WO2018094273A1 - Systems and methods for detection and analysis of faulty components in a rotating pulley system - Google Patents

Abstract

A vibration monitoring system described herein is used to detect and analyze mechanical characteristics such as vibrations emanating from a rotating system (including the shaft and bearing system). The analysis of the mechanical characteristics yields decision data as to whether and which component connected with the rotating system is faulty so that it may be replaced. An example of a rotating system would be any of the rotating accessories present in an automotive vehicle.

Description

ROTATING PULLEY SYSTEM CROSS REFERENCE

[0001] This application claims priority to U.S. Patent Application No. 62/423,479, filed November 17, 2016, the specification(s) of which is/are incorporated herein in their entirety by reference. FIELD OF THE INVENTION

[0002] The present invention relates to rotating systems comprised of a plurality of rotating components which exhibit different mechanical characteristics when a component of the rotating system is faulty and, more specifically, where an analysis of these differing mechanical characteristics yields data on which component is faulty. BACKGROUND OF THE INVENTION

[0003] Vibrations are but one example of parameters known as mechanical characteristics which define a material under force, pressure, or stress and strain of some kind. Other parameters include, but are not limited to, elastic or inelastic behavior, temperature, elongation, tensile strength, brittleness, bending, and an ability to conduct electricity in some measure. For the sake of clarity, this class of parameters will be herein represented using the term, vibrations. Rotating systems, or rotating components attached to stationary components, provide a particularly difficult case in which to identify a faulty component because of the rotation. Examples of such components in a rotating system in an automotive engine include, but are not limited to, an alternator and pulleys such as a crankshaft pulley, idler tension pulley, power steering pulley, water pump pulley, and compressor pulley. Complicating the fault identification even further is the presence of multiple sources of vibrations– such as within an automotive system– and those multiple sources make it more difficult to pinpoint the exact source of the defective vibration. [0004] The technique of identifying faulty components in a rotating system by spotting excessive vibrations of a rotating component has long been appreciated by those skilled in the art of auto mechanics worldwide. A more subtle variation of this technique has been to use instruments to detect vibrations not evident to most human perceptions. The vibration data recorded by those instruments is often processed and analyzed by applying known procedures in the art, such as Fourier analysis or a Fast Fourier Transform (“FFT”). Other techniques of detecting vibrations have been identified to determine mechanical characteristics in general and vibrations in particular, such as: piezoelectric crystals, a capacitance displacement probe, an inductance/eddy current displacement probe, an optical reflectance probe, or an accelerometer. The device used to measure vibrations is, for simplicity sake, hereafter referred to as a vibration detection device. [0005] Any feature or combination of features described herein are included within the scope of the present invention provided that the features included in any such combination are not mutually inconsistent as will be apparent from the context, this specification, and the knowledge of one of ordinary skill in the art. Additional advantages and aspects of the present invention are apparent in the following detailed description and claims. SUMMARY OF THE INVENTION

