Intelligent configuration of a user interface for a machine status monitoring system

Abstract

Machine operating state monitoring module (10) which processes machine vibration data based on vibration signals and provides the machine vibration data to a distributed control system (11), wherein the machine operating state monitoring module (10) comprises: a signal conditioning circuit arrangement (12) with an interface for receiving multiple analog sensor signals from multiple sensors (20) mounted on a machine, wherein the analog sensor signals include at least one analog tachometer signal, an amplification and filter circuit arrangement for conditioning the multiple analog sensor signals, and an analog-to-digital conversion circuit arrangement for converting multiple analog sensor signals into multiple digital sensor signals, wherein the analog-to-digital conversion circuit arrangement is operable to convert at least one analog tachometer signal into a digital tachometer signal; a processing circuit arrangement (14) in electrical connection with the signal conditioning circuit arrangement, wherein the processing circuit arrangement comprises several parallel digital signal processing channels, each channel being operable in parallel with the other channels for processing one corresponding to the several digital sensor signals in order to generate several different types of measurement data per channel, including a scalar vibration value and a vibration waveform, wherein the processing circuit arrangement (14) is operable to process the at least one digital tachometer signal in order to generate machine speed data; and a logic generator circuit arrangement (16) in electrical connection with the processing circuit arrangement (14) and with the signal conditioning circuit arrangement (12), wherein the logic generator circuit arrangement (16) is operable to receive a first type of measurement data from the processing circuit arrangement (14), and is operable to determine that a machine operating state, as indicated by the first type of measurement data, has changed, and is operable to configure the processing circuit arrangement (14) to generate a second type of measurement data based on the change in the machine operating state, and is operable to format the first type of measurement data and the second type of measurement data in accordance with an input / output data protocol that is native to the distributed control system (11), wherein the logic generator circuit arrangement (16) is operable to, based on that,that the machine speed data indicate a drop in machine speed from above a predetermined speed threshold to below the predetermined speed threshold, to determine that the machine operating state has changed, and is operable to configure the processing circuit arrangement (14) to generate the second type of measurement data while the machine operating state is below the predetermined speed threshold, and to generate the first type of measurement data while the machine operating state is above the predetermined speed threshold.

Description

AREA

[0001] This invention relates to the field of machine control and machine condition monitoring.

[0002] The task is to propose a system for automatically configuring a user interface screen in a distributed control system to simplify the display of machine condition monitoring configuration options based on specific types of measurements to be taken on a machine.

[0003] This problem is solved by the subject matter of the independent claims. Advantageous embodiments are defined in the dependent claims. BACKGROUND

[0004] Previous machine condition monitoring and machine protection systems required unique data acquisition hardware electronics for different measurement types, such as shaft relative vibration, housing vibration, axial thrust / differential expansion, housing expansion, eccentricity, and tachometer measurements. More recently, a hardware circuit arrangement has been developed that can be configured to perform multiple measurement types using common acquisition hardware electronics. However, due to software limitations or programming key combinations, the software user interface for configuring machine condition monitoring / machine protection systems and process control systems still offers configuration parameters that are not applicable to a specific measurement type.This unnecessarily complicates the process of configuring such systems for specific measurement types.

[0005] For example, in Fig. As shown in Figure 4, a known configuration user interface for a process control I / O card provides configuration tabs for both analog and digital channels, although the associated I / O module can only be an analog module or a digital module - not both.

[0006] In another example, which is in Fig. As shown in Figure 5, machine protection measurement “keyphasor” configurations for acceleration measurement are displayed (and grayed out), even though these configuration options are not applicable to the selected measurement type. This results in an unnecessarily complicated and cluttered configuration display screen.

[0007] In yet another recent example, which in Fig. As shown in Figure 6, the nX machine protection measurement configuration parameters are displayed (and grayed out), even though the measurement checkboxes have not been selected. This again results in an unnecessarily complicated configuration display screen.

[0008] Therefore, an intelligent user interface is needed that automatically provides the user with only those configuration options necessary for specific measurements to be carried out using specific sensor types.

[0009] US 2003 / 0200060 A1 discloses a monitoring device for rotating equipment comprising an array of sensors, such as temperature, speed, pressure, and vibration sensors, locally connected to a diagnostic unit. The diagnostic unit has an equipment communication interface and a processor implementing one or more diagnostic routines. The diagnostic unit collects data from the sensors and uses this data to perform diagnostics in order to detect actual or potential problems with the rotating equipment on a continuous or semi-continuous basis. Using the communication interface, the diagnostic unit automatically transmits signals indicating the detected states of the rotating equipment to a maintenance or control system via a standard or common communication network, such as a HART or fieldbus network.The diagnostic unit can also be temporarily connected to an offline computer, such as a service provider's computer, which can verify or further define the diagnostic data provided by the diagnostic unit.

[0010] DE 10 2012 001 083 A1 discloses a method for determining maintenance or repair needs in machines with a control computer, wherein operating data is recorded during machine operation and stored in a file on the control computer. The rules according to which the operating data is saved in the file depend on the machine's condition. Optionally, the operating data can be saved in the file only if the operating data to be recorded lies outside a predefined tolerance limit stored in the control computer. The times or periods at which the operating data is saved in the file can depend on the machine's condition. The tolerance limit can be below a maximum threshold at which machine failure is to be expected.The operating data of a machine component can be compared with the operating data of an identical or similar component of the same machine, and only deviations are recorded in the file. Optionally, the operating data of a machine component can be recorded or saved only during the period in which the component is active.

[0011] DE 103 47 891 A1 discloses a program creation method in which a function control program for the control system is created using a block diagram provided via a graphical modeling environment. The program includes signal lines for signal transmission between the function blocks. At least one signal line represents an input / output access point for an input / output device of the control system. A configuration environment generates an input / output control program, which is combined with the function control program to provide the overall control program. SUMMARY

[0012] Various embodiments of the invention provide a software user interface that filters relevant configuration parameters based on a selected machine measurement type, such that only those parameters applicable to the selected measurement type appear on the user interface screen. Furthermore, configuration parameters for individual measured values ​​within the measurement type are only made available when a specific measured value is selected for acquisition. This greatly simplifies the information displayed on the configuration user interface.

[0013] Embodiments of the present invention provide a machine operating state monitoring module according to claim 1, which processes machine vibration data based on vibration signals and makes the machine vibration data available to a distributed control system. Preferably, the machine operating state monitoring module comprises a signal conditioning circuit arrangement, a processing circuit arrangement, and a logic generator circuit arrangement. The signal conditioning circuit arrangement has an interface for receiving analog sensor signals from sensors mounted on a machine, an amplification and filtering circuit arrangement for conditioning the analog sensor signals, and an analog-to-digital conversion circuit arrangement for converting the analog sensor signals into digital sensor signals.The processing circuit arrangement contains multiple parallel digital signal processing channels, each of which can be operated to process a corresponding digital sensor signal to generate several different types of measurement data per channel. The logic generator circuit arrangement can be operated to receive a first type of measurement data from the processing circuit arrangement and to determine that a machine operating state, as indicated by the first type of measurement data, has changed. Furthermore, the logic generator circuit arrangement can be operated to configure the processing circuit arrangement to generate a second type of measurement data based on the change in the machine operating state. The logic generator circuit arrangement formats the first and second types of measurement data in accordance with an input / output data protocol, e.g., for the distributed control system or the...for the distributed control system. As the term is used here, a data protocol is "native" to a platform if it is formatted to be processed on that platform, where the platform can be an operating system or a device such as a DCS controller.

