MAGNETIC ADAPTER FOR MACHINE MONITORING DEVICE

Abstract

A magnetic adapter (100) is provided for attaching a monitoring device (10) to the monitored equipment (20). A mounting plate (110) of the adapter (100) includes a front surface (114), a rear surface (112), and a recess (120) in the rear surface (112). A magnet (130) is secured within the recess (120). The mounting plate (110) also includes threaded mounting holes (116) arranged in a hole pattern that corresponds to a bolt pattern on the monitoring device (10). The threaded mounting holes (116) are configured to receive threaded bolts (30) from the monitoring device (10) to secure the front surface (114) against the monitoring device (10). The magnet (130) is configured to adhere to the monitored equipment (20) and to cause at least a portion of the rear surface (112) to make contact with the monitored equipment (20).The adapter (100) transfers vibration and / or thermal energy from the monitored equipment (20) to the monitoring device (10).

Description

MAGNETIC ADAPTER FOR MACHINE MONITORING DEVICE Background of the Invention Equipment monitoring systems provide pump users with the ability to remotely monitor pump parameters. In some instances, a monitoring device may be provided as a single unit that can be attached to an external surface of the pump to detect pump characteristics such as vibration, temperature, and pump location. Brief Description of the Figures Figure 1 shows a diagram of an assembly view of a monitoring device with a magnetic adapter, according to one implementation; Figure 2 shows an exploded schematic view of the monitoring device with a magnetic adapter from Figure 1; Figure 3 shows a rear perspective view of the magnetic adapter of Figure 1; Figure 4 shows a rear view of the magnetic adapter from Figure 1; Figure 5 shows a front view of the magnetic adapter from Figure 1; Figure 6 shows a side cross-sectional view of the mounting plate of Figure 1; Ref. 342085 Figure 7A shows a side view of the magnetic adapter of Figure 1; Figure 7B shows a side cross-sectional view of a magnetic disk from Figure 1; Figure 8 shows a rear view of a magnetic adapter according to another implementation; and Figures 9A-9C show the rear, side, and rear assembly views, respectively, of a magnetic adapter according to yet another implementation. Detailed Description of the Invention The following detailed description refers to the accompanying figures. The same reference numbers in the different figures may identify the same or similar elements. Furthermore, the following detailed description does not limit the invention. Monitoring devices configured to physically connect (e.g., as a single unit) to pumping equipment provide a convenient way to deliver monitoring data for new, upgraded, or modernized pump applications. The monitoring device can support monitoring from internal sensors for vibration, temperature, and / or location, along with data uploaded via a wireless network. In one implementation, the monitoring device could be an Industrial Internet of Things (IIoT) device. A mechanical connection between the pumping equipment (e.g., the pump frame) and the monitoring device provides heat transfer (e.g., for temperature sensing) and mechanical contact (e.g., for vibration sensing). Previously, monitoring devices were mounted on pumps using mechanical fasteners, such as bolts, which require threaded holes in the pump frame. Some types of equipment that could benefit from a monitoring device lack convenient locations for drilling and tapping the necessary mounting holes. Drilling and tapping these holes requires precise alignment and can be a difficult field operation. Improper drilling can damage the pumping equipment. Furthermore, the threaded mounting holes can be stripped, requiring repair. According to the implementations described herein, a magnetic adapter is provided for securely mounting a monitoring device on a pump frame. The adapter includes a metal plate (e.g., stainless steel) with one or more machined receptacles on one side for mounting magnets. On the opposite side of the magnets, the plate includes mounting holes for attaching the plate to a monitoring device (e.g., an IIoT device). The mounting plate can be modified to conform to a flat or curved surface of the pump frame. The monitoring device / adapter can then be magnetically attached to any equipment containing ferrous metal. The magnets have sufficient holding force to withstand any vibration produced by the pumping equipment on which they are mounted without slippage. The magnetic adapter overcomes the disadvantages of previous mounting methods because there are no threaded holes in the pump frame to drill or potentially remove. The magnetic adapter also provides more mounting location options than previous methods because little to no preparation work or modifications to the pumping equipment are required before installation. Furthermore, no additional equipment is required to install the monitoring device when configured with the magnetic adapter. Figure 1 shows an assembly view diagram of a monitoring device 10 with a magnetic adapter 100, according to an implementation described herein. Figure 2 shows an exploded schematic view of the