[0006] As previously mentioned, the practice of acquiring and analyzing vibration data to detect faulty components in a rotating system is widely used in the automotive industry. However, no effective method of attaching a vibration detection device to a component of a rotating system such that unwanted vibrations are mitigated presently exists. Current vibration acquisition methods position the vibration detection device within the aperture of a rotating pulley with the rotational axis of the vibration detection device and the rotational axis of the pulley (to which the vibration detection device is attached) completely unaligned. This off-centered placement is apt to obviate the success of measurements taken because the vibration data measured is asymmetric to the pulley and likely subject to undesired forces that may distort the acquired rotational data. [0007] The present invention uniquely resolves the aforementioned problems by providing a device attachable to the center of a component (i.e. a pulley or shaft) in a rotating system such that the rotational axis of the vibration detection device is parallel and aligned with the rotational axis of the component to which the device is attached. In this way, unwanted radial vibrations are effectively eliminated. None of the presently known works or references has this inventive feature of the present invention. [0008] In some aspects, the present invention features a vibration monitoring system for identifying a faulty component in a rotating system. The rotating system may comprise one or more rotating components, each rotating component having a reference vibration signature. The vibration monitoring system may comprise a vibration detection unit comprising a vibration detection device comprising a motion sensor comprising a plurality of accelerometers, a processor unit operatively coupled to the motion sensor, a memory repository operatively coupled to the processor unit, and a wireless transmitter operatively coupled to the processor unit, where the vibration detection device is configured to detect and transmit a vibration emanating from each of the one or more rotating components; and a device base upon which the vibration detection device is disposed. The system may further include a wireless receiving unit having a user interface. [0009] In one aspect, the vibration detection unit may be disposed on a component of the one or more rotating components such that a rotational axis of the vibration detection unit is parallel and aligned with a rotational axis of the component to which the vibration detection unit is attached. When the component rotates, the vibration detection device can detect vibrations emanating from each component and collects each detected vibration into a set of vibrations. [0010] In some aspects, the motion sensor can acquire a set of measurements of the vibrations and transmits said measurements to the processor unit. The memory repository stores a set of computer- executable functions that, when executed by the processor unit, causes the processor unit to perform operations comprising performing an analysis of the measurements that compares the vibrations to the reference vibration signature and calculates deviations to determines whether the rotating component is faulty; storing the measurements and results of the analysis in the memory repository; and transmitting the measurements or said results to the wireless receiving unit. [0011] In further aspects, the wireless receiving unit is configured to acquire and transmit the measurements or the results to an analyzer. The analyzer is configured to perform another analysis of the measurements to determine whether the rotating component is faulty. The results may then be displayed on the user interface. DEFINITIONS

[0012] As used herein, the term“wireless” refers to an electromagnetic means of propagating a signal. Examples of wireless devices or systems include Bluetooth devices and radio. [0013] As used herein, the term“rotational axis” (or“axis of rotation”) refers to a fixed line passing through a moving body about which the moving body rotates. [0014] As used herein, the term“analyzer” or“analyzing unit” refers to the process of analyzing the mechanical characteristics of a rotating component(s) and yielding decision data as to whether and which rotating component of a rotating system is faulty (or not) and may be implemented on any device capable of said process (e.g., a cell phone application). BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The features and advantages of the present invention will become apparent from a consideration of the following detailed description presented in connection with the accompanying drawings in which: [0016] FIG.1A is a depiction of a vibration detection unit of the present invention disposed within a rotating system of an automotive engine.

FIG.1B shows a wireless receiving unit having a user interface disposed thereon.

[0017] FIG.2A is a view of an embodiment of the vibration detection unit, wherein the vibration detection unit comprises a vibration detection device, a base magnet and a device base.

[0018] FIG.2B shows an exploded view of the vibration detection unit of FIG. 2A. FIG. 2C shows a cross- sectional view of the vibration detection unit of FIG.2A.

[0020] FIG. 3 shows the retractable-hinged alignment aide used for a non-magnetic embodiment of the vibration detection unit.

[0021] FIG.4A shows the vibration detection unit operatively connected to a rotating system of an automotive engine.

[0022] FIG.4B shows a cross-sectional view of the vibration detection unit operatively connected to a rotating system.

[0023] FIG.5A is an alternate embodiment of the vibration detection unit.

[0024] FIG. 5B is an exploded view of the vibration detection unit shown in FIG.5A. The detection unit can mate with the device base via hexagonal cut-out disposed on a distal end of the device base. [0025] FIG.5C is a cross-sectional view of the vibration detection unit shown in FIG.5A, where a hexagonal cut-out is built into a posterior end of the base magnet to allow for best surface contact on a central shaft nut.

[0026] FIG.5D shows the vibration detection unit shown in FIG.5A placed inside a rotating pulley system of an automotive engine.

[0027] FIG.5E shows a cross-sectional view of the vibration detection unit shown in FIG.5A inside a rotating pulley system of an automotive engine.

[0028] FIG.6A shows another alternate embodiment of the vibration detection unit.

[0029] FIG.6B shows an exploded view of the vibration detection unit shown in FIG.6A.

[0030] FIG.6C shows a cross-sectional view of the vibration detection unit shown in FIG.6A, where the base the base magnet has female threads, which allows a user to remove an existing nut on a central pulley shaft and replace it with the vibration detection unit.

