Integrated machine speed signal waveform capture

Abstract

The subject matter of the present specification may be embodied, among other things, a method for controlling a turbine engine that includes measuring, by a speed sensor, a waveform indicative of a speed of a rotating machine. A waveform is received from a velocity sensor and data representative of the waveform is provided to a first signal path and a second signal path, where the second signal path is isolated from the first signal path such that data communication over the second signal path does not interfere with communication over the first signal path. One or more operations of the rotating machine are controlled in response to the data received along the first signal path. Data received along the second signal path, individual samples of the data, are stored in association with respective timestamps indicating the time at which the data was received.

Description

[0001] Priority Statement This application claims priority to U.S. Patent Application No. 18 / 336,717, filed June 16, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This manual relates to the monitoring and control of turbines. Background Technology

[0003] A turbine is a rotating mechanical device that converts energy from a fluid flow input into work output, such as by providing thrust or rotating mechanical power. A turbine is a type of turbomachinery that has at least one moving part called a rotor assembly, which is a shaft or drum to which blades are attached. The moving fluid acts on the blades, causing the blades to move and transfer rotational energy to the rotor.

[0004] Control of industrial turbines and aero-engine turbines requires feedback, which can be achieved by sensing the turbine / engine's rotational speed. Variable reluctance sensors and gears are typically used to sense the speed, where the gear's rotational speed is proportional to the speed of one or more turbine shafts. The resulting signal resembles a sine wave. Summary of the Invention

[0005] Generally, this document describes systems and techniques for monitoring and controlling the speed sensing of rotating machinery, such as turbines. More specifically, it describes techniques for monitoring and controlling mechanical speed sensing, such as mechanical speed sensor waveform analysis, diagnostics, troubleshooting, and control.

[0006] In a first example, a mechanical speed control system includes: a speed sensor configured to measure the speed of a rotating machine; a detection circuit communicating with and isolated from the speed sensor, the detection circuit being configured to receive a waveform measured by the speed sensor and provide data representing the waveform to both a first output and a second output, the second output being isolated from the first output such that data communication at the second output does not interfere with communication at the first output; a control circuit coupled to the first output of the detection circuit, the control circuit being configured to control one or more operations of the rotating machine in response to data from the detection circuit; and a measurement circuit coupled to the second output of the detection circuit, the measurement circuit being configured to sample the data from the detection circuit and associate individual samples with a corresponding timestamp indicating the time when the data was received.

[0007] In the second example, according to Example 1, each sample of the data includes multiple waveforms representing at least one complete rotation of the rotating machine.

[0008] In the third example, according to Example 1 or 2, each sample of the data includes first data representing a waveform measured by the speed sensor, and second data representing a gear tooth detection signal based on the waveform.

[0009] In the fourth example, according to any one of Examples 1 to 3, the measurement circuit includes a user interface configured to allow a user to access and view individual samples.

[0010] In the fifth example, according to any one of Examples 1 to 4, the measurement circuit is configured to determine, for at least one sample, the margin between the peak value of the waveform and the gear tooth detection threshold, and to store the margin in association with the sample.

[0011] In the sixth example, according to any one of Examples 1 to 5, the rotating machine is a gas turbine.

[0012] In the seventh example, according to any one of Examples 1 to 6, the rotating machine is a steam turbine.

[0013] In the eighth example, according to any one of Examples 1 to 7, the mechanical speed control system includes a machine learning model configured to receive multiple individual samples as input and to identify sensor faults based on comparisons of the individual samples.

[0014] In the ninth example, according to any one of Examples 1 to 8, the measurement circuit is configured for each individual sample to store a tooth detection threshold used by the control circuit at the time of the individual sample.

[0015] In the tenth example, according to any one of Examples 1 to 9, the speed sensor is a magnetic pickup unit, a proximity probe, an eddy current probe, or a variable magnetoresistive sensor.

[0016] In the eleventh example, a system includes a rotating machine having a speed control system comprising: a speed sensor coupled to the rotating machine and configured to measure the speed of the rotating machine; a detection circuit communicating with and magnetically isolated from the speed sensor, the detection circuit being configured to receive a waveform measured by the speed sensor and to provide data representing the waveform to both a first output and a second output, the second output being isolated from the first output such that data communication at the second output does not interfere with communication at the first output; a control circuit coupled to the first output of the detection circuit, the control circuit being configured to control one or more operations of the rotating machine in response to data from the detection circuit; and a measurement circuit coupled to the second output of the detection circuit, the measurement circuit being configured to sample the data from the detection circuit and to associate individual samples with a corresponding timestamp indicating the time when the data was received.

[0017] In the twelfth example, according to Example 11, each sample of the data includes multiple waveforms representing at least one complete rotation of the rotating machine.

[0018] In the thirteenth example, according to Example 11 or 12, each sample of the data includes first data representing a waveform measured by the speed sensor, and second data representing a gear tooth detection signal based on the waveform.

[0019] In the fourteenth example, according to any one of Examples 11 to 13, the measurement circuit includes a user interface configured to allow a user to access and view individual samples.

[0020] In the fifteenth example, according to any one of Examples 11 to 14, the measurement circuit is configured to determine, for at least one sample, a margin between the peak value of the waveform and a gear tooth detection threshold, and to store the margin in association with the sample.

[0021] In the sixteenth example, according to any one of Examples 11 to 15, the rotating machine is a gas turbine.

[0022] In the seventeenth example, according to any one of Examples 11 to 16, the rotating machine is a steam turbine.

[0023] In the eighteenth example, according to any one of Examples 11 to 17, the speed control system includes a machine learning model configured to receive a plurality of individual samples as input and to identify sensor faults based on comparisons of the individual samples.

[0024] In the nineteenth example, according to any one of Examples 11 to 18, the measurement circuit is configured for each individual sample to store a tooth detection threshold used by the control circuit at the time of the individual sample.

[0025] In a twentieth example, a machine control method includes: measuring a waveform indicating the speed of a rotating machine by a speed sensor; receiving the waveform from the speed sensor and providing data representing the waveform to a first signal path and a second signal path, wherein the second signal path is isolated from the first signal path such that data communication on the second signal path does not interfere with communication on the first signal path; controlling one or more operations of the rotating machine in response to data received along the first signal path; and storing the data received along the second signal path, individual samples of the data, and corresponding timestamps indicating the time when the data was received.