[0014] The analog sensor signals contain at least one analog tachometer signal, wherein the analog-to-digital conversion circuit arrangement converts the analog tachometer signal into a digital tachometer signal, wherein the processing circuit arrangement processes the digital tachometer signal to generate machine speed data, and wherein the logic generator circuit arrangement determines that the machine operating state has changed, as indicated by a change in the machine speed data.

[0015] In some embodiments, the logic generator circuit arrangement determines, based on the machine speed data, that the machine operating state has changed from a steady-state speed condition to a coasting-down state, and configures the processing circuit arrangement to generate the second type of measurement data, which includes a transition oscillation waveform that is measured while the machine is in the coasting-down state.

[0016] The logic generator circuit arrangement determines, based on the fact that the machine speed data indicates a drop in machine speed from above a predetermined speed threshold to below the predetermined speed threshold, that the machine operating state has changed, and configures the processing circuit arrangement to generate the second type of measurement data while the machine operating state is below the predetermined speed threshold, and to generate the first type of measurement data while the machine operating state is above the predetermined speed threshold.

[0017] In some embodiments, the first type of measurement data is acquired over a first frequency range, and the second type of measurement data is acquired over a second frequency range that differs from the first frequency range.

[0018] In some embodiments, at least one of the parallel digital signal processing channels of the processing circuit arrangement generates the measurement data in the form of a time signal shape of the digital tachometer signal.

[0019] In some embodiments, the logic generator circuit arrangement is electrically connected to an input / output bus of the distributed control system. Through this bus, the logic generator circuit arrangement receives discrete input values ​​indicating the machine's operating state, which are generated by other machine measurement modules connected to the input / output bus. Based on a change in one or more of these discrete input values, the logic generator circuit arrangement determines that the machine's operating state has changed and, based on this change, sets alarm levels or generates the second type of measurement data.

[0020] In some embodiments, the sensor signals contain a machine vibration signal, and the processing circuitry includes a peak detection channel that receives the machine vibration signal, samples the machine vibration signal during predetermined sampling periods, detects peak amplitude values ​​of the machine vibration signal during these sampling periods, and generates a time series of the peak amplitude values. In these embodiments, the first or second type of measurement data comprises the time series of peak amplitude values.

[0021] In another aspect, embodiments of the invention relate to a distributed control system according to claim 7 or 9, which includes an input / output bus, a machine function status monitoring module, a controller of a distributed control system, and, according to one embodiment, an operator computer of the distributed control system. Data is transmitted via the input / output bus in accordance with a data communication protocol, e.g., of the distributed control system or one that is native to the distributed control system. Preferably, the machine function status monitoring module includes a signal conditioning circuit arrangement, a processing circuit arrangement, and a logic generator circuit arrangement.The signal conditioning circuitry includes an interface for receiving analog vibration signals from vibration sensors mounted on a machine, an amplification and filtering circuitry for conditioning the analog vibration signals, and an analog-to-digital conversion circuitry for converting the analog vibration signals into digital vibration signals. The processing circuitry contains multiple parallel digital processing channels, each processing a corresponding digital vibration signal to generate multiple scalar vibration values ​​per channel. The logic generator circuitry receives the scalar vibration values ​​and formats them according to an input / output communication protocol, such as that of a distributed control system or one that is native to the distributed control system.The controller of the distributed control system contains an interface circuit arrangement with one or more high-speed sampler registers. This interface circuit arrangement can be operated to sample the input / output bus at a predefined rate in order to receive one or more of the scalar vibration values ​​stored in the high-speed sampler registers. The operator computer of the distributed control system runs user interface software for: - Generating an initial graphical user interface screen for display on a user interface device, containing a measurement type selection field and no sensor configuration option fields, - Receiving a measurement type selection entered by a user in the measurement type selection field, - Generating a second graphical user interface screen for display on the user interface device, containing one or more sensor configuration option fields not included in the first graphical user interface screen, based on the measurement type selection, wherein the sensor configuration option fields are specific to a sensor type to be used when performing a measurement specified by the measurement type selection. - Receiving sensor configuration selections entered by the user into the sensor configuration option fields, and - Generating configuration data to configure the machine operating status monitoring module based on the measurement type selection and sensor configuration selections.

[0022] In some embodiments, the operator computer of the distributed control system executes the user interface software to automatically assign one or more scalar vibration values ​​to be read into the one or more fast sampling registers, the assignment being based at least partially on the measurement type selection.

[0023] In some embodiments, the operator computer of the distributed control system runs user interface software for: - Generating a graphical user interface screen that includes a machine trigger time delay input field initially preset to a standard trigger time delay value as prescribed by an industry standard such as API 670, - Generating a graphical user interface screen that contains one or more input option fields for the machine trigger time delay, into which a user can enter trigger time delay values ​​other than the standard trigger time delay value, - Receiving a trigger time delay selection entered by a user into the machine trigger time delay input field, and - Generating configuration data to configure the control logic routine, at least partially, based on the trigger time delay selection.

[0024] In some embodiments, the operator computer of the distributed control system executes the user interface software to: - Generating configuration data for the control logic routine to initially implement machine protection bridging for multiple sensor inputs corresponding to the multiple sensors, as prescribed by the industry standard, - Generating the graphical user interface screen so that it contains one or more input option fields in which the user can select to deactivate the machine protection override for one or more of the sensor inputs, - Receiving a machine protection override selection entered by the user in one or more input option fields, and - Generating configuration data for the control logic routine, at least partially based on the machine protection bridging selection.

[0025] In some embodiments, the operator computer of the distributed control system executes the user interface software to: - Generating configuration data for the control logic routine to initially implement a trigger multiplication for all sensor inputs corresponding to the multiple sensors, as prescribed by the industry standard, - Generating the graphical user interface screen so that it contains one or more input value fields for trigger multiplication, - Generating the graphical user interface screen so that it contains one or more input option fields where the user can select to disable trigger multiplication for one or more of the sensor inputs, - Receiving trigger multiplication selections entered by the user into one or more input option fields, and generating configuration data for the control logic routine at least partially based on the trigger multiplication selections.

[0026] In some embodiments, the operator computer of the distributed control system executes the user interface software to: - Generating configuration data for the control logic routine to initially implement a tuning logic that allows or prevents a faulty sensor from contributing to a triggering vote as prescribed by the industry standard, - Generating the graphical user interface screen so that it contains one or more input option fields in which the user can select whether to allow or deny a malfunctioning sensor contributing to a vote for triggering, - Receiving user-entered tuning option selections of faulty sensors in one or more input option fields, and - Generating configuration data for the control logic routine, at least partially based on the tuning option selection of faulty sensors.