[0031] FIG.6D shows the vibration detection unit shown in FIG.6A placed inside a rotating pulley system of an automotive engine.

[0032] FIG.6E shows a cross-sectional view of the vibration detection unit shown in FIG.6A threaded onto a central pulley shaft of an automotive engine.

[0033] FIG. 7A shows a vibration detection device utilizing a hook and loop means for a non-magnetic attachment to a component in a rotating system.

[0034] FIG. 7B shows a cross-sectional view of the vibration detection device in FIG. 7A. Hook and loop material can be seen on the lower portion of the vibration detection unit. The loop pad is permanently adhered to the bottom of the vibration detection unit. The hook pad has adhesive on one end and may be affixed to a shaft in the rotating system with the help of the alignment aide.

[0035] FIG.7C shows an exploded view of the vibration detection unit in FIG.7A. The vibration detection unit, with a permanently affixed loop pad, is shown separated from the hook pad that would be placed on a shaft of the rotating system.

[0036] FIG. 7D shows the vibration detection unit of FIG. 7A affixed to the shaft of a rotating system in an automotive engine.

[0037] FIG.7E shows a cross-sectional view of the vibration detection unit of FIG.7A affixed to the shaft of a rotating system in an automotive engine.

[0038] FIG.8A shows a flow chart of a method for detecting and analyzing vibration in accordance with the present invention.

[0039] FIG.8B shows a schematic of the vibration monitoring system.

[0040] FIG.9 shows another alternate embodiment of the vibration detection unit.

[0041] FIG. 10 shows a bottom view of the vibration monitoring system in FIG. 9, which clearly depicts the hexagonal cut-out disposed on the posterior end of the base magnet.

[0042] FIG. 11 shows a close-up view of an embodiment where the vibration sensing unit is constrained to the base magnet by a bayonet latch mechanism.

[0043] FIG.12 shows a cross-sectional view of FIG.11 highlighting the bayonet mechanism. DETAILED DESCRIPTION OF THE INVENTION