[0026] Generally, the innovative aspects of the subject matter described in this specification can be embodied in a mechanical speed control system comprising a speed sensor, a detection circuit, a control circuit, and a measurement circuit. The speed sensor is configured to measure the speed of a rotating machine. The detection circuit communicates with and is isolated from the speed sensor. The detection circuit is configured to receive a waveform measured by the speed sensor and provide data representing the waveform to both a first output and a second output, the second output being isolated from the first output such that data communication at the second output does not interfere with communication at the first output. The control circuit is coupled to the first output of the detection circuit and is configured to control one or more operations of the rotating machine in response to data from the detection circuit. The measurement circuit is coupled to the second output of the detection circuit and is configured to sample the data from the detection circuit and associate individual samples with a corresponding timestamp indicating the time when the data was received. This and other implementations may each optionally include one or more of the following features.

[0027] In some implementations, each sample of data includes multiple waveforms representing at least one complete rotation of the rotating machine.

[0028] In some implementations, each sample of data includes first data representing a waveform measured by a speed sensor, and second data representing a gear tooth detection signal based on the waveform.

[0029] In some implementations, the measurement circuitry includes a user interface configured to allow users to access and view individual samples.

[0030] In some implementations, the measurement circuit is configured to determine, for at least one sample, the margin between the peak value of the waveform and the gear tooth detection threshold, and store the margin in association with the sample.

[0031] In some implementations, the rotating machine is a gas turbine. In other implementations, the rotating machine is a steam turbine.

[0032] Some implementations include machine learning models that are configured to receive multiple individual samples as input and identify sensor faults based on comparisons of these individual samples.

[0033] In some implementations, the measurement circuit is configured to store a tooth detection threshold used by the control circuit at the time of that individual sample for each individual sample.

[0034] In some implementations, the speed sensor is a magnetic pickup unit, a proximity probe, an eddy current probe, or a variable magnetoresistive sensor.

[0035] A second general aspect can be embodied in a system comprising a rotating machine having a speed control system. The speed control system includes: a speed sensor coupled to the rotating machine and configured to measure the speed of the rotating machine; and a detection circuit communicating with and magnetically isolated from the speed sensor. The detection circuit is configured to receive a waveform measured by the speed sensor and provide data representing the waveform to both a first output and a second output, the second output being isolated from the first output such that data communication at the second output does not interfere with communication at the first output. The speed control system also includes control circuitry coupled to the first output of the detection circuit and measurement circuitry coupled to the second output of the detection circuit. The control circuitry is configured to control one or more operations of the rotating machine in response to data from the detection circuit. The measurement circuitry is configured to sample the data from the detection circuit and associate individual samples with a corresponding timestamp indicating the time the data was received. This and other implementations may each optionally include one or more of the following features.

[0036] In some implementations, each sample of data includes multiple waveforms representing at least one complete rotation of the rotating machine.

[0037] In some implementations, each sample of data includes first data representing a waveform measured by a speed sensor, and second data representing a gear tooth detection signal based on the waveform.

[0038] In some implementations, the measurement circuitry includes a user interface configured to allow users to access and view individual samples.

[0039] In some implementations, the measurement circuit is configured to determine, for at least one sample, the margin between the peak value of the waveform and the gear tooth detection threshold, and store the margin in association with the sample.

[0040] In some implementations, the rotating machine is a gas turbine. In other implementations, the rotating machine is a steam turbine.

[0041] In some implementations, the speed control system includes a machine learning model configured to receive multiple individual samples as input and to identify sensor faults based on comparisons of these individual samples.

[0042] In some implementations, the measurement circuit is configured to store a tooth detection threshold used by the control circuit at the time of that individual sample for each individual sample.

[0043] In a second general aspect, the innovative aspect of the subject matter described in this specification can be embodied in a machine control method comprising the actions of: measuring a waveform indicating the speed of a rotating machine by a speed sensor; receiving the waveform from the speed sensor and providing data representing the waveform to a first signal path and a second signal path, wherein the second signal path is isolated from the first signal path such that data communication on the second signal path does not interfere with communication on the first signal path; controlling one or more operations of the rotating machine in response to the data received along the first signal path; and storing the data received along the second signal path, individual samples of the data, and a corresponding timestamp indicating the time when the data was received. Other implementations of this aspect include corresponding systems, apparatuses, and computer programs configured to perform the actions of the method and encoded on a computer storage device.

[0044] The systems and techniques described herein can provide one or more of the following advantages. For example, the system can provide accurate speed measurement and recording at various stages of a particular machine's lifespan. Some implementations enable the early detection of speed sensing failures, speed sensor measurement degradation, and / or early correction of speed sensing errors before mechanical damage results.

[0045] Details of one or more implementations are set forth in the accompanying drawings and the following description. Other features and advantages will be apparent from the description, drawings, and claims. Attached Figure Description

[0046] Figure 1 This is an example schematic diagram illustrating a system used to control a turbine engine.

[0047] Figure 2 This is a cross-sectional view of an example speed sensor.

[0048] Figure 3 yes Figure 1 The diagram shows a block diagram of an example speed sensing system.

[0049] Figure 4 This is a graph of an example velocity pulse waveform.

[0050] Figure 5A and 5B This is a graph showing the analog signal waveform of an example speed sensor and the speed pulse waveform generated from it.

[0051] Figure 6A and 6B This is another example of a speed sensor analog signal waveform and a graph of the speed pulse waveform generated from it.

[0052] Figure 7 This is an example process flow diagram for controlling a turbine.

[0053] Figure 8 This is an example schematic diagram of a general-purpose computer system.

[0054] In the various figures, the same reference numerals indicate the same elements. Detailed Implementation

[0055] This document describes the systems and techniques used for speed sensing systems to monitor and control rotating machinery, such as industrial turbines or aero engines. Industrial turbine and aero engine controllers typically use sensed turbine / engine speed as control feedback. Generally, the frequency / speed sensing system of an engine control system determines a controlled preset voltage and / or trigger threshold voltage, which is either fixed or adaptive as engine control conditions change.

[0056] Furthermore, turbine control systems use speed input as a critical control parameter. However, robust operation using speed sensing probes can be challenging because a wide range of variables affect the accuracy of speed measurements from sensor output waveforms. These variables can include speed wheel and gear dimensions, cable parameters, impedance matching, and the sensitivity of the sensing circuitry. In other words, visibility into the quality of the speed sensor waveform signal during turbine operation can improve system performance. Moreover, recording the sensor output over time allows for the early detection of speed sensor signal degradation before mechanical failures occur.