[0027] In some embodiments, the operator computer of the distributed control system executes the user interface software to: - Generating configuration data for the control logic routine to initially implement alarm or warning thresholds as prescribed by the industry standard, - Generating the graphical user interface screen so that it contains one or more input value fields for the alarm limits or warning limits, - Receiving alarm limit or warning limit selections entered by the user into one or more input value fields, and generating configuration data for the control logic routine at least partially based on the alarm limit or warning limit selections. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Further embodiments of the invention will become apparent with reference to the detailed description in conjunction with the figures, wherein elements are not to scale in order to show the details more clearly, wherein the same reference numerals denote the same elements throughout the multiple views, and wherein: Fig. 1 shows a machine function status monitoring module (MHM module) according to an embodiment of the invention; Fig. 2 shows a digital field FPGA signal processing circuit arrangement according to an embodiment of the invention; Fig. Figure 3 shows an example of control logic implemented by a DCS controller according to an embodiment of the invention; Fig. 4, Fig. 5 and Fig. Six examples of state-of-the-art machine protection software user interface screens are shown; Fig. 7-11 Examples of measurement channel configuration interface screens according to embodiments of the invention are shown; and Fig. Figures 12-14 show process flow diagrams for methods for configuring measurement channels according to embodiments of the invention. DETAILED DESCRIPTION

[0029] Embodiments of the present invention provide a vibration data acquisition and analysis module that is directly connected via an interface to an I / O backplane of a distributed control system to enable the direct acquisition of vibration data by the DCS for machine protection and predictive machine operating condition analysis. As used herein, a "distributed control system (DCS)" is a type of automated control system used in a process or plant in which control elements are distributed over an entire machine or over several machines to provide operating instructions for different parts of the machine(s). As used herein, "protection" refers to the use of data obtained from one or more sensors (vibration, temperature, pressure, etc.).) are collected to shut down a machine in situations where serious and costly damage could occur if the machine is allowed to continue running. On the other hand, "prediction" refers to the use of data collected by one or more vibration sensors, possibly in combination with data from other types of sensors, to observe trends in machine performance and to predict how much longer a machine can operate before it should be taken out of service for maintenance or replacement.

[0030] Fig. Figure 1 shows a machine function status monitoring module (MHM) 10, which is directly connected to a DCS 11 via an interface. In a preferred embodiment, the module 10 includes an analog field signal conditioning and sensor power card 12, which exemplarily comprises a signal conditioning circuit arrangement and receives and conditions the sensor signals; a digital field FPGA signal processing card 14, which exemplarily comprises a processing circuit arrangement and processes the sensor signals; and a DCS logic generator card (LGC) 16, which exemplarily comprises a logic generator circuit arrangement and provides an interface to a DCS I / O bus 18. Preferably, the field card 12 can accept input from at least eight measuring sensors 20 via a field signal interface connector 22. In a preferred embodiment, at least two of the sensor input channels can be configured as tachometer channels.

[0031] Preferably, galvanic electrical isolation is provided between the analog field card 12 and the digital field card 14. This electrical isolation prevents unintentional current flow, such as that caused by ground loops between the mounting locations of the sensors 20 and the DCS 11.

[0032] The sensor power circuit 24 and the signal conditioning circuit 25 can support a wide range of sensors 20, including piezoelectric accelerometers, piezoelectric ICPs for velocity, piezodynamic sensors for pressure, electrodynamic sensors for velocity, eddy current sensors for displacement, AC sensors for vibration, and DC sensors for displacement, with an input current of 4–20 mA. Supported tachometer sensors include eddy current displacement sensors, passive electromagnetic sensors, Hall-effect tachometer sensors, N-pulse / speed wave encoders, and TTL pulse sensors. As long as they are within the following exemplary voltage input ranges: 0 to +24 V, -24 V to +24 V, -12 V to +12 V, and 0 to -24 V, many additional sensor types are supported across the frequency range from DC to 20 kHz.In the preferred embodiment, up to eight sensor power circuits 24 can be individually programmed for a constant current between 0 and 20 mA, which can also be used as the lifting current for an electrodynamic (passive) velocity sensor. The input voltage ranges listed above are also individually programmable in each sensor channel. This allows any combination of sensor power and input range configuration between the channels and thus enables a combination of supported sensors.

[0033] With timing provided by a clock 26, an 8-channel analog-to-digital converter (8-channel ADC) 28 converts the eight analog signals into a single serial data stream comprising eight simultaneously sampled, interleaved channels of data. In some preferred embodiments, two tachometer trigger circuits 30 convert the signals from the two analog tachometers into tachometer pulses.

[0034] Field card 14 contains an 8-channel field-programmable gate array (8-channel FPGA) 36 for processing the vibration data. The FPGA 36 receives the digital 8-channel waveform data, including optionally from 2 channels of tachometer data, and processes the source data in parallel to generate scalar total vibration parameters and total vibration waveforms. The processed waveforms can include low-pass filtered, PeakVue™, order-tracking, high-pass filtered (DC-blocked), and optionally single-integrated (velocity), double-integrated (displacement), or non-integrated (acceleration) waveforms. These waveforms can also be generated in the two data channels allocated for tachometer data. Additionally, prediction data channels preferably include an upsampling data block to provide higher-resolution data for time-synchronous averaging (TSA) order-tracking applications.

[0035] The vibration card configuration circuit 32 of the analog field card 12 preferably includes a set of serial-parallel buffer registers that accept a serial data stream of configuration data from the application firmware of the LGC 16. This data is loaded into a parallel-serial shift register in the interface of the FPGA 36. Subsequently, the FPGA 36 handles the shifting of the serial data to the control buffers using a synchronous SPI format.

[0036] During operation of the preferred embodiment, the MHM module 10 appears to the DCS controller 19 as an analog multi-channel input card with scalar outputs similar to those of a standard DCS input module 21, allowing measured temperature, pressure, or valve position values ​​to be output. As discussed in more detail below, vibration signals are converted into scalar values ​​by the module 10 and passed to the DCS controller 19 via the DCS backplane. An example of a DCS controller 19 is the Ovation™ controller, manufactured by Emerson Process Management (a division of Emerson Electronic Co.). In this DCS architecture, up to sixteen scalar values ​​are passed from each I / O module to the DCS controller 19 as high-speed samples. In a high-speed sample, the DCS controller 19 can read these sixteen scalar values ​​at a rate of up to 10 ms.

[0037] The time signal shape block data (and additional scalar values) can be transferred to the DCS controller 19 via the DCS I / O bus 18 using a block data transfer method such as the Remote Desktop Protocol (RDP) at a rate lower than the sampling rate of the sixteen high-speed scalar values.