monitoring device 10 and the magnetic adapter 100. With reference to Figures 1 and 2, the monitoring device 10 can be coupled with the magnetic adapter 100 to connect the monitoring device 10 to the pump frame 20. The monitoring device 10 can be configured for physical coupling, as a single unit, with an outer surface of the pump frame 20. The monitoring device 10 can include an Internet of Things device (e.g., an IIoT), a machine-type communication (MTC) device, a machine-to-machine (M2M) device, an enhanced MTC (eMTC) device (also known as Cat-Mi), an end node employing low-energy wide-area (LPWA) technology such as narrowband (NB) IoT (NB-IoT) technology, or some other type of wireless end node.According to several example modalities, the monitoring device 10 may include hardware, such as a processor, an application-specific integrated circuit (ASIC), an array of field-programmable gates (FPGAs), or a combination of hardware and software (e.g., a processor running software) to perform various types of functions. As further described herein, the monitoring device 10 may include calibrated sensors to collect vibration, temperature, and / or other pump data, and to send or transmit the collected data via a wireless interface (not shown) for user access. The monitoring device 10 may include a sealed enclosure for protection against dust or spray.The monitoring device 10 may also include an internal battery that supports the monitoring of internal vibration, temperature, and / or location sensors, along with data upload via a wireless network. In another implementation, the monitoring device 10 may also include an external power port to provide additional continuous power monitoring and support for external sensors (e.g., flow sensors, other vibration sensors, other temperature sensors, etc.) through interconnected sensor ports of the monitoring device 10. The pump frame 20 (also referred to as the monitored equipment) may include a housing for a pump, motor, electric motor, bearing frame, or any other piece of equipment (e.g., rotating equipment) that the user wishes to monitor using vibration, temperature, and other sensors. According to the implementations described herein, the pump frame 20 may include a ferrous metal, such as steel, stainless steel, carbon steel, cast iron, etc. In some implementations, the pump frame 20 may include a mounting surface 22 onto which the monitoring device 10 may be attached. The mounting surface 22 may be a machined flat surface located, for example, on the bearing housing of the pump frame 20. In other implementations, the pump frame 20 may not include a dedicated mounting surface. Figures 3-5 show a rear perspective view, a rear view, and a front view of the magnetic adapter 100. The magnetic adapter 100 may include a mounting plate 110 and at least one magnetic disk 130 (shown as magnetic disks 130-1 and 130-2 in Figures 1-4). Figure 6 shows a side cross-sectional view of the mounting plate 110 along section AA of Figure 4. Figure 7A shows a side view of the magnetic adapter 100. Figure 7B shows a side cross-sectional view of the magnetic disk 130 along section AA of Figure 4. With reference to Figures 1-7B as a whole, the mounting plate 110 includes a rigid plate with a substantially parallel rear surface 112 and a front surface 114.The rear surface 112 can be configured to make contact with the pump frame 20 (for example, the mounting surface 22 or another portion of the pump frame 20). The front surface 114 can be configured to mate with the rear surface 14 (for example, a flat or substantially flat surface) of the monitoring device 10. The mounting plate 110 can be mechanically coupled to the monitoring device 10, and the rear surface 112 of the mounting plate 110 can adhere to the pump frame 20 due to the tensile force of the magnetic disks 130. When the rear surface 112 is secured against the pump frame 20, the sensors in the monitoring device 10 can detect pump indicators, such as vibration and temperature, by means of the magnetic adapter 10. The mounting plate 110 can be made of a non-magnetic material (e.g., austenitic stainless steel, aluminum, rigid plastic, etc.) or a magnetic material (e.g., ferritic stainless steel). The shape of the front / rear perimeter of the plate 110 (e.g., Figures 4 and 5) can generally be similar to the perimeter shape of the rear surface 14 of the monitoring device 10 (e.g., a square with rounded corners). In other embodiments, the mounting plate 110 can have other perimeter shapes, such as rectangular, circular, oval, or an irregular shape. The mounting plate 110 may include threaded holes 116, for example, at each corner of the plate 110 and at least one countersunk hole 118. In one implementation, the holes 116 may extend through the thickness of the mounting plate 100. According to one implementation, the mounting plate 110 may have a thickness T, of approximately 1.016-2.032 cm (0.4-0.8 in). The plate 110 can be attached to the rear surface 14 of the monitoring device 10 using, for example, threaded mounting pins 30 (e.g., screws / bolts) inserted through a housing of the monitoring device 10 and into the mounting holes 116. In another implementation, the holes 116 can open into the front surface 114 