[0057] The systems and processes described below provide turbine operators with data to enable diagnostic / predictive strategies to identify and correct problems in the turbine speed sensing system. Furthermore, the waveform capture system allows for the real-time capture and analysis of speed sensor data during turbine operation. In some implementations, waveform capture is independent of turbine speed control and safety functions to avoid interfering with the turbine's deterministic operational control. The waveform capture system can still be integrated into the turbine control system (without interfering with operational control and safety) and remains available to the user regardless of the turbine's operating state.

[0058] Figure 1 This is an example schematic diagram illustrating a system 100 for controlling a rotating machine, such as a turbine 101 that drives a load 102 (e.g., a working output). The turbine 101 can be, for example, a gas turbine or a steam turbine. The speed of the turbine 101 is controlled by a speed control signal provided by an engine controller 112 of a turbine system controller 110. The rotation or speed of the turbine 101 or the load 102 drives a speed sensing system 130, which will... Figure 2 The description is further detailed below. Engine controller 112 (e.g., a turbine engine controller) is also configured to receive feedback regarding the operating conditions of load 102 and / or turbine 101 (e.g., temperature, vibration level, intake air temperature, exhaust air temperature). Engine controller 112 may include turbine control algorithm 114 and actuator driver 116. Turbine control algorithm 114 is configured to receive feedback regarding the operating conditions of load 102 and / or turbine 101, and to regulate the operation of turbine 101 in response to such feedback. Turbine control algorithm 114 provides control signals to actuator driver(s)(one or more) 116. Actuator driver processes the control signals from turbine control algorithm 114 and controls the operation of turbine 101 by adjusting appropriate control valves 150 (e.g., fuel throttle valve, intake valve, cooling system valve, etc.). Speed ​​sensor 120 is mounted within turbine 101 and arranged to detect the rotational speed of turbine 101 or the rotational speed of turbine shaft. Reference is made below. Figure 2 Describe the details of the operation of speed sensor 120. Generally, speed sensor 120 can be a magnetic pickup unit (MPU), a proximity probe, an eddy current probe, or a variable magnetoresistive sensor.

[0059] In the example of system 100, speed sensing system 130 receives an analog sensor input signal waveform from speed sensor 120 in response to the rotation of the output of load 102 or turbine 101. Speed ​​sensing system 130 converts the analog sensor waveform into a frequency signal. The frequency signal is an analog or digital pulse sequence, similar to a digital or rectangular waveform provided as a feedback signal to turbine system controller 110 (e.g., for engine controller 112 to determine a speed control signal). In some implementations, the frequency signal may be provided directly to turbine system controller 110 as a feedback signal. In some implementations, the frequency signal may be provided to turbine system controller 110 in another form, such as a digital signal representing a frequency value or a digitized data stream representing a frequency signal.

[0060] The speed sensing system 130 is configured to receive configuration settings from the adaptive speed sensing signal processing module 140. As will be discussed in more detail below, the amplitude and shape of the analog sensor waveform can change with variations in the operating conditions of the load 102 and / or turbine 101, and can change throughout the entire service life of the turbine 101. The configuration settings define how the speed sensing system 130 determines the occurrence of periods in the analog sensor waveform and generates frequency signal pulses at different speeds of the load 102 and / or turbine 101 (e.g., how to provide a frequency pulse for each analog sensor waveform period).

[0061] In various implementations, different operating conditions of system 100, individually or in combination, can affect the analog sensor waveform. For example, the temperature of internal components of the sensor and / or the rotational speed of internal mechanical components of speed sensing system 130 can change the amplitude and / or shape of the waveform. Vibration and ambient electromagnetic radiation can introduce electrical noise into the analog sensor waveform. Mechanical load and / or acceleration of the engine can affect the analog sensor waveform. Cable degradation, probe alignment misalignment, and damage or wear of gear teeth can cause the shape of the analog sensor waveform to degrade over time, potentially leading to difficult-to-diagnose warnings and operational control errors. Signal processing module 140 is configured to receive information about the operating conditions of system 100 (such as these and / or other conditions) from turbine system controller 110 and speed sensing system 130 to adaptively and dynamically reconfigure the configuration settings provided to speed sensing system 130 as operating conditions change.

[0062] The operating modules of controller 110 may be provided as one or more computer-executable software modules, hardware modules, or a combination thereof. For example, turbine control algorithm 114, actuator driver 116, speed sensing system 130, and one or more of speed sensing systems 130 may be implemented as software code blocks with instructions that cause one or more processors of control system 100 to perform the operations described herein. Additionally or alternatively, one or more operating modules may be implemented in electronic circuitry, such as programmable logic circuitry, field-programmable arrays (FPGAs), or application-specific integrated circuits (ASICs).

[0063] Figure 2 This is a cross-sectional view of an example speed sensor 200. In some implementations, the speed sensor 200 may be... Figure 1 Example system 100 has a speed sensing system 130. The speed sensor 200 may be a variable magnetoresistive sensor or a magnetic pickup unit (MPU) in which motion (e.g., rotation of turbine 101) causes magnetic field fluctuations, which in turn create a periodic analog electrical signal 210 (e.g., an analog sensor waveform) that can be processed (e.g., to determine a frequency pulse sequence).

[0064] Industrial turbine and aero-engine control typically uses sensed turbine / engine speed as control feedback. Speed ​​can be sensed using a variable magnetoresistive sensor 220 and a gear 230, wherein the gear 230 is configured to rotate at a speed proportional to the engine or turbine speed.

[0065] The variable magnetoresistive sensor 220 includes a magnet 222 and an electrode 224. The magnet 222 generates a magnetic field around the electrode 224. A coil of wire 226 is wound around the electrode to form an electromagnetic pickup. The electrode 224 extends toward a gear 230, which includes an assembly of gear teeth 232. The gear 230 is made of ferrite or other magnetic material, and as the gear 230 rotates, the gear teeth 232 move into and out of the vicinity of the electrode 224. This changing proximity causes fluctuations in the magnetic field around the electrode 224 and the coil 226. These magnetic field fluctuations induce a current in the coil 226, which flows through a pair of connector pins 228 to the input of the speed sensing circuit 130. The fluctuating current can be measured at the connector pins 228 as a periodic analog electrical signal 210.

