrigeration-cycle system
US9690307B2 (en) 2004-08-11 2017-06-27 Emerson Climate Technologies, Inc. Method and apparatus for monitoring refrigeration-cycle systems
US10558229B2 (en) 2004-08-11 2020-02-11 Emerson Climate Technologies Inc. Method and apparatus for monitoring refrigeration-cycle systems
US9017461B2 (en) 2004-08-11 2015-04-28 Emerson Climate Technologies, Inc. Method and apparatus for monitoring a refrigeration-cycle system
US9885507B2 (en) 2006-07-19 2018-02-06 Emerson Climate Technologies, Inc. Protection and diagnostic module for a refrigeration system
US9823632B2 (en) 2006-09-07 2017-11-21 Emerson Climate Technologies, Inc. Compressor data module
US9310094B2 (en) 2007-07-30 2016-04-12 Emerson Climate Technologies, Inc. Portable method and apparatus for monitoring refrigerant-cycle systems
US10352602B2 (en) 2007-07-30 2019-07-16 Emerson Climate Technologies, Inc. Portable method and apparatus for monitoring refrigerant-cycle systems
US9194894B2 (en) 2007-11-02 2015-11-24 Emerson Climate Technologies, Inc. Compressor sensor module
US10458404B2 (en) 2007-11-02 2019-10-29 Emerson Climate Technologies, Inc. Compressor sensor module
US9140728B2 (en) 2007-11-02 2015-09-22 Emerson Climate Technologies, Inc. Compressor sensor module
US8473106B2 (en) 2009-05-29 2013-06-25 Emerson Climate Technologies Retail Solutions, Inc. System and method for monitoring and evaluating equipment operating parameter modifications
US9395711B2 (en) 2009-05-29 2016-07-19 Emerson Climate Technologies Retail Solutions, Inc. System and method for monitoring and evaluating equipment operating parameter modifications
US8761908B2 (en) 2009-05-29 2014-06-24 Emerson Climate Technologies Retail Solutions, Inc. System and method for monitoring and evaluating equipment operating parameter modifications
US9285802B2 (en) 2011-02-28 2016-03-15 Emerson Electric Co. Residential solutions HVAC monitoring and diagnosis
US10884403B2 (en) 2011-02-28 2021-01-05 Emerson Electric Co. Remote HVAC monitoring and diagnosis
US9703287B2 (en) 2011-02-28 2017-07-11 Emerson Electric Co. Remote HVAC monitoring and diagnosis
US10234854B2 (en) 2011-02-28 2019-03-19 Emerson Electric Co. Remote HVAC monitoring and diagnosis
US9876346B2 (en) 2012-01-11 2018-01-23 Emerson Climate Technologies, Inc. System and method for compressor motor protection
US8964338B2 (en) 2012-01-11 2015-02-24 Emerson Climate Technologies, Inc. System and method for compressor motor protection
US9590413B2 (en) 2012-01-11 2017-03-07 Emerson Climate Technologies, Inc. System and method for compressor motor protection
US9310439B2 (en) 2012-09-25 2016-04-12 Emerson Climate Technologies, Inc. Compressor having a control and diagnostic module
US9762168B2 (en) 2012-09-25 2017-09-12 Emerson Climate Technologies, Inc. Compressor having a control and diagnostic module
US10488090B2 (en) 2013-03-15 2019-11-26 Emerson Climate Technologies, Inc. System for refrigerant charge verification
US10274945B2 (en) 2013-03-15 2019-04-30 Emerson Electric Co. HVAC system remote monitoring and diagnosis
US9551504B2 (en) 2013-03-15 2017-01-24 Emerson Electric Co. HVAC system remote monitoring and diagnosis
US9638436B2 (en) 2013-03-15 2017-05-02 Emerson Electric Co. HVAC system remote monitoring and diagnosis
US10775084B2 (en) 2013-03-15 2020-09-15 Emerson Climate Technologies, Inc. System for refrigerant charge verification
US9803902B2 (en) 2013-03-15 2017-10-31 Emerson Climate Technologies, Inc. System for refrigerant charge verification using two condenser coil temperatures
US9765979B2 (en) 2013-04-05 2017-09-19 Emerson Climate Technologies, Inc. Heat-pump system with refrigerant charge diagnostics
US10443863B2 (en) 2013-04-05 2019-10-15 Emerson Climate Technologies, Inc. Method of monitoring charge condition of heat pump system
US10060636B2 (en) 2013-04-05 2018-08-28 Emerson Climate Technologies, Inc. Heat pump system with refrigerant charge diagnostics

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