# US 7,705,744 B2 · Monitoring systems and methods for monitoring the condition of one or more components of an electrical device

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- Number: US 7,705,744 B2
- Document ID: US7705744B2
- Status: Granted
- Kind: B2
- Application number: 11/752,960
- Filed: 2007-05-24
- Published: 2008-11-27
- Granted: 2010-04-27
- Earliest claimed: 2007-05-24
- Assignees: Cutsforth Products, Inc.
- Inventors: Robert S. Cutsforth
- Web page: https://patentgrep.com/patent/US7705744B2

## CPC

- G05B 23/0232: {based on qualitative trend analysis, e.g. system evolution}
- G05B 23/0283: {Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL] (preventive maintenance, i.e. planning maintenance according to the available resources without monitoring the system G06Q10/06)}
- G05B 2219/31447: Process error event detection and continuous process image detection, storage
- G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G)

## Abstract

Methods and systems for monitoring a component of an electrical device and/or a brush of a brush holder assembly are disclosed. One method includes receiving data from a plurality of remote monitoring locations at a central control unit, where the data may be evaluated in order to monitor states of brushes or other components of an electrical device at a plurality of remote electrical facilities. For example, multiple images of a component of an electrical device may be acquired. A comparison of the images, for example, a comparative imaging technique, such as pixel-by-pixel comparison or visual observation, may then be performed in order to evaluate a condition of the brush or other component, such as a threshold and/or anomalous condition of the brush or other component.

## Claims

### Claim 1

A system for monitoring the state of a brush of a brush holder assembly of an electrical device, the system comprising:
a brush holder assembly including a brush in contact with a moving contact surface of the electrical device;
an imaging device in line of sight of the moving contact surface for acquiring images of the moving contact surface; and
a processing unit for evaluating data generated from the images.

### Claim 2 (depends on 1)

The system of claim 1, wherein the processing unit is remote from the imaging device.

### Claim 3 (depends on 1)

The system of claim 1, wherein the processing unit includes a computer having a software program for evaluating data generated from the images.

### Claim 4 (depends on 1)

The system of claim 1, wherein the processing unit includes a monitor for displaying the images.

### Claim 5

A system for monitoring a component of an electrical generator, the system comprising:
a plurality of remote monitoring locations, wherein each remote monitoring location generates data regarding the position, coloration or level of emitted radiation of the component of the electrical generator; and
a central control unit for receiving data from the plurality of remote monitoring locations.

### Claim 6 (depends on 5)

The system of claim 5, wherein each remote monitoring location has one or more imaging devices for acquiring images of a component of an electrical generator.

### Claim 7 (depends on 5)

The system of claim 5, wherein the central control unit includes a computer having a software program for evaluating data from the plurality of remote monitoring locations.

### Claim 8 (depends on 5)

The system of claim 5, wherein the central control unit includes a monitor for displaying data from the plurality of remote monitoring locations.

### Claim 9

A method of monitoring conditions of one or more components of an electrical generator, the method comprising:
generating an image of a component of an electrical generator with an imaging device; and
analyzing the image to determine a condition of the electrical generator;
wherein the component of the electrical generator is a collector ring.

### Claim 10

A method of monitoring conditions of one or more components of an electrical generator, the method comprising:
generating an image of a component of an electrical generator with an imaging device; and
analyzing the image to determine a condition of the electrical generator;
wherein the component of the electrical generator is a commutator.

### Claim 11

A method of monitoring conditions of one or more components of an electrical generator, the method comprising:
generating an image of a component of an electrical generator with an imaging device; and
analyzing the image to determine a condition of the electrical generator;
wherein the component of the electrical generator is a brush.

### Claim 12

A method of monitoring conditions of one or more components of an electrical generator, the method comprising:
generating an image of a component of an electrical generator with an imaging device; and
analyzing the image to determine a condition of the electrical generator;
wherein the step of analyzing the image includes determining discoloration of the component.

### Claim 13

A method of monitoring conditions of one or more components of an electrical generator, the method comprising:
generating an image of a component of an electrical generator with an imaging device; and
analyzing the image to determine a condition of the electrical generator;
wherein the image is a thermal image; and
wherein the step of analyzing the image includes determining the level of emitted radiation of the component by evaluating the color, shade or intensity of the thermal image.