[0044] Referring now to FIGs. 1A-12, the present invention features a vibration monitoring system for identifying a faulty component in a rotating system, where the rotating system may comprise one or more rotating components. The rotating system may be, for example, one of the plurality of rotating systems comprising an automotive engine. Each of the one or more rotating components has a reference vibration signature modeling a normal vibration emanating from said component. In one embodiment, the vibration monitoring system comprises a vibration detection unit (100) having a vibration detection device (102) and a device base (104) upon which the vibration detection device (102) is disposed. The vibration detection device (102) disclosed herein may be any instrument configured to detect and transmit the vibration emanating from each of the aforementioned rotating components. Further, the one or more rotating components may be attached either directly or indirectly (e.g., via a pulley connection) to the vibration detection unit (100). [0045] In some embodiments, the vibration detection device (102) is a motion sensor comprising one or more accelerometers, a processor unit operatively coupled to the motion sensor, a memory repository operatively coupled to the processor unit, and a wireless transmitter operatively coupled to the processor unit. In another exemplary embodiment, the motion sensor comprises n accelerometers, each 360/n degrees out of phase, collecting motion data at a very high rate (e.g., about 10 kHz). In another embodiment, the memory repository is a Random Access Memory data storage device. In additional embodiments, the processor unit comprises a temporary storage unit, operatively coupled to the motion sensor and the memory repository, and a primary data analyzer, operatively coupled to the wireless transmitter and the memory repository. In other embodiments, the vibration detection device (102) may be powered by a battery. [0046] The system may further comprise a wireless receiving and analysis unit (300) having a user interface (302). In the present embodiment, the vibration detection unit (100) is disposed at the center of a component, of the one or more rotating components, such that the rotational axis of the vibration detection unit (100) is parallel and aligned with the rotational axis of the component to which the vibration detection unit (100) is attached. In some embodiments, as the component rotates, the vibration detection device (102) detects the vibration emanating from each component and collects each detected vibration into a set of vibrations. In other embodiments, the vibration detection device (102) then sends the set of vibrations as a signal to the wireless receiving and analysis unit (300). Examples of the wireless receiving and analysis unit (300) include, but are not limited to, a mobile device, for example, a mobile phone or tablet, or a laptop or a computer etc. [0047] In further embodiments, the processor or the wireless receiving and analysis unit processes and analyzes the signal and determines, based on comparing each vibration in the set of vibrations with the vibration signature of the corresponding component, which component is faulty. In an embodiment, a deviation from the vibration signature is determined and analyzed (i.e., to determine if a component is faulty) via machine learning algorithms such as neural networks and support vector machines. The wireless receiving and analysis (300) unit may then display, via the user interface (302), decision data comprising which component in the rotating system is faulty. [0048] In one embodiment, the processor or the wireless receiving and analysis unit performs a frequency- based analysis, such as Fourier Analysis or a FFT, to analyze the measurements. Alternatively, time-based and/or training and learning methodologies may also be performed to analyze the measurements. For instance, the wireless receiving and analysis unit can perform an analysis to compute an FFT, with the analysis further comprising the use of any machine learning algorithms (e.g. support vector machines) to support in determining the deviation of the vibration (identifying the faulty rotary component) from the vibration signature of the rotating component. [0049] In some embodiments of the system, the device base (104) is disposed on a base magnet (106) for magnetic attachment of the vibration detection unit (100) to a steel portion of a component in the rotating system. In this embodiment, the component upon which the vibration detection device (100) is disposed is a pulley. The vibration detection unit (100) is disposed within the center of the pulley such that the rotational axis of the vibration detection unit (100) is parallel and aligned with the rotational axis of the pulley. In this arrangement, the presence of undesired forces in the acquired data is effectively eliminated. [0050] A hexagonal shape may be built into the base magnet (106) to allow for best surface contact on a central shaft nut (FIGs.5A-5C). This method of attachment is critical because the shape of the base magnet (106) can help center the vibration detection unit (100). Without wishing to limit the invention to a particular theory or mechanism, this centering of the vibration detection unit (100) is what leads to the elimination of sensing unwanted vibrations. Referring to FIGs.6A to 6E, in another embodiment of the present system, the device base (104) is a threaded nut allowing a user to remove the existing nut on a central pulley shaft and replace it with the vibration detection unit (100). As a non-limiting example, a non-magnetic shaft/nut receptacle may have a hexagonal cut-out as shown in FIG.12. At the center of that shaft/nut receptacle may be a thru hole. A hexagonal base magnet (106) with a countersunk hole may be placed in the hexagonal cut- out. A screw may be passed through the hole and constrain the base magnet (106) into its appropriate position. In this embodiment, the base magnet (106) comprises a non-magnetic shell and a magnetic component being an additional piece inserted into the non-magnetic shell. In alternative embodiments, the shell of the base magnet (106) may comprise a partially magnetic-material, such as aluminum. In alternative embodiments, the entire base magnet (106) is comprised of a magnetic material. [0051] Aside from being attached via screws, in other embodiments, the vibration detection unit (100) may be constrained to the base magnet (106) by a bayonet latch mechanism coupled with a wave washer and retaining ring as shown in FIGs.11-12. The bayonet latch mechanism may comprise bayonet flutes in which bayonet posts are inserted. However, the vibration detection unit (100) may be attached to the device base (104) by any appropriate and sufficient means. [0052] An alignment aide (400) may be utilized in another embodiment of the present invention to position the vibration detection unit (600) on a component in the rotating system. In this