[0066] Determining speed based on magnetoresistive sensor signals generally involves determining the signal frequency, which is typically proportional to the turbine speed. The fundamental frequency of the periodic analog electrical signal 210 is equal to the number of gear teeth 232 multiplied by the number of revolutions per minute of gear 230, divided by sixty. The periodic analog electrical signal 210 resembles a sine wave, but its peaks may be sharper, its zero-crossing point may be nearly flat, and multiple peaks may exist in extreme cases. The periodic analog electrical signal 210 typically changes with engine speed, and the signal amplitude typically increases with increasing engine speed. Electrical noise and other operating conditions may further increase the complexity of the periodic analog electrical signal 210. This is achieved by implementing preset and trigger setpoints that can be dynamically adjusted according to changes in operating conditions and operating values ​​(e.g., Figure 1 (This can be achieved by the signal processing module 140), which, despite other complexities of the signal, can still obtain the actual fundamental frequency of the periodic analog electrical signal 210.

[0067] Figure 3 yes Figure 1 The following is a block diagram of an example speed sensing system 130. The speed sensing system 130 receives an analog sensor waveform 210 from a speed sensor 120 via electromagnetic compatibility (EMC) protection hardware / circuit 302. EMC protection 302 may include cable shielding, appropriate grounding connections, and / or electromagnetic interference (EMI) filters. EMC protection 302 improves the quality of the waveform 210 signal from the speed sensor 120 and minimizes signal noise caused by EMI.

[0068] Signal isolation 304 isolates the speed sensing system circuitry (and the rest of the turbine controller 110 circuitry) from the turbine field and other high-current / high-voltage circuitry of the turbine 101. Typically, speed sensor 120 is grounded to earth or turbine field ground, while controller 110 and speed sensing system 130 circuitry are grounded to processor ground. In some cases, speed sensor 120 may not be grounded, while controller 110 and speed sensing system 130 circuitry are grounded to processor ground. Signal isolation 304 may be magnetic signal isolation (e.g., one or more isolation transformers) and / or optical signal isolation.

[0069] The detection circuit 306 is configured to receive configuration settings from the signal processing module 140 and detect pulses in the analog waveform signal 210 to output pulses of a speed pulse waveform 330 representing the turbine speed. Each pulse of the speed pulse waveform 330 indicates the detection of gear teeth passing through the speed sensor 120, as referenced above. Figure 2 The configuration settings, as discussed below, include a preset threshold and a trigger level setting, which will be discussed in more detail below. The detection circuit 306 is also configured to provide a velocity pulse waveform 330 in response to a sensed input signal (e.g., the example periodic analog electrical signal 210) based on the preset threshold and trigger level settings.

[0070] The speed sensing system 130 is configured to generate or receive analog waveform signals 210, as having a connection with a physical object (e.g., Figure 1 A cyclic analog waveform proportional to the fundamental frequency of the example turbine 101 or example load 102 is generated. A speed pulse waveform 330 is also generated to represent the frequency or periodicity of the analog waveform signal 210. For example, the analog waveform signal 210 could be... Figure 2 Example: A periodic analog electrical signal 210 is generated in response to the rotation of gear 230. The trigger level setting represents the voltage (or current) level of the analog waveform signal 210 at which the speed sensing system 130 will generate a corresponding frequency edge signal (e.g., pulse 410). The preset threshold setting represents the voltage (or current) level that must be met before the pulse of the speed pulse waveform 330 can be triggered.

[0071] For example, Figure 4An example graph of a velocity pulse waveform 330 is shown. The frequency edge signal represents a defined frequency of the analog waveform signal 210. In the example shown, the velocity pulse waveform 330 is a stream of digital or quasi-digital electrical pulses 410 that are triggered at a rate matching or proportional to the occurrence of analog cycles within the analog waveform signal 210. For example, the velocity pulse waveform 330 may provide one or more pulses 410 for each analog waveform cycle of the analog waveform signal 210. In another example, the velocity pulse waveform 330 may provide one pulse 410 for every 1, 2, 5, 10, 100, or any other predetermined number of analog waveform cycles of the analog waveform signal 210. In yet another example, the velocity pulse waveform 330 may be a pulse width modulated signal, wherein the width of the pulse 410 varies proportionally to the fundamental frequency of the analog waveform signal 210. In some implementations, the velocity pulse waveform 330 may be an analog signal proportional to the fundamental frequency of the analog waveform signal 210. For example, the velocity pulse waveform 330 may be a voltage or current signal that increases or decreases proportionally with the fundamental frequency of the analog waveform signal 210. In some implementations, the velocity pulse waveform 330 may be a digital signal carrying a digital value representing the fundamental frequency of the analog waveform signal 210. For example, if the fundamental frequency of the analog waveform signal is 120.607 Hz, then the velocity pulse waveform 330 may be a computer signal carrying the digital value "120.607" as a digitally encoded value. To simplify the subsequent discussion of these processes and as an example only, the analog waveform signal 210 may be described as a series of short electrical pulses, wherein a single pulse is transmitted in response to the detection of a single analog cycle of the analog waveform signal 210.

[0072] In some implementations, the detection circuit 306 and / or signal processing module 140 can convert the frequency edge signal into turbine speed. For example, the pulse frequency in the frequency edge signal can be converted into turbine speed based on the number of teeth in the gear sensed by the speed sensor 120. The pulse frequency in the speed pulse waveform 330 is equal to the number of teeth multiplied by the gear's revolutions per minute, then divided by 60. The measured turbine speed can be output as a speed signal to the engine controller 112.

[0073] In some implementations, some or all of the preset threshold setting, trigger level setting, speed pulse waveform 330, analog waveform signal 210, and rotational speed signal may be analog signals. For example, one or both of the preset threshold setting and trigger level setting may be analog voltage or current levels provided by signal processing module 140 and used, for example, in a comparator circuit within speed sensing system 130 (e.g., for comparison with a sensed input signal) to determine the speed pulse waveform 330 and analog waveform signal 210. One or more of the speed pulse waveform 330, analog waveform signal 210, and rotational speed signal may be analog DC signals (e.g., voltage or current proportional to the values ​​they represent) or dynamic waveform signals.