[0038] Since the scalar values ​​generated by the machine status monitoring module 10 are read by the DCS controller 19, they are processed by software running on the DCS controller 19 in the same way as any other DCS data. A key function of the DCS controller 19 is to compare the scalar values ​​with alarm thresholds. If the thresholds are exceeded, alarms are generated. Logic within the DCS controller 19 can also determine, based on alarm conditions such as the closing of a relay, whether any action should be taken. The DCS controller 19 also performs software operations that include alarm relay logic, tuning, and time delays. Preferably, DCS control outputs, such as relay outputs and proportional 4-20 mA outputs, are driven by standard output modules 23 of the DCS.Predictive mass data is formatted in the LGC host processor 48 and transmitted via an Ethernet port 52a to a machine function management analysis computer (MHM analysis computer) 54 for detailed analysis and display. Protection mass data is also formatted in the LGC host processor 48, but transmitted via a separate Ethernet port 52b to the DCS operator computer 60.

[0039] In preferred embodiments, a DCS operator computer 60 includes an interface for displaying vibration parameters and other machine operating data (pressures, temperatures, speeds, alarm conditions, etc.) output by the DCS controller 19.

[0040] In Fig. Figure 2 shows a functional block diagram of a single channel of the digital field FPGA 36. A preferred embodiment includes seven additional channels with the same arrangement as that of the single channel shown in Figure 2. Fig. 2 channel shown. As described in more detail below, the digital waveform data of the channel can be passed through a variety of digital filters and integration stages before being converted into total vibration values ​​or packaged as “mass” time waveforms for further analysis by software running on the LGC card 16, or for transmission to DCS software or MHM software.

[0041] As in Fig. As shown in Figure 2, the ADC interface 70 receives via connector 34 (in Fig. (1 shown) the eight channels of continuous, simultaneously sampled data from the ADC 28 of the analog field card 12. Preferably, the data is in the form of a multiplexed synchronous serial data stream in Serial Peripheral Interface (SPI) format. The ADC interface 70 demultiplexes the data stream into data streams of eight separate channels.

[0042] Although all eight channels could be used for vibration signal processing, in a preferred embodiment two of the eight channels can be used for tachometer measurement processing. Preferably, each tachometer measurement channel contains: - a monostable flip-flop circuit 110, which is a “blanking” function with programmable trigger, which provides noise suppression for tachometer pulse sequences with excessive jitter or noise; - a division by N 111, which is a programmable pulse divider that divides the pulse rates of the tachometer signals generated by gears or code wheels; - a reverse rotation detector 112, which determines the direction of shaft rotation by comparing the phase of two tachometer pulse signals; - a speed indicator 115, which calculates the speed of the tachometer pulse current as a scalar total value; - a zero-speed detector 113 which provides a “zero speed” indication when the tachometer has been inactive for a programmable interval such as 0.1 s, 1 s, 10 s or 100 s; and - a detector 114 that provides an "over-range" indication when the tachometer exceeds a fixed threshold of 2 kHz or 62 kHz. In alternative embodiments, this threshold can be programmable.

[0043] Further based on Fig. 2 Each of the eight independent parallel channels of signal processing in the FPGA 36 preferably contains the following components: - a high-pass filter 72 for DC blocking, which can preferably be set to 0.01 Hz, 0.1 Hz, 1 Hz or 10 Hz and which can be selected or bypassed for the integrators described below based on the position of a switch 74; - two stages of integration of the digital signal shape including a first integrator 76 and a second integrator 78, which provide for the data unit a conversion of acceleration to velocity, acceleration to distance or velocity to distance; - a digital tracking bandpass filter 82 with a bandpass center frequency set by the tachometer frequency or by multiples of the tachometer frequency, and which receives as input, based on the position of a switch 80, either the "normal" data stream (no integration), the single integration data stream, or the double integration data stream, as described in more detail below; and - Blocks 88-100 for calculating the total scalar measurement value, which, as described below, determine total scalar values ​​of several different signal shapes.

[0044] In the preferred embodiment, the purpose of the digital tracking bandpass filter 82 is to provide a narrow bandpass frequency response (with high Q) with a center frequency determined by the rotational speed of a selected tachometer input. The center frequency can also be a selected integer multiple of the tachometer speed. When a waveform passes through this filter, only vibration components corresponding to multiples of the rotational speed of the monitored machine remain. When the RMS, peak, or peak-to-peak scalar value of the resulting waveform is calculated by the appropriate FPGA computation block (88, 90, or 92), the result is the same as a value that would be returned by an "nX peak" calculation performed in the application firmware of the LGC 16.Since this scalar calculation is performed as a continuous process in the FPGA 36 rather than as a calculation carried out in firmware, it is better suited for a "shutdown parameter" compared to a corresponding value generated at a lower rate in firmware. One application of this measurement is the monitoring of aeroderivative gas turbines, which generally require a tracking filter function for monitoring purposes.

[0045] For several of the scalar totals, the individual data type from which the values ​​are calculated can be selected from the normal data stream, the single integrated data stream, the double integrated data stream, the high-pass filtered (DC-blocked) data stream, or the tracking filter data stream, based on the positions of the switches 84a-84d. Furthermore, several of the scalar total channels have individually programmable low-pass filters 88a-88d. In the preferred embodiment, these scalar totals are generated independently of and in parallel with the time signal waveforms used for prediction or protection. The blocks for calculating the scalar total include: - an RMS block 88 which determines the RMS value of the time signal shape, wherein the RMS integration time can preferably be set to 0.01 s, 0.1 s, 1 s or 10 s; - a peak value block 90, which determines the larger of the positive or negative signal shape peak value relative to the average value of the signal shape, which is preferably measured over a period of time determined either by the tachometer duration or by a programmable time delay; - a peak-to-peak block 92 that determines the signal shape peak-to-peak value over a period of time determined either by the tachometer duration or by a programmable time delay; - a block 94 for the absolute ± peak value, which determines the value of the furthest positive signal shape migration and the value of the furthest negative signal shape migration relative to the zero point of the measuring range, which is preferably measured over a time period determined either by the tachometer duration or by a programmable time delay; - a DC block 96 which determines the DC value of the time signal shape, which has a measuring range which is preferably set to 0.01 Hz, 0.1 Hz, 1 Hz or 10 Hz; and - a PeakVue™ block 100 that determines a scalar value representing the peak value of the filtered and full-wave rectified PeakVue™ waveform, as described in U.S. Patent No. 5,895,857 to Robinson et al. (here inserted by reference), preferably measured over a time period determined either by the tachometer duration or by a programmable time delay. The full-wave rectification and peak-hold functions are implemented in function block 98. The PeakVue™ waveform from block 98 is also made available as a selectable input to the predictive time waveform and guard time waveform processing described herein.

[0046] The prediction time waveform processing section 116 of the FPGA 36 provides a continuous filtered time waveform for use by any prediction monitoring functions. An independent low-pass filter / decimator 104a is provided so that the prediction time waveform can have a different bandwidth than the protection time waveform. A waveform upsampling block 106 provides data rate multiplication for analysis types such as time-synchronous averaging (TSA) and order tracing. The input to the prediction time waveform processing section 116 can be selected from the normal data stream, the single-integrated data stream, the double-integrated data stream, the high-pass filtered (DC-blocked) data stream, or the PeakVue™ data stream, based on the positions of switch 102a.