embodiment, the vibration detection unit (600) further comprises a hook and loop pad (110) (e.g., Velcro) disposed on the device base (104) for a nonmagnetic attachment of the vibration detection unit (600) to the component. The loop pad (112) may be permanently fixed to the bottom of the vibration detection unit (600) and the hook pad (114) may affix permanently to the component of the rotating system. In this way, the vibration detection unit (600) may be placed for monitoring vibrations and subsequently removed from the component when measurements have been taken. The component upon which the vibration detection unit (600) is disposed may be a solid cylindrical shaft (602) having at least one accessible end (604). The aforementioned alignment aide (400) may be used to position the vibration detection unit (600) onto a center of the accessible end (604) of the shaft (602) such that the vibration detection unit (600) and the shaft (602) share a common axis of rotation. [0053] Further, the alignment aide (400) may be comprised of a ring (405) having a center aperture (404), a first hinged spring-loaded arm (401), a second hinged spring-loaded arm (402), and a third hinged spring- loaded arm (403). These spring-loaded arms may be disposed equidistantly on the ring (405) and may be expandable and retractable concentrically (e.g., to reflect the circumference of the vibration detection unit (600)). The center aperture (404) may allow for marking the center of the accessible end (604) of the shaft (602). To attach the vibration detection unit (600) to the center of the accessible end (604) of the shaft (602), via the hook and loop pad (110), the three hinged spring-loaded arms may be adjusted to contact the circumference of the vibration detection unit (600). The center aperture (404) may then be used to align the vibration detection unit (600) with the center of the accessible end (604) of the shaft (602), which may then be affixed to the accessible end (604) of the shaft (602) by the hook and loop pad (110). [0054] In another embodiment, the vibration emanating from each of the one or more rotating components comprising the rotating system may comprise one or more of the following: a physical vibration, elastic or inelastic behavior, temperature, elongation, tensile strength, brittleness, bending or electrical conductivity. [0055] A further embodiment of the system features at least two components of the rotating system each having a vibration detection unit (100) disposed therein or a vibration detection unit (600) disposed thereon. The wireless receiving and analysis unit analyzes an aggregate set of vibrations for the detection of one or more faulty components. [0056] Consistent with previous embodiments, the wireless receiving and analysis (300) unit or sensor processor may analyze the set of vibration data received from the vibration detection unit (100 or 600). Examples of analyzation techniques may include, but are not limited to: spectral analysis (e.g., Fourier Analysis or FFT) or time-based analysis. Processing the data in this way allows the analysis to be conducted in the frequency spectrum, where vibrations not evident to most human perceptions may be detected and evaluated against the vibration signature of the rotating component. [0057] In additional embodiments, the vibration detection unit (100) further comprises a detection analysis unit. In one embodiment, the detection analysis unit performs an analysis of the set of vibrations. Results from the analysis may be transmitted to the wireless receiving and analysis unit (300), which may then perform a secondary analysis of said results. In an alternate embodiment, the detection analysis unit analyzes the set of vibrations to determine, based on comparing each vibration in the set of vibrations with the vibration signature of the corresponding component, which component is faulty. [0058] The present invention further comprises a method for identifying a faulty component in a rotating system. The rotating system may comprise one or more rotating components, each component having a reference vibration signature. In some embodiments, the method comprises providing any of the vibration monitoring system as described herein. For example, the vibration monitoring system may comprise a vibration detection unit (100) and a wireless receiving and analysis unit (300) having a user interface (302). In further embodiments, the vibration detection unit (100) comprises a vibration detection device (102) configured to detect and transmit a vibration emanating from each of the one or more rotating components; and a device base (104) upon which the vibration detection device (102) is disposed. [0059] In some embodiments, the method further comprises attaching the vibration detection unit (100) to a center of a component of the one or more rotating components such that a rotational axis of the vibration detection unit (100) is parallel and aligned with a rotational axis of the component to which the vibration detection unit (100) is attached, wherein as the component rotates, the vibration detection device (102) detects the vibration emanating from each component and collects each detected vibration into a set of vibrations and sends the set of vibrations as a signal to the wireless receiving and analysis unit (300); processing and analyzing the signal, via the wireless receiving and analysis unit (300), wherein said processing and analysis determines, based on comparing each vibration in the set of vibrations with the vibration signature of the corresponding component, which component is faulty; and displaying, via the user interface (302), decision data comprising which component in the rotating system is faulty. [0060] In supplementary embodiments, the device base (104) is disposed on a base magnet (106) for magnetic attachment of the vibration detection unit (100) to a steel portion of a component in the rotating system. In this embodiment, the component upon which the vibration detection device (100) is disposed is a pulley. The vibration detection unit (100) is disposed within the center of the pulley such that the rotational axis of the vibration detection unit (100) is parallel and aligned with the rotational axis of the pulley. In this arrangement, the presence of undesired forces in the acquired data is effectively eliminated. Further, a hexagonal shape may be built into the base magnet (106) to allow for best surface contact on a central shaft nut. This method of attachment is highly significant to the present embodiment because the shape of the base magnet (106) will help center the vibration detection unit (100), this centering of the vibration detection unit (100) is what leads to the elimination of unwanted vibrations. [0061] Referring to FIGs.6A-6E, in another embodiment, the device base (104) is a threaded nut allowing a user to remove the existing nut on a central pulley shaft and replace it with the vibration detection unit (100). In another embodiment, a