[0074] In some implementations, some or all of the preset threshold setting, trigger level setting, speed pulse waveform 330, and rotational speed signal may be digital signals. For example, one or both of the preset threshold setting and trigger level setting may be frequency or pulse width modulated signals that can be decoded by circuitry in the speed sensing system 130. In another example, one or both of the speed pulse waveform 330 and rotational speed signal may be frequency or pulse width modulated signals representing their respective frequencies and / or speed values.

[0075] In some implementations, some or all of the preset threshold setting, trigger level setting, speed pulse waveform 330, and rotational speed signal can be data signals. For example, one or more signals can be digitally encoded data streams representing configuration settings and / or sensing results.

[0076] Figures 5A-5B A graph 500a of an example analog waveform signal 510 and a graph 500b of a frequency edge signal 580 generated from the analog waveform signal 510 are shown. In some implementations, the analog waveform signal 510 may be... Figure 2 and 3 Example analog waveform signal 210. The graph also shows example trigger setting 520 and example preset level setting 530. In some implementations, trigger setting 520 may be an example trigger level setting value, while preset level setting 530 may be an example preset threshold setting value.

[0077] In the example shown, the analog waveform signal 510 resembles a sine wave that varies between a peak positive voltage and a peak negative voltage. As an example, for ease of description of the functionality of trigger setting 520 and preset level setting 530, the analog waveform signal 510 is described as a cyclic signal ranging between -10V and +10V over a complete cycle. Also, for the sake of describing only one possible example, trigger setting 520 could be +5V without setting preset level setting 530. In such an example, the voltage of the analog waveform signal 510 could start at 0V and rise towards +10V, and when the voltage reaches +5V at point 550, a pulse (e.g., one of pulses 410) could be transmitted in the example velocity pulse waveform 330. In some implementations, trigger setting 520 can also identify the directionality of the trigger, such as a rising voltage or a falling voltage. For example, trigger setting 520 could be +5V on a falling voltage. In this example, the voltage of the analog waveform signal 210 can start from 0V and rise to +10V. When the voltage reaches +5V at point 550 during the rise, no pulse will be transmitted in the speed pulse waveform 330. As the voltage of the analog waveform signal 210 reaches its peak at the example +10V maximum value and begins to fall towards the example -10V minimum value, a pulse can be transmitted in the example speed pulse waveform 330 when the voltage reaches +5V at point 552 during the fall.

[0078] Still referencing Figures 5A-5B The preset level setting 530 can be set to affect the trigger. For example, the preset level setting 530 could be +3V, while the trigger setting 520 could remain at +4V. In such an example, the voltage of the analog waveform signal 510 can start at 0V and rise towards +10V. When the voltage reaches +3V, the trigger is preset (e.g., placed in a state where the trigger setting is recognizable). As the voltage continues to rise towards the example +10V peak to +4V, a pulse can be transmitted in the example speed pulse waveform 330 (e.g., one of pulses 410), and the preset is reset. When the voltage reaches its peak and drops past +4V during the negative half-cycle, no triggering occurs because the trigger is not preset at this time.

[0079] The detection circuit 306 provides the speed pulse waveform 330 and / or rotation edge signal to the engine controller 112 directly or via the signal processing module 140 using a single signal path. Additionally, the detection circuit 306 provides the analog waveform signal, the speed pulse waveform 330, or both to the waveform measurement system 310 via a second, separate signal path. This second signal path is isolated from the first signal path, ensuring that data communication on the second path does not interfere with communication on the first signal path. In this way, communication with the waveform measurement system 310 is isolated from turbine operation and control signals in the remainder of the controller 110.

[0080] The waveform measurement system 310 is configured to store and optionally analyze speed sensor waveform samples used to control the operation of turbine 101. The waveform system 310 provides a mechanism for turbine operators to safely view speed sensing signals regardless of turbine operating conditions. The waveform measurement system 310 operates independently of the speed control and safety functions of controller 110 and does not interfere with the deterministic control of turbine 101 during operation. As long as controller 110 is powered on, the waveform measurement system 310 provides users with access to speed sensor data for maintenance and diagnostics.

[0081] Direct acquisition of turbine speed sensing data is crucial at various points in the turbine's lifecycle. One such phase is field commissioning. During initial installation, it is important to verify that the speed sensor signal output (e.g., analog waveform signal 210) is sufficient for turbine operation. This is difficult to achieve using conventional methods because signal shape is just as important as signal amplitude. Both vary significantly across the speed operating range. Waveform capture, accessible during commissioning or at any time thereafter, is a tool that improves installation time and the reliability of turbine control. Another example is the variation in signal integrity over time. By periodically capturing waveforms, waveform measurement system 308 can monitor signal shape over time to improve turbine uptime. In some implementations, waveform measurement system 310 can perform automated diagnostic / prognostic analysis on current and stored waveforms. For example, waveform measurement system 310 can employ machine learning models to preemptively detect and correct degradation of the speed sensor output over time.

[0082] The waveform measurement system 308 may include a waveform digitizer 310, a waveform storage device 312, and a waveform analyzer 316. The waveform measurement system 308 may interface with a user interface 314. The user interface may be an interface integrated into the turbine controller 110, such as a touchscreen interface or a display with a keyboard or other user input devices. The user interface 314 may be a separate computer device (e.g., a laptop computer, tablet computer, smartphone, etc.) that can be connected to the input / output interface of the waveform measurement system 308. The user interface 314 may be directly connected to the turbine controller 110 via the input / output interface of the waveform measurement system 308. In some implementations, the input / output interface is a wireless interface configured to establish a wireless connection with the user interface 314. The user interface 314 may interact with the waveform measurement system 308 to allow the turbine operator to access and view stored waveforms and / or analyses performed by the waveform measurement system 308.

[0083] Waveform digitizer 310 receives sensor data signals (e.g., analog waveform signal 210 and velocity pulse waveform 330) from detection circuit 306. Waveform digitizer 310 can convert the sensor data signals into a digital format. For example, waveform digitizer 310 may include an analog-to-digital converter (A / D converter), a quantizer, and an encoder to convert the sensor data signals into a digital format, for example, for storage and / or analysis. Waveform digitizer 310 can digitize individual samples of the sensor data signals and store them in waveform storage device 312. For example, waveform digitizer 310 can be configured to record waveform samples representing one or more complete rotations of turbine 101. In some examples, each individual waveform sample represents sensor data equivalent to one complete rotation of turbine 101. Thus, each waveform sample records a sensor waveform representing the detection signal of each tooth in the turbine gear.