and can extend partially through the thickness of the mounting plate 110 to prevent the installed mounting pins 30 from extending beyond the rear surface 112. The mounting holes 116 in the plate 110 can be configured to receive the mounting pins 30 inserted through the holes 12 of the monitoring device 10. The mounting holes 116 can be configured in a pattern to align with the pattern of holes 12 in the monitoring device 10. In particular, in the example shown, four mounting holes 116, each distributed at a corner of the mounting plate 110, can be coupled with four holes 12 of the monitoring device 10. According to one implementation, at least four mounting holes 116 and the corresponding mounting pins 30 (e.g., located near the respective corners of the plate 110) can be used to ensure that vibration and thermal energy are effectively transmitted between the magnetic adapter 100 and the monitoring device 10.In other implementations, other numbers or quantities of 116 mounting holes may be used (e.g., 2, 6, etc.). As shown, for example, in Figure 5, the front surface 114 (and the corresponding rear surface 112) includes a substantially square perimeter, with each of the mounting holes 116 located near a different corner of the substantially square perimeter. According to one implementation, each of the mounting holes 116 can be positioned within an area C, which can include the intersection of 15 percent of the length L (for example, 0.15L) along each side of the perimeter. In other implementations, the mounting plate 110 can include additional mounting holes (for example, holes 826, Figure 8) to accommodate different hole patterns for different types of monitoring devices 10. In one implementation, the mounting pins 30 may include threaded bolts that are separate from the monitoring device housing 10. In another implementation, the mounting pins 30 may be integrated into the monitoring device housing 10. The mounting pins 30 may be inserted through the holes 12 of the monitoring device 10 and may be secured in the mounting holes 116 to couple the monitoring device 10 with the magnetic adapter 100. The magnetic adapter 100 can be configured to transfer thermal energy from the pump frame 20 to the monitoring device 10, where sensors in the monitoring device 10 can detect changes in surface temperature. According to one implementation, the monitoring device 10 coupled to the pump frame 20 via the magnetic adapter 100 can be calibrated differently for thermal detection, taking into account the heat transfer through the magnetic adapter 100, compared to the monitoring device 10 that is directly coupled to the pump frame 20. The magnetic adapter 100 can also transfer mechanical vibrations from the pump frame 20 to the monitoring device 10 for detection. The mounting plate 110 may include one or more receptacles 120 (shown as receptacles 120-1 and 120-2 in Figures 1-6, also referred to as a recess) machined into the back surface 112. Each receptacle 120 may be configured to receive a magnetic disk 130. In one implementation, the depth H of the receptacle 120 may correspond to the height of the magnetic disk 130, and a diameter D of the receptacle 120 may correspond to a diameter of the magnetic disk 130 (with nominal tolerances). According to another implementation, a lever indentation 122 could also be machined into the rear surface 112. The lever indentation 122 may include a hole 123 along the perimeter of the rear surface 112. The lever indentation 122 may facilitate the removal of the magnetic adapter 100, for example, from the pump frame 20.For example, the lever slot 122 can be configured to accommodate or adapt a tool, such as a flathead screwdriver or small pry bar. The orientation of the lever slot 122 relative to the monitoring device 10 can be adjusted during the coupling of the magnetic adapter 100 with the monitoring device 1C. For example, depending on the location and shape of the pump frame assembly 20, it might be preferable to orient the lever slot 122 with the hole 123 facing upward, downward, to the left, or to the right to allow access for the tool. The magnetic disc 130 may include a magnet, such as a rate magnet, with sufficient pulling capacity to securely retain the combination of the monitoring device 10 and the magnetic adapter 100 against the pump frame 20. The pulling force of the magnetic disc 130 may be sufficient to prevent movement of the monitoring device 10 / magnetic adapter 100 relative to the pump frame 20 during pumping operation. As a non-limiting example, the magnetic discs 130 in combination may have a pulling force in the range of 40.8233–81.6466 kg (90–180 lb). For example, each of the magnetic discs 130 may have a pulling capacity of 20.4117, 27.2155, or 40.8233 kg (45, 60, or 90 lb). The 130 magnetic disk may include, for example, a neodymium cup magnet with a thickness of approximately 5-8 millimeters (0.2-0.3 inches) and a diameter of 32 mm (1.26 inches).In some implementations, the magnetic disk 130 may include a steel reinforcing cover 132, a magnet 134, and / or spacer material (not shown). According to one implementation, the magnetic disk 130 may also include a hole 136 to receive a bolt 140 or screw. The bolt 140 may be inserted, for