non-magnetic shaft/nut receptacle may have a hexagonal cut-out as depicted in FIG.12. At the center of that shaft/nut receptacle may be a thru hole. A hexagonal magnet with a countersunk hole may be placed in the hexagonal cut-out. A screw may be passed through the hole and constrain the magnet into its appropriate position. The base magnet has a non-magnetic shell and the magnetic component is an additional piece inserted into the non-magnetic shell. In alternative embodiments, the shell of the base magnet (106) may comprise a partially magnetic-material, such as aluminum. In alternative embodiments, the entire base magnet (106) is comprised of a magnetic material. [0062] In some embodiments, the vibration detection unit (100) is constrained to the base magnet (106) by a bayonet latch mechanism coupled with a wave washer and retaining ring as shown in FIGs.11-12. Again, the vibration detection unit (100) may be attached to the device base (104) by any appropriate and sufficient means, and is not limited to the bayonet latch or screw mechanism. [0063] An alignment aide (400) may be utilized in another embodiment of the present invention to position the vibration detection unit (600) on a component in the rotating system. In this embodiment, the vibration detection unit (600) further comprises a hook and loop pad (110) (e.g., Velcro) disposed on the device base (104) for a nonmagnetic attachment of the vibration detection unit (600) to the component. The loop pad (112) may be permanently fixed to the bottom of the vibration detection unit (600) and the hook pad (114) may affix permanently to the component of the rotating system. In this way, the vibration detection unit (600) may be placed for monitoring vibrations and subsequently removed from the component when measurements have been taken. The component upon which the vibration detection unit (600) is disposed may be a solid cylindrical shaft (602) having at least one accessible end (604). The aforementioned alignment aide (400) may be used to position the vibration detection unit (600) onto a center of the accessible end (604) of the shaft (602) such that the vibration detection unit (600) and the shaft (602) share a common axis of rotation. [0064] Further, the alignment aide (400) may be comprised of a ring (405) having a center aperture (404), a first hinged spring-loaded arm (401), a second hinged spring-loaded arm (402), and a third hinged spring- loaded arm (403). These spring-loaded arms may be disposed equidistantly on the ring (405) and may be expandable and retractable concentrically (e.g., to reflect the circumference of the vibration detection unit (600)). The center aperture (404) may allow for marking the center of the accessible end (604) of the shaft (602). To attach the vibration detection unit (600) to the center of the accessible end (604) of the shaft (602), via the hook and loop pad (110), the three hinged spring-loaded arms may be adjusted to contact the circumference of the vibration detection unit (600). The center aperture (404) may then be used to align the vibration detection unit (600) with the center of the accessible end (604) of the shaft (602), which may then be affixed to the accessible end (604) of the shaft (602) by the hook and loop pad (110). [0065] In another embodiment, the vibration emanating from each of the one or more rotating components comprising the rotating system may comprise one or more of the following: a physical vibration, elastic or inelastic behavior, temperature, elongation, tensile strength, brittleness, bending or electrical conductivity. [0066] A further embodiment features at least two components of the rotating system each having a vibration detection unit (100) disposed therein or a vibration detection unit (600) disposed thereon. Each sensor processor or the wireless receiving and analysis unit can analyze an aggregate set of vibrations for the detection of one or more faulty components. [0067] Consistent with previous embodiments, the wireless receiving and analysis (300) unit or sensor processor may analyze the set of vibration data received from the vibration detection unit (100 or 600). In some embodiments, a deviation from the vibration signature is determined and analyzed (i.e., to determine if a component is faulty) via machine learning algorithms such as neural networks and support vector machines. Examples of analysis techniques may include, but are not limited to: spectral analysis (e.g., Fourier Analysis or FFT) or time-based analysis. Processing the data in this way allows the analysis to be conducted in the frequency spectrum, where vibrations not evident to most human perceptions may be detected and evaluated against the vibration signature of the rotating component. [0068] In additional embodiments, the vibration detection unit (100) further comprises a detection analysis unit. In one embodiment, the detection analysis unit performs a primary analysis of the set of vibrations. Results from the primary analysis may be transmitted to the wireless receiving and analysis unit (300), which may then perform a secondary analysis of said results. In an alternate embodiment, the detection analysis unit analyzes the set of vibrations to determine, based on comparing each vibration in the set of vibrations with the vibration signature of the corresponding component, which component is faulty. [0069] As used herein, the term“about” refers to plus or minus 10% of the referenced number. [0070] The disclosures of the following U.S. Patents are incorporated in their entirety by reference herein: U.S. Pat. No. 4646754, U.S. Pat. No. 9188498, U.S. Pat. No. 6363303, U.S. Pat. Application No. 2014/0174186, and U.S. Pat. Application No.2007/0063048. [0071] Various modifications of the invention, in addition to those described herein, will be apparent to those skilled in the art from the foregoing description. Such modifications are also intended to fall within the scope of the appended claims. Although there has been shown and described the preferred embodiment of the present invention, it will be readily apparent to those skilled in the art that modifications may be made thereto which do not exceed the scope of the appended claims. Therefore, the scope of the invention is only to be limited by the following claims. Reference numbers recited in the claims are exemplary and for ease of review by the patent office only, and are not limiting in any way. In some embodiments, the figures presented in this patent application are drawn to scale, including the angles, ratios of dimensions, etc. In some embodiments, the figures are representative only and the claims are not limited by the dimensions of the figures. In some embodiments, descriptions of the inventions described herein using the phrase“comprising” includes embodiments that could be described as“consisting of”, and as such the written description requirement for claiming one or more embodiments of the present invention using the phrase“consisting of” is met.