[0084] In some implementations, the waveform digitizer 310 attaches metadata to a single waveform sample. The metadata may include, for example, a timestamp indicating the date and time of signal reception, turbine operating characteristics, data associating a sample of the analog waveform signal 210 with a corresponding speed pulse waveform 330 generated from that particular analog waveform signal 210, or a combination thereof. Turbine operating characteristics may include calculated turbine speed, operating load output, vibration, ambient air temperature, fuel flow, and / or other operating characteristics. In some implementations, the waveform digitizer 310 may receive a current threshold level setting and a preset threshold setting used by the detection circuit 306. The waveform digitizer 310 may store these values ​​as metadata along with the associated single waveform sample, for example, for viewing by the turbine operator.

[0085] Waveform storage device 312 may include any suitable type of computer memory, including, for example, semiconductor memory devices such as EPROM, EEPROM and flash memory devices; disks such as internal hard disks and removable disks; magneto-optical disks; and CD-ROM and DVD-ROM optical disks.

[0086] In some implementations, the waveform measurement system 308 includes a waveform analyzer 316. The waveform analyzer 316 can receive waveform samples from the waveform digitizer 310 or access stored waveform samples from the waveform storage device 312. The waveform analyzer 316 can analyze the waveform samples to perform automatic diagnostics. For example, the waveform analyzer 316 can compare stored waveform samples with current waveform samples to detect changes in speed sensor measurements. The waveform analyzer 316 can compare waveform samples obtained under similar turbine operating characteristics. In some implementations, the waveform analyzer 316 can detect changes in waveform shape and / or amplitude that indicate alterations or degradation of the speed sensor 120, including movement of the sensor 120, cable damage or degradation, etc. For example, a change in signal strength (amplitude) might indicate an increase in the distance between the sensor probe and the teeth, thus indicating displacement of the speed sensor within the turbine housing or mounting. As another example, a change in waveform shape could indicate degradation of the cable or speed wheel (e.g., damaged teeth). In some implementations, waveform analyzer 316 may employ a machine learning model to identify changes in the sensor waveform indicating alterations or degradation of the speed sensor 120. For example, waveform analyzer 316 may communicate with a cloud-based machine learning model via user interface 314 to perform waveform analysis.

[0087] In some implementations, the waveform analyzer 316 can determine the margin based on the pulse detection trigger setting value and / or the pulse detection preset level setting value. For example, Figures 6A-6B A graph 600a of an example analog waveform signal 610 and a graph 600b of the corresponding frequency edge signal 680 generated from the analog waveform signal 610 are shown. In some implementations, the analog waveform signal 610 may be... Figure 2 and 3 Example analog waveform signal 210. The graph also shows example trigger setting 620 and example preset level setting 630. Generally, analog waveform signal 610 is... Figure 5A The example analog waveform signal 510 is a slightly more complex example. Analog waveform signal 610 includes double peaks in each period, such as an absolute maximum 660 and a local maximum 662 in period 612a. Such double peaks may be the result of variations in the aforementioned sensor signal variables (e.g., wheel / gear size, cable parameters, impedance matching, etc.). Such double peaks can cause inaccurate speed measurements because when the trigger setting is preset and retried by the second peak, a shadow pulse 684 is generated in the frequency edge signal 680.

[0088] The amplitude and overall shape of analog frequency signals from speed sensors (such as analog waveform signals 510 and 610) typically change with rotational speed, and because of this waveform shape variation, the preset and trigger thresholds of typical speed sensors can be difficult to configure. Therefore, maintaining a record of the waveform that causes such dual triggering can be important. For industrial turbine control, the challenge may be even greater, as industrial installations use many different probe types, gear types, cable lengths, cable types, etc. This can lead to greater variations in the speed sensing waveform generated by variable magnetoresistive sensors, as well as potential noise detected by turbine / engine control. The following describes in more detail an example system and techniques for adaptively and dynamically setting preset and trigger thresholds to provide a clearer and more useful frequency signal (e.g., from which turbine speed can be determined) from sensor signals with different waveforms.

[0089] In the example shown, due to the complexity of the analog waveform signal 610, the voltage crosses the trigger value 620 four times at points 670a, 670b, and 670c within a single cycle 612. However, also due to the complexity of the analog waveform signal 610, the number of crossings is not consistent or proportional across cycles. For example, only two such crossings exist in cycle 612b, resulting in a correct pulse 682 and a shadowed pulse 684 generated in the frequency edge signal 680. Without the additional use of a preset level setting 630 at a predetermined and appropriate threshold, even if the fundamental frequency of the analog waveform signal 610 is approximately the same from cycle 612a to cycle 612b, cycle 612a might trigger two frequency pulses (pulses 682 and 684), while cycle 612b might trigger only one frequency pulse (pulse 682).

[0090] In some implementations, the waveform analyzer 316 can detect the shadow pulse 682 and output an alarm to the user interface 314. For example, the waveform analyzer 316 can identify the shadow pulse 682 based on abrupt changes in the frequency or shape of the pulse in the frequency edge signal 680. In some implementations, the data indicating the detection of the shadow pulse 682 can be stored as metadata associated with the corresponding waveform sample.

[0091] In some implementations, waveform analyzer 316 can determine the margin based on a preset level setting and a threshold level setting. For example, waveform analyzer 316 can detect a margin 676 between the preset level setting 630 and the double peaks (e.g., a local maximum 662) of the analog waveform signal pulse. For example, waveform analyzer 316 can use signal analysis techniques to detect the local maximum 662 and the corresponding voltage value, and determine the voltage margin based on the preset level setting value used for pulse detection when sampling the corresponding waveform. Waveform analyzer 316 can detect a margin 678 between the trigger setting 620 and the maximum peak value (e.g., a maximum value 660) of the analog waveform signal pulse. For example, waveform analyzer 316 can use signal analysis techniques to detect the local maximum 662 and the corresponding voltage value, and determine the voltage margin based on the preset level setting value used for pulse detection when sampling the corresponding waveform.

[0092] In some implementations, waveform analyzer 316 can isolate individual tooth detection pulses from analog waveform signal 610 for further analysis. In some implementations, waveform analyzer 316 can compare the waveform shapes between individual tooth detection pulses in analog waveform signal 610 to detect changes in speed sensor 120 or turbine gear. For example, the shape difference between the pulse in period 612a and the pulse in period 612b may indicate damage (e.g., burrs or chips) to a tooth on the turbine gear.