example, through a countersunk hole 132 in the magnetic disk 130 and into the corresponding hole 118-1, 118-2 in the plate 110. As shown in Figures 3 and 7A, for example, each bolt 140 could secure the magnetic disk 130 in the receptacle 120 so that the magnetic disk 130 and the back surface 112 are substantially level. In another implementation, the exposed surface of the magnetic disk 130 may protrude from the receptacle 120 slightly beyond the back surface 112. Heat transfer between the pump frame and the monitoring device 10 can occur via the mounting plate 110 and / or the magnetic discs 130. According to one implementation, the material of the mounting plate 110 (e.g., type 304 stainless steel) can provide a similar thermal conductivity to the materials of the magnetic disc 130 (e.g., neodymium and steel). According to another implementation, the material of the mounting plate 110 (e.g., aluminum) can provide a different thermal conductivity than the materials of the magnetic disc 130 (e.g., neodymium and steel).The thickness of the mounting plate 110 can be minimized to provide optimal and predictable heat transfer between the pump frame 20 and the monitoring device 10, while preventing the installed mounting pins 30 from extending beyond the surface 112 when the monitoring device 10 is coupled with the mounting plate 110. Thus, according to one implementation, the thickness T (Figure 7A) of the mounting plate 110 cannot exceed 2.032 cm (0.8 in). According to one implementation, the magnetic adapter 100 can be supplied pre-assembled with the monitoring device 10 as factory-supplied equipment. In other implementations, the magnetic adapter 100 can be supplied as an upgrade or retrofit component. For example, for pump frames 20 that have mounting holes configured to receive the monitoring device 10, the magnetic adapter 100 can provide an alternative to repairing damaged or stripped threads in the pump frame 20 mounting holes. Figure 8 shows a rear view of the magnetic adapter 100 according to another implementation. Generally, in the configuration shown in Figure 8, the magnetic adapter 100 can be configured to include a mounting plate 810 with a magnetic disk 830. With reference to Figure 8, the mounting plate 810 includes a rear surface 812 with a receptacle 120 thereon. Similar to the mounting plate 110 configurations described in connection with Figures 1-7B, the rear surface 812 can be configured to contact the pump frame 20, and the opposite front surface can be configured to mate with the rear surface 14 of the monitoring device 10. The mounting plate 810 may include different patterns of threaded holes 116 and 826. Threaded holes 116 may be located, for example, at each corner of plate 810 to accommodate a hole pattern of the monitoring device 10. Threaded holes 826 may be located, for example, in different locations on the plate. 810 to accommodate a different hole pattern for a different type of monitoring device 10. In this way, the mounting plate 810 can be configured to accept mounting bolt patterns for multiple different types of monitoring devices (e.g., different sizes, different manufacturers, etc.). The mounting plate 810 may include a receptacle 820 machined into its rear surface 812. The receptacle 820 may be configured to receive a magnetic disk 830. As described above in connection with Figures 1-7B, the receptacles 120 may include a threaded hole 118 to receive a bolt 140. The magnetic disk 830 may include a magnet with sufficient pulling capacity to securely retain the monitoring device 10 and magnetic adapter 100 combination against the pump frame 20. For example, the pulling force of the magnetic disk 830 may be sufficient to prevent movement of the monitoring device 10 / magnetic adapter 100 relative to the pump frame 20 during pump operating vibrations (e.g., including any vibrations produced by pump malfunction). As non-limiting examples, the magnetic disk 830 may have a pulling capacity of 27.2155, 40.8233, or 54.4311 kg (60, 90, or 120 lb). In the implementation of Figure 8, the magnetic disk 830 may be secured to the mounting plate 810 using the threaded fasteners 140. Figures 9A-9C show the rear, side, and rear assembly views, respectively, of the magnetic adapter 100 configured according to another implementation. Generally, in the configuration of Figures 9A-9C, the magnetic adapter 100 can be configured with the bar magnets 930 to accommodate mounting on a non-flat surface of the pump frame 200. More specifically, the magnetic adapter 100 can be configured to adhere to a curved surface with the bar magnets 930 aligned parallel to an axis of the radius of curvature of the adhered surface (for example, as shown in Figure 9B). As shown in Figure 9C, the mounting plate 110 can be configured with threaded holes 926 opening into the rear surface 112 and extending, at least partially, into the mounting plate 110. The bar magnets 930 could be secured to the rear surface 112 of the mounting plate 110 using threaded fasteners 940 inserted, for example, through the bar magnets 930 into the holes 926. According to one implementation, the bar magnets 930 (and the corresponding set of holes 926) can be positioned parallel to each other near opposite ends