Claims

WHAT IS CLAIMED IS: 1. A vibration monitoring system for identifying a faulty component in a rotating system, wherein the rotating system comprises one or more rotating components, each rotating component having a reference vibration signature, wherein the vibration monitoring system comprises:

(a) a vibration detection unit (100) comprising:

(i) a vibration detection device (102) comprising:

A) a motion sensor comprising a plurality of accelerometers;

B) a processor unit operatively coupled to the motion sensor;

C) a memory repository operatively coupled to the processor unit; and

D) a wireless transmitter operatively coupled to the processor unit;

wherein the vibration detection device (102) is configured to detect and transmit a vibration emanating from each of the one or more rotating components; and

(ii) a device base (104) upon which the vibration detection device (102) is disposed; and (b) a wireless receiving unit (300) having a user interface (302),

wherein the vibration detection unit (100) is disposed on a component of the one or more rotating components such that a rotational axis of the vibration detection unit (100) is parallel and aligned with a rotational axis of the component to which the vibration detection unit (100) is attached, wherein as the component rotates, the vibration detection device (102) detects vibrations emanating from each component and collects each detected vibration into a set of vibrations,

wherein the motion sensor acquires a set of measurements of the vibrations and transmits said measurements to the processor unit ,

wherein the memory repository stores a set of computer-executable functions that, when executed by the processor unit, causes the processor unit to perform operations comprising:

I. performing an analysis of the measurements that compares the vibrations to the reference vibration signature and calculates deviations to determines whether the rotating component is faulty;