[0093] The waveform measurement system 311 can record such analysis data for later review by the user, for analysis (e.g., by the waveform analyzer system 316), and for detecting setting errors in preset level settings and / or trigger settings. The analysis data can be stored in metadata associated with the corresponding waveform sample.

[0094] In some implementations, the user interface 314 may allow the turbine operator to access current or stored waveform samples. The user interface 314 may allow the turbine operator to interact with a graphical representation of the waveform samples. For example, the user interface 314 may present a traceable graph of the waveform sample. In other words, the user interface 314 may display an interactive graphical representation that allows the user to trace the graphical representation with a cursor and present the voltage value of the waveform at the location traced along the waveform graph.

[0095] Figure 7 This is a flowchart of an example process 700 for controlling a turbine engine. In some implementations, process 700 can be... Figure 1 The example system 100 is executed in whole or in part, or by Figure 1 and 3 The example speed sensing system 130 and / or the example waveform measurement system 308 are implemented.

[0096] The control system measures a waveform (e.g., analog signal waveform 210) that indicates the speed of the rotating machine (710). For example, the control system may use a speed sensor, such as a variable magnetoresistive sensor or a magnetic pickup unit (MPU), to measure and detect magnetic / electric pulses generated by the rotating gears of the machine (e.g., a turbine).

[0097] The control system receives a waveform (720) from the speed sensor and provides the analog signal waveform to a first signal path (730) and a second signal path (730). The first signal path and the second signal path are isolated from each other, so that communication on each signal path does not interfere with communication on the other signal path. For example, the first signal path is a control signal path within the control system, used to provide control and safety data communication for machine operation. The second signal path is a data logging or diagnostic signal path. Communication on the second signal path is not critical to machine operation.

[0098] In some implementations, the control system performs a speed detection process on the waveform to determine the machine's rotational speed. For example, as described above, the system can detect pulses within the waveform representing gear teeth passing in front of a speed sensor to generate a speed pulse waveform (e.g., speed pulse waveform 330). The system can then determine the speed of the rotating machine based on the pulse waveform. In such an implementation, the system can provide both an analog signal waveform and the speed pulse waveform to both the first and second signal paths.

[0099] The control system controls the operation of the machine based on the speed represented by the speed sensor waveform from the first signal path (740).

[0100] The control system stores the waveforms (760) received from the second signal path. For example, the system stores individual samples of data associated with a corresponding timestamp indicating when the data was received. In some cases, each stored sample includes both a representation of the analog signal waveform measured by the speed sensor and a representation of the speed pulse waveform representing the gear tooth detection signal based on the analog signal waveform. Waveforms can be sampled in such a way that each stored waveform represents one or more complete rotations of the machine.

[0101] In some implementations, waveform samples may be stored along with additional metadata associated with the samples. For example, metadata may include threshold level settings and preset threshold settings used by the detection circuit to detect pulses, timestamps indicating the date and time of signal reception, turbine operating characteristics, or combinations thereof.

[0102] The system may include a user interface (UI) or a user interface connection that allows access to stored waveforms. In response to user input on the user interface, the system may access the stored waveforms (770) and provide the requested waveform for display on the user interface (780). For example, the user interface may be configured to run an application programmed to interface with the control system. This application may access a database index of waveforms stored by the control system and allow the user to select and view past speed sensor waveforms.

[0103] In some implementations, the control system can analyze stored waveforms (790). For example, the system can analyze stored waveforms to identify changes in the operation of the speed sensor or the speed sensing circuitry of the control system. The system can compare the waveforms at the time of initial mechanical installation and / or the time of the speed sensor's most recent replacement or maintenance with the current waveforms to detect damage or degradation in sensor performance.

[0104] Figure 8 This is an example schematic diagram of a general-purpose computer system 800 (e.g., a data processing device). According to one implementation, system 800 can be used for the operations described in association with method 300.

[0105] System 800 includes a processor 810, memory 820, storage device 830, and input / output device 840. Each of components 810, 820, 830, and 840 is interconnected using a system bus 850. Processor 810 is capable of processing instructions for execution within system 800. In one implementation, processor 810 is a single-threaded processor. In another implementation, processor 810 is a multi-threaded processor. Processor 810 is capable of processing instructions stored in memory 820 or storage device 830 to display graphical information for a user interface on input / output device 840.

[0106] Memory 820 (e.g., non-temporary memory) stores information within system 800. In one implementation, memory 820 is a computer-readable medium. In one implementation, memory 820 is a volatile memory cell. In another implementation, memory 820 is a non-volatile memory cell.

[0107] Storage device 830 (e.g., a non-transitory storage device) provides mass storage for system 800. In one implementation, storage device 830 is a computer-readable medium. In various other implementations, storage device 830 may be a floppy disk device, a hard disk device, an optical disk device, or a magnetic tape device.

[0108] Input / output device 840 provides input / output operations for system 800. In one implementation, input / output device 840 includes a keyboard and / or a pointing device. In another implementation, input / output device 840 includes a display unit for displaying a graphical user interface.

[0109] The described features can be implemented in digital electronic circuits, or in computer hardware, firmware, software, or a combination thereof. The device can be implemented as a computer program product tangibly embodied in an information carrier (e.g., in a machine-readable storage device) for execution by a programmable processor; and the method steps can be executed by a programmable processor executing an instruction program to perform the function of the implementation by manipulating input data and generating output. The features can advantageously be implemented in one or more computer programs that can be executed on a programmable system including at least one programmable processor coupled to receive and transmit data and instructions from a data storage system, at least one input device, and at least one output device. A computer program is a set of instructions that can be used directly or indirectly in a computer to perform a specific activity or produce a specific result. Computer programs can be written in any form of programming language (including compiled or interpreted languages) and can be deployed in any form, including as a standalone program or as a module, component, subroutine, or other unit suitable for use in a computing environment.