along the rear surface 112. The bar magnets 930 can be installed in place of, or in addition to, the magnetic disks 130. In the configuration of Figures 9A-9C, the magnetic adapter 100 can be coupled to the monitoring device 10 in a manner similar to that described above in connection with Figures 1-8. The orientation of the bar magnets 930 with respect to the monitoring device 10 can be altered by rotating the mounting plate 110 90° before coupling with the monitoring device 10. When mounted on the mounting plate 110, each of the bar magnets 930 may have an exposed surface 932 that lies in a different plane than its rear surface 112. As shown, for example, in Figure 9B, the different planes of surfaces 112 and 932 may allow for multiple points of contact, since both of the bar magnets 930 make contact simultaneously with the pump frame 20 along two radially separated lengths of a curved surface of the pump frame 20. Depending on the implementation, the bar magnets 930 may have the same or different pulling capacity as the magnetic disks 830. For example, if the bar magnets 930 are used with the magnetic disks 830 (for example, as shown in Figures 9A–9C), the pulling force of all four magnets 830 / 930 combined could be around 40.8233 and 81.6466 kg (90 and 180 pounds).According to one implementation, the magnetic adapter 100 of Figures 9A-9C (for example, with holes 926 in mounting plate 110, bar magnets 930, and threaded fasteners 940) can be provided to customers as a package that can be configured on-site for selective mounting on a flat or curved surface of the monitored equipment. A magnetic adapter is provided for attaching a monitoring device to monitored equipment. The adapter's mounting plate includes a front surface, a rear surface, and a recess in the rear surface. A magnet is secured within the recess so that an exposed surface of the magnet within the recess is substantially flush with the rear surface. The mounting plate also includes, for example, four threaded mounting holes arranged in a pattern that corresponds to a bolt pattern on the monitoring device. The threaded mounting holes are configured to receive threaded bolts from the monitoring device to secure the front surface against the monitoring device. The magnet is configured to adhere to the monitored equipment and to cause at least a portion of the rear surface to make contact with the monitored equipment.The adapter transfers vibration and thermal energy from the monitored equipment to the monitoring device. As noted in this description and illustrated by the figures, reference is made to the terms an example modality, a modality, modalities, etc., which may include a particular configuration, structure, or characteristic in connection with a modality(ies). However, the use of the phrase or term "a modality," "modalities," etc., in various places in the description does not necessarily refer to all the modalities described, nor does it necessarily refer to the same modality, nor are these separate, alternative modalities necessarily mutually exclusive of other modalities. The same applies to the term "implementation," "implementations," etc. The foregoing description of the embodiments provides an illustration, although it is not intended to be exhaustive or to limit the embodiments to the precise form described. Consequently, modifications to the embodiments described herein may be possible. For example, various modifications and changes may be made to the embodiment, and additional embodiments may be implemented, without departing from the broader scope of the invention as set forth in the following claims. Accordingly, the description and figures shall be regarded as illustrative rather than restrictive. The terms "a," "an," and "the" are intended to be interpreted as including one or more items. Furthermore, the phrase "based on" is intended to be interpreted as being based, at least in part, on, unless otherwise explicitly stated. The term "and / or" is intended to be interpreted as including any and all combinations of one or more of the associated items. The word "example" is used herein to mean "serves as an example." Any modality or implementation described as exemplary is not necessarily to be interpreted as preferred or advantageous over other modalities or implementations. The use of ordinal terms, such as first, second, third, etc., in claims to modify a claim element does not in itself connote any priority, precedence, or order of one claim element with respect to another, the temporal order in which method steps are performed, the temporal order in which instructions executed by a device are performed, etc., but is used only as a label to distinguish one claim element having a certain name from another element having the same name (although for the use of the ordinal term) to distinguish the claim elements. No element, step, or instruction used in the description of this application should be interpreted as critical or essential to the invention unless explicitly described as such. It is hereby stated that, as of this date, the best method known to the applicant for putting the aforementioned invention into practice is the one that is clear from the present description of the invention.