II. storing the measurements and results of the analysis in the memory repository; and

III. transmitting the measurements or said results to the wireless receiving unit (300);

wherein the wireless receiving unit (300) is configured to acquire and transmit the measurements or the results to an analyzer, wherein the analyzer is configured to perform another analysis of the measurements to determine whether the rotating component is faulty, wherein either one or both of the results are displayed on the user interface. 2. The system of claim 1, wherein the device base (104) is disposed on a base magnet (106) for magnetic attachment of the vibration detection unit (100) to a metal portion of the component of the rotating system. 3. The system of claim 2, wherein the component upon which the vibration detection unit (100) is disposed on is a pulley, wherein the vibration detection unit (100) is magnetically attached to the center of the pulley such that a rotational axis of the vibration detection unit (100) is parallel and aligned with a rotational axis of the pulley. 4. The system of claim 2, wherein the component upon which the vibration detection unit (100) is disposed on is a shaft, wherein the vibration detection unit (100) is magnetically attached to the shaft such that a rotational axis of the vibration detection unit (100) is parallel and aligned with a rotational axis of the shaft. 5. The system of claim 4, wherein the base magnet (106) is screwed onto the shaft via mating threads. 6. The system of claim 1, wherein the vibration detection device (102) is attached to the device base (104) via screws. 7. The system of claim 1, wherein the vibration detection device (102) is attached to the device base (104) via a bayonet-latch mechanism. 8. The system of claim 1, wherein the vibration detection unit (600) further comprises a hook and loop pad (110) disposed on the device base (104) for a nonmagnetic attachment of the vibration detection unit (600) to the component of the rotating system. 9. The system of claim 8, wherein the loop pad (112) is affixed to the vibration detection unit (600) and the hook pad (114) is affixed to the component of the rotating system. 10. The system of claim 8, wherein the component upon which the vibration detection unit (100) is disposed is a solid cylindrical shaft (602) having at least one accessible end (604), wherein an alignment aide (400) is used to position the vibration detection unit (600) onto a center of the accessible end (604) of the shaft (602) such that the vibration detection unit (600) and the shaft (602) share a common axis of rotation. 11. The system of claim 10, wherein the alignment aide (400) comprises a ring (405) having a center aperture (404), a first hinged spring-loaded arm (401), a second hinged spring-loaded arm (402), and a third hinged spring-loaded arm (403), wherein the first hinged spring-loaded arm (401), the second hinged spring-loaded arm (402) and the third hinged spring-loaded arm (403) are disposed equidistantly on the ring (405) and are expandable and retractable,

wherein to attach the vibration detection unit (600) to the center of the accessible end (604) of the shaft (602), the first hinged spring-loaded arm (401), the second hinged spring-loaded arm (402), and the third hinged spring-loaded arm (403) expand and retract concentrically to contact a circumference of the vibration detection device (600), wherein the center aperture (404) aides in aligning the vibration detection unit (600) with the center of the shaft (602). 12. The system of claim 1, wherein the vibrations derived from each of the one or more rotating components is a physical vibration, elastic or inelastic behavior, temperature, elongation, tensile strength, brittleness, bending or electrical conductivity. 13. The system of claim 1, wherein at least two components of the rotating system each have a vibration detection unit (100) disposed thereon, wherein the processor unit or the wireless receiving unit (300) analyzes an aggregate set of vibrations to detect one or more faulty components. 14. The system of claim 1, wherein the device base (104) of the vibration detection unit (100) is a threaded nut allowing replacement of an existing nut on a central pulley shaft with the vibration detection unit (100). 15. A method for identifying a faulty component in a rotating system, wherein the rotating system comprises one or more rotating components, each component having a reference vibration signature, wherein the method comprises:

a) providing a vibration monitoring system according to any one of claims 1-14;

b) attaching the vibration detection unit (100) to a center of a component of the one or more rotating components such that a rotational axis of the vibration detection unit (100) is parallel and aligned with a rotational axis of the component to which the vibration detection unit (100) is attached, wherein as the component rotates, the vibration detection device (102) detects the vibration emanating from each component and collects each detected vibration into a set of vibrations; c) processing and analyzing the signal, via the processor or the wireless receiving unit (300), wherein each vibration in the set of vibrations is compared to the vibration signature of the corresponding component to determine which component is faulty; and

d) displaying, via a user interface (302), data indicating which component in the rotating system is faulty.