[0047] The protection time waveform section 118 of the FPGA 36 provides a continuous filtered time waveform for use by protection monitoring functions. An independent low-pass filter / decimator 104b is provided, allowing the protection time waveform to have a different bandwidth than the prediction time waveform. The input to the protection time waveform processing section 118 can be selected from the normal data stream, the single integrated data stream, the double integrated data stream, the high-pass filtered (DC-blocked) data stream, or the PeakVue™ data stream, based on the positions of switch 102b.

[0048] Preferred embodiments provide transition data acquisition, wherein continuous, parallel time signal waveforms can be acquired from each signal processing channel for transmission to an external data storage system. Preferably, transition signal waveforms have a fixed bandwidth and are acquired from the protection time signal waveform data stream.

[0049] As in Fig. As shown in Figure 1, the scalar total values ​​and the digitally filtered time signal shapes are transmitted via the LGC interface 38 to the LGC logic board 16 for further processing and transport to the DCS controller 19 via the DCS I / O backplane board 18 or via the Ethernet port 52 to external software applications running on the MHM data analysis computer 54.

[0050] Fig. Figure 3 shows an example of a control logic routine (here also referred to as a control sheet) executed by the DCS controller 19. In preferred embodiments, a control sheet is scheduled for execution at a predetermined rate, such as 1 s, 0.1 s, or 0.01 s, by the DCS software running in the controller 19. While the control sheet, which controls the vibration process, is executing, total scalar vibration values ​​are sampled from the DCS I / O bus 18, and output values ​​are generated at the execution rate of the control sheet.

[0051] Preferably, the logic functions performed by the control sheets include: - a voting logic such as a logic to determine that a warning condition exists if 2 out of 2 scalar values ​​are above the threshold or if 2 out of 3 are above the threshold. - Combining vibration data with other DCS process parameter data (such as pressure and temperature). - Trigger multiplication, which is a temporary condition determined by the current machine state or by a manual input that increases an alarm level. Trigger multiplication is commonly used during the start-up of a rotating machine such as a turbine. As the turbine accelerates, it typically passes through at least one mechanical resonant frequency. Because higher than normal vibration conditions are measured during this resonance, trigger multiplication is used to temporarily raise some or all of the alarm levels to prevent false alarms. The trigger multiplication input can be set manually with an operator input or can be set automatically based on the rotational speed or another machine state input. - Trip override, which is typically a manual input to suppress the operation of the output logic to lock trip functions, such as during machine startup. Trip override is a function that suppresses either all generated vibration alarms, any outputs that would be used as a trip control, or both. The trip override input can be set manually with an operator input or can be set automatically based on a "machine state" input.

[0052] A time delay is a delay that is typically programmed to ensure that triggering conditions have persisted for a specified period before a machine trip is allowed to occur. As recommended by the API 670 standard, trip time delays are usually set between 1 and 3 seconds. The purpose of this delay is to reject false alarms caused by mechanical or electrical spikes or disturbances. Intelligent user interface configuration

[0053] As discussed above, the DCS operator computer 60 provides an interface for displaying vibration parameters and other machine operating data output by the DCS controller 19. In a preferred embodiment, the DCS operator computer 60 executes user interface (UI) software that, among other things, generates a configuration file for configuring the measurement channels of the MHM module 10. The configuration file is preferably received by the LGC host processor 48, which uses it to configure many of the other components of the MHM module 10.

[0054] Examples of UI screens for configuring the measurement channels are in Fig. 7-11 shown. Fig. Figures 12-14 show process flow diagrams for embodiments of methods for configuring measurement channels.

[0055] Fig. Figure 7 shows an initial channel configuration screen 200, which allows the configuration of eight vibration measurement channels 202 and two external tachometer channels 204 (step 300 in Fig. 12). In this initial configuration screen 200, no measurement type has been selected for channel 1 on the input configuration tab and no measurement-specific configuration input fields are displayed. Fig. Figure 8 shows the channel configuration screen 200, where a measurement type, Wave Relative Vibration, has been selected in input field 206 for channel 1 in the input configuration tab (step 302). When the Wave Relative Vibration measurement type is selected, screen 200 automatically updates to display only configuration input fields 208 for the input configuration tab of channel 1 that are associated with this specific measurement type (step 304). For example, input fields for the following parameters are revealed to allow the selection of the appropriate configuration values: lower cutoff frequency, converter model, sensor operating range start, sensor operating range end, sensor model, and sensor sensitivity.

[0056] Fig. Figure 9 shows the channel configuration screen 200, in which a measurement type "Tachometer" has been selected in input field 206 for channel 7 in the input configuration tab (step 302). When the measurement type "Tachometer" is selected, screen 200 automatically updates to display only the configuration parameter input fields 208 in the input configuration tab for channel 7 that are associated with tachometer measurements (step 304). Fig. Figure 10 shows an example where the parameter tab of the channel configuration screen 200 has been selected for a measurement type called tachometer (step 306). At this point, no tachometer readings have been selected in the input fields 210, and no configuration parameters are displayed. Fig. Figure 11 shows an example in which several speed measurements (RPM, zero-speed detection, reverse rotation detection, rotor acceleration, gap DC voltage, and on-demand tachometer waveform data) have been selected (step 308). Based on the selection of these measurements, the input fields 210 for several relevant configuration parameters are automatically revealed to allow the configuration of the selected measurements (step 310).

[0057] As previously discussed, the MHM module 10 converts vibration signals into scalar values ​​and makes these scalar values ​​available to the DCS controller 19 via the DCS I / O bus 18 ( Fig. 1) In the typical DCS architecture, sixteen scalar values ​​are made available as high-speed samples, which the DCS controller 19 reads at a predefined rate, such as every 10 ms. These values ​​are read into "fast sample" registers in the DCS controller 19.

[0058] Based on the availability of sixteen high-speed samples on the DCS I / O bus 18, two fast-sampling registers are assigned to each of the eight channels of the MHM module 10. As discussed previously, the parallel measurement processing channels of the MHM module 10 can actually generate more than two types of measured values ​​for each sensor input. In a preferred embodiment, software running on the DCS logic generator card 16 automatically selects two of the multiple measured values ​​for each measurement channel, based on the type of measurement selected (step 312 in Fig. 12). For example, the two selected measurements to be assigned to the fast-scan registers could be the total peak-to-peak voltage and the gap DC voltage if the selected measurement type is the wave relative oscillation.

[0059] In some preferred embodiments, firmware executed in the DCS logic generator card 16 monitors the machine state (step 316) based, for example, on machine speed measurements (step 314). Fig. 13) and initiates unique machine operating state measurements or sets specific alarm levels according to the unique machine state (step 318). For example, if the machine speed output by the speed indicator 115 shows that the machine state has changed from a steady-state speed condition to a trip / slow-down state, the software initiates the recording of a continuous transition waveform of vibration data during the slow-down period. This waveform data can come from the prediction time waveform processing section 116 of the FPGA 36. As another example, the software can perform an eccentricity measurement to measure the amount of a bent shaft if the speed indicator 115 shows that the machine state is less than 600 min⁻¹. -1 is. At over 600 minutes -1The software disables this measurement. In a third example, a vertical water turbine can have four different operating states, specified by discrete input values ​​made available via the DCS I / O bus 18. Based on the specific machine operating state, the software can set certain alarm levels or make specific measurement types available for output.