[0110] Processors suitable for executing instructions include, for example, both general-purpose microprocessors and special-purpose microprocessors, as well as a single processor or one or more processors in any type of computer. Generally, a processor receives instructions and data from read-only memory or random access memory, or both. The basic components of a computer are a processor for executing instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include one or more mass storage devices for storing data files, or operatively coupled to and communicating with them; such devices include disks, such as internal hard disks and removable disks; magneto-optical disks; and optical disks. Storage devices suitable for tangibly representing computer program instructions and data include all forms of non-volatile memory, including (for example) semiconductor memory devices, such as EPROM, EEPROM, and flash memory devices; disks, such as internal hard disks and removable disks; magneto-optical disks; and CD-ROM and DVD-ROM optical disks. The processor and memory may be supplemented or incorporated into ASICs (Application-Specific Integrated Circuits).

[0111] To provide interaction with the user, these features can be implemented on a computer with a display device for showing information to the user, such as a CRT (cathode ray tube) or LCD (liquid crystal display) monitor; and a keyboard and pointing device (such as a mouse or trackball) through which the user can provide input to the computer.

[0112] These features can be implemented in a computer system that includes back-end components (such as data servers), middleware components (such as application servers or internet servers), front-end components (such as client computers with graphical user interfaces or internet browsers), or any combination thereof. The components of the system can be connected via digital data communication of any form or medium, such as a communication network. Examples of communication networks include, for example, LANs, WANs, and the computers and networks that form the Internet.

[0113] Computer systems can include clients and servers. Clients and servers are generally geographically separated and typically interact via a network (such as the aforementioned network). The client-server relationship arises from computer programs running on their respective computers that have a client-server relationship with each other.

[0114] While some implementations have been described in detail above, other modifications are possible. For example, the concept is not limited to aircraft engine control or industrial turbine control; it will be applicable to any suitable frequency signal derived from a variable magnetoresistive sensor. Furthermore, the logical flow depicted in the figures does not require the specific or sequential order shown to achieve the desired result. Additionally, other steps may be provided in the flow, or steps may be removed from the flow; and other components may be added to the system, or components may be removed from the system. Therefore, other implementations are also within the scope of the following claims.

Claims

1. A mechanical speed control system, comprising: A speed sensor, configured to measure the speed of a rotating machine; A detection circuit that communicates with and is isolated from the speed sensor is configured to receive a waveform measured by the speed sensor and provide data representing the waveform to both a first output and a second output, wherein the second output is isolated from the first output such that data communication at the second output does not interfere with communication at the first output. A control circuit coupled to a first output of the detection circuit, the control circuit being configured to control one or more operations of the rotating machine in response to data from the detection circuit; as well as A measurement circuit, coupled to a second output of the detection circuit, is configured to sample data from the detection circuit and associate individual samples with a corresponding timestamp indicating the time the data was received.

2. The mechanical speed control system according to claim 1, wherein each sample of the data comprises a plurality of waveforms representing at least one complete rotation of the rotating machine.

3. The mechanical speed control system according to claim 1 or 2, wherein each sample of the data includes first data representing a waveform measured by the speed sensor, and second data representing a gear tooth detection signal based on the waveform.

4. The mechanical speed control system according to any one of claims 1 to 3, wherein the measurement circuit includes a user interface configured to allow a user to access and view individual samples.

5. The mechanical speed control system according to any one of claims 1 to 4, wherein the measuring circuit is configured as follows: For at least one sample, determine the margin between the peak value of the waveform and the gear tooth detection threshold; and The margin is associated with the sample and stored.

6. The mechanical speed control system according to any one of claims 1 to 5, wherein the rotating machine is a gas turbine.

7. The mechanical speed control system according to any one of claims 1 to 6, wherein the rotating machine is a steam turbine.

8. The mechanical speed control system according to any one of claims 1 to 7, comprising a machine learning model configured to receive a plurality of individual samples as input and to identify sensor faults based on comparisons of the individual samples.

9. The mechanical speed control system according to any one of claims 1 to 8, wherein the measuring circuit is configured to store a tooth detection threshold used by the control circuit at a time for each individual sample.

10. The mechanical speed control system according to any one of claims 1 to 9, wherein the speed sensor is a magnetic pickup unit, a proximity probe, an eddy current probe, or a variable magnetoresistive sensor.

11. A system comprising: A rotating machine having a speed control system, the speed control system comprising: A speed sensor, coupled to the rotating machine and configured to measure the speed of the rotating machine; A detection circuit that communicates with and is magnetically isolated from the speed sensor is configured to receive a waveform measured by the speed sensor and provide data representing the waveform to both a first output and a second output, wherein the second output is isolated from the first output such that data communication at the second output does not interfere with communication at the first output. A control circuit coupled to a first output of the detection circuit, the control circuit being configured to control one or more operations of the rotating machine in response to data from the detection circuit; and A measurement circuit, coupled to a second output of the detection circuit, is configured to sample data from the detection circuit and associate individual samples with a corresponding timestamp indicating the time the data was received.

12. The system of claim 11, wherein each sample of the data comprises a plurality of waveforms representing at least one complete rotation of the rotating machine.

13. The system of claim 11 or 12, wherein each sample of the data includes first data representing a waveform measured by the speed sensor, and second data representing a gear tooth detection signal based on the waveform.

14. The system according to any one of claims 11 to 13, wherein the measurement circuitry includes a user interface configured to allow a user to access and view individual samples.

15. The system according to any one of claims 11 to 14, wherein the measurement circuit is configured to: For at least one sample, determine the margin between the peak value of the waveform and the gear tooth detection threshold; and The margin is associated with the sample and stored.

16. The system according to any one of claims 11 to 15, wherein the rotating machine is a gas turbine.

17. The system according to any one of claims 11 to 16, wherein the rotating machine is a steam turbine.

18. The system according to any one of claims 11 to 17, wherein the speed control system includes a machine learning model configured to receive a plurality of individual samples as input and to identify sensor faults based on comparisons of the individual samples.

19. The system according to any one of claims 11 to 18, wherein the measurement circuit is configured to store, for each individual sample, a tooth detection threshold used by the control circuit at a time specified in the individual sample.

20. A machine control method, comprising: The waveform indicating the speed of the rotating machine is measured using a speed sensor; The waveform is received from the speed sensor, and data representing the waveform is provided to a first signal path and a second signal path, wherein the second signal path is isolated from the first signal path, so that data communication on the second signal path does not interfere with communication on the first signal path; In response to data received along the first signal path, control one or more operations of the rotating machine; The data received along the second signal path, individual samples of the data, and corresponding timestamps indicating the time when the data was received are associated and stored.

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