Claims

1. An adapter for a monitoring device, characterized in that it comprises: a mounting plate including: a front surface, a rear surface, at least two threaded mounting holes extending through the front and rear surfaces, and at least one recess in the rear surface;and one or more magnets secured within at least the recess, wherein the at least two threaded mounting holes are positioned in a hole pattern that corresponds to a bolt pattern of the monitoring device, wherein the at least two threaded mounting holes are configured to receive threaded bolts from the monitoring device to secure the front surface against the monitoring device, wherein the one or more magnets are configured to adhere to a monitored equipment frame and to cause at least a portion of the rear surface to make contact with the monitored equipment frame, and wherein the mounting plate is configured to transfer at least some of the vibration or thermal energy from the monitored equipment frame to the monitoring device.

2. The adapter according to claim 1, characterized in that the mounting plate includes a ferrous metal material.

3. The adapter according to claim 1, characterized in that the mounting plate includes a non-ferrous metal material.

4. The adapter according to claim 1, characterized in that the mounting plate further comprises: a lever slot including a hole in a perimeter of the rear surface.

5. The adapter according to claim 1, characterized in that the one or more magnets are configured to provide a combined pulling capacity within a range of 40.8233-81.6466 kg (90-180 lbs).

6. The adapter according to claim 1, characterized in that the mounting plate includes two recesses in the rear surface, with one or more magnets secured within each of the two recesses.

7. The adapter according to claim 1, characterized in that it further comprises: a pair of bar magnets mounted on the rear surface in a parallel orientation, wherein an exposed surface of each of the bar magnets is in a different plane than the rear surface.

8. The adapter according to claim 1, characterized in that the front surface is parallel to the rear surface, and wherein the mounting plate has a thickness in the range of 1.016-2.032 cri (0.4-0.8 inches).

9. A system, characterized in that it comprises: a monitoring device configured to be mounted on the equipment and to collect vibration and temperature data from the equipment; and an adapter for a monitoring device, the adapter including: a mounting plate having a front surface, a rear surface, at least four threaded mounting holes extending through the front surface, and at least one recess in the rear surface, and one or more magnets secured within at least the recess, wherein the at least four threaded mounting holes are positioned in a hole pattern that corresponds to a bolt pattern of the monitoring device, wherein the at least four threaded mounting holes are configured to receive threaded bolts of the monitoring device to secure the front surface against the monitoring device.wherein one or more magnets are configured to adhere to a frame of the piece of equipment and to cause at least a portion of the back surface to make contact with the frame, and wherein the mounting plate is configured to transfer vibration and thermal energy from the piece of equipment to the monitoring device.

10. The system according to claim 9, characterized in that the mounting plate includes a non-ferrous material.

11. The system according to claim 9, characterized in that the mounting plate further comprises: a lever slot including a hole in a perimeter of the rear surface.

12. The system according to claim 9, characterized in that the one or more magnets are configured to provide a combined pulling capacity within a range of 40.8233-81.6466 kg (90-180 lbs).

13. The system according to claim 9, characterized in that the adapter further comprises: threaded holes in the rear surface extending, at least partially, into the mounting plate, and a pair of bar magnets configured to be mounted in a parallel orientation on the rear surface, using the threaded holes, wherein an exposed surface of each of the bar magnets is in a different plane than the rear surface.

14. The system according to claim 13, characterized in that the front surface of the adapter is configured to engage with a flat surface of the monitoring device, and wherein the rear surface of the adapter is configured to make contact with a curved surface of the equipment at multiple points.

15. The system according to claim 9, characterized in that the rear surface includes a substantially square perimeter and wherein each of the at least four threaded mounting holes is located near a different corner of the substantially square perimeter.

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