[0060] In some preferred embodiments, firmware running on the DCS logic generator board 16 monitors a first set of machine function state measurements acquired over a first range to determine a unique machine state (step 314) and, based on the machine state indicated by the first set of measurements, initiates a second set of unique machine function state measurements over a second range (step 320). For example, the MHM module 10 might normally only acquire spectral vibration data up to 2 kHz. However, a second measurement with a spectrum of 20 kHz can be initiated to enable the determination of the cause of the alarm in the high-frequency range if a first set of measurements indicates that the high-frequency detection band is an alarm condition. API-670 control sheet logic

[0061] The API 670 standard, as defined by the American Petroleum Institute (API), provides precise requirements for the monitoring and protection of equipment used on critical rotating machinery in oil refinery and petrochemical plants. This standard includes the minimum requirements for a machine protection system capable of measuring radial shaft vibration, casing vibration, shaft axial position, shaft speed, piston rod drop, phase reference, overspeed, overvoltage detection, and critical machine temperatures (such as bearing metal and motor windings).

[0062] Combining machine vibration monitoring with machine control typically requires either (1) configuring a vibration machine protection system and then integrating that system with a process control system, or (2) directly inputting vibration information into the process control system and manually configuring it according to vibration machine protection best practices, such as those outlined in API 670. Option (1) presents several challenges, including a time-consuming integration process that requires training, additional hardware, software, configuration, and ongoing support. Option (2) is problematic because process control system operators are typically inexperienced in safely configuring a process control system for the application task of protecting machinery from high vibration.

[0063] The preferred embodiments described here create a system that addresses the problems associated with option (2). The system includes UI software for a process control system that guides a user and accepts user input based on vibration industry best practices and the API 670 standard. The system uses built-in UI programming logic to guide an inexperienced user in constructing an API 670 control sheet for a process control system.

[0064] In preferred embodiments, the user interface (UI) program logic, in accordance with the API 670 standard, selects one second in advance as the default time delay before a machine trigger occurs and automatically generates an analog input block with this default time delay (step 322 in Fig.14) As the term is used here, an analog input block (Al block) is an object within the control logic used to read analog input signals from analog input hardware. Typically, the Al block has internal alarm thresholds that may have configurable time delays before being declared. By automatically generating an Al block with the desired settings, preferred embodiments of the invention relieve the user of having to manually drag and drop the Al block from a palette onto a workstation and then open / configure it with a time delay to trigger an alarm.

[0065] Furthermore, the UI program logic offers user-selectable options for delay values ​​other than those acceptable under API 670, namely 2 seconds and 3 seconds, and automatically generates an AI block with the user-selected delay (step 326). In some embodiments, the UI program logic provides the user with an option to deviate from the API 670 standard by entering a user-selected delay value, with the software automatically generating an AI block containing the user-selected delay. The user has the option to accept the custom value as an accepted deviation (step 324), which is then automatically saved in a list of deviations.

[0066] In some embodiments, the UI program logic automatically generates control sheet logic for each sensor input to implement a machine protection override according to API 670. Preferably, the UI program logic provides the user with the option to enable or disable this override for each sensor input (step 328). A machine protection override, also referred to here as a trip override, allows the machine shutdown alarm thresholds to be bypassed. Such a override would be necessary, for example, if maintenance is being performed on the protection system to prevent accidental tripping of the machine.

[0067] Furthermore, the UI program logic provides the user with a means to create sensor groupings, allowing multiple sensors to be bypassed with a single user input. Additionally, the UI program logic provides the user with a means to select a "force" that compels an output relay state to change or remain in a given state (step 332), automatically creating bypasses, groupings, and forces in the control sheet (step 330).

[0068] In some embodiments, the UI program logic automatically generates a control sheet to implement trigger multiplication for each sensor input according to the API 670 standard. Preferably, the UI program logic provides the user with an option to select a default value, enter an optional API 670 value, or enter a user-preferred value that is outside the API 670 specification (step 334). Furthermore, the UI program logic can provide the user with an option to enable or disable trigger multiplication for each sensor input. Additionally, the UI program logic can provide the user with a means to create sensor groupings so that trigger multiplication can be applied to multiple sensors with a single user input, and so that it automatically generates trigger multiplications and groupings in a control sheet (step 330).

[0069] In some embodiments, the UI program logic offers the user an option to implement the API 670 standard for radial sensors, which prevents a faulty sensor from contributing to a trigger vote. Preferably, the user is offered an alternative option to allow a faulty sensor, converter, or cable to contribute to a trigger vote (step 336). In these embodiments, the control sheet automatically selects the condition of the sensor, converter, and cable for trigger decisions based on the user's input (step 330).

[0070] In some embodiments, the UI program logic offers the user an option to implement a standard condition of API 670 that allows a faulty thrust sensor to contribute to a trigger vote. Preferably, the user is offered an alternative option to prevent a faulty sensor, converter, or cable from contributing to a trigger vote (step 336). In these embodiments, the control sheet automatically selects the sensor, converter, and cable condition for trigger decisions based on the user input (step 330).

[0071] In some embodiments, the UI program logic provides the user with an option to select buffering or non-buffering relays for each control system output (step 338). The UI program logic automatically generates a control sheet to buffer the relay or automatically reset it if the alarm condition is true and then becomes false (step 330).

[0072] In some embodiments, the UI program logic provides a method for the user to enter alarm limits, warning limits, and pre-warning limits for each measurement channel or group of measurement channels (step 340), with the UI program logic automatically applying these limits to the control sheet to determine alarms and relay activation (step 330).

[0073] In some embodiments, the UI program logic generates a control sheet that automatically: (1) inserts a date and time stamp into all incoming vibration and status data; (2) configures a digital input (DI) to reset buffer relays; (3) configures a digital output (DO) and a visible UI element to explain bridging; and (4) configures a DO in the control sheet to output the status of all hardware.

[0074] In some embodiments, sensor gap voltages and sensor bias voltages are initially set with standard voltage values, and the UI program logic allows the user to edit these values ​​(step 342), after which they are automatically updated in the control sheet (step 330).

[0075] In some embodiments, the UI program logic generates the control sheet in accordance with the API 670 standard to automatically capture and update the highest shaft radial vibration measurement at each bearing, all axial measurements, the highest machine housing vibration measurement, the highest speed measurement, the highest rod drop measurement, and the highest temperature measurement at each bearing.

[0076] In some embodiments, the UI program logic provides the user with an option to select relay options (step 344), which the UI program logic uses to automatically configure the control sheet logic based on the user selection (step 330). Preferably, these relay options include normally unexcited, normally energized, unexcited for alarm, and energized for shutdown.