### Claim 14

A method of monitoring conditions of one or more components of an electrical generator, the method comprising:
generating an image of a component of an electrical generator with an imaging device; and
analyzing the image to determine a condition of the electrical generator;
wherein the step of analyzing the image includes evaluating the position of the component.

### Claim 15

A method of monitoring conditions of one or more components of an electrical generator, the method comprising:
generating an image of a component of an electrical generator with an imaging device; and
analyzing the image to determine a condition of the electrical generator;
wherein the step of analyzing the image includes evaluating the temperature of the component.

### Claim 16

A method of monitoring electrical generators at a plurality of remote facilities, an electrical generator having one or more brush holder assemblies including one or more brushes, the method comprising:
providing a central control unit in communication with a plurality of remote monitoring locations;
receiving data from the plurality of remote monitoring locations at the central control unit; and
evaluating the data at the central control unit to monitor conditions of the electrical generators at the plurality of remote facilities.

### Claim 17 (depends on 16)

The method of claim 16, further comprising the step of alerting personnel of an anomalous or threshold condition at one of the plurality of remote monitoring locations.

### Claim 18 (depends on 16)

The method of claim 16, further comprising the step of scheduling maintenance at one of the plurality of remote monitoring locations.

### Claim 19 (depends on 16)

The method of claim 16, further comprising the step of routing personnel to one of the plurality of remote monitoring locations.

### Claim 20 (depends on 16)

The method of claim 16, further comprising the step of scheduling distribution or delivery of a replacement brush to one of the plurality of remote monitoring locations.

### Claim 21 (depends on 16)

The method of claim 16, wherein the plurality of remote monitoring locations are networked with the central control unit.

### Claim 22

A method for determining the state of a brush of a brush holder assembly, the brush being in contact with a rotating conductive surface of an electrical device, the method comprising:
acquiring a first image of the rotating conductive surface or the brush;
acquiring a second image of the rotating conductive surface or the brush;
comparing the first image to the second image using an image analysis technique; and
evaluating a state of the brush of the brush holder assembly.

### Claim 23 (depends on 22)

The method of claim 22, wherein the image analysis technique is a visual observation technique.

### Claim 24 (depends on 22)

The method of claim 22, wherein the image analysis technique is a pixel-by-pixel comparison technique.

### Claim 25 (depends on 22)

The method of claim 22, further comprising generating a graphical representation of the state of the brush of the brush holder assembly.

### Claim 26 (depends on 22)

The method of claim 22, further comprising notifying personnel of an anomalous state of the brush of the brush holder assembly.

### Claim 27 (depends on 26)

The method of claim 26, wherein the anomalous state of the brush of the brush holder assembly is arcing, etching or burning.

### Claim 28 (depends on 22)

The method of claim 22, further comprising notifying personnel of a threshold state of the brush of the brush holder assembly.

### Claim 29 (depends on 28)

The method of claim 28, wherein the threshold state is the moment when the temperature of the brush exceeds a normal operating temperature.

### Claim 30 (depends on 29)

The method of claim 29, wherein the normal operating temperature is in the range of about 150° F to about 250° F.

### Claim 31 (depends on 29)

The method of claim 29, wherein the normal operating temperature is in the range of about 180° F to about 200° F.

### Claim 32 (depends on 22)

The method of claim 22, wherein the step of evaluating a state of the brush of the brush holder assembly includes comparing actual acquired data with modeled data.

### Claim 33

A method of monitoring one or more components of an electrical generator, the method comprising:
providing a processing unit;
receiving a signal representative of a image of one or more components of an electrical generator at the processing unit; and
evaluating the signal to determine an occurrence of an anomalous or threshold condition of the one or more components of the electrical generator.

### Claim 34 (depends on 33)

The method of claim 33, further comprising the step of notifying personnel of the anomalous or threshold condition.

### Claim 35 (depends on 33)

The method of claim 33, further comprising the step of scheduling maintenance of the electrical device.