[0077] In some embodiments, the UI program logic provides the user with options to select standard ranges for axial shear measurements (such as -1016 to +1016 micrometers [-40 to +40 milliinches]) and radial vibration measurements (0 to 125 micrometers) or to enter custom values ​​for these ranges. User selections can be edited and saved for future standard configurations. The UI program logic generates the control sheet for each selected range based on the standard or custom values. Custom values ​​are preferably recorded in an API 670 standard deviation report. In a preferred embodiment, the UI program logic automatically configures a circuit fault in the control sheet for a vibration greater than 254 micrometers [10 milliinches].

[0078] In some embodiments, the UI program logic automatically configures the control sheet according to the standard in the event of high vibration or sensor interference, so that it receives a vote to trigger when a 2-of-3 logic is selected for axial thrust measurements.

[0079] In some embodiments, the UI program logic automatically configures the control sheet according to a standard to a temperature range up to the full scale value, such as 0°C to 150°C, and digital readings in the control logic are automatically configured with a resolution of 1 degree when a temperature sensor is used as input. Preferably, the UI program logic configures dual tuning for temperature as the standard configuration according to API 670. Other tuning configurations adopted by the user are noted in the API 670 exception list.

[0080] In some embodiments, the UI program logic uses the configuration settings for each configured channel to automatically generate graphical elements that are displayed to the user on the DCS operator computer 60 during runtime. Preferably, these graphical elements: (1) contain bar graphs proportional to oscillation, position, temperature, or any principal value; (2) provide a graphical indication of alarm, warning, and pre-warning levels; (3) include engineering notations; (4) provide a graphical indication of a highest measured value; (5) provide a label or description for each displayed value; (6) configure automatically to the range up to the full-scale value; (7) provide an indication of the sensor, cable, and converter operating status; (8) provide a positive indication of a fault or no fault.(9) they provide information on the status of relays; (10) they provide information on circuit faults; (11) they provide information on voting results; (12) they provide a procedure for starting a trend of historical and live values; (13) they provide a password protection procedure for the user to edit alarm thresholds; and (14) they provide a procedure for the user to reset buffer relays.

[0081] In some embodiments, the user interface display screen includes a button that the user can click to reset the highest measured peak speed value. Preferably, the control logic is automatically configured for this software user input or DI that resets the peak speed value.

[0082] In some embodiments, pre-configured HART devices automatically pass their configuration data to the control logic, which then automatically configures the control sheet accordingly.

[0083] In general, machine protection is a balancing act between safety and machine availability. Some applications may automatically prioritize safety, such as triggering within 100 ms or counting a faulty sensor as a trigger signal. Other applications may prioritize availability, such as implementing a three-second delay before triggering or not counting a faulty sensor as a trigger signal. Accordingly, some implementations of the UI program logic allow the user to "tune" several aspects of the control sheet configuration more towards safety or more towards availability.For example, a single graphical slider can be displayed on the DCS operator computer to provide input that allows the user to select a point along a slider scale with maximum security at one end and maximum availability at the other. In this embodiment, the UI program logic automatically sets the trigger time and tuning logic based on the slider setting.

[0084] Some embodiments implement a method for automatically accessing configuration information for the MHM module 10 and for accessing configuration information for the distributed control system 11, and for generating a control system configuration file that is used when configuring the distributed control system to receive data from the MHM module 10 in the distributed control system's native data format. Some features of such a method are described in US patents 8,463,417 B2 and 8,958,900 B2.

Claims

[1] Machine operating state monitoring module (10) which processes machine vibration data based on vibration signals and provides the machine vibration data to a distributed control system (11), wherein the machine operating state monitoring module (10) comprises: a signal conditioning circuit arrangement (12) with an interface for receiving multiple analog sensor signals from multiple sensors (20) mounted on a machine, wherein the analog sensor signals include at least one analog tachometer signal, an amplification and filter circuit arrangement for conditioning the multiple analog sensor signals, and an analog-to-digital conversion circuit arrangement for converting multiple analog sensor signals into multiple digital sensor signals, wherein the analog-to-digital conversion circuit arrangement is operable to convert at least one analog tachometer signal into a digital tachometer signal; a processing circuit arrangement (14) in electrical connection with the signal conditioning circuit arrangement, wherein the processing circuit arrangement comprises several parallel digital signal processing channels, each channel being operable in parallel with the other channels for processing one corresponding to the several digital sensor signals in order to generate several different types of measurement data per channel, including a scalar vibration value and a vibration waveform, wherein the processing circuit arrangement (14) is operable to process the at least one digital tachometer signal in order to generate machine speed data; and a logic generator circuit arrangement (16) in electrical connection with the processing circuit arrangement (14) and with the signal conditioning circuit arrangement (12), wherein the logic generator circuit arrangement (16) is operable to receive a first type of measurement data from the processing circuit arrangement (14), and is operable to determine that a machine operating state, as indicated by the first type of measurement data, has changed, and is operable to configure the processing circuit arrangement (14) to generate a second type of measurement data based on the change in the machine operating state, and is operable to format the first type of measurement data and the second type of measurement data in accordance with an input / output data protocol that is native to the distributed control system (11), wherein the logic generator circuit arrangement (16) is operable to, based on that,that the machine speed data indicate a drop in machine speed from above a predetermined speed threshold to below the predetermined speed threshold, to determine that the machine operating state has changed, and is operable to configure the processing circuit arrangement (14) to generate the second type of measurement data while the machine operating state is below the predetermined speed threshold, and to generate the first type of measurement data while the machine operating state is above the predetermined speed threshold. [2] Machine operating state monitoring module (10) according to claim 1, wherein the logic generator circuit arrangement (16) is operable to determine, on the basis of the machine speed data, that the machine operating state has changed from a steady speed condition to a coasting state, and is operable to configure the processing circuit arrangement (14) to generate the second type of measurement data, which comprises a transition vibration signal waveform that is measured while the machine is in the coasting state. [3] Machine functional state monitoring module (10) according to claim 1, wherein the first type of measurement data is acquired over a first frequency range and the second type of measurement data is acquired over a second frequency range which is different from the first frequency range. [4] Machine function status monitoring module (10) according to claim 1, wherein at least one of the parallel digital signal processing channels of the processing circuit arrangement (14) is operable to generate the measurement data in the form of a time signal shape of the digital tachometer signal. [5] Machine operating state monitoring module (10) according to claim 1, wherein the logic generator circuit arrangement (16) is electrically connected to an input / output bus of the distributed control system (11), via which the logic generator circuit arrangement (16) receives discrete input values ​​indicating the machine operating state, which are generated by other machine measurement modules connected to the input / output bus (18), and wherein the logic generator circuit arrangement (16) is operable to determine, on the basis of a change in one or more of the discrete input values, that the machine operating state has changed, and wherein the logic generator circuit arrangement (16) is operable to set alarm levels or to generate the second type of measurement data on the basis of a change in one or more of the discrete input values. [6] Machine operating condition monitoring module (10) according to claim 1, wherein the sensor signals include a machine vibration signal and wherein the processing circuit arrangement (14) includes a peak detection channel which is operable to receive the machine vibration signal, to sample the machine vibration signal during predetermined sampling periods, to detect peak amplitude values ​​of the machine vibration signal during the sampling periods and to generate a time series of the peak amplitude values, and wherein the first or the second type of measurement data comprises the time series of the peak amplitude values. [7] Distributed tax system (11), which includes: an input / output bus (18) over which data is transmitted in accordance with a data communication protocol that is native to the distributed control system (11), a machine operating status monitoring module (10) in electrical connection with the input / output bus (18), wherein the machine operating status monitoring module (10) comprises: a signal conditioning circuit arrangement (12) with an interface for receiving multiple analog sensor signals from multiple sensors (20) attached to a machine, wherein the analog sensor signals include at least one analog tachometer signal, an amplification and filter circuit arrangement for processing the multiple analog sensor signals, and an analog-to-digital conversion circuit arrangement (28) for converting the multiple analog sensor signals into multiple digital sensor signals, wherein the analog-to-digital conversion circuit arrangement is operable to convert the at least one analog tachometer signal into a digital tachometer signal; a processing circuit arrangement (14) in electrical connection with the signal conditioning circuit arrangement (12), wherein the processing circuit arrangement (14) comprises several parallel digital processing channels, each channel serving to process one corresponding of the several digital sensor signals in order to generate several scalar sensor values ​​per processing channel, wherein the processing circuit arrangement (14) is operable to process the at least one digital tachometer signal in order to generate machine speed data; and a logic generator circuit arrangement (16) in electrical connection with the processing circuit arrangement (14), wherein the logic generator circuit arrangement (16) executes instructions to automatically select one or more scalar sensor values ​​from each of the processing channels based on a measurement type, and to format the selected scalar sensor values ​​from each processing channel in accordance with the data communication protocol native to the input / output bus (18) of the distributed control system (11), wherein the logic generator circuit arrangement (16) is operable to determine, based on the fact that the machine speed data indicates a drop in machine speed from above a predetermined speed threshold to below the predetermined speed threshold, that the machine operating state has changed, and is operable toto configure the processing circuit arrangement (14) to generate the second type of measurement data while the machine operating state is below the specified speed threshold, and to generate the first type of measurement data while the machine operating state is above the specified speed threshold; and, a controller (19) of the distributed control system in electrical connection with the input / output bus (18), wherein the controller (19) of the distributed control system includes an interface circuit arrangement with several fast sampling registers, wherein the interface circuit arrangement is operable to sample the input / output bus (18) at a predetermined rate in order to receive one or more of the selected scalar sensor values ​​in the one or in the several fast sampling registers. [8] Distributed control system (11) according to claim 7, further comprising an operator computer (60) of the distributed control system which generates the measurement type selection based on the input of a user. [9] Distributed tax system (11), which includes: an input / output bus (18) over which data is transmitted in accordance with a data communication protocol that is native to the distributed control system (11); a machine operating status monitoring module (10) in electrical connection with the input / output bus (18), wherein the machine operating status monitoring module (10) comprises: a signal conditioning circuit arrangement (12) with an interface for receiving multiple analog sensor signals from multiple sensors (20) attached to a machine, wherein the analog sensor signals include at least one analog tachometer signal, an amplification and filter circuit arrangement for processing the multiple analog sensor signals, and an analog-to-digital conversion circuit arrangement (28) for converting the multiple analog sensor signals into multiple digital sensor signals, wherein the analog-to-digital conversion circuit arrangement is operable to convert the at least one analog tachometer signal into a digital tachometer signal; a processing circuit arrangement (14) in electrical connection with the signal conditioning circuit arrangement (12), wherein the processing circuit arrangement (14) comprises several parallel digital processing channels, each channel serving to process one corresponding of the several digital sensor signals in order to generate several scalar sensor values ​​per channel, wherein the processing circuit arrangement (14) is operable to process the at least one digital tachometer signal in order to generate machine speed data; and a logic generator circuit arrangement (16) in electrical connection with the processing circuit arrangement (14), wherein the logic generator circuit arrangement (16) is operable to receive the multiple scalar sensor values ​​and to format the multiple scalar sensor values ​​in accordance with an input / output communication protocol that is native to the distributed control system (11), wherein the logic generator circuit arrangement (16) is operable to determine, on the basis that the machine speed data indicates a drop in machine speed from above a predetermined speed threshold to below the predetermined speed threshold, that the machine operating state has changed, and is operable to enable the processing circuit arrangement (14) to generate the second type of measurement data while the machine operating state is below the predetermined speed threshold, and to generate the first type of measurement data.to configure the machine operating state while the specified speed threshold is above the specified speed value; and, a controller (19) of the distributed control system, which includes, an interface circuit arrangement that samples the input / output bus (18) at a predetermined rate in order to receive one or more of the scalar sensor values ​​therefrom; and a logic circuit arrangement for executing a control logic routine that generates control signals based on the logic processing of one or more of the scalar sensor signals, wherein the control logic routine is initially configured to implement a standard trigger time delay as prescribed by an industry standard, wherein the control logic routine is automatically configured to implement a selected trigger time delay other than the standard trigger time delay based on a trigger time delay selection; and an operator computer (60) of the distributed control system in electrical connection with the controller (19) of the distributed control system, wherein the operator computer (60) of the distributed control system generates configuration data to automatically configure the control logic routine, implementing the selected trigger time delay, which is based at least partially on the trigger time delay selection. [10] Distributed control system according to claim 9, wherein the operator computer (60) of the distributed control system is operable to generate configuration data for configuring the machine function status monitoring module based on the selection of the measurement type. [11] Distributed control system according to claim 9, wherein: the logic generator circuit arrangement (16) executes commands to automatically select two of the scalar sensor values ​​from at least one of the processing channels based on the selection of the measurement type, and to format the two selected scalar sensor values ​​according to the data communication protocol that is native to the input / output bus; and The interface circuit arrangement of the controller (19) of the distributed control system samples the input / output bus (18) at a predetermined rate to receive the two selected scalar sensor values ​​in two of the fast-sampling registers. [12] Distributed control system according to claim 9, wherein the control logic routine is initially configured to implement machine guard bypass as required by the industry standard for a plurality of sensor inputs corresponding to the plurality of sensors, and is automatically configured to disable the machine guard bypass for one or more of the sensor inputs based on a machine guard bypass selection. [13] Distributed control system according to claim 9, wherein the control logic routine is initially configured to implement a trigger multiplication according to the industry standard for all sensor inputs according to the plurality of sensors, and is automatically configured to disable the trigger multiplication for one or more of the sensor inputs based on a trigger multiplication selection. [14] Distribution control system according to claim 9, wherein the control logic routine is initially configured to implement a voting logic that allows or prohibits a faulty sensor from contributing to a vote for triggering as required by the industry standard. [15] Distribution control system according to claim 9, wherein the control logic routine is initially configured to implement alarm limits or warning limits as required by the industry standard and is automatically configured based on alarm limit selections or warning limit selections. [16] Distribution control system according to claim 9, wherein the operator computer (60) of the distributed control system executes instructions for generating the configuration data in the form of an analog input block comprising an object within the control logic routine that is used when reading the analog sensor signals from the signal conditioning circuit arrangement (12).

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